service indicator NISSAN ALMERA 2001 User Guide

Pin and Pin BootNJBR0041S0104Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
SBR219C
ROTORNJBR0041S02Rubbing SurfaceNJBR0041S0201Check rotor for roughness, cracks or chips.
RunoutNJBR0041S02021. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (ªREAR WHEEL
BEARINGº, ªOn-vehicle Serviceº).
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
ThicknessNJBR0041S0203Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
SBR247B
AssemblyNJBR00421. Insert cam with depression facing towards open end of cylin-
der.
REAR DISC BRAKE (CAM & STRUT TYPE)
Inspection (Cont'd)
BR-39

SBR219C
ROTORNJBR0145S02Rubbing SurfaceNJBR0145S0201Check rotor for roughness, cracks or chips.
RunoutNJBR0145S02021. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (ªREAR WHEEL
BEARINGº, ªOn-vehicle Serviceº).
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
ThicknessNJBR0145S0203Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
NBR374
NBR375
InstallationNJBR0146CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Do not drain (factory) filled brake fluid from (new) caliper
assemblies.
1. Install caliper assembly.
+As shown in the figure, align the piston's concave to the pad's
convex, then install the cylinder body to the torque member.
2. Remove the plug from the cylinder body and brake hose.
CAUTION:
Care should be taken as not to let:
+Air enter the cylinder body and brake hose.
+Brake fluid spill from the cylinder body and brake hose.
3. Install brake hose to caliper securely.
4. Install all parts and secure all bolts.
5. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
REAR DISC BRAKE (BALL & RAMP TYPE)
Inspection (Cont'd)
BR-46

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

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

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

Inspection ProcedureNJEC0593
1 INSPECTION START
1. Visually check the following:
+Air cleaner clogging
+Hoses and ducts for leaks
+EGR valve operation
+Electrical connectors
+Gasket
+Throttle valve and throttle position sensor operation
2. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge.
Ensure engine stays below 1,000 rpm.
SEF090Y
3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.
SEF977U
4. Make sure that no DTC is displayed with CONSULT-II or GST.
OK or NG
OK©GO TO 3.
NG©GO TO 2.
2 REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding ªDiagnostic Procedureº.
©GO TO 3.
BASIC SERVICE PROCEDUREQG
Inspection Procedure
EC-47

26 CHECK ªCOº %
1. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge.
SEF090Y
2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.
SEF978U
3. Check ªCOº %.
Idle CO:3-11%
4.
Without CONSULT-II
After checking CO%,
a. Disconnect the resistor from terminals of engine coolant temperature sensor.
b. Connect engine coolant temperature sensor harness connector to engine coolant temperature sensor.
OK or NG
OK©GO TO 27.
NG©GO TO 28.
BASIC SERVICE PROCEDUREQG
Inspection Procedure (Cont'd)
EC-55

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.
JEF352Y
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.
JEF353Y
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.
JEF354Y
7. Remove the chain tensioner.
a. Push the plunger of the chain tensioner, then fix it with a tool
such as a push pin.
JEF355Y
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

VALVE SEAT RESURFACE LIMITNJEM0031S08Unit: mm (in)
AEM343
Depth (L)Intake 35.95 - 36.55 (1.4154 - 1.4390)
Exhaust 35.92 - 36.52 (1.4142 - 1.4378)
Camshaft and Camshaft BearingNJEM0032Unit: mm (in)
Engine modelQG18DE with intake valve timing con-
trolExcept for QG18DE with intake valve
timing control
Cam height ªAºIntake 40.610 - 40.800 (1.5988 - 1.6063) 39.880 - 40.070 (1.5701 - 1.5776)
Exhaust 40.056 - 40.246 (1.5770 - 1.5845)
Cam wear limit0.20 (0.0079)
EM671
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059)
Inner diameter of camshaft bearingNo. 1 28.000 - 28.021 (1.1024 - 1.1032)
Ð
No. 2 to No. 5 24.000 - 24.021 (0.9449 - 0.9457)
Outer diameter of camshaft journalNo. 1 27.935 - 27.955 (1.0998 - 1.1006)
Ð
No. 2 to No. 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.1 (0.004)
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.20 (0.0079)
*Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Valve (Cont'd)
EM-72

Connecting RodNJEM0035Unit: mm (in)
Center distance140.45 - 140.55 (5.5295 - 5.5335)
Bend limit [per 100 (3.94)]0.15 (0.0059)
Torsion limit [per 100 (3.94)]0.3 (0.012)
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 0.5 (0.020)
*After installing in connecting rod
CrankshaftNJEM0036Unit: mm (in)
Main journal dia. ªDmºGrade 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. ªDpºGrade 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)
Center distance ªrº43.95 - 44.05 (1.7303 - 1.7342)
Out-of-round (X þ Y)Standard Less than 0.003 (0.0001)
Limit Less than 0.005 (0.0002)
Taper (A þ 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 - 0.220 (0.0024 - 0.0087)
Limit 0.3 (0.012)
*: Total indicator reading
Main BearingNJEM0037STANDARDNJEM0037S01
Grade No. Thickness ªTº mm (in) Identification color
0 1.826 - 1.830 (0.0719 - 0.0720) Black
1 1.830 - 1.834 (0.0720 - 0.0722) Brown or 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
UNDERSIZENJEM0037S02Unit: mm (in)
Thickness ªTº
0.25 (0.0098) 1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Connecting Rod
EM-75