NISSAN ALMERA N16 2003 Electronic Repair Manual

Tool name Description
TORX socket
NT807
Standard Universal
NT808
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATIONYD
Commercial Service Tools (Cont’d)
EM-7

NJEM0051
NVH Troubleshooting — Engine NoiseNJEM0051S01Use the chart below to help you find the cause of the symptom.
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.
Location of
noiseTy p e o f
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingC A—A B—Tappet
noiseValve clearance EM-60
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal
clearance
Camshaft runoutEM-49, 49
Crankshaft
pulley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—B B—Piston pin
noisePiston and piston
pin clearance
Connecting rod
bushing clearanceEM-71, 79
Slap or
rapA——B B APiston slap
noisePiston-to-bore
clearance
Piston ring side
clearance
Piston ring end gap
Connecting rod
bend and torsionEM-71, 72,
72, 73
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod
bushing clearance
(Small end)
Connecting rod
bearing clearance
(Big end)EM-79, 77
Knock A B — A B CMain bear-
ing noiseMain bearing oil
clearance
Crankshaft runoutEM-75, 75
Front of
engine
Timing
chain
coverTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noiseTiming chain
cracks and wear
Timing chain ten-
sioner operationEM-22, 20
Front of
engineSqueaking
or fizzingA B—B—COther
drive belts
(Sticking
or slipping)Drive belts deflec-
tion
EM-11
CreakingABABABOther
drive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakAB—BABWater
pump
noiseWater pump opera-
tionLC-39
A: Closely related B: Related C: Sometimes related —: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGYD
NVH Troubleshooting — Engine Noise
EM-8

NJEM0053
JEM111G
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-39, “CONSULT-II Inspection
Procedure”.
Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
Carefully remove glow plugs to prevent any damage or
breakage.
Handle with care to avoid applying any shock to glow
plugs.
SEM112G
7. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
3,138 (31.38, 32.0, 455)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin-
der block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plugs.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-9

d. Install fuel injection pump fuse [ENG CONT2 (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self-diagnosis. Refer to EC-39, “CONSULT-II Inspec-
tion Procedure”.
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-10

JEM249G
InspectionNJEM0088Before 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 con-
tacting surfaces and edge areas.
When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point.
When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning the crankshaft two turns or more, re-adjust to
the specified value to avoid variation in deflection
between pulleys.
Tighten idler pulley lock nut by hand and measure deflec-
tion without looseness.
Belt Deflection:
Applied beltBelt specifica-
tionBelt deflection with 98 N (10 kg, 22 lb) force
applied* mm (in)
New AdjustedLimit for re-
tightening
Air conditioner
compressor
beltHA type low
edge belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator &
water pump
beltHA type low-
edge wide
angle belt9.0 - 10.5
(0.354 -
0.413)11 . 0 - 1 2 . 5
(0.433 -
0.492)16.5 (0.650)
*: When engine is cold.
AdjustmentNJEM0089Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator
CAUTION:
When a new belt is installed as a replacement, adjust it to
the value specified under “New” accommodations
because of insufficient adaptability with pulley grooves.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
DRIVE BELTSYD
Inspection
EM-11

If the belt deflection of the current belt is out of the “Limit
for re-tightening”, adjust to the “Adjusted value”.
When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning crankshaft two turns or more, re-adjust it to
the specified value to avoid variation in deflection
between pulleys.
Make sure the belts are fully fitted into the pulley grooves
during installation.
Handle with care to avoid smearing the belts with oil or
cooling water etc.
Do not twist or bend the belts with strong force.
JEM251G
AIR CONDITIONER COMPRESSOR BELTNJEM0089S011. Remove RH splash cover (with undercover attached).
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
Refer to EM-11, “Inspection” for adjustment values.
4. Tighten lock nut (A).
Nut A:
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
ALTERNATOR & WATER PUMP BELTNJEM0089S021. Loosen adjuster lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
Refer to EM-11, “Inspection” for adjustment values.
4. Tighten nut (C) and bolt (D) in this order.
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)
RemovalNJEM00901. Loosen each belt. Refer to EM-11, “Adjustment”.
2. Remove air conditioner compressor belt.
3. Remove alternator & water pump belt.
DRIVE BELTSYD
Adjustment (Cont’d)
EM-12

InstallationNJEM00911. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer to EM-11, “Adjustment”.
3. Tighten nuts and bolts provided for adjustment to the specified
torque.
4. Check again that each belt tension is as specified.GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
DRIVE BELTSYD
Installation
EM-13

Changing Air Cleaner FilterNJEM0092VISCOUS PAPER TYPENJEM0092S01The viscous paper type filter does not need cleaning.
AIR CLEANERYD
Changing Air Cleaner Filter
EM-14

ComponentsNJEM0054
YEM052
RemovalNJEM0055CAUTION:
When removing the upper oil pan from engine, first remove
the crankshaft position sensor (TDC sensor) from the assem-
bly.
Be careful not to damage sensor edges and signal plate teeth.
1. Remove right engine undercover.
2. Drain engine oil.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
OIL PANYD
Components
EM-15

JEM114G
3. Remove air compressor bracket.
4. Remove lower oil pan bolts.
Loosen bolts in the reverse order of that shown in the figure.
SEM544G
5. Remove lower oil pan.
a. Insert Tool between upper oil pan and lower oil pan.
Be careful not to damage aluminum mating surface.
Do not insert screwdriver, or oil pan flange will be
deformed.
SEM545G
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove lower oil pan.
6. Remove oil strainer.
7. Remove front exhaust tube and its support.
Refer to FE-26, “Removal and Installation”.
JEM553G
8. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger.
Place the jack as close to the center as possible for support.
9. Remove front and rear engine mounting nuts and bolts.
10. Remove center member.
11. Remove crankshaft position sensor (TDC sensor) from oil pan.
12. Remove oil pan cover.
OIL PANYD
Removal (Cont’d)
EM-16