ad blue NISSAN ALMERA N16 2003 Electronic Repair Manual

Description=NJGI0003S02
Number Item Description
1 Power conditionThis shows the condition when the system receives battery positive voltage (can be
operated).
2 Fusible linkThe double line shows that this is a fusible link.
The open circle shows current flow in, and the shaded circle shows current flow out.
3Fusible link/fuse loca-
tionThis shows the location of the fusible link or fuse in the fusible link or fusebox.For
arrangement, refer to EL-12, “POWER SUPPLY ROUTING”.
4FuseThe single line shows that this is a fuse.
The open circle shows current flow in, and the shaded circle shows current flow out.
5 Current rating This shows the current rating of the fusible link or fuse.
6 ConnectorsThis shows that connector E3 is female and connector M1 is male.
The G/R wire is located in the 1A terminal of both connectors.
Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ con-
nector. Refer to GI-20.
7 Optional splice The open circle shows that the splice is optional depending on vehicle application.
8 Splice The shaded circle shows that the splice is always on the vehicle.
9 Page crossingThis arrow shows that the circuit continues to an adjacent page.
The A will match with the A on the preceding or next page.
10 Common connectorThe dotted lines between terminals show that these terminals are part of thesamecon-
nector.
11 Option abbreviation This shows that the circuit is optional depending on vehicle application.
12 RelayThis shows an internal representation of the relay. For details, refer to EL-9, “STAN-
DARDIZED RELAY”.
13 Connectors This shows that the connector is connected to the body or a terminal with bolt or nut.
14 Wire colorThis shows a code for the color of the wire.
B=Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
LG = Light GreenBR = Brown
OR = Orange
P = Pink
PU = Purple
GY = Gray
SB = Sky Blue
CH = Dark Brown
DG=DarkGreen
When the wire color is striped, the base color is given first, followed by the stripe color as
shown below:
Example: L/W = Blue with White Stripe
15 Option description This shows a description of the option abbreviationused on the page.
16 SwitchThis shows that continuity exists between terminals 1 and 2 when the switchis in the A
position. Continuity exists between terminals 1 and 3 when the switch is inthe B posi-
tion.
17 Assembly parts Connector terminal in component shows that it is a harness incorporated assembly.
18 Cell codeThis identifies each page of the wiring diagram by section, system and wiring diagram
page number.
19 Current flow arrowArrow indicates electric current flow, especially where the direction ofstandard flow (ver-
tically downward or horizontally from left to right) is difficult to follow.
A double arrow “
” shows that current can flow in either direction depending on cir-
cuit operation.
HOW TO READ WIRING DIAGRAMS
Description
GI-14

EM-64
[QG]
CYLINDER HEAD
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illus-
tration.
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
6. Using valve guide reamer, apply reamer finish to valve guide.
VALVE SEAT CONTACT
●After confirming that the dimensions of valve guides and valves
are within specifications, perform this procedure.
●Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.
●Check if the contact area band is continuous all around the cir-
cumference.
●If not, grind to adjust valve fitting and check again. If the contact-
ing surface still has N.G conditions even after the re-check,
replace valve seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this.
SEM008A
PBIC0577E
Standard
Intake and exhaust
: 5.500 - 5.515 mm (0.2165 - 0.2171 in) dia.
SEM932C
EMA0487D

CYLINDER BLOCK
EM-83
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. Apply journal diameter grade (0, 1 or 2) on crankshaft front to
column in main bearing selection table.
3. Select main bearing (STD 0 - 4) at the point where selected row
and column meet in following main bearing selection table.
When Cylinder Block and Crankshaft are Reused
1. Measure dimension of main bearing housing on cylinder block.
2. Find measured dimension in “Cylinder block main bearing housing inner diameter” row in following main
bearing selection table.
3. Measure crankshaft journal diameter.
4. Find measured dimension in “Crankshaft journal outer diameter” column in following main bearing selec-
tion table.
5. Select main bearing (STD 0 - 4) at the point where selected row and column meet in following main bear-
ing selection table.
Main Bearing Selection Table
Unit: mm (in)
Use Undersize Bearing Usage Guide
●Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
●When using undersize (US) bearing, measure the bearing inner diameter with bearing installed, and grind
journal until oil clearance falls within specification.
PBIC0607E
Connecting block main bearing housing ID53.644 - 53.652
(2.1120 - 2.1123)53.652 - 53.660
(2.1123 - 2.1126)53.660 - 53.668
(2.1126 - 2.1129)
Crankshaft journal
ODGrade
(punched)012
49.956 - 49.964
(1.9668 - 1.9671)0
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 0
1.826 - 1.830
(0.0719 - 0.0720)
0.020 - 0.044
(0.0008 - 0.0017)
BlackSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
Green
49.948 - 49.956
(1.9665 - 1.9668)1
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.0008 - 0.0017)
Ye l l o w
49.940 - 49.948
(1.9661 - 1.9665)2
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.008 - 0.0017)
Ye l l o wSTD 4
1.842 - 1.846
(0.0725 - 0.0727)
0.020 - 0.044
(0.0008 - 0.0017)
Blue

