NISSAN ALMERA 2001 Service Manual

JEF346Y
Inspection for Spill Tube AirtightnessNJEC0619S01Before the rocker cover is installed, perform the inspection as fol-
lows.
1. Connect the handy vacuum pump to the spill hose.
2. Check that the airtightness is maintained after the negative
pressure shown below is applied.
Standard:
±53.3 to ±66.7 kPa (±533 to ±667 mbar, ±400 to ±500
mmHg, ±15.75 to ±19.69 inHg)
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Air Bleeding of Fuel PipingNJEC0619S02After the repair, bleed air in the piping by pumping the priming
pump up and down until it becomes heavy.
JEF348Y
Injection Pressure TestNJEC0619S031. Install injection nozzle assembly to injection nozzle tester and
bleed air from flare nut.
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
New
21,476 - 22,457 kPa (214.7 - 224.5 bar, 219 - 229
kg/cm
2, 3,114 - 3,256 psi)
Limit
18,275 kPa (182.7 bar, 186 kg/cm
2, 2,650 psi)
+The injection nozzle assembly has a 2-stage pressure injection
function. However, the judgement should be made at the first
stage of the valve opening pressure.
Always check initial injection pressure using a new nozzle.
BASIC SERVICE PROCEDUREYD
Injection Tube and Injection Nozzle (Cont'd)
EC-617

SEF434Z
Spray Pattern TestNJEC0619S051. Check spray pattern by pumping tester handle one full stroke
per second.
NG spray pattern:
Does not inject straight and strong (B in the figure).
Fuel drips (C in the figure).
Does not inject evenly (D in the figure).
2. If the spray pattern is not correct, replace injection nozzle
assembly.
Electronic Control Fuel Injection Pump
REMOVAL AND INSTALLATIONNJEC0620
JEF350Y
RemovalNJEC0620S011. Remove the parts shown below.
+Engine hood
+Engine coolant (drain)
+Engine cover
+Heater pipe under intake manifold
+Injection tubes
+Right splash cover (with undercover)
+Right front wheel
BASIC SERVICE PROCEDUREYD
Injection Tube and Injection Nozzle (Cont'd)
EC-618

JEF351Y
2. Disconnect the fuel hoses from the fuel injection pump.
3. Disconnect the harness connector from the fuel injection
pump.
+Disconnect the connector by pulling the connector stopper
fully.
+When the stopper is fully pulled, the connector will be discon-
nected together. For installation, push the connector half way
first, then press the stopper until it locks, so that the connec-
tor is connected together.
4. Remove the fuel injection pump rear bracket.
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5. Remove the front chain case.
+Move the power steering fluid reservoir tank from the bracket.
+Loosen and remove the mounting bolts in the reverse order of
the numbers shown in the figure.
+As for bolts 6, 10, and 11, remove with rubber washer because
there is not enough space for removing only the bolts.
CAUTION:
To prevent foreign objects from getting in the engine, cover
the opening during the removal of the front chain case.
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6. Adjust the No. 1 cylinder to the top dead center position.
+Turn the crankshaft pulley clockwise, then align the alignment
mark (punched mark) of the camshaft sprocket to the position
shown in the figure.
+There is no indicator on the crankshaft pulley.
+It is not necessary to mark the secondary timing chain for
removal because it can be matched by the link color for instal-
lation. However, the alignment mark on the fuel injection pump
sprocket is difficult to see; mark it if necessary.
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7. Remove the chain tensioner.
a. Push the plunger of the chain tensioner, then fix it with a tool
such as a push pin.
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b. Using the hexagon wrench (face to face: 5 mm) (SST), remove
the mounting bolts, then remove the chain tensioner.
+A multi-purpose tool may also be used.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-619

JEF356Y
8. Remove the timing chain slack guide.
+Using the hexagon wrench (face to face: 6 mm, short-type)
(SST), remove the mounting bolts, then remove the timing
chain slack guide.
JEF357Y
9. Remove the timing chain tension guide.
10. Remove the secondary timing chain.
+Only the timing chain can be removed without removing the
sprockets.
JEF358Y
11. Fix the fuel injection pump sprocket.
a. Insert the positioning stopper pin (SST) in the 6 mm (0.24 in)
dia. hole of the fuel injection pump sprocket.
b. Using the torx wrench (SST), turn the pump shaft gradually to
adjust the hole position of the fuel injection pump sprocket.
c. Insert the positioning stopper pin through the fuel injection
pump body to fix the sprocket.
JEF359Y
+Insert the positioning stopper pin until its flange contacts the
fuel injection pump sprocket.
d. Remove the torx wrench (SST).
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-620

