lock NISSAN ALMERA 2001 Service Manual

Code Section Wiring Diagram Name
MULTI EL Multi-remote Control System
NATS EL Nissan Anti-Theft System
NAVI EL Navigation System
NONDTC AT Non-detectable Items
O2H1B1 EC Front Heated Oxygen Sensor Heater
(E-OBD)
O2H2B1 EC Rear Heated Oxygen Sensor Heater
(E-OBD)
O2S1B1 EC Front Heated Oxygen Sensor
(E-OBD)
O2S2B1 EC Rear Heated Oxygen Sensor
(E-OBD)
OVRCSV AT Overrun Clutch Solenoid Valve
P/ANT EL Power Antenna
PGC/V EC EVAP Canister Purge Volume Con-
trol Solenoid Valve
PHASE EC Camshaft Position Sensor (PHASE)
PNP/SW EC Park/Neutral Position Switch
PNP/SW AT Park/Neutral Position Switch
POS EC Crankshaft Position Sensor (POS)
POWER EL Power Supply Routing
PST/SW EC Power Steering Oil Pressure Switch
R/FOG EL Rear Fog Lamp
ROOM/L EL Interior Room Lamp
RRO2 EC Rear Heated Oxygen Sensor (Non
E-OBD)
RRO2/H EC Rear Heated Oxygen Sensor Heater
(Non E-OBD)
S/SIG EC Start Signal
SHIFT AT A/T Shift Lock System
S/LOCK EL Power Door Lock Ð Super Lock Ð
SROOF EL Sunroof
SRS RS Supplemental Restraint System
SSV/A AT Shift Solenoid Valve A
SSV/B AT Shift Solenoid Valve B
START SC Starting System
STOP/L EL Stop Lamp
SWL/C EC Swirl Control Valve Control Solenoid
Valve (Non E-OBD)
SWL/V EC Swirl Control Valve Control Solenoid
Valve (E-OBD)
TAIL/L EL Parking, License and Tail LampsCode Section Wiring Diagram Name
TCV AT Torque Converter Clutch Solenoid
Valve
THEFT EL Theft Warning System
TLID EL Trunk Lid Opener
TP/SW EC Throttle Position Switch
TPS AT Throttle Position Sensor
TPS EC Throttle Position Sensor
TURN EL Turn Signal and Hazard Warning
Lamps
VSS EC Vehicle Speed Sensor
VSSA/T AT Vehicle Speed Sensor A/T (Revolu-
tion Sensor)
VSSMTR AT Vehicle Speed Sensor MTR
WARN EL Warning Lamps
WINDOW EL Power Window
WIP/R EL Rear Wiper and Washer
WIPER EL Front Wiper and Washer
WIRING DIAGRAM CODES (CELL CODES)
EL-576

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

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

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

NJEM0005
NVH Troubleshooting Ð Engine NoiseNJEM0005S01Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
Engine
Rocket
Cover Cyl-
inder HeadTicking or
clickC A Ð A B Ð Tappet
noise+Valve clearance EM-44
Rattle C A Ð A B C Camshaft
bearing
noise+Camshaft journal
clearance
+Camshaft runoutEM-38
Crankshaft
Pulley
Cylinder
block (Side
of Engine)
Oil panSlap or
knockÐ A Ð B B Ð Piston pin
noise+Piston and piston pin
clearance
+Connecting rod bush-
ing clearanceEM-56, 61
Slap or
rapA Ð Ð B B A Piston slap
noise+Piston-to-bore clear-
ance
+Piston ring side clear-
ance
+Piston ring end gap
+Connecting rod bend
and torsionEM-56, 57,
58
Knock A B CB B B Connecting
rod-bearing
noise+Connecting rod bear-
ing clearance (Big
end)
+Connecting rod bush-
ing clearance (Small
end)EM-60, 61
Knock A B Ð A B C Main bear-
ing noise+Main bearing oil clear-
ance
+Crankshaft runoutEM-59
Front of
Engine Tim-
ing Chain
CoverTapping or
tickingAAÐBBBTiming
chain and
chain ten-
sioner noise+Timing chain cracks
and wear
+Timing chain tensioner
operationEM-27
Front of
EngineSqueak or
fizzingA B Ð B Ð C Other drive
belts (stick-
ing or slip-
ping)+Drive belts deflection EM-16
CreakingABABABOther drive
belts (slip-
ping)+Idler pulley bearing
operation
Squall or
creakABÐBABWater pump
noise+Water pump operation LC-14
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGQG
NVH Troubleshooting Ð Engine Noise
EM-9