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-103
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
CONNECTING ROD
Unit: mm (in)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
*: Total indicator reading
MAIN BEARING
Standard size
Unit: mm (in)
Undersize
Unit: mm (in)
Bearing Clearance
Unit: mm (in) Center distance 140.45 - 140.55 (5.5295 - 5.5335)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod bushing inner diameter* (small end) 19.000 - 19.012 (0.7480 - 0.7485)
Connecting rod big end inner diameter 43.000 - 43.013 (1.6929 - 1.6934)
Side clearanceStandard 0.200 - 0.470 (0.0079 - 0.0185)
Limit 0.50 (0.0197)
Main journal dia. “Dm”Grade No. 0 49.956 - 49.964 (1.9668 - 1.9671)
Grade No. 1 49.948 - 49.956 (1.9665 - 1.9668)
Grade No. 2 49.940 - 49.948 (1.9661 - 1.9665)
Pin journal dia. “Dp”Grade No. 0 39.968 - 39.974 (1.5735 - 1.5738)
Grade No. 1 39.962 - 39.968 (1.5733 - 1.5735)
Grade No. 2 39.956 - 39.962 (1.5731 - 1.5733)
Out-of-round (X − Y)Standard Less than 0.003 (0.0001)
Limit Less than 0.005 (0.0002)
Taper (A − B)Standard Less than 0.004 (0.0002)
Limit Less than 0.005 (0.0002)
Runout [TIR*]Standard Less than 0.04 (0.0016)
Limit Less than 0.05 (0.0020)
Free end playStandard 0.060 - 0.260 (0.0024 - 0.0102)
Limit 0.3 (0.012)
Grade No. Thickness Identification color
0 1.826 - 1.830 (0.0719 - 0.0720) Black
1 1.830 - 1.834 (0.0720 - 0.0722) Red
2 1.834 - 1.838 (0.0722 - 0.0724) Green
3 1.838 - 1.842 (0.0724 - 0.0725) Yellow
4 1.842 - 1.846 (0.0725 - 0.0727) Blue
Thickness
0.25 (0.0098) 1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
Main bearing clearanceStandard 0.020 - 0.044 (0.0008 - 0.0017)
Limit 0.1 (0.004)

62.951 - 62.959
(2.4784 - 2.4787)2Bearing grade No.
Bearing thickness
Oil clearance
Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
3. When the specified oil clearance is not obtained with standard
size main bearings, use undersized bearings.
When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind crank-
shaft journal so that the specified oil clearance is obtained.
JEM216G
Undersize bearingUnit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
AEM027
Connecting Rod Bearing (Big end)NJEM0073S08021. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter “C” of connecting rod.
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
AEM034
4. Measure outer diameter “Dp” of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing.
JEM215G
When using a new crankshaft and connecting rods:
Identify the pin diameter grade (No. 0, 1, or 2) on front surface
of crankshaft and select the connecting rod bearings of the
same grade.
There is no grading for the inner diameter of the big end of the
connecting rod.
When re-using the removed crankshaft and connecting rods:
Measure the inner diameter of the big end of the connecting
rod and make sure it is within the specified range.
Measure the outer diameter of the crankshaft pin.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER BLOCKYD
Inspection (Cont’d)
EM-77

