belt NISSAN ALMERA N16 2003 Electronic User Guide

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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ENGINE MECHANICAL
QG
PRECAUTIONS .......................................................... 3
Precautions for Drain Coolant .................................. 3
Precautions for Disconnecting Fuel Piping .............. 3
Precautions for Removal and Disassembly ............. 3
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 3
Precautions for Assembly and Installation ............... 3
Parts Requiring Angular Tightening ......................... 3
Precautions for Liquid Gasket .................................. 4
REMOVAL OF LIQUID GASKET SEALING .......... 4
LIQUID GASKET APPLICATION PROCEDURE ..... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 9
NVH Troubleshooting —Engine Noise ..................... 9
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 10
DRIVE BELTS ............................................................11
Checking Drive Belts ............................................... 11
Tension Adjustment ................................................ 12
POWER STEERING PUMP AND WATER PUMP
BELT ................................................................... 12
ALTERNATOR AND AIR CONDITIONER COM-
PRESSOR BELT ................................................. 12
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
AIR CLEANER AND AIR DUCT ............................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Changing Air Cleaner Element ............................... 15
INTAKE MANIFOLD ................................................. 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 18EXHAUST MANIFOLD AND CATALYTIC CON-
VERTER .................................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
Disassembly and Assembly .................................... 21
DISASSEMBLY ................................................... 21
ASSEMBLY ......................................................... 21
OIL PAN AND OIL STRAINER ..............................
... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 23
IGNITION COIL ......................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
SPARK PLUG (CONVENTIONAL) ........................... 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 25
INSTALLATION ................................................... 25
FUEL INJECTOR AND FUEL TUBE ........................ 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 28
ROCKER COVER ..................................................... 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 30
CAMSHAFT .............................................................. 32
Removal and Installation ........................................ 32
REMOVAL ........................................................... 32
INSTALLATION ................................................... 35

EM-10
[QG]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom.
EBS00LPX
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseTy p e o f
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
Top of
engine
Rocker
cover
Cylinder
headTick in g o r
clickingCA—AB—Tappet
noise
●Valve clearanceEM-42
Rattle C A — A B CCamshaft
bearing
noise
●Camshaft journal
clearance
●Camshaft runoutEM-39EM-39
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—B B—Piston pin
noise
●Piston and piston pin
clearance
●Connecting rod
bushing clearanceEM-84EM-87
Slap or
rapA——B B APiston
slap noise
●Piston-to-bore clear-
ance
●Piston ring side
clearance
●Piston ring end gap
●Connecting rod bend
and torsionEM-88
EM-85
EM-86
EM-86
Knock A B C B B BConnect-
ing rod
bearing
noise
●Connecting rod
bushing clearance
(Small end)
●Connecting rod bear-
ing clearance (Big
end)EM-87EM-87
Knock A B — A B CMain
bearing
noise
●Main bearing oil
clearance
●Crankshaft runoutEM-91EM-90
Front of
engine
Timing
chain
coverTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noise●Timing chain cracks
and wear
●Timing chain ten-
sioner operationEM-51EM-47
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)
●Drive belts deflection
EM-11
CreakingABABABDrive belts
(Slipping)●Idler pulley bearing
operation
Squall
CreakAB—BABWater
pump
noise
●Water pump opera-
tionLC-14

DRIVE BELTS
EM-11
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LPY
●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 contacting surfaces and edge areas.
●When measuring deflection, apply 98 N (10 kg, 22 lb) at the ▼ marked point.
CAUTION:
When measuring belt tension immediately after belt is installed, first set the tension to the standard.
Then, rotate crankshaft for more than two turns in order to eliminate variance in belt deflection
between the pulleys. Re-measure and adjust the tension to the standard.
PBIC0764E
Deflection adjustment Unit: mm (in)
Used belt
New belt
Limit After adjustment
AlternatorWithout air conditioner compressor 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
With air conditioner compressor 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)
Power steering oil pump 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)

