belt NISSAN ALMERA 2001 User Guide
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2001, Model line: ALMERA, Model: NISSAN ALMERA 2001Pages: 2898, PDF Size: 60.76 MB
Page 661 of 2898
Removal and InstallationNJBT00151. Remove rear seat. Refer to ªREAR SEATº for details, BT-60.
2. Remove shoulder anchor bolts. Refer to RS-5, ªFront Seat Beltº for details.
3. Remove front pillar garnishes, center pillar upper garnishes, center pillar lower garnishes and rear pillar
garnishes. Refer to ªSIDE AND FLOOR TRIMº for details, BT-31.
4. Push back the front seat back.
5. Remove sunroof and spot lamp switch, then disconnect connectors. (Model with sunroof)
6. Remove sunroof welt. (Model with sunroof)
7. Remove interior lamp assembly, then disconnect connectors.
8. Remove rear interior lamp assembly, then disconnect connector.(For Hatchback)
9. Remove rear seat belt center finisher.
(For Hatchback)
10. Remove sun visors.
11. Remove assist grips.
12. Remove clips securing headlining, then remove headlining from vehicle through front passenger side.
SBT055A
ROOF TRIM
Removal and Installation
BT-43
Page 725 of 2898
ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
QG
TROUBLE DIAGNOSIS - INDEX..................................10
Alphabetical & P No. Index for DTC .........................10
PRECAUTIONS.............................................................16
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER².............16
Precautions for On Board Diagnostic (OBD)
System of Engine and A/T.........................................16
Engine Fuel & Emission Control System ..................17
Wiring Diagrams and Trouble Diagnosis ...................19
PREPARATION.............................................................20
Special Service Tools ................................................20
Commercial Service Tools .........................................20
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.........................................................................21
Engine Control Component Parts Location ...............21
Circuit Diagram ..........................................................25
System Diagram ........................................................29
Vacuum Hose Drawing ..............................................30
System Chart .............................................................31
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION...............................................32
Multiport Fuel Injection (MFI) System .......................32
Electronic Ignition (EI) System ..................................34
Air Conditioning Cut Control ......................................35
Fuel Cut Control (at no load & high engine
speed) ........................................................................36
Evaporative Emission System ...................................36
Positive Crankcase Ventilation ..................................39
BASIC SERVICE PROCEDURE...................................40
Fuel Pressure Release ..............................................40
Fuel Pressure Check .................................................40
Fuel Pressure Regulator Check ................................41
Injector .......................................................................41
How to Check Idle Speed and Ignition Timing ..........43
Preparation ................................................................44
Inspection Procedure .................................................47
Idle Air Volume Learning ...........................................57ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................59
Introduction ................................................................59
Two Trip Detection Logic ...........................................59
Emission-related Diagnostic Information ...................60
NATS (Nissan Anti-theft System) ..............................74
Malfunction Indicator (MI) ..........................................74
OBD System Operation Chart (With Euro-OBD
Models Only)..............................................................78
CONSULT-II ...............................................................83
Generic Scan Tool (GST) ..........................................94
TROUBLE DIAGNOSIS - INTRODUCTION..................96
Introduction ................................................................96
Work Flow ..................................................................98
TROUBLE DIAGNOSIS - BASIC INSPECTION.........100
Basic Inspection/Sedan ...........................................100
Basic Inspection/Hatchback.....................................128
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION.............................................................153
DTC Inspection Priority Chart..................................153
Fail-safe Chart .........................................................154
Symptom Matrix Chart .............................................155
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................159
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................161
ECM Terminals and Reference Value .....................164
TROUBLE DIAGNOSIS - SPECIFICATION VALUE..173
Description ...............................................................173
Testing Condition .....................................................173
Inspection Procedure ...............................................173
Diagnostic Procedure ..............................................174
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT.....................................................................177
Description ...............................................................177
Diagnostic Procedure ..............................................177
TROUBLE DIAGNOSIS FOR POWER SUPPLY........178
Main Power Supply and Ground Circuit ..................178
Page 731 of 2898
ECM Terminals and Reference Value .....................578
Wiring Diagram ........................................................579
Diagnostic Procedure - Load Signal - .....................583
Diagnostic Procedure - Heater Control Panel
(Fan Switch) - ..........................................................589
