timing case NISSAN ALMERA N16 2003 Electronic Repair Manual

EM-48
[QG]
TIMING CHAIN
2. Disconnect battery ground cable.
3. Remove undercover, front RH wheel and RH splash cover.
4. Drain engine coolant from radiator and cylinder block. Refer to LC-17, "Changing Engine Coolant".
5. Drain engine oil from oil pan.
6. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
7. Remove power steering pump from adjusting bar.
8. Remove alternator. SC-33, "Removal and Installation".
9. Remove ignition coils. Refer to EM-24, "
IGNITION COIL" .
10. Remove rocker cover. Refer to EM-29, "
Removal and Installation" .
11. Remove oil level gauge.
12. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
13. Remove center member.
14. Remove gusset.
15. Remove rear plate (lower) (A/T models).
16. Remove oil pan and oil strainer. Refer to EM-22, "
Removal and Installation" .
17. For safe operation, and to reduce load to mount insulator, install removed center member again.
18. Remove engine front-side (right side of vehicle) engine mount. Refer to EM-67, "
ENGINE ASSEMBLY" .
a. Remove any parts that cause difficulties for operation around mount, or perform transfer.
b. Support cylinder block bottom surface with a transmission jack.
CAUTION:
●When applying jack, use a wooden block to avoid damage to oil pan mounting surface.
●While performing following operations, support engine front-side with jack.
c. Separate engine mounting insulator and bracket.
d. Remove engine mounting bracket.
19. Remove cylinder head front cover.
●Move harness which was previously fixed on front surface.
20. Remove auxiliary bolts of cylinder head.
21. Set the No. 1 cylinder to the compression TDC.
a. Turn the crankshaft pulley clockwise, and align the timing indica-
tor of the gear case to the timing mark of the crankshaft pulley.
PBIC0557E
PBIC0750E

CYLINDER BLOCK
EM-75
[QG]
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17. Remove crankshaft.
CAUTION:
●When placing crankshaft on ground, be careful not to
damage signal plate.
●Never remove signal plate unless it is necessary.
NOTE:
If it is removed, positioning dowel pin (dowel pins for crankshaft
and signal plate are specified as a single set) must be rein-
stalled.
18. Remove main bearing and thrust bearing from cylinder block and main bearing cap.
CAUTION:
Check mounting positions, and store them without mixing them up.
19. Remove baffle plate.
ASSEMBLY
1. Blow air sufficiently through engine coolant passage of cylinder block, oil passage, crank case and cylin-
der bore to remove foreign objects.
2. Install oil jet for timing chain lubrication.
●Face its flat surface upward, and push it as far as it will go.
3. Install baffle plate.
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the lower cylinder block.
b. Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block.
●Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
c. Install the main bearings paying attention to the direction.
●The main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
●Main bearings (cylinder block side) for journal No. 1 and for
No. 2 to No. 5 are different.
●Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
●When installing, align the bearing stopper to the notch.
●Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
SEM928F
PBIC0588E
PBIC0264E
PBIC0590E

Tool number
Tool nameDescription
KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate
NT617
Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
NT041
Changing shims
ST16610001
Pilot bushing puller
NT045
Removing crankshaft pilot bushing
KV10111100
Seal cutter
NT046
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder
head, etc.
KV10109300
Pulley holder
NT628
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
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PREPARATIONYD
Special Service Tools (Cont’d)
EM-5

JEM121G
3. Remove front chain case.
Move power steering fluid reservoir tank from the bracket.
Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
SEM514G
CAUTION:
While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
Do not remove two mass dampers on the back of cover.
SEM515G
4. Set the No. 1 piston to TDC on its compression stroke.
Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
No position indicator is provided on the crankshaft pulley.
When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
JEM124G
5. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
JEM125G
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
remove bolts to remove chain tensioner.
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TIMING CHAINYD
Secondary Timing Chain (Cont’d)
EM-21

