tow NISSAN ALMERA N15 1995 Workshop Manual

InjectionpumppUlley
TIMING
BELT
[fQ]

Injection PumpTiming Belt(Cont'd)

3. Remove timingbelt.
1) Loosen tensioner locknutand turn tensioner clockwise to
free beltfrom tension. Thentemporarily tightentensioner
nut.
2) Remove timingbelt.

INSTAllATION

1. Confirm thatNO.1 piston isset atTDC onitscompression
stroke. (TDCisindicated bycrankshaft pulleynotchwithout
painted mark.)
• Ifinjection pumppulley wasremoved, confirmthatitis
re-installed asillustrated.

Identification ofalignment:
Use mark "A"

2. Set timing belt.

a. Align white linesontiming beltwith punchmarks oncam-
shaft sprocket andinjection pumpsprocket.
b. Point arrow ontiming belttoward beltcover.

3. Adjust belttension.
1) Loosen tensioner locknuttoapply tension totiming belt.
2) Rotate crankshaft clockwisetwoturns.

Do not turn crankshaft bycamshaft sprockets.

3) Tighten tensioner locknutwhile holding tensioner witha
screwdriver.

Belt tension:
147:l:49 N(15:l:5 kg,33:l:11 Ib)

INSPECTION

Refer toINSPECTION in"Camshaft TimingBelt"(EM-122).

INJECTION TIMINGADJUSTMENT

Refer toEC section.

EM-125
•

OILSEAL REPLACEMENT

Install newvalve oilseals forNo.1 andNO.4 cylinders as
illustrated. Reinstallvalvesprings. (narrowpitchside
toward cylinder head)
Install valvespring retainers onintake valves andvalve
rotators onexhaust valves,andremount valveassembly.
Set NO.2 cylinder at
TOG.

Replace valveoilseals forNo.2 andNo.3 cylinders accord-
ing tosteps 2)and 3).
Install valvelifters inoriginal positions.
5.
Remove valveliftersandmark order No.oneach lifter.
6. Replace valveoilseal according tothe following procedure.

When replacing valveallseal, setthe corresponding pistonat
TOe. Failure todo socauses thevalve todrop intothecylin-
der.
1) Set NO.1 cylinder at
TOG.

2) Remove valvesprings andvalve oilseals forNO.1 andNo.
4 cylinders. Valvespring seatsshould notberemoved.

VALVE
OilSEAL

1. Remove bothtiming belts.
2. Remove camshaft sprockets andback covers.
3. Remove camshaft bracketsbyloosening bracketnutsfrom
center tooutside intwo orthree stages.
4. Remove camshaft oilseals andcamshaft.

3)

+0.3
15.2 -0.3
mm

(0598
+0.012
In)

4)

. -0.012

5)

6)
~ 7)
SEM512D
Engine
/'t

inside
Y
r-l'\.
Engine
LV outside CAMSHAFT
ANDCRANKSHAFT OilSEAL INSTALLING
DIRECTION ANDMANNER
• When installing camshaftandcrankshaft oilseals, becare-
ful toinstall themcorrectly, asshown inthe figure.
• Apply engine oiltooil seal lip,outer face,camshaft and
bracket. .
• Wipe offexcess allafter installing oilseal.
Oil seal lip Dust
seallip
SEM715A CAMSHAFT OilSEALS

1. Remove timingbelts,sprockets andback covers.
2. Pull outoilseal withasuitable tool.

EM-126

SEM202
SEM731BA

Grade number
Tightening sequence

r
1
@@
~.~.~

o
,..0
W

@
@ @
Facing frontofengine
(position 2)

SEM528DCYLINDER
HEAD
[£Q]

Inspection {Cont'd)

4. Remove cambracket capsandmeasure maximum widthof
plastigage. Camshaft bearingclearance:
Limit
0.1 mm (0.004 in)

5. Ifclearance appearstoexceed thelimit, replace camshaft
or cylinder head.
• Which partstobe replaced shouldbedecided uponafter
measuring thediameters ofthe parts concerned.

