alternator NISSAN ALMERA N16 2001 Electronic Repair Manual

REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
..........................................60
FLYWHEEL/DRIVE PLATE RUNOUT........................60
Assembly ...................................................................60
PISTON..................................................................60
CRANKSHAFT.........................................................61
SERVICE DATA AND SPECIFICATIONS (SDS).........64
General Specifications ...............................................64
Compression Pressure ..............................................64
Belt Deflection............................................................64
Spark Plug .................................................................65
Cylinder Head ............................................................65
Valve ..........................................................................66
VALVE....................................................................66
VALVE SPRING.......................................................66
VALVE LIFTER........................................................66
VALVE CLEARANCE................................................67
VALVE GUIDE.........................................................67
AVAILABLE SHIMS..................................................67
VALVE SEAT...........................................................70
VALVE SEAT RESURFACE LIMIT.............................71
Camshaft and Camshaft Bearing ..............................71
Cylinder Block ............................................................72
Piston, Piston Ring and Piston Pin ...........................73
PISTON..................................................................73
PISTON RING.........................................................73
PISTON PIN............................................................73
Connecting Rod .........................................................74
Crankshaft..................................................................74
Main Bearing..............................................................74
STANDARD.............................................................74
UNDERSIZE............................................................74
Connecting Rod Bearing ...........................................75
STANDARD SIZE....................................................75
UNDERSIZE............................................................75
Bearing Clearance .....................................................75
Miscellaneous Components.......................................75
YD
PRECAUTIONS.............................................................76
Parts Requiring Angular Tightening ...........................76
Liquid Gasket Application Procedure ........................76
PREPARATION.............................................................77
Special Service Tools ................................................77
Commercial Service Tools .........................................79
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................81
NVH Troubleshooting - Engine Noise .......................81
MEASUREMENT OF COMPRESSION PRESSURE....82
DRIVE BELTS................................................................84
Inspection...................................................................84
Adjustment .................................................................84
AIR CONDITIONER COMPRESSOR BELT................85
ALTERNATOR & WATER PUMP BELT.....................85
Removal .....................................................................85
Installation ..................................................................86
AIR CLEANER...............................................................87
Changing Air Cleaner Filter .......................................87
VISCOUS PAPER TYPE...........................................87
OIL PAN.........................................................................88
Components...............................................................88
Removal .....................................................................88
Installation ..................................................................90
TIMING CHAIN..............................................................93
Secondary Timing Chain ...........................................93
REMOVAL...............................................................93
INSPECTION...........................................................95
INSTALLATION........................................................95
Primary Timing Chain ................................................98
REMOVAL...............................................................99
INSPECTION.........................................................101
INSTALLATION......................................................101
INTAKE MANIFOLD....................................................106
Removal and Installation .........................................106
PREPARATIVE WORK...........................................106
FUEL PIPING........................................................107
INTAKE MANIFOLD...............................................107
EGR VOLUME CONTROL VALVE...........................107
WATER HOSE.......................................................107
Inspection.................................................................108
INTAKE MANIFOLD...............................................108
CATALYST..................................................................109
Removal and Installation .........................................109
PREPARATIVE WORK...........................................109
CATALYST............................................................109
GUSSET............................................................... 110
EXHAUST MANIFOLD, TURBOCHARGER............... 111
Removal and Installation ......................................... 111
PREPARATIVE WORK........................................... 111
EXHAUST MANIFOLD AND TURBOCHARGER....... 111
EXHAUST MANIFOLD GASKET............................. 112
Disassembly and Assembly ..................................... 112
TURBOCHARGER................................................. 112
Inspection................................................................. 113
EXHAUST MANIFOLD........................................... 113
TURBOCHARGER................................................. 113
ROCKER COVER........................................................ 116
Removal and Installation ......................................... 116
PREPARATIVE WORK........................................... 116
ROCKER COVER.................................................. 116
CYLINDER HEAD........................................................ 118
Components............................................................. 118
Removal ................................................................... 119
PREPARATIVE WORK........................................... 119
CAMSHAFT........................................................... 119
CYLINDER HEAD..................................................120
Disassembly.............................................................120
Inspection.................................................................121
CONTENTS(Cont'd)
EM-2

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
pumpQG15DE 8.5 (0.335)5.2 - 5.8
(0.205 -
0.228)4.6 - 5.2
(0.181 -
0.205)
QG18DE 7.1 (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-16

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-38, 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-23

SEM909F
ReplacementNJEM0015VALVE OIL SEALNJEM0015S011. Remove rocker cover.
2. Remove camshaft.
3. Remove valve spring. Refer to EM-36.
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-31

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-38, 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-17,
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-50

