front NISSAN ALMERA N16 2003 Electronic User Guide

NJMA0036
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard tothe conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION
Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
Inspect for interior and exterior metal and paint damage
Check for spare tire, jack, tools (wheel chock), and literature
Wash, clean interior and exterior
: Not applicable to this model
PRE-DELIVERY INSPECTION ITEMS
MA-2

Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year)
=NJMA0043S03The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K — Sustained high speed driving
L — For models without Euro-OBD system
Driving conditionMaintenance
itemMaintenance
operationMaintenance interval
ABCD........Engine oil & engine oil filter
Petrol models ReplaceEvery 7,500 km (4,500 miles) or 6
months
Diesel models ReplaceEvery 10,000 km (6,000 miles) or 6
months
A...........Air cleaner filter
Petrol models ReplaceEvery 30,000 km (18,000 miles) or
24 months
Diesel models ReplaceEvery 30,000 km (18,000 miles) or
18 months
A...E.......Fuel filter
Diesel models ReplaceEvery 20,000 km (12,000 miles) or
12 months
...........LHeated Oxygen Sensor 1 (Front)
Petrol models InspectEvery 30,000 km (18,000 miles) or
24 months
...........LHeated Oxygen Sensor 2 (Rear)
Petrol models InspectEvery 30,000 km (18,000 miles) or
24 months
A...........Ventilation air filter
Petrol models ReplaceEvery 15,000 km (9,000 miles) or
12 months
Diesel models ReplaceEvery 10,000 km (6,000 miles) or 6
months
.....F......Brake fluid
Petrol models ReplaceEvery 15,000 km (9,000 miles) or
12 months
Diesel models ReplaceEvery 20,000 km (12,000 miles) or
12 months
GI
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year)
MA-11

Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year)
=NJMA0043S06The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K — Sustained high speed driving
L — For models without Euro-OBD system
Driving conditionMaintenance
itemMaintenance
operationMaintenance interval
ABCD........Engine oil & engine oil filter
Petrol models Replace Every 7,500 km (4,500 miles)
Diesel models Replace Every 10,000 km (6,000 miles)
A...........Air cleaner filter
Petrol models Replace Every 30,000 km (18,000 miles)
Diesel models Replace Every 30,000 km (18,000 miles)
A...E.......Fuel filter
Diesel models Replace Every 30,000 km (18,000 miles)
...........LHeated Oxygen Sensor 1 (Front)
Petrol models Inspect Every 60,000 km (36,000 miles)
...........LHeated Oxygen Sensor 2 (Rear)
Petrol models Inspect Every 60,000 km (36,000 miles)
A...........Ventilation air filter
Petrol models Replace Every 15,000 km (9,000 miles)
Diesel models Replace Every 10,000 km (6,000 miles)
.....F......Brake fluid
Petrol models Replace Every 30,000 km (18,000 miles)
Diesel models Replace Every 30,000 km (18,000 miles)
..C....H....Automatic transaxle fluid
Petrol models Replace Every 60,000 km (36,000 miles)
A.C...GHI...Brake pads, rotors & other brake system components
Petrol models Inspect Every 15,000 km (9,000 miles)
Diesel models Inspect Every 10,000 km (6,000 miles)
GI
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km/year)
MA-17

EM-8
[QG]
PREPARATION
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer Reaming valve guide 1 or hole for oversize
valve guide 2
Intake & Exhaust:
d
1 : 5.5 mm (0.217 in) dia.
d
2 : 9.685 mm (0.3813 in) dia.
Front oil seal drift Installing front oil seal
a: 50 mm (1.97 in) dia.
b: 44 mm (1.73 in) dia.
Rear oil seal drift Installing rear oil seal
a: 102 mm (4.02 in) dia.
b: 90 mm (3.54 in) dia. Tool nameDescription
NT015
NT016
NT049
NT049

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-13
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
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-16
[QG]
INTAKE MANIFOLD
INTAKE MANIFOLD
PFP:14003
Removal and InstallationEBS00LQ3
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1. Release fuel pressure.
Refer to EC-34, "
FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-427, "FUEL PRESSURE
RELEASE" (WITHOUT EURO-OBD).
2. Remove air duct and air cleaner case.
Refer to EM-14, "
Removal and Installation" .
3. Disconnect harness on engine top surface, and move it aside.
4. Disconnect fuel injector/fuel tube assembly from intake manifold, and move it aside.
●It is not necessary to disconnect fuel hose.
5. Disconnect the following vacuum hoses.
6. Disconnect blow-by hose (between intake manifold collector and rocker cover).
KBIA1363E
1. Electric throttle control actuator 2. Gasket 3. Intake manifold collector
4.EVAP canister purge volume control
solenoid valve5. Vacuum hose 6. Vacuum hose
7. Hose clamp 8. Intake manifold support (front) 9. Harness bracket
10. Vacuum hose 11. Intake manifold 12. PCV hose
13. Gasket 14. Vacuum hose 15. Gasket
16. Intake manifold support (rear) 17. Harness bracket 18. Intake manifold support (engine rear)
19. Grounding wire

INTAKE MANIFOLD
EM-17
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
7. Loosen mounting bolts in reverse order shown in figure to
remove electric throttle control actuator.
CAUTION:
●Do not shock it.
●Do not disassembly and adjusting.
NOTE:
Remove intake manifold collector and electronic throttle control
as a single assembly, then remove electronic throttle control
itself.
8. Remove bolt on cylinder head side of intake manifold collector.
9. Loosen intake manifold collector nuts and bolts in reverse of the
order shown in the figure.
●Do not remove intake manifold collector at this stage.
10. Move harness, which is fixed on intake manifold support, with bracket.
11. Remove intake manifold supports (rear, front, engine rear).
12. Loosen nuts and bolts in reverse order shown in the figure, and
remove intake manifold from cylinder head.
13. Disconnect intake manifold collector from intake manifold, and
pull out between engine and body.
PBIC0534E
KBIA1365E
KBIA1366E
PBIC0535E

EXHAUST MANIFOLD AND CATALYTIC CONVERTER
EM-19
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
EXHAUST MANIFOLD AND CATALYTIC CONVERTERPFP:14004
Removal and InstallationEBS00LQ4
REMOVAL
1. Remove undercover.
2. Disconnect exhaust front tube from catalytic converter. Refer to FE-10, "Removal and Installation".
3. Remove exhaust manifold support from both sides of catalytic converter.
4. Disconnect heated oxygen sensor harness connector.
5. Remove heated oxygen sensor.
●Follow below steps to remove each heated oxygen sensor.
YEM048
1. Heated oxygen sensor 1 2. Ground nut 3. Gasket
4. Stud bolt 5.Exhaust manifold and catalytic con-
verter assembly6. Support
7. Exhaust manifold cover 8.Heated oxygen sensor harness
bracket

EM-22
[QG]
OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER
P F P : 1111 0
Removal and InstallationEBS00LQ6
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove undercover.
2. Drain engine oil. Refer to LC-8, "Changing Engine Oil".
3. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
4. Using a transmission jack, be sure to support the bottom of tran-
saxle oil pan, and remove center member.
5. Remove gusset and engine rear plate (lower) [A/T vehicle].
6. Loosen and remove mounting nuts and bolts in reverse order
shown in figure.
PBIC0548E
1. Oil strainer 2. Washer 3. Drain plug
4. Oil pan
SEM067F
SEM072F