Assembly
1. Install valvecomponent parts.
Install valvespring withitsnarrow pitchsidetoward cylinder
head side.
• Always installnewvalve oilseals.
Refer tooil seal replacement.
• Before installing oilseal, install valve-spring seat.
• When installing valve,applyengine oilonthe valve stem
and lipofvalve oilseal.
• Check whether thevalve faceisfree from foreign matter.
• Install valvespring retainers onthe intake sideandvalve
rotators onthe exhaust side.
• Valve rotators cannotbedisassembled.
2. Install camshaft andbrackets andtighten bracket nutstothe
specified torqueintwo orthree stages.
Camshaft-bracket nuts:
~: 18-22 N'm (1.8-2.2 kg-m, 13-16 ft-Ib)
• Tighten bracketfromcenter tooutside.
• Apply sealant tobrackets No.1and No.5.
• When installing "brackets, setcamshaft sothat thepinof
camshaft fronthead isuppermost.
• Install newcamshaft oilseals.
Refer tooil seal replacement.

17.5 (0.689)

o

o
13.0
(0.512)

NO.1 journal bracket No.5journal bracket
Unit: mm(in)
SEM676D
EM-136

SEC.112 ENGINE
REMOVAL

~~ 44.54(4.5.5.5,33 -40)
~44 .54 (4.5 .5.5, 33.40) ~~
~ 44•54 (4.5 .5.5, 33•40)"\ ~
-~1J.
~1

~~' ~64.74,

_' 2
(6.5.7.5, / \
~ 47.54),/'
rJ44. 54(4.5.5.5,33 -40) ~\
'" ~~~44.54 \....

