ECU NISSAN ALMERA N16 2003 Electronic User Guide

CAMSHAFT
EM-37
[QG]
C
D
E
F
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CAUTION:
Stopper pin is easily detached. Secure it with vinyl tape to prevent detachment.
a. Install timing chain by aligning its mating mark (marked when
timing chain is removed) with mark on camshaft sprocket.
●Align dowel pin on camshaft front surface and pinhole on
sprocket backside, then install.
b. While holding hexagonal part of camshaft with a spanner,
tighten intake camshaft sprocket mounting bolts.
●Make sure that stopper pin is not detached.
6. Install exhaust camshaft sprocket as follows.
a. Install timing chain by aligning its mating mark (marked when
timing chain is removed) with mark on camshaft sprocket.
●Align dowel pin on camshaft front surface and pinhole on
sprocket, then install.
b. While holding hexagonal part of camshaft with a spanner,
tighten exhaust camshaft sprocket mounting bolts.
NOTE:
Tightening torque is different from intake side tightening torque.
c. Make sure that mating marks on intake/exhaust camshaft
sprockets and mating mark on timing chain are aligned.
7. Install chain tensioner.
●Hold plate and plunger with a stopper pin, then install them.
●After installation, remove stopper pin and release plunger.
●Make sure again that mating marks on intake/exhaust cam-
shaft sprockets and mating mark on timing chain are aligned.
MBIB0208E
MBIB0209E
MBIB0210E
MBIB0211E

CAMSHAFT
EM-45
[QG]
C
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5. With valve spring compressed, securely place tip of lifter stopper
(special service tool) onto surroundings of valve spring. Then
remove camshaft pliers (special service tool).
CAUTION:
If camshaft pliers are suddenly turned back, lifter stopper
may contact and damage camshaft journals. Turn back
camshaft pliers carefully to remove.
6. Keep adjusting shim slightly up from valve lifter.
●Insert a slotted screwdriver with extra-thin tip into cutout on
valve lifter for this purpose.
7. Using a magnetic handle, remove adjusting shim.
8. Using a micrometer, measure thickness (t1) of removed adjust-
ing shim at camshaft contact face (around center).
9. Use following formula to select proper replacement adjusting shim.
●Formula to calculate adjusting shim thickness (unit: mm)
Thickness of replacement valve lifter = t1+ ( C1 - C2 )
t1 = Thickness of removed valve lifter
C1 = Measured valve clearance
C2=Standard valve clearance:
PBIC1013E
PBIC1014E
MBIB0229E
Hot engine:
Intake : 0.37 mm (0.015 in)
Exhaust : 0.40 mm (0.016 in)
Reference values with cold engine:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.35 mm (0.014 in)

TIMING CHAIN
EM-49
[QG]
C
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b. Make sure that the camshaft sprocket mating mark is in the
position shown in the figure.
●If the mating mark is not in position, turn the crankshaft pulley
once more and position it.
22. Remove crankshaft pulley with the following procedure:
a. Secure crankshaft counter weight with handle of a hammer, and
loosen crankshaft pulley bolts.
CAUTION:
Take care to prevent foreign material from entering the
engine.
b. Remove crankshaft pulley using crankshaft pulley puller (com-
mercial service tool).
CAUTION:
●Hook tab onto back of crankshaft pulley only.
●Do not remove crankshaft pulley bolt. Fully loosen, and
then use it as support point.
NOTE:
If oil pan is not removed, remove crankshaft pulley as follows.
i. Remove rear plate (lower).
ii. Engage drive plate ring gear with a flat-head screwdriver to fix
crankshaft in position, and loosen crankshaft pulley bolt.
iii. Remove crankshaft pulley using crankshaft pulley puller (com-
mercial service tool).
23. Remove water pump pulley and idler pulley bracket assembly.
MBIB0194E
PBIC0565E
KBIA1437E
KBIA1438E

EM-50
[QG]
TIMING CHAIN
24. Remove front cover with the following procedure:
a. To increase freedom of front cover posture during removal/
installation, pull oil pump drive spacer out through front oil seal.
●Pull it straight out using long-nose priers or two flat-bladed
screwdrivers.
CAUTION:
Be careful not to damage side of oil pump drive spacer and
front oil seal lip.
b. Remove power steering pump adjusting bar.
c. Remove front cover carefully.
●Remove mounting bolts A - E shown in figure.
NOTE:
Bolts C and E have been removed in step b.
CAUTION:
●When removing, be careful not to damage or bend front
end of cylinder head gasket. Also after peeling off con-
tact face between front cover and gasket, their surfaces
shall be smooth.
●If cylinder head gasket is damaged, replace it with new
one.
d. Remove O-rings from front cover and cylinder block.
25. Pull two dowel pins for front cover out of cylinder block.
●Heat them with industrial dryer sufficiently, then pull them out
using locking pliers.
NOTE:
This operation is performed as preparation operation for front
cover installation. This operation can be performed after
removal of timing chain.
26. If front oil seal is need to be replaced, remove it from front cover.
●Insert a flat-bladed screwdriver in notch on oil seal mounting
point, and lift oil seal to remove.
NOTE:
Remove timing chain and its related parts with the following pro-
cedure:
27. Secure intake camshaft sprocket in most advanced position. Refer to EM-32, "
REMOVAL" .
NOTE:
Removal of timing chain and related parts is described in following steps.
28. Remove chain tensioner. Refer to EM-32, "
REMOVAL" .
29. Remove camshaft sprocket. Refer to EM-32, "
REMOVAL" .
CAUTION:
After this step is completed, do not rotate crankshaft and camshaft separately in order to prevent
interference between valve and piston.
PBIC0566E
EMD0850D
PBIC0567E
PBIC0558E