Component Inspection .............................................590
MI & DATA LINK CONNECTORS..............................591
Wiring Diagram ........................................................591
SERVICE DATA AND SPECIFICATIONS (SDS).......593
Fuel Pressure Regulator..........................................593
Idle Speed and Ignition Timing ................................593
Mass Air Flow Sensor..............................................593
Intake Air Temperature Sensor ................................593
Engine Coolant Temperature Sensor ......................593
Throttle Position Sensor ..........................................593
Heated Oxygen Sensor 1 Heater (Front) ................593
Heated Oxygen Sensor 2 Heater (Rear).................593
Fuel Tank Temperature Sensor (Where Fitted) .......594
EGR Volume Control Valve (Where Fitted) .............594
EGR Temperature Sensor (Where Fitted) ...............594
EVAP Canister Purge Volume Control Valve ..........594
IACV-AAC Valve ......................................................594
Injector .....................................................................594
Ignition Coil with Power Transistor ..........................594
Condenser ...............................................................594
Fuel Pump ...............................................................594
Crankshaft Position Sensor (POS) ..........................595
Camshaft Position Sensor (PHASE) .......................595
YD
TROUBLE DIAGNOSIS - INDEX................................596
Alphabetical & P No. Index for DTC .......................596
PRECAUTIONS...........................................................598
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...........598
Engine Fuel & Emission Control System ................599
Precautions ..............................................................600
Wiring Diagrams and Trouble Diagnosis .................601
PREPARATION...........................................................602
Special Service Tools ..............................................602
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.......................................................................603
Engine Control Component Parts Location .............603
Circuit Diagram ........................................................606
System Diagram ......................................................608
System Chart ...........................................................609
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION.............................................610
Fuel Injection Control System .................................610
Fuel Injection Timing Control System...................... 611
Air Conditioning Cut Control ....................................612Fuel Cut Control (at no load & high engine
speed) ......................................................................612
Crankcase Ventilation System .................................613
BASIC SERVICE PROCEDURE.................................614
Injection Tube and Injection Nozzle ........................614
Electronic Control Fuel Injection Pump ...................618
Fuel Filter .................................................................625
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION.............................................................627
DTC and MI Detection Logic ...................................627
Diagnostic Trouble Code (DTC) ..............................627
Malfunction Indicator (MI) ........................................628
CONSULT-II .............................................................632
TROUBLE DIAGNOSIS - INTRODUCTION................637
Introduction ..............................................................637
Work Flow ................................................................639
TROUBLE DIAGNOSIS - BASIC INSPECTION.........641
Basic Inspection.......................................................641
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION.............................................................646
Symptom Matrix Chart .............................................646
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................656
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................658
ECM Terminals and Reference Value .....................659
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT.....................................................................665
Description ...............................................................665
Diagnostic Procedure ..............................................665
TROUBLE DIAGNOSIS FOR POWER SUPPLY........666
Main Power Supply and Ground Circuit ..................666
DTC P0100 MASS AIR FLOW SEN...........................673
Component Description ...........................................673
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................673
ECM Terminals and Reference Value .....................673
On Board Diagnosis Logic.......................................673
DTC Confirmation Procedure ..................................673
Wiring Diagram ........................................................675
Diagnostic Procedure ..............................................677
DTC P0115 COOLANT TEMP SEN............................680
Description ...............................................................680
On Board Diagnosis Logic.......................................680
DTC Confirmation Procedure ..................................680
Wiring Diagram ........................................................682
Diagnostic Procedure ..............................................683
DTC P0120 ACCEL POS SENSOR............................685
Description ...............................................................685
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................685
ECM Terminals and Reference Value .....................685
CONTENTS(Cont'd)
EC-7
Page 740 of 2898
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEC0002The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnoses sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnoses sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harness can be identified by yellow harness connector.
