check engine NISSAN ALMERA 2001 Service Manual

CompressorNJHA0174
ModelCALSONIC make CSV613
TypeSwash plate (Variable displacement)
Displacement cm
3(cu in)/rev.6.0 - 125 (0.37 - 7.63)
Direction of rotationClockwise (viewed from drive end)
Drive beltQG engine model: Poly V
YD engine model: Type A
LubricantNJHA0175
ModelCALSONIC make CSV613
NameNissan A/C System Oil Type S
Part numberKLH00-PAGS0
Capacity
m!(Imp fl oz)Total in system 180 - 200 (6.3 - 7.0)
Compressor (Service part) charging amount 180 - 200 (6.3 - 7.0)
RefrigerantNJHA0176
TypeHFC-134a (R-134a)
Capacity kg (lb)0.45 - 0.55 (0.99 - 1.21)
Engine Idling Speed (When A/C is On)NJHA0177+Refer to EC-593 (QG), EC-834 (YD), ªIdle Speed and Ignition Timingº.
Belt TensionNJHA0178+Refer to EM-16 (QG), EM-85 (YD), ªChecking Drive Beltsº.
SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor
HA-97

Electronic fuel injection pump ........ EC-618, 716,
723, 757, 764, 771, 778, 785, 803
Engine compartment ................................. BT-78
Engine control circuit diagram .......... EC-25, 606
Engine control component parts
location .......................................... EC-21, 603
Engine control module (ECM) ....... EC-391, 659,
714, 792, 794, 799, 801
Engine control system diagram and
chart .............................................. EC-29, 608
Engine coolant temperature sensor
(ECTS) ........................................ EC-201, 680
Engine fail-safe system ........................... EC-154
Engine oil precautions .................................. GI-7
Engine outer component parts ................. EM-11
Engine removal ................................ EM-51, 137
Engine room - See Engine
compartment .......................................... BT-78
Engine serial number ................................. GI-41
Evaporative emission (EVAP)
system ................................................... EC-36
Exhaust gas recirculation (EGR)
valve .................................... EC-343, 425, 491
Exhaust system ................................... FE-15, 32
Exterior ...................................................... BT-47
F
F/PUMP - Wiring diagram ....................... EC-563
FR02 - Wiring diagram ... EC-219, 239, 247, 451
FR02/H - Wiring diagram ................ EC-254, 458
FUEL - Wiring diagram ................... EC-299, 307
Fan switch ................................................. HA-54
Final drive (FF A/T) .................................. AT-442
Final drive (FF M/T) .............. MT-44, 77, 93, 107
Finisher, interior - See Trim ....................... BT-31
Finisher, trunk lid ....................................... BT-45
Floor trim ................................................... BT-31
Fluid temperature sensor (A/T) ................ AT-194
Fluids ........................................................ MA-16
Flywheel (clutch) ....................................... CL-22
Flywheel runout ................................ EM-62, 154
Fog lamp, front, removal and
installation ................................................ BT-7
Fog lamp, front .......................................... EL-89
Fork rod (M/T) .............................. MT-32, 56, 94
Forward clutch ......................................... AT-412
Freeze frame data .............................. EC-61, 72
Front axle .................................................... AX-2
Front bumper ............................................... BT-7
Front combination lamp removal and
installation ................................................ BT-7
Front disc brake ........................................ BR-27
Front door .................................................. BT-16
Front fog lamp removal and
installation ................................................ BT-7
Front fog lamp ........................................... EL-89
Front heated oxygen sensor (HO2S)
heater .......................................... EC-252, 457Front heated oxygen sensor (HO2S) ..... EC-216,
224, 230, 236, 245, 450
Front seat belt ............................................. RS-5
Front seat .................................................. BT-56
Front suspension ........................................ SU-2
Front washer ............................................ EL-215
Front wiper ............................................... EL-215
Fuel cut control (at no load & high
engine speed) ............................... EC-36, 612
Fuel gauge ............................................... EL-144
Fuel injection system .............. EC-297, 305, 610
Fuel injector ............................................ EC-541
Fuel precautions ........................................... GI-8
Fuel pressure check ................................. EC-40
Fuel pressure regulator ............................. EC-41
Fuel pressure release ............................... EC-40
Fuel pump relay ...................................... EC-561
Fuel pump ............................................... EC-561
Fuel system ........................................... FE-5, 20
Fuel tank vacuum relief valve ................... EC-37
Fuse block ............................................... EL-577
Fuse ........................................................... EL-38
Fusible link ................................................. EL-38
G
GLOW - Wiring diagram ......................... EC-806
Garage jack and safety stand .................... GI-45
Gauges .................................................... EL-144
Gear components (M/T) ............... MT-31, 55, 93
Generator - See Alternator ....................... SC-31
Generic scan tool (GST) ........................... EC-94
Glass .......................................................... BT-17
Glow plug ................................................ EC-806
Glow relay ............................................... EC-806
Grease ...................................................... MA-16
Ground distribution .................................... EL-39
H
H/LAMP - Wiring diagram ................... EL-60, 61
HEATER - Wiring diagram ........................ HA-24
HFC134a (R134a) system
precaution ................................................ HA-2
HFC134a (R134a) system service
procedure .............................................. HA-78
HFC134a (R134a) system service
tools ....................................................... HA-11
HFC134a system service equipment
precaution ................................................ HA-6
HORN - Wiring diagram .................. EL-234, 235
HSEAT - Wiring diagram ................. EL-288, 290
Harness connector ...................................... EL-6
Harness layout ......................................... EL-522
Hazard warning lamp ................................ EL-96
Headlamp removal and installation ............. BT-7
Headlamp washer .................................... EL-231
Headlamp .................................................. EL-60
ALPHABETICAL INDEX
IDX-4