General SpecificationsNJEM0028
EngineQG15DE QG18DE
ClassificationGasoline
Cylinder arrangement4, in-line
Displacement
cm
3(cu in)1,497 (91.35) 1,769 (107.94)
Bore´stroke
mm (in)73.6´88.0 (2.898´3.465) 80.0´88.0 (3.150´3.465)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio9.5 (9.9*)
*: For QG15DE for Europe
EM120
abcde f
Valve timingQG18DE 222É 236É 0É (20É) 56É (36É) þ2É 44É
QG15DE 222É 222É 0É 42É þ2É 44É
( ): Valve timing control ON
Compression PressureNJEM0029Unit: kPa (bar, kg/cm2, psi)/350 rpm
Standard1,324 (13.24, 13.5, 192)
1,372 (13.720, 13.99, 198.9)*
Minimum1,128 (11.28, 11.5, 164)
1,176 (11.759, 11.99, 170.5)*
Difference limit between cylinders 98 (0.98, 1.0, 14)
*: For QG15DE
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)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
General Specifications
EM-64

JEM249G
InspectionNJEM0088+Before inspecting the engine, make sure the engine has
cooled down; wait approximately 30 minutes after the engine
has been stopped.
+Visually inspect all belts for wear, damage, or cracks on con-
tacting surfaces and edge areas.
+When measuring deflection, apply 98 N (10 kg, 22 lb) at the.
marked point.
+When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning the crankshaft two turns or more, re-adjust to
the specified value to avoid variation in deflection
between pulleys.
+Tighten idler pulley lock nut by hand and measure deflec-
tion without looseness.
Belt Deflection:
Applied beltBelt specifica-
tionBelt deflection with 98 N (10 kg, 22 lb) force
applied* mm (in)
New AdjustedLimit for re-
tightening
Air conditioner
compressor
beltHA type low
edge belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator &
water pump
beltHA type low-
edge wide
angle belt9.0 - 10.5
(0.354 -
0.413)11.0 - 12.5
(0.433 -
0.492)16.5 (0.650)
*: When engine is cold.
AdjustmentNJEM0089+Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator
CAUTION:
+When a new belt is installed as a replacement, adjust it to
the value specified under ªNewº accommodations
because of insufficient adaptability with pulley grooves.
DRIVE BELTSYD
Inspection
EM-84

+If the belt deflection of the current belt is out of the ªLimit
for re-tighteningº, adjust to the ªAdjusted valueº.
+When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning crankshaft two turns or more, re-adjust it to
the specified value to avoid variation in deflection
between pulleys.
+Make sure the belts are fully fitted into the pulley grooves
during installation.
+Handle with care to avoid smearing the belts with oil or
cooling water etc.
+Do not twist or bend the belts with strong force.
JEM251G
AIR CONDITIONER COMPRESSOR BELTNJEM0089S011. Remove RH splash cover (with undercover attached).
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
+Refer to EM-84, ªInspectionº for adjustment values.
4. Tighten lock nut (A).
Nut A:
: 31 - 39 N´m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
ALTERNATOR & WATER PUMP BELTNJEM0089S021. Loosen adjuster lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
+Refer to EM-84, ªInspectionº for adjustment values.
4. Tighten nut (C) and bolt (D) in this order.
Nut C:
: 19 - 24 N´m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N´m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)
RemovalNJEM00901. Loosen each belt. Refer to EM-84, ªAdjustmentº.
2. Remove air conditioner compressor belt.
3. Remove alternator & water pump belt.
DRIVE BELTSYD
Adjustment (Cont'd)
EM-85

crankshaft position sensor (TDC sensor) from the assem-
bly.
+Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, ªChanging Engine Coolantº.
3. Remove the following parts:
+Battery
+RH and LH front wheels
+RH and LH splash covers (combined with undercover)
+Auxiliary belts
+Alternator
+Alternator brackets
+Radiator and cooling fan
+Engine cover
+Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
+Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
YEM024
14. Install engine slingers to cylinder head.
: 30 - 37 N´m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
+Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-137

JEM233G
16. Install rear oil seal retainer.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-76, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
JEM234G
17. Install pilot bushing.
+Force fit with the drift [approx. 19 mm (0.75 in) dia.].
SEM513G
18. Install fuel injection pump bracket.
+Install insulator according to the shape of the block, and secure
by placing the bracket against the insulator. (Not installed on
some models)
+Align the bracket with the dowel pins on the block to install.
+The two bolts used for dowel pins have a longer shanks than
the other two.
+Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
19. Install parts to the engine in the reverse order of disassembly.
+Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque.
: 57 - 65 N´m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel.
+Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
+Tighten bolts uniformly in a crisscross manner.
SEM500GA
REPLACEMENT OF PILOT BUSHINGNJEM0074S031. Remove pilot bushing using tool or suitable tool.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-157