Precautions for On Board Diagnostic (OBD)
System of Engine and A/T
NJEC0003The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
+Be sure to turn the ignition switch ªOFFº and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause the MI to light up.
+Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
+Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector.
For description and how to disconnect, refer to EL section, ªDescriptionº, ªHARNESS CONNEC-
TORº.
+Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause the MI to light up due to the short circuit.
+Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of fuel injection system, etc.
+Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission Control Module) before returning the vehicle to the customer.
PRECAUTIONSQG
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EC-16
Page 1322 of 2898
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEC0601The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harness can be identified by yellow harness connector.
PRECAUTIONSYD
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EC-598
Page 1559 of 2898
ELECTRICAL SYSTEM
SECTION
EL
CONTENTS
PRECAUTIONS...............................................................5
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............5
Wiring Diagrams and Trouble Diagnosis .....................5
HARNESS CONNECTOR................................................6
Description ...................................................................6
STANDARDIZED RELAY................................................8
Description ...................................................................8
POWER SUPPLY ROUTING.........................................10
Schematic/Sedan .......................................................10
Wiring Diagram - POWER -/Sedan With
Gasoline Engine ........................................................ 11
Wiring Diagram - POWER -/Sedan With Diesel
Engine ........................................................................19
Schematic/Hatchback ................................................26
Wiring Diagram - POWER -/Hatchback ....................28
Inspection...................................................................38
GROUND........................................................................39
Ground Distribution ....................................................39
COMBINATION SWITCH..............................................56
Check/Sedan .............................................................56
Check/Hatchback .......................................................57
Replacement ..............................................................58
STEERING SWITCH......................................................59
Check .........................................................................59
HEADLAMP...................................................................60
Wiring Diagram - H/LAMP -/Hatchback.....................60
Wiring Diagram - H/LAMP -/Sedan ...........................61
Trouble Diagnoses.....................................................63
Bulb Replacement .....................................................64
Aiming Adjustment .....................................................65
HEADLAMP - DAYTIME LIGHT SYSTEM -.................67
System Description ....................................................67
Schematic/Sedan .......................................................68
Wiring Diagram - DTRL -/Sedan ...............................69
Schematic/Hatchback ................................................72
Wiring Diagram - DTRL -/Hatchback .........................73
Trouble Diagnoses.....................................................76
Bulb Replacement .....................................................76Aiming Adjustment .....................................................77
HEADLAMP - HEADLAMP AIMING CONTROL -........78
Wiring Diagram - H/AIM -/Sedan...............................78
Wiring Diagram - H/AIM -/Hatchback ........................79
PARKING, LICENSE AND TAIL LAMPS.....................81
Wiring Diagram - TAIL/L -/Sedan ..............................81
Wiring Diagram - TAIL/L -/Hatchback ........................83
STOP LAMP..................................................................85
Wiring Diagram - STOP/L -/Sedan ............................85
Wiring Diagram - STOP/L -/Hatchback .....................86
BACK-UP LAMP............................................................87
Wiring Diagram - BACK/L -/Sedan ............................87
Wiring Diagram - BACK/L -/Hatchback .....................88
FRONT FOG LAMP.......................................................89
Wiring Diagram - F/FOG -/Sedan..............................89
Wiring Diagram - F/FOG -/Hatchback .......................90
Bulb Replacement .....................................................91
Aiming Adjustment .....................................................92
REAR FOG LAMP.........................................................93
Wiring Diagram - R/FOG -/Sedan .............................93
Wiring Diagram - R/FOG -/Hatchback.......................95
TURN SIGNAL AND HAZARD WARNING LAMPS.....96
System Description/Sedan ........................................96
Schematic/Sedan .......................................................98
Wiring Diagram - TURN -/Sedan...............................99
Trouble Diagnoses/Sedan .......................................101
Electrical Components Inspection ...........................101
System Description/Hatchback ................................102
Wiring Diagram - TURN -/Hatchback ......................103
Trouble Diagnoses/Hatchback.................................107
ILLUMINATION............................................................108
Schematic/Sedan .....................................................108
Wiring Diagram - ILL -/Sedan ..................................109
Schematic/Hatchback .............................................. 111
Wiring Diagram - ILL -/Hatchback ........................... 112
INTERIOR ROOM LAMP............................................. 115
System Description/Sedan With Interior Room
Lamp Timer .............................................................. 115
Page 1563 of 2898