SEM071FA
SEM110G
6. Remove engine gussets.
Refer to MT-24 or AT-355, ªInstallationº.
7. Remove rear plate cover (A/T models).
SEM365EB
8. Remove oil pan.
a. Insert Tool between cylinder block and oil pan.
1)Be careful not to damage aluminum mating face.
Do not insert screwdriver, or oil pan flange will be dam-
aged.
b. Slide Tool by tapping on the side of the Tool with a hammer.
SEM295C
InstallationNJEM00101. Use a scraper to remove old liquid gasket from mating surface
of oil pan.
+Also remove old liquid gasket from mating surface of cyl-
inder block.
SEM015E
2. Apply a continuous bead of liquid gasket to mating surface of
oil pan.
+Use Genuine Liquid Gasket or equivalent.
+Apply to groove on mating surface.
+Allow 7 mm (0.28 in) clearance around bolt holes.
OIL PANQG
Removal (Cont'd)
EM-21

ComponentsNJEM0011
YEM012
1. Chain tensioner
2. Camshaft sprocket (Intake)
3. Camshaft sprocket (Exhaust)
4. O-ring
5. Slack side timing chain guide
6. Timing chain tension guide7. Timing chain
8. Crankshaft sprocket
9. Oil pump drive spacer
10. Front cover
11. O-ring
12. Oil seal13. Crankshaft pulley
14. Cylinder head front cover
15. Camshaft position sensor
(PHASE)
16. Cylinder block dowels
TIMING CHAINQG
Components
EM-23

CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing chain tensioner, oil seats, or other sliding
parts, lubricate contacting surfaces with new engine oil.
+Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
+When removing oil pump assembly, remove camshaft
position sensor (PHASE), then remove timing chain from
engine.
+Be careful not to damage sensor edges.
SEM869F
RemovalNJEM01051. Drain engine coolant from radiator and cylinder block.
Be careful not to spill coolant on drive belts.
2. Remove reservoir tank.
3. Release fuel pressure.
Refer to EC-40, ªFuel Pressure Releaseº.
4. Remove the following belts.
+Power steering pump drive belt
+Alternator drive belt
5. Remove front right-side wheel.
6. Remove front/right splash undercover.
7. Remove front exhaust tube.
SEM870F
8. Remove vacuum hoses, fuel hoses, and so on.
9. Remove ignition coils.
10. Remove spark plugs.
SEM102G
11. Remove rocker cover bolts in numerical order as shown in the
figure.
TIMING CHAINQG
Components (Cont'd)
EM-24

SEM104G
27. Remove RH engine mounting bracket.
28. Remove idler pulley and bracket.
SEM883F
29. Remove water pump pulley and water pump.
30. Remove front cover bolts and front cover as shown.
H1: Located on water pump
H2: Located on power steering pump adjusting bar
+Inspect for oil leakage at front oil seal. Replace seal if oil leak
is present.
SEM884F
SEM897F
31. Remove timing chain.
32. Remove oil pump drive spacer.
33. Remove chain guides.
34. Remove crankshaft sprocket.
35. Remove O-rings from cylinder block and front cover.
SEM885F
InspectionNJEM0106Check for cracks and excessive wear at roller links. Replace
if necessary.
TIMING CHAINQG
Removal (Cont'd)
EM-27

SEM886F
InstallationNJEM01071. Install crankshaft sprocket on crankshaft.
+Make sure mating marks on crankshaft sprocket face front
of engine.
SEM890F
2. Position crankshaft so that No. 1 piston is at TDC and key way
is at 12 o'clock.
SEM891F
3. Install slack side timing chain guide and timing chain tension
guide.
SEM892F
4. Install timing chain on crankshaft sprocket.
+Support chain with a suitable tool to keep the mating mark
aligned.
+Set timing chain by aligning its mating mark with that on
the crankshaft sprocket.
+Make sure sprocket's mating mark faces engine front.
SEM905F
5. Install camshaft sprocket.
+Set timing chain by aligning mating marks with those of
camshaft sprockets.
TIMING CHAINQG
Installation
EM-28