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
QG
ENGINE LUBRICATION SYSTEM..................................3
Precautions ..................................................................3
LIQUID GASKET APPLICATION PROCEDURE............3
Preparation ..................................................................3
SPECIAL SERVICE TOOLS........................................3
Lubrication Circuit ........................................................4
Oil Pressure Check......................................................5
Oil Pump ......................................................................5
REMOVAL AND INSTALLATION.................................5
DISASSEMBLY AND ASSEMBLY................................6
INSPECTION.............................................................7
REGULATOR VALVE INSPECTION............................8
Changing Engine Oil....................................................8
Changing Oil Filter .......................................................9
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK..........................................10
OIL PUMP INSPECTION..........................................10
REGULATOR VALVE INSPECTION..........................10
OIL CAPACITY........................................................10
ENGINE COOLING SYSTEM........................................ 11
Precautions ................................................................ 11
LIQUID GASKET APPLICATION PROCEDURE.......... 11
Preparation ................................................................ 11
SPECIAL SERVICE TOOLS...................................... 11
Cooling Circuit ...........................................................12
System Check............................................................12
CHECKING COOLING SYSTEM HOSES...................12
CHECKING RADIATOR............................................13
CHECKING RADIATOR CAP....................................13
CHECKING COOLING SYSTEM FOR LEAKS............13
Water Pump ...............................................................14
REMOVAL AND INSTALLATION...............................14
INSPECTION...........................................................14
Thermostat .................................................................15
REMOVAL AND INSTALLATION...............................15
INSPECTION...........................................................16
Radiator .....................................................................16
COMPONENTS.......................................................16
Cooling Fan ...............................................................17
COMPONENTS.......................................................17
CONTROL SYSTEM................................................18
Changing Engine Coolant..........................................18
- DRAINING ENGINE COOLANT -............................18
- REFILLING ENGINE COOLANT -...........................19
- FLUSHING COOLING SYSTEM -............................20
Radiator (Aluminum type) ..........................................21
PREPARATION.......................................................21
DISASSEMBLY........................................................21
ASSEMBLY.............................................................22
INSPECTION...........................................................23
Overheating Cause Analysis .....................................24
Service Data and Specifications (SDS).....................25
THERMOSTAT........................................................25
RADIATOR..............................................................25
COOLANT CAPACITY..............................................25
YD
ENGINE LUBRICATION SYSTEM................................26
Precautions ................................................................26
LIQUID GASKET APPLICATION PROCEDURE..........26
Preparation ................................................................26
SPECIAL SERVICE TOOLS......................................26
Lubrication Circuit ......................................................27
Oil Pressure Check....................................................28
Oil Pump ....................................................................28
REMOVAL AND INSTALLATION...............................28
DISASSEMBLY AND ASSEMBLY..............................29
OIL PUMP INSPECTION..........................................29
REGULATOR VALVE INSPECTION..........................30
Changing Engine Oil..................................................31
Oil Filter Bracket ........................................................32
REMOVAL AND INSTALLATION...............................32
Changing Oil Filter .....................................................32
REMOVAL...............................................................33
INSTALLATION........................................................33
Oil Cooler ...................................................................34
REMOVAL AND INSTALLATION...............................34
Service Data and Specifications (SDS).....................35
OIL PRESSURE CHECK..........................................35