EM-12
[QG]
DRIVE BELTS
Tension Adjustment
EBS00LPZ
CAUTION:
●When belt is replaced with a new one, tighten it a little
stronger than current one to accommodate for insufficient
adaptability with pulley grooves.
●When tension of belt being used exceeds “Retightening
limit”, adjust it to value for “Used belt”.
●When installing belt, make sure that it is correctly engaged with pulley groove.
●Keep oil and water away from belt.
●Do not twist or bend belt excessively.
●When adjusting belt, remove snap retainer from adjusting bolt thread (to prevent the retainer from
becoming pinched or missing).
●After adjustment, be sure to install snap retainer to adjusting bolt thread.
NOTE:
Snap retainer can prevent adjusting bolt from dropping due to vibration during driving.
POWER STEERING PUMP AND WATER PUMP BELT
1. Loosen lock nut (A) and power steering pump mounting nut (B).
2. Turn adjusting bolt (C) to adjust. Refer to EM-11, "
Checking
Drive Belts" .
3. Tighten lock nut (A) and power steering pump mounting nut (B)
in this order.
ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
1. Remove RH splash cover (with undercover attached).
2. Loosen lock nut (G).
3. Turn adjusting bolt (H) to adjust.
Refer to EM-11, "
Checking Drive Belts" .
4. Tighten lock nut (G).
Portion Belt tightening method for adjustment
Power steering pump and water pump
beltAdjusting bolt on power steering pump
Alternator and air conditioner compres-
sor beltAdjusting bolt on idler pulley
PBIC0531E
Nut A :
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Nut B :
: 26.5 - 36.3 N·m (2.7 - 3.7 kg-m, 20 - 26 ft-lb)
PBIC0532E
Nut G :
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)

DRIVE BELTS
EM-13
[QG]
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Removal and InstallationEBS00LQ0
REMOVAL
●Loosen each belt while referring to “Tension Adjustment”, and remove them one by one starting from the
one in front.
INSTALLATION
1. Install belts to pulley in reverse order of removal.
2. Adjust belt tension.
CAUTION:
●When checking belt tension immediately after installation, first, adjust to specified value. Then,
after turning crankshaft more than two turns, re-adjust to specified value to avoid variation in
deflection between pulleys.
●Tighten idler pulley lock nut by hand and measure tension without looseness.
3. Tighten each adjusting bolt and nut to the specified torque.
4. Make sure that tension of each belt is within the standard.

EM-48
[QG]
TIMING CHAIN
2. Disconnect battery ground cable.
3. Remove undercover, front RH wheel and RH splash cover.
4. Drain engine coolant from radiator and cylinder block. Refer to LC-17, "Changing Engine Coolant".
5. Drain engine oil from oil pan.
6. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
7. Remove power steering pump from adjusting bar.
8. Remove alternator. SC-33, "Removal and Installation".
9. Remove ignition coils. Refer to EM-24, "
IGNITION COIL" .
10. Remove rocker cover. Refer to EM-29, "
Removal and Installation" .
11. Remove oil level gauge.
12. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
13. Remove center member.
14. Remove gusset.
15. Remove rear plate (lower) (A/T models).
16. Remove oil pan and oil strainer. Refer to EM-22, "
Removal and Installation" .
17. For safe operation, and to reduce load to mount insulator, install removed center member again.
18. Remove engine front-side (right side of vehicle) engine mount. Refer to EM-67, "
ENGINE ASSEMBLY" .
a. Remove any parts that cause difficulties for operation around mount, or perform transfer.
b. Support cylinder block bottom surface with a transmission jack.
CAUTION:
●When applying jack, use a wooden block to avoid damage to oil pan mounting surface.
●While performing following operations, support engine front-side with jack.
c. Separate engine mounting insulator and bracket.
d. Remove engine mounting bracket.
19. Remove cylinder head front cover.
●Move harness which was previously fixed on front surface.
20. Remove auxiliary bolts of cylinder head.
21. Set the No. 1 cylinder to the compression TDC.
a. Turn the crankshaft pulley clockwise, and align the timing indica-
tor of the gear case to the timing mark of the crankshaft pulley.
PBIC0557E
PBIC0750E

