fuel pressure NISSAN ALMERA 2001 Repair Manual

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

NJEM0053
JEM111G
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-10, ªTrouble Diagnosis Ð
INDEXº.
+Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
+Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
+Carefully remove glow plugs to prevent any damage or
breakage.
+Handle with care to avoid applying any shock to glow
plugs.
SEM112G
7. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
+Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
3,138 (31.38, 32.0, 455)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
+When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
+If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin-
der block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Install glow plugs.
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-83

d. Install fuel injection pump fuse [ENG CONT2 (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self- diagnosis. Refer to EC-10, ªTrouble Diagnosis Ð
INDEXº.
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-84

JEM193G
d. Hoist up engine and install it on the engine stand (SST).
+Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
+Exhaust manifold
+Turbocharger assembly
+Injection tube
+Intake manifold
+Oil pan (upper and lower)
+Secondary timing chain
+Fuel injection pump
+Primary timing chain
+Rocker cover
+High pressure injection nozzle assembly
+Camshaft
+Cylinder head
+Thermostat, water pipes
+Oil cooler
+Auxiliary component brackets
5. Remove fuel injection pump bracket.
SEM500G
6. If the replacement of pilot bushing is necessary, remove it with
pilot bushing puller (SST).
7. Remove rear oil seal retainer.
+Insert a flat-bladed screwdriver between main bearing cap and
rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
+Punch out with a flat-bladed screwdriver.
+Be careful not to damage rear oil seal retainer.
JEM195G
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
+Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-144, ªCONNECT-
ING ROD SIDE CLEARANCEº.
10. Remove connecting rod bearings from connecting rod and
connecting rod cap.
CYLINDER BLOCKYD
Disassembly (Cont'd)
EM-142

SMA803A
Checking Fuel LinesNJFE0009Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
Removal and InstallationNJFE0004WARNING:
When replacing fuel line parts, be sure to observe the following.
+Put a ªCAUTION: FLAMMABLEº sign in workshop.
+Be sure to furnish workshop with a CO
2fire extinguisher.
+Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
+Before removing fuel line parts, carry out the following procedures:
a) Put drained fuel in an explosion-proof container and put the lid on securely.
b) Release fuel pressure from fuel line. Refer to EC-40, ªFuel Pressure Releaseº.
c) Disconnect battery ground cable.
+Always replace O-ring and clamps with new ones.
+Do not kink or twist tubes when they are being installed.
+Do not tighten hose clamps excessively to avoid damaging hoses.
+After installing tubes, run engine and check for fuel leaks at connections.
FUEL SYSTEMQG
Checking Fuel Lines
FE-5

SFE649A
JFE613A
REMOVALNJFE0006S01For SedanNJFE0006S01011. Release fuel pressure from fuel line.
Refer to EC-40, ªFuel Pressure Releaseº.
2. Disconnect battery ground cable.
3. Open fuel filler lid and filler cap.
4. Drain fuel from fuel tank.
5. Remove rear seat cushion. Refer to BT-60, ªRemoval and
Installationº.
6. Remove inspection hole cover under the rear seat.
FUEL SYSTEMQG
Fuel Tank (Cont'd)
FE-7

Fuel Pump, Fuel Level Sensor Unit and Fuel
Filter
NJFE0007
SFE671A
JFE613A
REMOVALNJFE0007S01For SedanNJFE0007S01011. Release fuel pressure from fuel line.
Refer to EC-40, ªFuel Pressure Releaseº.
2. Disconnect battery ground cable.
3. Open fuel filler lid and filler cap.
4. Remove rear seat cushion. Refer to BT-60, ªRemoval and
Installationº.
5. Remove inspection hole cover under the rear seat.
JFE608A
6. Disconnect electrical connector.
7. Disconnect the quick connectors.
+For disconnect of quick connectors, refer to step 8. of ªFuel
Tank Removalº.
8. Remove the six screws and retainer.
CAUTION:
Use genuine bolts only when fixing retainer.
FUEL SYSTEMQG
Fuel Pump, Fuel Level Sensor Unit and Fuel Filter
FE-12

SMA803A
Checking Fuel LinesNJFE0019Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.
If necessary, repair or replace.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
SMA794C
Water Draining from Fuel FilterNJFE0028DRAINING WATERNJFE0028S01Open drain valve at the bottom of fuel filter.
FUEL FILTER CHECKNJFE0028S02Check fuel filter for fuel leakage, damage and other abnormal
sings.
JFE598A
Changing Fuel FilterNJFE0021REMOVALNJFE0021S011. Take out air duct and upper air cleaner case.
2. Remove connector from water in fuel filter sensor.
3. Remove fuel filter using a fuel filter wrench (commercial ser-
vice tool).
CAUTION:
Do not spill the fuel during removal. If the fuel is spilt, imme-
diately wipe it off. Be especially careful to prevent the fuel
from adhering to the insulators of the engine mounts.
4. Remove water in fuel filter sensor from fuel filter.
FUEL SYSTEMYD
Checking Fuel Lines
FE-20

Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically. Continued refueling may cause fuel
overflow, resulting in fuel spray and possibly a fire.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do
not carelessly disconnect the harness connectors which are
related to the engine control system and TCM (Transmission
Control Module) system. The connectors should be discon-
nected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
SGI787
PRECAUTIONS FOR MULTIPORT FUEL INJECTION
SYSTEM OR ENGINE CONTROL SYSTEM
NJGI0001S04+Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to ªOFFº position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
+Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
+Be careful not to jar components such as ECM and mass air
flow sensor.
PRECAUTIONS FOR THREE WAY CATALYSTNJGI0001S05If a large amount of unburned fuel flows into the catalyst, the cata-
lyst temperature will be excessively high. To prevent this, follow the
instructions below:
+Use unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
+When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
+Do not run engine when the fuel tank level is low, otherwise the
engine may misfire, causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flammable
material off the exhaust pipe and the three way catalyst.
SMA019D
PRECAUTIONS FOR HOSESNJGI0001S06Hose Removal and InstallationNJGI0001S0601+To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
PRECAUTIONS
Precautions (Cont'd)
GI-6

NJGI0011
ISO 15031-2 Terminology ListNJGI0011S01All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure sensor BARO sensor ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List
GI-50