NISSAN ALMERA N16 2003 Electronic Repair Manual

JEF356Y
8. Remove the timing chain slack guide.
Using the hexagon wrench (face to face: 6 mm, short-type)
(SST), remove the mounting bolts, then remove the timing
chain slack guide.
JEF357Y
9. Remove the timing chain tension guide.
10. Remove the secondary timing chain.
Only the timing chain can be removed without removing the
sprockets.
JEF358Y
11. Fix the fuel injection pump sprocket.
a. Insert the positioning stopper pin (SST) in the 6 mm (0.24 in)
dia. hole of the fuel injection pump sprocket.
b. Using the torx wrench (SST), turn the pump shaft gradually to
adjust the hole position of the fuel injection pump sprocket.
c. Insert the positioning stopper pin through the fuel injection
pump body to fix the sprocket.
JEF359Y
Insert the positioning stopper pin until its flange contacts the
fuel injection pump sprocket.
d. Remove the torx wrench (SST).
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BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont’d)
EC-27

JEF360Y
JEF361Y
12. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), remove the mounting bolts of the fuel injection pump
sprocket.
It is not necessary to remove the washer of the fuel injection
pump sprocket.
JEF362Y
JEF363Y
13. Using the sprocket holder (SST), hold the fuel injection pump
sprocket to prevent falling.
When the sprocket holder is installed, if the positioning stop-
per pin interferes, pull out the stopper pin approximately 10
mm (0.39 in), then install it.
After the sprocket holder is installed temporarily, insert the
extension bar (SST) and Torx socket in the three holes A. After
positioning the holes, tighten the holder mounting bolts. (Refer
to the step 14 about the tool.)
The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
Make sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket 15 mm (0.59 in) (small
diameter side).
CAUTION:
Do not remove the sprocket holder until the fuel injection
pump is installed.
After the sprocket holder is installed, pull out the positioning
stopper pin (SST) from the fuel injection pump sprocket.
JEF364Y
14. Using the extension bar [SST: whole length 43 mm (1.69 in)]
and the Torx socket (Q6-E12: commercially available), remove
the mounting bolts, them remove the fuel injection pump
toward the rear of the engine.
Even after all the mounting bolts are removed, the fuel injec-
tion pump is still held by a dowel pin.
CAUTION:
Do not disassemble or adjust the fuel injection pump.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont’d)
EC-28

JEF365Y
15. Remove the fuel injection pump mounting bolts.
The seal washer of the mounting bolts cannot be reused.
CAUTION:
For removal, be careful not to drop the seal washer into the
engine.
JEF366Y
InstallationNJEC0620S02It is not necessary to adjust the injection timing by changing the
installation angle which used to be performed with conven-
tional fuel injection pumps. The installation position can be
simply decided by the dowel pin and the mounting bolts.
1. Before the fuel injection pump is installed, check that the notch
of its flange and the 6 mm (0.24 in) dia. hole on the body are
aligned.
JEF367Y
2. Insert the fuel injection pump to the mounting position from the
rear of the engine.
Adjust the fuel injection pump bracket position to the dowel pin,
then install it.
JEF364Y
3. Using the extension bar (SST) and the Torx socket, tighten the
mounting bolts of the fuel injection pump.
4. Remove the sprocket holder (SST).
JEF358Y
5. Using the torx wrench (SST), turn the pump shaft gradually to
adjust the position of the flange. Then, insert the positioning
stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the fuel
injection pump sprocket through the pump flange and the
pump body.
6. Remove the torx wrench (SST).
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BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont’d)
EC-29