OIL SEAL
EM-55
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Removal and Installation of Front Oil SealEBS00LQF
REMOVAL
1. Remove the following parts:
●Undercover (with splash cover)
●Drive belt; Refer to EM-11, "DRIVE BELTS" .
●Crankshaft pulley; Refer to EM-47, "TIMING CHAIN" .
2. Using flat-head screwdriver, remove front oil seal.
CAUTION:
Be careful not to damage front timing chain cover and crankshaft.
INSTALLATION
1. Apply engine oil on new front oil seal.
2. Using a suitable drift, press fit until the height of front oil seal is
level with the mounting surface.
●Suitable drift : outer diameter 50 mm (1.97 in), inner diameter
44 mm (1.73 in).
CAUTION:
●Be careful not to damage front cover and crankshaft.
●Press oil seal straight so that it is not curling up or
inclined.
3. Perform steps in the reverse order of removal for the following
operations.
Removal and Installation of Rear Oil SealEBS00LQG
REMOVAL
1. Remove transaxle assembly. Refer to MT-23, "Removal" (RS5F30A), MT-23, "Removal" (RS5F70A) and
AT-411, "Removal" (AUTOMATIC TRANSAXLE).
2. Remove drive plate. Refer to EM-70, "
CYLINDER BLOCK" .
3. Using flat-head screwdriver, remove front oil seal.
CAUTION:
Be careful not to damage mounting surface.
INSTALLATION
1. Using a suitable drift, press rear oil seal to rear oil seal retainer.
●Suitable drift : outer diameter 102 mm (4.02 in), inner diame-
ter 90 mm (3.54 in).
CAUTION:
●Do not touch grease applied on oil seal lip
●Be careful not to damage rear oil seal retainer and crank-
shaft.
●Press in straight to avoid causing any burrs or tilting of
oil seal.
SEM912F
SEM715A
SEM097F

EM-68
[QG]
ENGINE ASSEMBLY
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 completely 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-34 (WITH EURO-OBD), EC-428 (WITHOUT EURO-OBD).
●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 crankshaft position sensor (POS) from the cylin-
der 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.
REMOVAL
1. Drain coolant from radiator and cylinder block. Refer to LC-17, "Chacking Engine Coolant".
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.
9. Remove the following parts:
●RH and LH front tires
●Splash covers
●RH and LH brake caliper assemblies
Refer to BR-28,"Removal".
Brake hose does not need to be disconnected from brake
caliper assembly. Never depress brake pedal.
●RH & LH drive shaft. Refer to AX-11, "Removal".
When removing drive shaft, be careful not to damage
transaxle side grease seal.
●Disconnect control rod and support rod from transaxle. (M/T
models.)
Refer to MT-26, "Removal".
●Disconnect control cable from transaxle. (A/T models.)
Refer to AT-411, "Removal".
SEM174D
SEM109G

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-93
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00LQP
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Unit: mm (in) EngineQG15DE QG18DE
ClassificationGasoline
Cylinder arrangement4, in-line
Displacement
cm
3 (cu in)1,497 (91.35) 1,769 (107.94)
Bore and stroke mm (in)73.6 x 88.0
(2.898 x 3.465)80.0 x 88.0
(3.150 x 3.465)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio9.9 9.5
Compression pressure
kPa (bar, kg/cm
2 , psi) / 350 rpmStandard1,372 (13.72, 13.99,
198.9)1,324 (13.24, 135,
192)
Minimum1,176 (11.76, 12.0,
170.5)1,128 (11.28, 11.5,
164)
Differential limit between cylinders 98 (0.98, 1.0, 14)
Valve timing
(Intake valve timing control - OFF)
Unit: degree
abcde f
208 228−856−230
PBIC0187E
Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Deflection adjustment
Used belt
New belt
Limit After adjustment
AlternatorWithout air conditioner compressor 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
With air conditioner compressor 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)

EM-94
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in) Power steering oil pump 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)Deflection adjustment
Used belt
New belt
Limit After adjustment
Make NGK Champion
Ty p eStandard LFR5A-11 REC10YC4
Hot LFR4A-11 —
Cold LFR6A-11 —
Plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.9 (4.642) —
QG15DE QG18DE
Valve head diameter “D”Intake 28.9 - 29.2 (1.138 - 1.150) 29.9 - 30.2 (1.177 - 1.189)
Exhaust 23.9 - 24.2 (0.941 - 0.953) 24.9 - 25.2 (0.980 - 0.992)
Valve length “L”Intake 92.00 - 92.50 (3.6220 - 3.6417)
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter “d”Intake 5.465 - 5.480 (0.2152 - 0.2157)
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve seat angle “α”44°15′ - 44°45′
Valve margin “T” 0.8 - 0.14 (0.031 - 0.055)
Valve margin “T” limit More than 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
SEM188
For adjusting For checking
Hot Cold* (reference data) Hot