JEF360Y
JEF361Y
12. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), remove the mounting bolts of the fuel injection pump
sprocket.
+It is not necessary to remove the washer of the fuel injection
pump sprocket.
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JEF363Y
13. Using the sprocket holder (SST), hold the fuel injection pump
sprocket to prevent falling.
+When the sprocket holder is installed, if the positioning stop-
per pin interferes, pull out the stopper pin approximately 10
mm (0.39 in), then install it.
+After the sprocket holder is installed temporarily, insert the
extension bar (SST) and Torx socket in the three holes A. After
positioning the holes, tighten the holder mounting bolts. (Refer
to the step 14 about the tool.)
+The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
+Make sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket 15 mm (0.59 in) (small
diameter side).
CAUTION:
Do not remove the sprocket holder until the fuel injection
pump is installed.
+After the sprocket holder is installed, pull out the positioning
stopper pin (SST) from the fuel injection pump sprocket.
JEF364Y
14. Using the extension bar [SST: whole length 43 mm (1.69 in)]
and the Torx socket (Q6-E12: commercially available), remove
the mounting bolts, them remove the fuel injection pump
toward the rear of the engine.
+Even after all the mounting bolts are removed, the fuel injec-
tion pump is still held by a dowel pin.
CAUTION:
Do not disassemble or adjust the fuel injection pump.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-621

JEF365Y
15. Remove the fuel injection pump mounting bolts.
+The seal washer of the mounting bolts cannot be reused.
CAUTION:
For removal, be careful not to drop the seal washer into the
engine.
JEF366Y
InstallationNJEC0620S02+It is not necessary to adjust the injection timing by changing the
installation angle which used to be performed with conven-
tional fuel injection pumps. The installation position can be
simply decided by the dowel pin and the mounting bolts.
1. Before the fuel injection pump is installed, check that the notch
of its flange and the 6 mm (0.24 in) dia. hole on the body are
aligned.
JEF367Y
2. Insert the fuel injection pump to the mounting position from the
rear of the engine.
+Adjust the fuel injection pump bracket position to the dowel pin,
then install it.
JEF364Y
3. Using the extension bar (SST) and the Torx socket, tighten the
mounting bolts of the fuel injection pump.
4. Remove the sprocket holder (SST).
JEF358Y
5. Using the torx wrench (SST), turn the pump shaft gradually to
adjust the position of the flange. Then, insert the positioning
stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the fuel
injection pump sprocket through the pump flange and the
pump body.
6. Remove the torx wrench (SST).
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-622

JEF360Y
7. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), tighten the sprocket mounting bolt.
+When the washer of the fuel injection pump sprocket is
removed, install it with the marking ªFº (front) facing the front
of the engine.
8. Pull out the positioning stopper pin (SST).
JEF368Y
9. Install the secondary timing chain.
+Align the alignment marks of the sprockets and those of the
chain, then install it.
+The figure shows the installation state and names of the sec-
ondary timing chain and other related parts.
10. Install timing chain tension guide.
+The upper installation bolt is longer than the lower.
JEF356Y
11. Using a hexagon wrench (face to face: 6 mm, short-type)
(SST), install the timing chain slack guide.
JEF355Y
12. Install the chain tensioner.
a. Push the plunger of the chain tensioner, then hold it with a tool
such as a push pin, and install it.
b. Using a hexagon wrench (face to face: 5 mm) (SST), tighten
the mounting bolts.
+Installation is possible by a multi-purpose tool also.
c. Pull out the tool such as a push pin which holds the plunger.
+Make sure that the alignment marks of the sprockets and
timing chain are aligned.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-623