JEF360Y
7. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), tighten the sprocket mounting bolt.
When the washer of the fuel injection pump sprocket is
removed, install it with the marking “F” (front) facing the front
of the engine.
8. Pull out the positioning stopper pin (SST).
JEF368Y
9. Install the secondary timing chain.
Align the alignment marks of the sprockets and those of the
chain, then install it.
The figure shows the installation state and names of the sec-
ondary timing chain and other related parts.
10. Install timing chain tension guide.
The upper installation bolt is longer than the lower.
JEF356Y
11. Using a hexagon wrench (face to face: 6 mm, short-type)
(SST), install the timing chain slack guide.
JEF355Y
12. Install the chain tensioner.
a. Push the plunger of the chain tensioner, then hold it with a tool
such as a push pin, and install it.
b. Using a hexagon wrench (face to face: 5 mm) (SST), tighten
the mounting bolts.
Installation is possible by a multi-purpose tool also.
c. Pull out the tool such as a push pin which holds the plunger.
Make sure that the alignment marks of the sprockets and
timing chain are aligned.
BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont’d)
EC-30

JEF369Y
13. Install the front chain case.
a. Install the tension guide to the back side of the front chain
case.
If the front chain case is tilted, the tension guide may fall off.
Therefore, when installing the front chain case, hold it verti-
cally.
JEF370Y
b. Apply Three Bond 1207C (KP510 00150) to both ends of the
arch area of the oil pump (contact surface of rear chain case)
as shown in the figure.
c. Install the front chain case.
Align the dowel pin of the oil pump case to the pin hole, then
install it.
Install bolts 6, 10, and 11 (shown in the figure) with the rubber
washer to the front chain case.
JEF352Y
d. Tighten the mounting bolts in the numerical order shown in the
figure.
e. After all bolts are tightened, tighten the mounting bolts in the
numerical order shown in the figure again.
14. Install the fuel injection pump rear bracket.
Tighten all the bolts temporarily, then tighten them securely
with the mounting face securely contacting the fuel injection
pump and the pump bracket.
JEF351Y
15. Connect the fuel injection pump harness connector.
Insert the harness connector securely until the stopper locks.
Push the connector half way first, then press the stopper until
it locks, so that the connector is connected together.
16. Connect the fuel hoses.
When the hoses are disconnected at the fuel gallery side,
insert until the hoses contact the valve, then install the clamp
securely.
17. Install other parts in the reverse order of removal.
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BASIC SERVICE PROCEDUREYD
Electronic Control Fuel Injection Pump (Cont’d)
EC-31

Fuel Filter
DESCRIPTIONNJEC0623A water draining cock is on the lower side and a priming pump for
bleeding air is on the upper side.
SEF375Y
AIR BLEEDINGNJEC06241. After the repair, bleed air from the piping by pumping the prim-
ing pump up and down until it becomes heavy.
2. To start the engine, rotate the starter for a maximum of 30
seconds. To start the engine more quickly, crank the engine
while pumping the priming pump (requires two workers).
3. If the engine does not start after rotating the starter for a maxi-
mum of 30 seconds, stop it once, and pump the priming pump
again until it becomes heavy.
4. Rotate the starter again until the engine starts running.
5. After the engine starts, let it idle for at least 1 minute to stabi-
lize the behavior.
When air is bled completely, the pumping of the priming
pump suddenly becomes heavy. Stop the operation at that
time.
If it is difficult to bleed air by the pumping of the priming
pump (the pumping of the priming pump does not become
heavy), disconnect the fuel supply hose between the fuel
filter and the injection pump. Then, perform the operation
described above, and make sure that fuel comes out. (Use
a pan, etc. so as not to spill fuel. Do not let fuel get on
engine and other parts.) After that, connect the hose, then
bleed air again.
Start engine and let it idle for at least one minute after
performing air bleeding.
WATER DRAININGNJEC06251. Remove the fuel filter, filter bracket, protector assembly from
the dash panel as follows.
a. Remove the air cleaner case (upper), air duct assembly, and
vacuum hose for brake booster (between the vacuum pump
and vacuum pipe).
CAUTION:
After the duct is removed, cover the opening with gum tape,
etc. to prevent foreign object from getting into the engine
during the operation.
b. Disconnect the water level warning sensor harness connector.
c. Remove the mounting nuts on the dash panel, then remove the
fuel filter, filter bracket, and protector assembly from the dash
panel.
It is not necessary to disconnect the fuel hose.
2. Using a tool such as a pliers, loosen the water draining cock
at the bottom of the water level warning sensor located under
the fuel filter.
BASIC SERVICE PROCEDUREYD
Fuel Filter
EC-32