JEM126G
3. Using a hexagon-head wrench (face to face: 6 mm, SST),
install timing chain slack guide.
JEM125G
4. Install chain tensioner.
a. Push the plunger of the chain tensioner. While holding it with
a push pin, install the chain tensioner.
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.
SEM514G
5. Install front chain case.
a. Install tension guide on the back surface of front chain case.
Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
JEM129G
b. Apply specified liquid gasket (Refer to EM-3, “Liquid Gasket
Application Procedure”.) on both ends of arched area (loca-
tions where rear chain case is adjoined) as shown in the fig-
ure.
c. Install front chain case.
When installing, align dowel pin on oil pump case with the pin
hole.
JEM121G
Install No. 6, 10, and 11 bolts with the rubber washer to the
front chain case.
d. Tighten fixing bolts in the numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
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TIMING CHAINYD
Secondary Timing Chain (Cont’d)
EM-23

REMOVALNJEM0094S011. Remove engine and transaxle assembly. Refer to EM-63,
“ENGINE ASSEMBLY”.
2. Remove transaxle from engine. Place engine onto engine
stand (SST). Refer to EM-67, “CYLINDER BLOCK”, “Disas-
sembly”.
3. Remove the following parts:
Oil pan (upper and lower)
Refer to EM-15, “OIL PAN”.
Oil filter bracket
Refer to LC-31, “Oil Filter Bracket”.
Injection tube
Refer to EC-21, “Injection Tube and Injection Nozzle”.
4. Remove secondary timing chain and associated parts.
Refer to EM-20, “Secondary Timing Chain”.
5. When removing rear chain case, remove camshaft sprockets.
Refer to EM-46, “CAMSHAFT”.
JEM131G
6. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
JEM132G
c. Using pulley puller (SST), remove crankshaft pulley.
Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM133G
7. Remove oil pump.
Loosen bolts in the reverse order of that shown in the figure
and remove them.
Use seal cutter (SST) etc. for removal.
8. Remove front oil seal from oil pump.
Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
Be careful not to damage the oil pump.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-26

JEM138G
16. Remove rear chain case.
Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
Use seal cutter (SST) for removal.
INSPECTIONNJEM0094S02Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATIONNJEM0094S03
JEM139G
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-28

JEM140G
1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM141G
b. Install four O-rings to the grooves of the cylinder block, fuel
injection pump bracket.
JEM138G
c. Install rear chain case.
When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20mm(0.79in):BoltNo.3,4,6,9,10,11,13,14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-29

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) as shown in the
figure.
Apply liquid gasket on oil pump-side surface.
JEM144G
13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM145G
b. Install oil pump drive spacer to crankshaft.
Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
JEM133G
d. Install oil pump.
When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM146G
14. Check gaps on upper oil pan mounting surface.
Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
Rear chain case and cylinder block
–0.25 to 0.13 mm (–0.0098 to 0.0051 in)
If the measured value is out of the above range, install again.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-31