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEL0001The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
Wiring Diagrams and Trouble DiagnosisNJEL0002When you read wiring diagrams, refer to the following:
+Refer to GI-11, ªHOW TO READ WIRING DIAGRAMSº
+Refer to EL-10, ªPOWER SUPPLY ROUTINGº for power distribution circuit
When you perform trouble diagnosis, refer to the following:
+Refer to GI-32, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSESº
+Refer to GI-21, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº
Check for any Service bulletins before servicing the vehicle.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EL-5
Page 2135 of 2898
ENGINE MECHANICAL
SECTION
EM
CONTENTS
QG
PRECAUTIONS...............................................................4
Parts Requiring Angular Tightening .............................4
Liquid Gasket Application Procedure ..........................4
PREPARATION...............................................................5
Special Service Tools ..................................................5
Commercial Service Tools ...........................................7
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................9
NVH Troubleshooting - Engine Noise .........................9
OUTER COMPONENT PARTS..................................... 11
Removal and Installation ........................................... 11
MEASUREMENT OF COMPRESSION PRESSURE....15
DRIVE BELTS................................................................16
Checking ....................................................................16
AIR CLEANER...............................................................18
Cleaning and Changing .............................................18
VISCOUS PAPER TYPE...........................................18
DRY PAPER TYPE..................................................18
SPARK PLUG................................................................19
Checking and Changing ............................................19
OIL PAN.........................................................................20
Components...............................................................20
Removal .....................................................................20
Installation ..................................................................21
TIMING CHAIN..............................................................23
Components...............................................................23
Removal .....................................................................24
Inspection...................................................................27
Installation ..................................................................28
OIL SEAL.......................................................................32
Replacement ..............................................................32
VALVE OIL SEAL.....................................................32
FRONT OIL SEAL....................................................32
REAR OIL SEAL......................................................33
CYLINDER HEAD..........................................................34
Components...............................................................34
Removal .....................................................................35
Disassembly...............................................................37Inspection...................................................................37
CYLINDER HEAD DISTORTION...............................37
CAMSHAFT VISUAL CHECK....................................37
CAMSHAFT RUNOUT..............................................38
CAMSHAFT CAM HEIGHT.......................................38
CAMSHAFT JOURNAL CLEARANCE........................38
CAMSHAFT END PLAY............................................39
CAMSHAFT SPROCKET RUNOUT...........................39
VALVE GUIDE CLEARANCE....................................39
VALVE GUIDE REPLACEMENT................................40
VALVE SEATS.........................................................41
REPLACING VALVE SEAT FOR SERVICE PARTS....41
VALVE DIMENSIONS...............................................42
VALVE SPRING.......................................................42
VALVE LIFTER AND VALVE SHIM............................43
Valve Clearance.........................................................44
CHECKING.............................................................44
ADJUSTING............................................................45
Assembly ...................................................................46
Installation ..................................................................47
ENGINE ASSEMBLY.....................................................51
Removal and Installation ...........................................51
REMOVAL...............................................................52
INSTALLATION........................................................53
CYLINDER BLOCK.......................................................54
Components...............................................................54
Removal and Installation ...........................................55
Disassembly...............................................................55
PISTON AND CRANKSHAFT....................................55
Inspection...................................................................56
PISTON AND PISTON PIN CLEARANCE..................56
PISTON RING SIDE CLEARANCE............................56
PISTON RING END GAP..........................................56
CONNECTING ROD BEND AND TORSION...............57
CYLINDER BLOCK DISTORTION AND WEAR...........57
PISTON-TO-BORE CLEARANCE..............................58
CRANKSHAFT.........................................................59
BEARING CLEARANCE...........................................59
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
..........................................................61
Page 2136 of 2898
REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
..........................................62
FLYWHEEL/DRIVE PLATE RUNOUT........................62
Assembly ...................................................................62
PISTON..................................................................62
CRANKSHAFT.........................................................63