REGULATOR VALVE INSPECTION..........................35
OIL PUMP INSPECTION..........................................35
ENGINE OIL CAPACITY...........................................35
ENGINE COOLING SYSTEM........................................36
Precautions ................................................................36
LIQUID GASKET APPLICATION PROCEDURE..........36
Preparation ................................................................36
SPECIAL SERVICE TOOLS......................................36
Cooling Circuit ...........................................................37
System Check............................................................38
CHECKING COOLING SYSTEM HOSES...................38
CHECKING RADIATOR............................................38
CHECKING RADIATOR CAP....................................38
CHECKING COOLING SYSTEM FOR LEAKS............39
Water Pump ...............................................................39
REMOVAL AND INSTALLATION...............................39
REMOVAL...............................................................40
INSPECTION...........................................................40
INSTALLATION........................................................40
Thermostat .................................................................41
REMOVAL AND INSTALLATION...............................41
INSPECTION...........................................................42
Radiator .....................................................................42
COMPONENTS.......................................................42
REMOVAL AND INSTALLATION...............................43
Cooling Fan ...............................................................43
COMPONENTS.......................................................43
CONTROL SYSTEM................................................43
Changing Engine Coolant..........................................44
- DRAINING ENGINE COOLANT -............................44
- REFILLING ENGINE COOLANT -...........................45
- FLUSHING COOLING SYSTEM -............................46
Radiator (Aluminum type) ..........................................47
Overheating Cause Analysis .....................................47
Service Data and Specifications (SDS).....................48
THERMOSTAT........................................................48
RADIATOR..............................................................48
ENGINE COOLANT CAPACITY................................48
CONTENTS(Cont'd)
LC-2

SEM853F
Oil Pressure CheckNJLC0004WARNING:
+Be careful not to burn yourself, as the engine and oil may
be hot.
+For M/T models, put gearshift lever in Neutral ªNº posi-
tion. For A/T models, put selector lever in Park ªPº posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.
SLC926-A
3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
For Sedan
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
600 More than 69 (0.69, 0.7, 10)
2,000 More than 284 (2.84, 2.9, 41)
6,000 More than 422 (4.22, 4.3, 61)
For Hatchback
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
600 More than 98 (0.98, 1.0, 14)
2,000 More than 294 (2.94, 3.0, 43)
6,000 More than 392 (3.92, 4.0, 57)
+If difference is extreme, check oil passage and oil pump
for oil leaks.
6. Install oil pressure switch with sealant.
: 13 - 17 N´m (1.25 - 1.75 kg-m,9-12ft-lb)
Oil Pump
REMOVAL AND INSTALLATIONNJLC0005+Make sure that O-ring is fitted properly.
1. Drain engine oil.
2. Remove drive belts.
3. Remove oil pan. Refer to EM-20, ªOIL PANº.
4. Remove oil strainer.
5. Remove front cover. Refer to EM-23, ªTIMING CHAINº.
6. Install front cover.
7. Reinstall parts in reverse order of removal.
ENGINE LUBRICATION SYSTEMQG
Oil Pressure Check
LC-5

