NISSAN ALMERA N16 2003 Electronic Repair Manual

Special Service ToolNJFE0031
Tool number
Tool nameDescription
KV999G0010
Fuel tank lock ring
socket
NT057
Removing and installing fuel tank lock
ring
Commercial Service ToolNJFE0027
Tool name Description
Fuel filter wrench
NT553
Removing fuel filter
a: Max. 100 mm (3.94 in) dia.
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PREPARATIONYD
Special Service Tool
FE-13

Removal and InstallationNJFE0013CAUTION:
Do not disassemble the accelerator pedal assembly. Do not remove the sensors and the switches
from the assembly.
Avoid impact from dropping etc. during handling.
Be careful to keep the assembly away from water.
Do not adjust the adjusting screw (painted white) of the accelerator work unit.
When the connector of the accelerator sensor is disconnected, reconnect the connector, and touch
“CLEAR” in “OFF ACCEL PO SIG” of the active test using the CONSULT-II. Or, warm up the engine,
then leave it idling for approximately 10 minutes.
YFE007
InspectionNJFE0020Check that the accelerator pedal moves smoothly within the
whole operation range.
Check that the accelerator pedal securely returns to the origi-
nal position.
Check that the drum of the accelerator work unit can be fully
opened.
Refer to EC-48, “Basic Inspection” for the inspection of the
accelerator work unit and the accelerator pedal switch.
ACCELERATOR CONTROL SYSTEMYD
Removal and Installation
FE-14

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
things.
JFE598A
Changing Fuel FilterNJFE0021REMOVALNJFE0021S011. Take out air duct and upper air cleaner case.
2. 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.
3. Remove fuel-level warning sensor from fuel filter.
YFE008
INSTALLATIONNJFE0021S02Install in the reverse order of removal.
Tighten the fuel filter so that the sealing face contacts the
packing, then retighten it manually by approximately 2/3 turn.
After installation, operate the priming pump vertically to per-
form air bleeding.
Refer to FE-16, “Bleeding Fuel Filter”.
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FUEL SYSTEMYD
Checking Fuel Lines
FE-15

JEM238G
Bleeding Fuel FilterNJFE00231. 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 pump-
ing 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.
NOTE:
When air is bled completely, pumping the priming pump sud-
denly becomes heavy.
Stop the operation at that time.
If it is difficult to bleed air by pumping the priming pump (the
priming pump does not become heavy during pumping), dis-
connect the fuel supply hose between the fuel filter and the
injection pump. Then, pump the priming pump up and down,
and make sure that fuel comes out. (Use a pan and be care-
ful not to spill fuel. Keep fuel clear of the engine.) After that,
connect the hose, then bleed air again.
DEF017
Checking Priming PumpNJFE0024Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from the
hose end. If not, replace priming pump.
Removal and InstallationNJFE0015WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a “CAUTION: FLAMMABLE” 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) Disconnect battery ground cable.
FUEL SYSTEMYD
Bleeding Fuel Filter
FE-16

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 TankNJFE0016
SFE599AA
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FUEL SYSTEMYD
Removal and Installation (Cont’d)
FE-17

SFE638A
FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-18

JFE613A
SFE600A
SFE601A
REMOVALNJFE0016S01For SedanNJFE0016S01011. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Drain fuel from fuel tank.
4. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
5. Remove inspection hole cover under the rear seat.
6. Disconnect electrical connector.
7. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct
installation.
SFE562A
JFE628A
b. Hold the connector while pushing in tabs, and pull out the tube.
CAUTION:
The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
Do not bend or twist the tube during installation and
removal.
Only when the tube is replaced, remove the remaining
retainer.
When the tube is replaced, also replace the retainer with
a new one.
Retainer color:
Orange (Feed hose side)
White (Return hose side)
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FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-19

SFE602A
8. Remove exhaust center tube.
9. From rear left area of fuel tank, remove filler hose, vent hose,
and EVAP hose.
CAUTION:
To prevent fuel from flowing out, install a blind cap immedi-
ately after the fuel hose is disconnected.
JFE610A
10. Set a suitable transmission jack under fuel tank.
11. Remove fuel tank mounting band bolts while supporting fuel
tank.
JFE611A
12. Lower the fuel tank by 70 to 80 mm (2.76 to 3.15 in), remove
the nuts and clips holding the protector, and then remove the
protector.
To remove the clips, use pliers to squeeze the extensions as
shown by the arrows in the figure at left, and then remove the
clip from above.
13. Remove fuel tank.
FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-20

JFE613A
SFE639A
SFE640A
For HatchbackNJFE0016S01021. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Drain fuel from fuel tank.
4. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
5. Remove inspection hole cover under the rear seat.
6. Disconnect electrical connector.
7. Disconnect the quick connector as follows.
a. Put mating marks on tubes and connectors for correct instal-
lation.
SFE562A
b. Hold the connector while pushing in tabs, and pull out the tube.
CAUTION:
The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
Do not bend or twist the tube during installation and
removal.
SFE641A
8. From rear left area of fuel tank, remove filler hose, vent hose,
and EVAP hose.
CAUTION:
To prevent fuel from flowing out, install a blind cap immedi-
ately after the fuel hose is disconnected.
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FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-21

SFE642A
9. Remove exhaust center tube.
SFE643A
10. Remove heat insulators from fuel tank side.
SFE644A
11. Set a suitable transmission jack under fuel tank.
12. Remove fuel tank mounting band bolts while supporting fuel
tank.
13. Remove fuel tank.
SFE560AB
SFE657AA
INSTALLATIONNJFE0016S02To install, reverse the removal procedure. Connect the quick con-
nector as follows:
Align mating marks on tubes and connectors for correct instal-
lation.
Insert tube into the center of the connector until you hear a
click.
FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-22