.- ,9
(4.5.5.5,
ttJJ 44-54 (4.5 •5.5, 33-40)
7
ttJJ64.75 ------~

@--."
('.5•7.5, 4~' \
y~

~~.~~ ~~f;fi\
~~~'~i':-l~"

k(j' --.
II!~o' ~

/'Oolk..,
ttJJ64.75 (6.5•7.5, 47•54) ~
~'o
@\
8,.'~

~- I
2
rJ64. 75(6.5 .7.5,47.54)..1"""-../
~2ft -."~
°
>

~44. 54
~@
ttJJ44.54(4.5 -5.5, 33. 40)
j~~~1 ~-/.~/

(4.5 -5.5, 33•40)
ti ~~
44•54
~'@
A

5~'
!-'~
~35'-4~.)5'~ ~/
,0
7

~ I~. '
.Vi
rJ44.54(4.5.5.5,33.40)

~ ~l
ttJJ44•54 (4.5 •5.5, 33•40)

~ 'l
o.o~

I...",;S'"
1.
..J'-;:7o
6
ttJJ44.54 (4.5 •5.5, 33•40)

~l \

'LrJ 44•54 (4.5 -5.5, 33•40)
ttJJ 44.54 (4.5 .5_5, 33.40)

rJ
N.m(kg-m. ft-Ibl

G)
Engine frontmounting

@
Engine mounting bracket

@
Gusset

@
Buffer rodbracket
@

Buffer rod

@
Center member

(J)
Transaxle mounting

@
Transaxle mountingbracket
SEM050F

@
Rolldamper

@)
Engine rearmounting

@
Engine rearmounting bracket

@
Dynamic damper

WARNING:
• Situate vehicle onaflat and solid surface.
• Place chocks atfront andback ofrear wheels.
• Donot remove engineuntilexhaust systemhascompletely
cooled off.Otherwise, youmay burn yourself and/orfire
may break outin.the fuel line.
• For safety during subsequent steps,thetension ofwires
should beslackened againsttheengine.
• Before removing frontaxlefrom transaxle, placesafety
stands underdesignated frontsupporting points.RefertoGI
section forlifting points andtowing.
• Besure tohoist engine andtransaxle inasafe manner.
• For engines notequipped withengine slingers, attach
proper slingers andbolts described inPARTS CATALOG.
CAUTION:
• When liftingengine, besure toclear surrounding parts.
Take special careforaccelerator wirecasing, brakelines
and brake master cylinder.
• Inhoisting theengine, alwaysuseengine slingers inasafe
manner.
• Inremoving driveshaft, becareful nottodamage transaxle
oil seal.

EM-140

CYLINDERBLOCK

Inspection (Cont'd)

Front
0000

•

SEM1768

Reboring1. The size towhich cylinders mustbehoned, isdetermined
by adding piston-to-cylinder clearancetothe piston skirt
diameter" A".
Dimension "a":
Approximately 62mm (2.44 in)
Rebored sizecalculation

o
=
A
+
B-C
=
A
+
[0.03 to0.05 mm
(0.0012 to0.0020 in)]
where,

o

A B

C
Honed
diameter
Skirt diameter asmeasured
Piston-to-wall clearance
Machining allowance
0.02 mm(0.0008 in)
2. Install mainbearing capsandtighten boltstothe specified
torque. Thiswillprevent distortion ofcylinder bores.
3. Cut cylinder boresinthe order of2-4-1-3.
Do not cuttoo much outofthe cylinder boreatatime. Cutonly
0.05 mm(0.0020 in)orso indiameter atatime.
4. Hone thecylinders tothe required sizereferring toSOS

(EM-173).

5. Measure thefinished cylinder boreforout-of-round and
taper.
Measurement ofajust machined cylinderborerequires utmost
care since itis expanded bycutting heat.

62

mm

(2.44
in)

SEM904-A
PISTON-TO-BORE CLEARANCE

Using micrometer
1. Measure pistonandcylinder borediameter.
Piston diameter "A":
Refer toSDS (EM-174).
Measuring point"a"(Distance fromthebottom):
Approximately 62mm (2.44 in)
Bore diameter
"0":

Refer toSDS (EM-173).
Measuring point(Distance fromthetop):
Approximately 70mm (2.76 in)
2. Check thatpiston clearance iswithin thespecification.
Piston clearance
(0-
A):
0.025 -0.045 mm(0.0010 -0.0018 in)

EM-151

GENERALINFORMATION •
SECTION
G
I

CONTENTS
PRECAUTIONS 2

Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 2
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 2
Precautions forNATS V2.0(ForGasoline
Engine Model) 3
General Precautions 3
Precautions forMultiport FuelInjection
System orECCS Engine 5
Precautions forThree WayCatalyst 5
Engine Oils 5
Precautions forFuel 6

HOW TOUSE THIS
MANUAL 7

HOW TOREAD WIRING DIAGRAMS 9

Sample/Wiring Diagram-EXAMPL - 9
Description 11
Wiring Diagram Codes(CellCodes) 17

HOW TOPERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENT 18

Work Flow 18
Incident Simulation Tests 19
Circuit Inspection 23
HOW
TOFOLLOW FLOWCHART INTROUBLE
DIAGNOSES 29
CONSULT CHECKING SYSTEM
32

Function andSystem Application 32
Lithium BatteryReplacement.. 32
Checking Equipment 32

IDENTIFICATION INFORMATION 33

Model Variation 33
Identification Number 36
Di mens ions 39
Wheels andTires 39

LIFTING POINTSANDTOW TRUCK TOWING ..40

Preparation 40
Board-on
Lift
40
Garage JackandSafety Stand 41
2-pole Lift 42
Tow Truck Towing 43

TIGHTENING TORQUEOFSTANDARD BOLTS
44

SAE J1930 TERMINOLOGY LIST 45

SAE J1930 Terminology List.. 45

HOWTOPERFORM EFFICIENT DIAGNOSIS FORANELECTRICAL INCIDENT