SEM855F
SEM856F
INSPECTIONNJLC0007Using a feeler gauge, check the following clearances.
Standard clearance:
For Sedan
Unit: mm (in)
Body to outer rotor radial clearance10.114 - 0.200 (0.0045 - 0.0079)
Inner rotor to outer rotor tip clearance
2Below 0.18 (0.0071)
Body to inner rotor clearance30.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor axial clearance40.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of hous-
ing clearance50.045 - 0.091 (0.0018 - 0.0036)
For Hatchback
Unit: mm (in)
Body to outer rotor radial clearance10.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance
2Below 0.18 (0.0071)
Body to inner rotor clearance30.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance40.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of hous-
ing clearance50.045 - 0.091 (0.0018 - 0.0036)
SEM857FA
+If the tip clearance (2) exceeds the limit, replace rotor set.
+If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace front cover assembly.
ENGINE LUBRICATION SYSTEMQG
Oil Pump (Cont'd)
LC-7

SLC986AA
REGULATOR VALVE INSPECTIONNJLC00081. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
If damaged, replace regulator valve set or front cover assem-
bly.
SLC101B
4. Check regulator valve to front cover clearance.
Clearance 6:
For Sedan
0.040 - 0.097 mm (0.0016 - 0.0038 in)
For Hatchback
0.052 - 0.088 mm (0.0020 - 0.0035 in)
If it exceeds the limit, replace front cover assembly.
SMA915C
Changing Engine OilNJLC0035WARNING:
+Be careful not to burn yourself, as the engine oil is hot.
+Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil specification and viscosity:
+API grade SG, SH or SJ
+ILSAC grade GF-I & GF-II
Refer to MA-16, ªRECOMMENDED FLUIDS AND LUBRI-
CANTSº.
Refill oil capacity (Approximate):
Unit:!(Imp qt)
With oil filter change 2.7 (2-3/8)
Without oil filter change 2.5 (2-1/4)
Dry engine (engine overhaul) 3.1 (2-3/4)
CAUTION:
+Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N´m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
+The refill capacity changes depending on the oil tempera-
ture and drain time, use these values as a reference and
be certain to check with the dipstick when changing the
oil.
ENGINE LUBRICATION SYSTEMQG
Oil Pump (Cont'd)
LC-8

SMA390C
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
ALC094
Changing Oil FilterNJLC0010The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
+Use Tool KV10115801 for removing oil filter.
SLC275B
1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
SMA010
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
SMA229B
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
+Clean excess oil from engine.
ENGINE LUBRICATION SYSTEMQG
Changing Engine Oil (Cont'd)
LC-9

Service Data and Specifications (SDS)
OIL PRESSURE CHECKNJLC0011
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Sedan Hatchback
600 More than 69 (0.69, 0.7, 10) More than 98 (0.98, 1.0, 14)
2,000 More than 284 (2.84, 2.9, 41) More than 294 (2.94, 3.0, 43)
6,000 More than 422 (4.22, 4.3, 61) More than 392 (3.92, 4.0, 57)
OIL PUMP INSPECTIONNJLC0013Unit: mm (in)
Model Sedan Hatchback
Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079) 0.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor clearance 0.030 - 0.070 (0.0012 - 0.0028) 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of housing clear-
ance0.045 - 0.091 (0.0018 - 0.0036)
REGULATOR VALVE INSPECTIONNJLC0012Unit: mm (in)
Model Sedan Hatchback
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0382) 0.052 - 0.088 (0.0020 - 0.0035)
OIL CAPACITYNJLC0036Unit:!(Imp qt)
With oil filter change2.7 (2-3/8)
Without oil filter change2.5 (2-1/4)
Dry engine (engine overhaul)3.1 (2-3/4)
ENGINE LUBRICATION SYSTEMQG
Service Data and Specifications (SDS)
LC-10

Cooling CircuitNJLC0016
SLC317B
System CheckNJLC0017WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid escaping from the
radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap
by turning it all the way.
CHECKING COOLING SYSTEM HOSESNJLC0017S01Check hoses for the following:
+Improper attachment
+Leaks
+Cracks
+Damage
+Loose connections
+Chafing
+Deterioration
ENGINE COOLING SYSTEMQG
Cooling Circuit
LC-12