SERVICE DATA AND SPECIFICATIONS (SDS).........66
General Specifications ...............................................66
Compression Pressure ..............................................66
Belt Deflection............................................................67
Spark Plug .................................................................67
Cylinder Head ............................................................67
Valve ..........................................................................68
VALVE....................................................................68
VALVE SPRING.......................................................68
VALVE LIFTER........................................................68
VALVE CLEARANCE................................................69
VALVE GUIDE.........................................................69
AVAILABLE SHIMS..................................................69
VALVE SEAT...........................................................71
VALVE SEAT RESURFACE LIMIT.............................72
Camshaft and Camshaft Bearing ..............................72
Cylinder Block ............................................................73
Piston, Piston Ring and Piston Pin ...........................74
PISTON..................................................................74
PISTON RING.........................................................74
PISTON PIN............................................................74
Connecting Rod .........................................................75
Crankshaft..................................................................75
Main Bearing..............................................................75
STANDARD.............................................................75
UNDERSIZE............................................................75
Connecting Rod Bearing ...........................................76
STANDARD SIZE....................................................76
UNDERSIZE............................................................76
Bearing Clearance .....................................................76
Miscellaneous Components.......................................76
YD
PRECAUTIONS.............................................................77
Parts Requiring Angular Tightening ...........................77
Liquid Gasket Application Procedure ........................77
PREPARATION.............................................................78
Special Service Tools ................................................78
Commercial Service Tools .........................................80
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................82
NVH Troubleshooting - Engine Noise .......................82
MEASUREMENT OF COMPRESSION PRESSURE....83
DRIVE BELTS................................................................85
Inspection...................................................................85
Adjustment .................................................................85
AIR CONDITIONER COMPRESSOR BELT................86
ALTERNATOR & WATER PUMP BELT.....................86
Removal .....................................................................86
Installation ..................................................................87
AIR CLEANER...............................................................88
Changing Air Cleaner Filter .......................................88
VISCOUS PAPER TYPE...........................................88
OIL PAN.........................................................................89
Components...............................................................89
Removal .....................................................................89
Installation ..................................................................91
TIMING CHAIN..............................................................94
Secondary Timing Chain ...........................................94
REMOVAL...............................................................94
INSPECTION...........................................................96
INSTALLATION........................................................96
Primary Timing Chain ................................................99
REMOVAL.............................................................100
INSPECTION.........................................................102
INSTALLATION......................................................102
INTAKE MANIFOLD....................................................107
Removal and Installation .........................................107
PREPARATIVE WORK...........................................107
FUEL PIPING........................................................108
INTAKE MANIFOLD...............................................108
EGR VOLUME CONTROL VALVE...........................108
WATER HOSE.......................................................108
Inspection.................................................................109
INTAKE MANIFOLD...............................................109
CATALYST.................................................................. 110
Removal and Installation ......................................... 110
PREPARATIVE WORK........................................... 110
CATALYST............................................................ 110
GUSSET............................................................... 111
EXHAUST MANIFOLD, TURBOCHARGER............... 112
Removal and Installation ......................................... 112
PREPARATIVE WORK........................................... 112
EXHAUST MANIFOLD AND TURBOCHARGER....... 112
EXHAUST MANIFOLD GASKET............................. 113
Disassembly and Assembly ..................................... 113
TURBOCHARGER................................................. 113
Inspection................................................................. 114
EXHAUST MANIFOLD........................................... 114
TURBOCHARGER................................................. 114
ROCKER COVER........................................................ 117
Removal and Installation ......................................... 117
PREPARATIVE WORK........................................... 117
ROCKER COVER.................................................. 117