EM-52
[QG]
TIMING CHAIN
2. Install front oil seal to front cover.
●Install it so that identification letters on oil seal will face toward
front side of the engine.
●Using an oil seal drift (commercial service tool), press oil seal
in until it is flush with end surface of mounting position.
●Make sure that oil seal outer circumference is free from dam-
age and burr.
3. Install front cover with the following procedure:
a. Install O-ring to cylinder block.
b. Using a flat-bladed screwdriver, apply a continuous bead of liq-
uid gasket to contact surface between cylinder head gasket
lower surface and cylinder block (2 locations shown in figure).
Use Genuine Liquid Gasket or equivalent.
c. Apply a continuous bead of liquid gasket to back surface of front
cover (location shown in figure).
CAUTION:
●Do not apply liquid gasket to groove A shown in figure.
●Especially for locations indicated by * mark in figure,
strictly observe application range of liquid gasket.
d. Apply liquid gasket to top surface of front cover lightly and
evenly.
Use Genuine Liquid Gasket or equivalent.
e. Install O-ring to back surface of front cover.
f. With socket of oil pump inner rotor placed on crankshaft top sur-
face (clearance between front cover top surface and cylinder
head gasket lower surface is secured), move front cover close to
cylinder block. (Right side in figure)
g. Lift front cover at an angle and install it to mounting position so
that front cover will come in contact with both cylinder head gas-
ket lower surface and cylinder block front surface at the same
time. (Right side in figure)
CAUTION:
●During work, be sure not to damage cylinder head gas-
ket.
●When installing, avoid discontinuous bead of liquid gas-
ket caused by allowing it to adhere to an unnecessary area.
PBIC0530E
PBIC0561E
PBIC0562E
PBIC0563E

TIMING CHAIN
EM-53
[QG]
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h. Install front cover with mounting bolts temporarily so that front
cover will not move.
i. Press fit dowel pin into cylinder block through front cover.
j. Tighten front cover mounting bolts temporarily.
●A [M6 x 20 mm (0.79 in)], B [M6 x 40 mm (1.57 in)], C [M8 x
70 mm (2.76 in)], D [M6 x 73 mm (2.87 in)]
●Bolt C also secures power steering pump adjusting bar.
●Bolt E [M6 x 12 mm (0.47 in)] is for installing power steering
pump adjusting bar.
k. Tighten cylinder head auxiliary bolts (M6) temporarily.
l. Tighten front cover mounting bolts and cylinder head auxiliary
bolts to specified torque.
4. Install oil pump drive spacer.
●When installing, align with flat of oil pump inner rotor.
●If they are not aligned, rotate inner rotor with a flat-bladed
screwdriver to align them.
CAUTION:
Be careful not to damage oil seal lips.
5. Install water pump pulley and idler pulley bracket assembly.
6. Install crankshaft pulley.
●When installing it, make sure that front oil seal lip is not inverted and garter spring is in position.
●For direction of mounting bolt washer, refer to “Component Parts Location”.
●With same procedure as “removal”, secure crankshaft, and tighten mounting bolts.
7. Install cylinder head front cover.
●Apply liquid gasket to cylinder head front cover.
●Use Genuine Liquid Gasket or equivalent.
8. Install engine front mounting bracket.
9. Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●In order to allow liquid gasket to be cured, perform inspection at least 30 minutes after the last step in
which parts sealed with liquid gasket are installed.
●With engine warmed up, check each part for engine oil leakage.
PBIC0564E
EMD0850D
PBIC0566E
PBIC0968E

REMOVALNJEM0094S011. Remove engine and transaxle assembly. Refer to EM-63,
“ENGINE ASSEMBLY”.
2. Remove transaxle from engine. Place engine onto engine
stand (SST). Refer to EM-67, “CYLINDER BLOCK”, “Disas-
sembly”.
3. Remove the following parts:
Oil pan (upper and lower)
Refer to EM-15, “OIL PAN”.
Oil filter bracket
Refer to LC-31, “Oil Filter Bracket”.
Injection tube
Refer to EC-21, “Injection Tube and Injection Nozzle”.
4. Remove secondary timing chain and associated parts.
Refer to EM-20, “Secondary Timing Chain”.
5. When removing rear chain case, remove camshaft sprockets.
Refer to EM-46, “CAMSHAFT”.
JEM131G
6. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
JEM132G
c. Using pulley puller (SST), remove crankshaft pulley.
Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM133G
7. Remove oil pump.
Loosen bolts in the reverse order of that shown in the figure
and remove them.
Use seal cutter (SST) etc. for removal.
8. Remove front oil seal from oil pump.
Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
Be careful not to damage the oil pump.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-26

JEM158G
SEM301G
3. Heat cylinder head to 110 to 120°C (230 to 248°F) by soaking
in heated oil.
4. Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.
WARNING:
Do not touch cold valve seat with your bare hands.
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-90).
CAUTION:
Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-52, “Valve Seats”.
JEM253G
8. Use a depth gauge to measure the distance between the
mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit “L”:
Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)
GI
MA
LC
EC
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SU
BR
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RS
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SC
EL
IDX
CYLINDER HEADYD
Inspection (Cont’d)
EM-53

JEM175G
3. Install camshaft brackets.
Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N·m (0.2 kg-m, 17 in-lb).
Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N·m (0.6 kg-m, 52 in-lb).
c. Tightento12to13N·m(1.2to1.4kg-m,9to10ft-lb).
5. Install camshaft sprockets.
Camshaft sprockets are commonly used for RH and LH.
Align camshaft sprocket and dowel pin on camshaft, and
install.
Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-59,
“Valve Clearance”.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
GI
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LC
EC
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MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER HEADYD
Installation (Cont’d)
EM-59

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, “Changing Engine Coolant”.
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-64