NISSAN ALMERA N16 2003 Electronic Repair Manual

Removal and InstallationNJFE0033
PBIC0742E
1. Accelerator pedal assembly (work
unit)
REMOVALNJFE0033S011. Remove harness connector.
2. Loosen nuts, and remove accelerator pedal assembly.
CAUTION:
Do not disassemble the accelerator pedal assembly. Do
not remove the sensors and the switches from the assem-
bly.
Avoid impact from dropping etc. during handling.
Be careful to keep the assembly away from water.
When the harness connector of the accelerator sensor is
disconnected, perform “Accelerator Pedal Released Posi-
tion Learning”. Refer to “Basic Service Procedure” in EC
section.
INSTALLATIONNJFE0033S02Install in the reverse order of removal.
INSPECTION AFTER INSTALLATIONNJFE0033S03Check that the accelerator pedal moves smoothly within the
whole operation range.
Check that the accelerator pedal securely returns to the origi-
nal position.
For the electrical inspection of the accelerator pedal assembly,
refer to EC-211, “DTC P0226 APP SENSOR” (QG engine mod-
els WITH EURO-OBD), EC-536, “DTC P0226 APP SENSOR”
(QG engine models WITHOUT EURO-OBD).
Check that the drum of the accelerator work unit can be fully
opened.
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ACCELERATOR CONTROL SYSTEMQG
Removal and Installation
FE-3

SMA803A
Checking Fuel LinesNJFE0009Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
Removal and InstallationNJFE0004WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a “CAUTION: FLAMMABLE” sign in workshop.
Be sure to furnish workshop with a CO
2fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
a) Put drained fuel in an explosion-proof container and put the lid on securely.
b) Release fuel pressure from fuel line. Refer to EC-34, “Fuel Pressure Release”.
c) Disconnect battery ground cable.
Always replace O-ring and clamps with new ones.
Do not kink or twist tubes when they are being installed.
Do not tighten hose clamps excessively to avoid damaging hoses.
After installing tubes, run engine and check for fuel leaks at connections.
FUEL SYSTEMQG
Checking Fuel Lines
FE-4

Fuel TankNJFE0006
YFE013
JFE613A
REMOVALNJFE0006S011. Release fuel pressure from fuel line.
Refer to EC-34, “Fuel Pressure Release”.
2. Disconnect battery ground cable.
3. Open fuel filler lid and filler cap.
4. Drain fuel from fuel tank.
5. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
6. Remove inspection hole cover under the rear seat.
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FUEL SYSTEMQG
Fuel Tank
FE-5

PBIC0648E
7. Disconnect electrical connector.
8. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct instal-
lation.
PBIC0709E
b. Hold the connector while pushing in buttons, and pull out the
tube.
CAUTION:
The tube can be removed when the buttons are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
Do not bend or twist the tube during installation and
removal.
PBIC0713E
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
SFE650A
9. From rear left area of fuel tank, remove filler hose, vent hose,
and VEEP hose.
CAUTION:
To prevent fuel from flowing out, install a blind cap immedi-
ately after the fuel hose is disconnected.
FUEL SYSTEMQG
Fuel Tank (Cont’d)
FE-6

SFE642A
10. Remove exhaust center tube.
SFE643A
11. Remove heat insulators from fuel tank side.
SFE644A
12. Set a suitable transmission jack under fuel tank.
13. Remove fuel tank mounting band bolts while supporting fuel
tank.
14. Remove fuel tank.
YFE028
INSTALLATIONNJFE0006S02To install, reverse the removal procedure. Connect the quick con-
nector as follows:
Align mating marks on tubes and connectors for correct instal-
lation.
Insert tube into the center of the connector until you hear a
click.
YFE029
After connecting quick connector, make sure the connection is
firmly made using the following method.
Pull on the fuel tube and connector to make sure they are firmly
connected.
Start the engine, increase engine speed and verify that there
are no leaks.
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FUEL SYSTEMQG
Fuel Tank (Cont’d)
FE-7

Fuel Pump, Fuel Level Sensor Unit and Fuel
Filter
NJFE0007
YFE030
JFE613A
REMOVALNJFE0007S011. Release fuel pressure from fuel line.
Refer to EC-34, “Fuel Pressure Release”.
2. Disconnect battery ground cable.
3. Open fuel filler lid and filler cap.
4. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
5. Remove inspection hole cover under the rear seat.
PBIC0648E
6. Disconnect electrical connector.
7. Disconnect the quick connectors.
For disconnect of quick connectors, refer to step 8. of “Fuel
Tank Removal”.
FUEL SYSTEMQG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter
FE-8

SFE376A
8. Remove lock ring using a lock ring socket (SST).
SFE648A
9. Pull out the fuel level sensor unit and fuel pump.
Do not damage the arm of the fuel level sensor unit and
fuel tank temperature sensor.
INSTALLATIONNJFE0007S02Installation is in reverse order of removal.
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FUEL SYSTEMQG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter (Cont’d)
FE-9

SMA211A
Checking Exhaust SystemNJFE0010Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.
Removal and InstallationNJFE0005CAUTION:
Always replace exhaust gaskets with new ones when
reassembling.
With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
Check to ensure that mounting brackets and mounting
insulators are installed properly and free from undue
stress. Improper installation could result in excessive
noise or vibration.
Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; use a new one.
Before installing a new oxygen sensor, clean exhaust sys-
tem threads using oxygen sensor thread cleaner tool and
apply anti-seize lubricant.
Do not overtorque the oxygen sensor. Doing so may
cause damage to the oxygen sensor, resuiting in the MIL
coming on.
Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
Be careful not to cut your hand on the insulator edge.
EXHAUST SYSTEMQG
Checking Exhaust System
FE-10

YFE026
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EXHAUST SYSTEMQG
Removal and Installation (Cont’d)
FE-11

YFE027
EXHAUST SYSTEMQG
Removal and Installation (Cont’d)
FE-12