CYLINDER HEAD........................................................ 119
Components............................................................. 119
Removal ...................................................................120
PREPARATIVE WORK...........................................120
CAMSHAFT...........................................................120
CYLINDER HEAD..................................................121
Disassembly.............................................................121
Inspection.................................................................122
CONTENTS(Cont'd)
EM-2
Page 2137 of 2898
CYLINDER HEAD DISTORTION.............................122
CAMSHAFT VISUAL CHECK..................................123
CAMSHAFT RUNOUT............................................123
CAMSHAFT CAM HEIGHT.....................................123
CAMSHAFT JOURNAL CLEARANCE......................123
CAMSHAFT END PLAY..........................................124
CAMSHAFT SPROCKET RUNOUT.........................124
VALVE GUIDE CLEARANCE..................................124
VALVE GUIDE REPLACEMENT..............................125
VALVE SEATS.......................................................126
REPLACING VALVE SEAT FOR SERVICE PARTS..126
VALVE DIMENSIONS.............................................128
VALVE SPRING.....................................................128
VALVE LIFTER......................................................128
Assembly .................................................................129
Installation ................................................................129
CYLINDER HEAD GASKET SELECTION.................130
CYLINDER HEAD BOLT DEFORMATION CHECK...131
CYLINDER HEAD-TO-BLOCK DIFFERENCE
CHECK
.................................................................131
LIQUID GASKET APPLICATION ON REAR CHAIN
CASE
....................................................................131
CYLINDER HEAD INSTALLATION..........................132
GLOW PLUG INSTALLATION.................................132
CAMSHAFT INSTALLATION...................................132
Valve Clearance.......................................................133
CHECKING...........................................................133
ADJUSTING..........................................................134
ENGINE ASSEMBLY...................................................137
Removal and Installation .........................................137
REMOVAL.............................................................138
INSTALLATION......................................................139
CYLINDER BLOCK.....................................................140
Components.............................................................140
Removal and Installation .........................................141
Disassembly.............................................................141
PISTON AND CRANKSHAFT..................................141
Inspection.................................................................144
CRANKSHAFT END PLAY.....................................144
CONNECTING ROD SIDE CLEARANCE.................144
PISTON AND PISTON PIN CLEARANCE................145
PISTON RING SIDE CLEARANCE..........................145
PISTON RING END GAP........................................145
CONNECTING ROD BEND AND TORSION.............146
CYLINDER BLOCK DISTORTION AND WEAR.........146
PISTON-TO-BORE CLEARANCE............................147
CRANKSHAFT.......................................................148
MAIN BEARING HOUSING INNER DIAMETER........149
BEARING CLEARANCE.........................................149
MAIN BEARING CRUSH HEIGHT...........................153
MAIN BEARING CAP BOLT DEFORMATION...........153
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
........................................................153
CONNECTING ROD BOLT DEFORMATION............154
FLYWHEEL RUNOUT............................................154
OIL JET................................................................154
OIL JET RELIEF VALVE.........................................154
Assembly .................................................................155
PISTON................................................................155
CRANKSHAFT.......................................................155
REPLACEMENT OF PILOT BUSHING.....................158
SERVICE DATA AND SPECIFICATIONS (SDS).......160
General Specifications .............................................160
Compression Pressure ............................................160
Belt Deflection..........................................................160
Cylinder Head ..........................................................160
Valve ........................................................................161
VALVE..................................................................161
VALVE CLEARANCE..............................................161
AVAILABLE SHIMS................................................161
VALVE SPRING.....................................................162
VALVE LIFTER......................................................162
VALVE GUIDE.......................................................163
Valve Seat................................................................164
Camshaft and Camshaft Bearing ............................166
Cylinder Block ..........................................................167
Piston, Piston Ring and Piston Pin .........................167
AVAILABLE PISTON..............................................167
PISTON RING.......................................................168
PISTON PIN..........................................................168
Connecting Rod .......................................................168
Crankshaft................................................................168
Available Main Bearing ............................................169
UNDERSIZE..........................................................169
Available Connecting Rod Bearing..........................169
CONNECTING ROD BEARING...............................169
UNDERSIZE..........................................................170
Miscellaneous Components.....................................170
BEARING CLEARANCE.........................................170
CONTENTS(Cont'd)
EM-3