EC-5
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ECA Wiring Diagram .................................................... 353
Diagnostic Procedure ........................................... 354
DTC P1706 PNP SWITCH ...................................... 356
Component Description ........................................ 356
CONSULT-II Reference Value in Data Monitor Mode
. 356
On Board Diagnosis Logic ................................... 356
DTC Confirmation Procedure ............................... 356
Overall Function Check ........................................ 357
Wiring Diagram .................................................... 358
Diagnostic Procedure ........................................... 359
DTC P1805 BRAKE SWITCH ................................ 360
Description ........................................................... 360
CONSULT-II Reference Value in Data Monitor Mode
. 360
On Board Diagnosis Logic ................................... 360
DTC Confirmation Procedure ............................... 360
Wiring Diagram .................................................... 361
Diagnostic Procedure ........................................... 362
Component Inspection ......................................... 364
IGNITION SIGNAL .................................................. 365
Component Description ........................................ 365
Wiring Diagram .................................................... 366
Diagnostic Procedure ........................................... 369
Component Inspection ......................................... 373
Removal and Installation ...................................... 374
INJECTOR CIRCUIT ............................................... 375
Component Description ........................................ 375
CONSULT-II Reference Value in Data Monitor Mode
. 375
Wiring Diagram .................................................... 376
Diagnostic Procedure ........................................... 377
Component Inspection ......................................... 380
Removal and Installation ...................................... 380
FUEL PUMP CIRCUIT ............................................ 381
Description ........................................................... 381
CONSULT-II Reference Value in Data Monitor Mode
. 381
Wiring Diagram .................................................... 382
Diagnostic Procedure ........................................... 383
Component Inspection ......................................... 385
Removal and Installation ...................................... 386
REFRIGERANT PRESSURE SENSOR ................. 387
Component Description ........................................ 387
Wiring Diagram .................................................... 388
Diagnostic Procedure ........................................... 389
Removal and Installation ...................................... 391
ELECTRICAL LOAD SIGNAL ................................ 392
Description ...................................................
........ 392
CONSULT-II Reference Value in Data Monitor Mode
. 392
Wiring Diagram .................................................... 393
Diagnostic Procedure ........................................... 394
MI & DATA LINK CONNECTORS .......................... 397
Wiring Diagram—LHD Models ............................. 397
Wiring Diagram—RHD Models ............................ 398
EVAPORATIVE EMISSION SYSTEM ..................... 399
Description ........................................................... 399
Component Inspection ......................................... 401POSITIVE CRANKCASE VENTILATION ...............402
Description ............................................................402
Component Inspection ..........................................402
SERVICE DATA AND SPECIFICATIONS (SDS) ....404
Fuel Pressure .......................................................404
Idle Speed and Ignition Timing .............................404
Calculated Load Value ..........................................404
Mass Air Flow Sensor ...........................................404
Intake Air Temperature Sensor .............................404
Engine Coolant Temperature Sensor ...................404
Heated Oxygen Sensor 1 Heater .........................404
Heated Oxygen sensor 2 Heater ..........................404
Crankshaft Position Sensor (POS) .......................404
Camshaft Position Sensor (PHASE) ....................404
Throttle Control Motor ...........................................405
Injector ..................................................................405
Fuel Pump ............................................................405
QG (WITHOUT EURO-OBD)
INDEX FOR DTC .....................................................406
Alphabetical Index ................................................406
DTC No. Index ......................................................407
PRECAUTIONS ......................................................409
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ...............................................................409
On Board Diagnostic (OBD) System of Engine ....409
Precaution ............................................................409
Wiring Diagrams and Trouble Diagnosis ..............412
PREPARATION .......................................................413
Special Service Tools ...........................................413
Commercial Service Tools ....................................413
ENGINE CONTROL SYSTEM ................................415
System Diagram ...................................................415
Vacuum Hose Drawing .........................................416
System Chart ........................................................417
Multiport Fuel Injection (MFI) System ...................417
Electronic Ignition (EI) System .............................419
Air Conditioning Cut Control .................................420
Fuel Cut Control (at No Load and High Engine
Speed) ..................................................................421
CAN Communication ............................................421
BASIC SERVICE PROCEDURE .............................424
Idle Speed and Ignition Timing Check ..................424
Accelerator Pedal Released Position Learning ....425
Throttle Valve Closed Position Learning ...............425
Idle Air Volume Learning ......................................425
Fuel Pressure Check ............................................427
ON BOARD DIAGNOSTIC (OBD) SYSTEM ..........429
Introduction ...........................................................429
Two Trip Detection Logic ......................................429
Emission-related Diagnostic Information ..............429
NATS (Nissan Anti-theft System) .........................431
Malfunction Indicator (MI) .....................................432
TROUBLE DIAGNOSIS ..........................................436
Trouble Diagnosis Introduction .............................436
DTC Inspection Priority Chart ...............................440
Fail-safe Chart ......................................................441