Available Main BearingNJEM0085
SEM255G
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717)
19.9 - 20.1 (0.783 - 0.791)Black
1 1.820 - 1.824 (0.0717 - 0.0718) Red or Brown
2 1.824 - 1.828 (0.0718 - 0.0720) Green
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
UNDERSIZENJEM0085S01Unit: mm (in)
Thickness Main journal diameter “Dm”
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)Grind so that bearing clearance is the specified
value.
Available Connecting Rod BearingNJEM0086CONNECTING ROD BEARINGNJEM0086S01
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color (mark)
0 1.492 - 1.496 (0.0587 - 0.0589)
22.9 - 23.1
(0.902 - 0.909)Black
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.504 (0.0591 - 0.0592) Green
UNDERSIZENJEM0086S02Unit: mm (in)
Thickness Crank pin journal diameter “Dp”
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the specified
value. 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous ComponentsNJEM0087Unit: mm (in)
Flywheel runout [TIR]*Less than 0.15 (0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Available Main Bearing
EM-96

AT-8
PRECAUTIONS
●Internal failure of stator roller clutch.
●Heavy clutch debris due to overheating (blue converter).
●Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
●The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
●The threads in one or more of the converter bolt holes are damaged.
●Transaxle failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
●Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
EURO-OBD SELF-DIAGNOSIS — EURO-OBD —
●A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the O/D OFF indicator lamp or the malfunction indicator (MI). Refer to the table on
AT- 4 2 , "
SELF-DIAGNOSTIC RESULT TEST MODE" for the indicator used to display each self-diagnostic
result.
●The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memo-
ries.
Always perform the procedure AT- 3 9 , "
HOW TO ERASE DTC" to complete the repair and avoid
unnecessary blinking of the MI.
●The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the O/D OFF indicator lamp does not indicate any malfunctions.
–PNP switch
–A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of EURO-OBD, refer to AT-37, "
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION" .
●Certain systems and components, especially those related to EURO-OBD, may use a new style
slide-locking type harness connector.
For description and how to disconnect, refer to EL-7, "HARNESS CONNECTOR".
Wiring Diagrams and Trouble DiagnosisECS007N9
When you read wiring diagrams, refer to the following:
●GI-12, "How to Read Wiring Diagrams".
●EL-11, "POWER SUPPLY ROUTING".
When you perform trouble diagnosis, refer to the following:
●GI-22, "How to Perform Efficient Diagnosis for an Electrical Incident".
●GI-32, "How to Follow Trouble Diagnosis".

ATC-10
PRECAUTIONS
●A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
●Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis
during a future service.
●Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
●Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
●Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.
●Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result.
●The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
Wiring Diagrams and Trouble DiagnosisEJS001YX
When you read wiring diagrams, refer to the followings:
●GI-12, "How to Read Wiring Diagram" in GI section.
●EL-11, "Power Supply Routing" in PG section.
When you perform trouble diagnosis, refer to the followings:
●GI-22, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.
●GI-32, "How to Follow Trouble Diagnosis" in GI section.
SHA436FA

ATC-12
PREPARATION
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color: Light blue
Container marking: HFC-134a (R-
134a)
Fitting size: Thread size
●Large container 1/2″ -16 ACME
KLH00-PAGS0
Nissan A/C System Oil Type SType: Poly alkylene glycol oil (PAG),
type S
Application: HFC-134a (R-134a)
swash plate compressors (Nissan
only)
Lubricity: 40 m [Liter] (1.4 Imp fl oz)
Recovery/Recycling/
Recharging equipment (ACR4)Function: Refrigerant Recovery and
Recycling and Recharging
Electrical leak detectorPower supply:
DC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses
(J-41459) Refrigerant dye injector
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
S-NT196
S-NT197
RJIA0195E
SHA705EB
ZHA200H

PREPARATION
ATC-13
C
D
E
F
G
H
I
K
L
MA
B
AT C
(J-42220)
Fluorescent dye leak detectorPower supply: DC 12V (Battery
terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system.
Includes: UV lamp and UV safety
glasses
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PAG oil
Container: 1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
(J-43872)
Dye cleanerFor cleaning dye spills.
Manifold gauge set (with hoses
and couplers)
Identification:
●The gauge face indicates R-134a.
Fitting size: Thread size
●1/2″ -16 ACME
Service hoses
●High side hose
●Low side hose
●Utility hose
Hose color:
●Low hose: Blue with black stripe
●High hose: Red with black stripe
●Utility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
●1/2″ -16 ACME Tool number
Tool nameDescription
SHA438F
SHA439F
SHA440F
SHA441F
RJIA0196E
S-NT201