JEF369Y
13. Install the front chain case.
a. Install the tension guide to the back side of the front chain
case.
+If the front chain case is tilted, the tension guide may fall off.
Therefore, when installing the front chain case, hold it verti-
cally.
JEF370Y
b. Apply Three Bond 1207C (KP510 00150) to both ends of the
arch area of the oil pump (contact surface of rear chain case)
as shown in the figure.
c. Install the front chain case.
+Align the dowel pin of the oil pump case to the pin hole, then
install it.
+Install bolts 6, 10, and 11 (shown in the figure) with the rubber
washer to the front chain case.
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d. Tighten the mounting bolts in the numerical order shown in the
figure.
e. After all bolts are tightened, tighten the mounting bolts in the
numerical order shown in the figure again.
14. Install the fuel injection pump rear bracket.
+Tighten all the bolts temporarily, then tighten them securely
with the mounting face securely contacting the fuel injection
pump and the pump bracket.
JEF351Y
15. Connect the fuel injection pump harness connector.
+Insert the harness connector securely until the stopper locks.
+Push the connector half way first, then press the stopper until
it locks, so that the connector is connected together.
16. Connect the fuel hoses.
+When the hoses are disconnected at the fuel gallery side,
insert until the hoses contact the valve, then install the clamp
securely.
17. Install other parts in the reverse order of removal.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont'd)
EC-624

Fuel Filter
DESCRIPTIONNJEC0623A water draining cock is on the lower side and a priming pump for
bleeding air is on the upper side.
SEF375Y
AIR BLEEDINGNJEC06241. After the repair, bleed air from the piping by pumping the prim-
ing pump up and down until it becomes heavy.
2. To start the engine, rotate the starter for a maximum of 30
seconds. To start the engine more quickly, crank the engine
while pumping the priming pump (requires two workers).
3. If the engine does not start after rotating the starter for a maxi-
mum of 30 seconds, stop it once, and pump the priming pump
again until it becomes heavy.
4. Rotate the starter again until the engine starts running.
5. After the engine starts, let it idle for at least 1 minute to stabi-
lize the behavior.
+When air is bled completely, the pumping of the priming
pump suddenly becomes heavy. Stop the operation at that
time.
+If it is difficult to bleed air by the pumping of the priming
pump (the pumping of the priming pump does not become
heavy), disconnect the fuel supply hose between the fuel
filter and the injection pump. Then, perform the operation
described above, and make sure that fuel comes out. (Use
a pan, etc. so as not to spill fuel. Do not let fuel get on
engine and other parts.) After that, connect the hose, then
bleed air again.
+Start engine and let it idle for at least one minute after
performing air bleeding.
WATER DRAININGNJEC0625+If the MI lights up (not flashes) during the engine operation,
drain the water as follows. (If water in fuel filter sensor is
equipped.)
1. Remove the fuel filter, filter bracket, protector assembly from
the dash panel as follows.
a. Remove the air cleaner case (upper), air duct assembly, and
vacuum hose for brake booster (between the vacuum pump
and vacuum pipe).
CAUTION:
After the duct is removed, cover the opening with gum tape,
etc. to prevent foreign object from getting into the engine
during the operation.
b. Disconnect the water level warning sensor harness connector.
c. Remove the mounting nuts on the dash panel, then remove the
fuel filter, filter bracket, and protector assembly from the dash
panel.
+It is not necessary to disconnect the fuel hose.
2. Using a tool such as a pliers, loosen the water draining cock
BASIC SERVICE PROCEDUREYD
Fuel Filter
EC-625

at the bottom of the water level warning sensor located under
the fuel filter.
JEF377Y
3. Install the fuel filter, filter bracket, and protector assembly tem-
porarily. Then, drain the water by pumping the priming pump
with the filter standing straight.
+Extend the drain hose if necessary.
Water amount when the MI lights up:
65 - 100 m!(2.3 - 3.5 Imp fl oz)
CAUTION:
When the water is drained, the fuel is also drained. Use a pan,
etc. to avoid fuel adherence to the rubber parts such as the
engine mount insulator.
4. Tighten the water draining cock, then install the fuel filter, filter
bracket, protector assembly in the reverse order of removal.
CAUTION:
Do not over-tighten the water draining cock. This will damage
the cock thread, resulting in water or fuel leak.
5. Bleed air of the fuel filter. Refer to EC-625.
+Start engine and let it idle for at least one minute after
performing air bleeding.
6. Start the engine, then check that the MI goes off. (If water in
fuel filter sensor is equipped.)
BASIC SERVICE PROCEDUREYD
Fuel Filter (Cont'd)
EC-626