3. Install the fuel filter, filter bracket, and protector assembly tem-
porarily. Then, drain the water by pumping the priming pump
with the filter standing straight.
Extend the drain hose if necessary.
Water amount when the MI lights up:
65 - 100 m(2.3 - 3.5 Imp fl oz)
CAUTION:
When the water is drained, the fuel is also drained. Use a pan,
etc. to avoid fuel adherence to the rubber parts such as the
engine mount insulator.
4. Tighten the water draining cock, then install the fuel filter, filter
bracket, protector assembly in the reverse order of removal.
CAUTION:
Do not over-tighten the water draining cock. This will damage
the cock thread, resulting in water or fuel leak.
5. Bleed air of the fuel filter. Refer to EC-32.
Start engine and let it idle for at least one minute after
performing air bleeding.
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BASIC SERVICE PROCEDUREYD
Fuel Filter (Cont’d)
EC-33

DTC and MI Detection LogicNJEC0626When a malfunction is detected, the malfunction (DTC) is stored in the ECM memory.
The MI will light up each time the ECM detects malfunction. For diagnostic items causing the MI to light up,
refer to “TROUBLE DIAGNOSIS — INDEX”, EC-4.
Diagnostic Trouble Code (DTC)NJEC0627HOW TO READ DTCNJEC0627S01The DTC can be read by the following methods.
Without CONSULT-II
ECM displays the DTC by a set of four digit numbers with MI illumination in the diagnostic test mode II (Self-
diagnostic results). Example: 0103, 0807, 1002, etc.
With CONSULT-II
CONSULT-II displays the DTC in “SELF-DIAG RESULTS” mode. Examples: P0115, P0571, P1202, etc.
These DTCs are prescribed by ISO15031-6.
(CONSULT-II also displays the malfunctioning component or system.)
Output of the trouble code means that the indicated circuit has a malfunction. However, in the Mode
II it does not indicate whether the malfunction is still occurring or occurred in the past and returned
to normal.
CONSULT-II can identify them. Therefore, using CONSULT-II (if available) is recommended.
HOW TO ERASE DTCNJEC0627S02How to Erase DTC (With CONSULT-II)NJEC0627S02011. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Touch “ENGINE”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
SEF246Z
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELF-
DIAG RESULTS” mode with CONSULT-II.
How to Erase DTC (Without CONSULT-II)NJEC0627S02021. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-36.)
The emission related diagnostic information in the ECM can be erased by changing the diagnostic test mode.
If the battery is disconnected, the emission-related diagnostic information will be lost after approx.
24 hours.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONYD
DTC and MI Detection Logic
EC-34

Erasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.
Malfunction Indicator (MI)
DESCRIPTIONNJEC0628
SAT652J
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check.
If the MI does not light up, refer to EL-129, EL-129, “WARNING LAMPS” or see EC-213.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has detected an engine system malfunction.
If MI illuminates or blinks irregularly after starting engine, water may have accumulated in fuel filter.
Drain water from fuel filter. Refer to “WATER DRAINING”, EC-32.
On Board Diagnostic System FunctionNJEC0628S01The on board diagnostic system has the following three functions.
Diagnostic Test
ModeKEY and ENG.
StatusFunction Explanation of Function
Mode I Ignition switch in
ON position
Engine stopped
BULB CHECK This function checks the MI bulb for damage (blown,
open circuit, etc.).
If the MI does not come on, check MI circuit. (See
EC-213.)
Engine running
MALFUNCTION
WARNINGThis is a usual driving condition. When ECM detects a
malfunction, the MI will light up to inform the driver that
a malfunction has been detected.
Mode II Ignition switch in
ON position
Engine stopped
SELF-DIAGNOSTIC RESULTS This function allows DTCs to be read.
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ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONYD
Diagnostic Trouble Code (DTC) (Cont’d)
EC-35

How to Switch Diagnostic Test ModesNJEC0628S02
SEF878Y
*1: EC-213 *2: EC-35 *3: EC-213
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONYD
Malfunction Indicator (MI) (Cont’d)
EC-36