steering NISSAN ALMERA 2001 Workshop Manual

Belt deflection:
Unit: mm (in)
Applied engineUsed belt deflection
Deflection
of new belt
LimitDeflection
after
adjustment
AlternatorWith air
conditioner
compressorQG15´18DE 8.1 (0.319)5.3 - 5.7
(0.209 -
0.224)4.5 - 5.0
(0.177 -
0.197)
Without air
conditioner
compressorQG15´18DE10.2
(0.402)6.5 - 7.0
(0.256 -
0.276)5.5 - 6.1
(0.217 -
0.240)
Power steering oil
pumpSedan with
QG15DE8.5 (0.335)5.2 - 5.8
(0.205 -
0.228)4.6 - 5.2
(0.181 -
0.205)
Except for
Sedan with
QG15DE7.1 (0.280)4.4 - 4.9
(0.173 -
0.193)3.9 - 4.4
(0.154 -
0.173)
Applied pushing force 98 N (10 kg, 22 lb)
Inspect drive belt deflections when engine is cold.
DRIVE BELTSQG
Checking (Cont'd)
EM-17

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

SEM909F
ReplacementNJEM0015VALVE OIL SEALNJEM0015S011. Remove rocker cover.
2. Remove camshaft.
3. Remove valve spring. Refer to EM-37.
4. Remove valve oil seal with Tool.
Piston concerned should be set at TDC to prevent valve from
falling.
SEM910F
5. Apply new engine oil to new valve oil seal and install it with
Tool.
SEM911F
FRONT OIL SEALNJEM0015S021. Remove the following parts:
+Engine under cover
+RH engine side cover
+Alternator and power steering drive belts
+Crankshaft pulley
2. Remove front oil seal from front cover.
+Be careful not to scratch front cover.
SEM715A
SEM912F
3. Apply new engine oil to new oil seal and install it using a suit-
able tool.
+Install new oil seal in the direction shown.
OIL SEALQG
Replacement
EM-32

WARNING:
+Position vehicle on a flat and solid surface.
+Place chocks at front and back of rear wheels.
+Do not remove engine until exhaust system has com-
pletely cooled off, otherwise, you may burn yourself
and/or fire may break out in fuel line.
+Before disconnecting fuel hose, release pressure.
Refer to EC-40, ªFuel Pressure Releaseº.
+Be sure to lift engine and transaxle in a safe manner.
+For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
+When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.
+When lifting the engine, always use engine slingers in a
safe manner.
+When removing drive shaft, be careful not to damage
grease seal of transaxle.
+Before separating engine and transaxle, remove crank-
shaft position sensor (POS) from the cylinder block
assembly.
+Always be extra careful not to damage edge of crankshaft
position sensor (POS), or signal plate teeth.
Engine cannot be removed separately from transaxle. Remove
engine with transaxle as an assembly.
REMOVALNJEM0022S011. Drain coolant from radiator and cylinder block. Refer to LC-18,
ªChanging Engine Coolantº.
2. Remove coolant reservoir tank and bracket.
3. Drain engine oil.
4. Remove battery and battery tray.
5. Remove air cleaner and air duct.
6. Remove drive belts.
7. Remove alternator and air conditioner compressor from
engine.
8. Remove power steering oil pump from engine and position
aside.
Power steering oil pump does not need to be disconnected
from power steering tubes.
ENGINE ASSEMBLYQG
Removal and Installation (Cont'd)
EM-52

Belt DeflectionNJEM0045Unit: mm (in)
Applied engineUsed belt deflection
Deflection of new belt
LimitDeflection after adjust-
ment
AlternatorWith air conditioner
compressorQG15´18DE 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)
Without air conditioner
compressorQG15´18DE 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
Power steering oil pumpSedan with QG15DE 8.5 (0.335)5.2 - 5.8
(0.205 - 0.228)4.6 - 5.2
(0.181 - 0.205)
Except for Sedan with
QG15DE7.1 (0.280)4.4 - 4.9
(0.173 - 0.193)3.9 - 4.4
(0.154 - 0.173)
Applied pushing force 98 N (10 kg, 22 lb)
Spark PlugNJEM0046
NGK Champion
TypeStandard BKR5E-11 RC10YC4
Hot BKR4E-11 Ð
Cold BKR6E-11 Ð
Plug gap mm (in)1.0 - 1.1 (0.039 - 0.043)
Cylinder HeadNJEM0030Unit: mm (in)
Standard Limit
Head surface flatness Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.8 - 118.0 (4.638 - 4.646) Ð
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Belt Deflection
EM-67

JEM121G
3. Remove front chain case.
+Move power steering fluid reservoir tank from the bracket.
+Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
+Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
SEM514G
CAUTION:
+While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
+Do not remove two mass dampers on the back of cover.
SEM515G
4. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
+No position indicator is provided on the crankshaft pulley.
+When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
JEM124G
5. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
JEM125G
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
remove bolts to remove chain tensioner.
TIMING CHAINYD
Secondary Timing Chain (Cont'd)
EM-95

JEM134G
9. Remove chain tensioner.
+When removing chain tensioner, push the sleeve of chain ten-
sioner and keep it pressed with a push pin, etc.
10. Remove timing chain slack guide.
JEM135G
11. Hold fuel injection pump sprocket and remove bolt.
a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel injection pump sprocket.
b. Using a TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel injection pump sprocket so that the
holes align.
c. Push positioning stopper pin (SST) through pump sprocket to
fuel injection pump body to hold pump sprocket, and remove
bolt.
JEM136G
12. Remove primary timing chain with fuel injection pump sprocket
and crankshaft sprocket.
JEM137G
13. Remove chain guide and tension guides.
14. Remove fuel injection pump.
15. Remove power steering pump.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-101

JEM137G
2. Install power steering pump.
3. Install fuel injection pump.
+Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM136G
6. Install primary timing chain with fuel injection pump sprocket.
+When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
+Install fuel injection pump sprocket washer with the surface
marked ªFº (front mark) facing the front of the engine.
7. Install timing chain onto power steering pump sprocket and
through chain guide.
JEM135G
8. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt.
+Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt.
JEM134G
9. Install timing chain slack guide.
10. Install chain tensioner.
+Push the plunger of the chain tensioner. While keeping plunger
pressed down with a push pin, etc., install the chain tensioner.
+After installation, pull out the push pin holding the plunger.
+Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
JEM142G
11. Install front oil seal to oil pump.
+Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
+Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-104

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) as shown in
the figure.
+Apply liquid gasket on oil pump-side surface.
JEM144G
13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM145G
b. Install oil pump drive spacer to crankshaft.
+Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
JEM133G
d. Install oil pump.
+When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
+When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM146G
14. Check gaps on upper oil pan mounting surface.
+Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
±0.14 to 0.14 mm (±0.0055 to 0.0055 in)
Rear chain case and cylinder block
±0.25 to 0.13 mm (±0.0098 to 0.0051 in)
+If the measured value is out of the above range, install again.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-105