Incident Simulation Tests(Cont'd)
FREEZING

Freezing test

Solenoid
Water
in

connector
The
customer mayindicate theincident goesaway afterthecar
warms up(winter time).Thecause couldberelated towater
freezing somewhere inthe wiring/electrical system.
There aretwo methods tocheck forthis. Thefirst isto arrange
for the owner toleave hiscar overnight. Makesureitwill get
cold enough todemonstrate hiscomplaint. Leavethecar
parked outside overnight. Inthe morning, doaquick andthor-
ough diagnosis ofthose electrical components whichcouldbe
affected.

SGI843
Thesecond method isto put the suspect component intoa
freezer longenough forany water tofreeze. Reinstall thepart
into thecar and check forthe reoccurrence ofthe incident. Ifit
occurs, repairorreplace thecomponent.
Water Intrusion test
WATER
INTRUSION

The incident mayoccur onlyduring highhumidity orinrainy/
snowy weather. Insuch cases theincident couldbecaused by
water intrusion onan electrical part.Thiscanbesimulated by
soaking thecar orrunning itthrough acar wash.

Do not spray waterdirectly onany electrical components.
SGI844

Electrical loadtest

AIC SGI845ELECTRICAL
LOAD

The incident maybeelectrical loadsensitive. Performdiagno-
sis with allaccessories (includingA/C,rearwindow defogger,
radio, foglamps) turnedon.

COLD ORHOT START UP

On some occasions anelectrical incidentmayoccur onlywhen
the car isstarted cold.Oritmay occur whenthecar isrestarted
hot shortly afterbeing turned off.Inthese cases youmay have
to keep thecar overnight tomake aproper diagnosis.

GI-22

HOWTOFOLLOW FLOWCHART INTROUBLE DIAGNOSES
NOTICE

The flow chart indicates workprocedures requiredtodiagnose
problems effectively. Observethefollowing instructions before
diagnosing.
1) Use theflow chart afterlocating probable causesofaprob-
lem following the"Preliminary Check",the"Symptom
Chart" orthe "Work Flow".
2) After repairs, re-check thattheproblem hasbeen com-
pletely eliminated.
3) Refer toComponent PartsandHarness Connector Location
for the Systems described ineach section foridentificationl
location ofcomponents andharness connectors.
4) Refer tothe Circuit Diagram forQuick Pinpoint Check.
If you must check circuit continuity betweenharnesscon-
nectors inmore detail, suchaswhen asub-harness isused,
refer toWiring Diagram ineach individual sectionandHar-
ness Layout inEL section foridentification ofharness con-
nectors.
5) When checking circuitcontinuity, ignitionswitchshould be

"OFF" .

6) Before checking voltageatconnectors, checkbattery volt-
age.
7) After accomplishing theDiagnostic Procedures andElectri-
cal Components Inspection,makesurethatallharness con-
nectors arereconnected asthey were.
•

Example
m ..
-=-=~-----------~

~

~i5
[YJ

SGI561
~

OISCONNECT

18
SGI562
INSPECTION
START
CHECK POWER SUPPLY.
1) Turn ignition switch"ON".
2) Check voltage between terminal
@

and ground.

~Ba"ery voltageshouldexist.

OK

2

Ii)
CHECK GROUND CIRCUIT.
1) Turn ignition switch"OFF"
2) Disconnect camshaftpositionsensor
harness connector.
3) Check resistance betweenterminal

@
and ground.

Resistance: Approximately
on

OK
GI-29 NG
Check
thefollowing
items. 1) Harness continuity
between camshaft
position sensorand
battery
2) ECCS relay-1
3) "SR" fusible link
4) Power source for

ECM

5) Ignition switch
Check thefollowing
items. 1) Harness continuity
between camshaft
position sensorand
ground
2) Ground circuitfor

ECM

SG1800-C

LIFTINGPOINTSANDTOW TRUCK TOWING
Preparation
SPECIAL SERVICE TOOLS

Tool number
Tool name

LM4086-0200

Board onattachment

LM4519-0000

Safety standattachment Description

NT001
NT002

\

'\ Front

\\ F

\\1_ L.--
<

'f- --

r\-=-
Attachment
Attachment

Side sill ISST. No.LM40B6.0200)

AGI016Board-on

Lift

CAUTION: Make surevehicle isempty whenlifting.
• The board-on
lift
attachment (LM4086-0200) setatfront end
of vehicle shouldbeset onthe front ofthe sillunder the
front dooropening.
• Position attachments atfront andrear ends ofboard-on lift.
GI-40

LIFTINGPOINTSANDTOW TRUCK TOWING
Garage JackandSafety Stand
WARNING:
• Never getunder thevehicle whileitis supported onlybythe jack. Always usesafety stands when
you have toget under thevehicle.
• Place wheel chocks atboth front andback ofthe wheels onthe ground.
•

Safety stand
8GI909

Note:
Safety stand
points arethe
same as
pantograph
jack points.

Garage
jackpoints
Attachment SST No.LM4519.0000
Use
safety stand
adapter asshown
for stable support.
GI-41