NISSAN ALMERA N16 2003 Electronic Repair Manual

JEM134G
9. Remove chain tensioner.
When removing chain tensioner, push the sleeve of chain ten-
sioner and keep it pressed with a push pin, etc.
10. Remove timing chain slack guide.
JEM135G
11. Hold fuel injection pump sprocket and remove bolt.
a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel injection pump sprocket.
b. Using a TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel injection pump sprocket so that the
holes align.
c. Push positioning stopper pin (SST) through pump sprocket to
fuel injection pump body to hold pump sprocket, and remove
bolt.
JEM136G
12. Remove primary timing chain with fuel injection pump sprocket
and crankshaft sprocket.
JEM137G
13. Remove chain guide and tension guides.
14. Remove fuel injection pump.
15. Remove power steering pump.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
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JEM138G
16. Remove rear chain case.
Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
Use seal cutter (SST) for removal.
INSPECTIONNJEM0094S02Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATIONNJEM0094S03
JEM139G
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-28

JEM140G
1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM141G
b. Install four O-rings to the grooves of the cylinder block, fuel
injection pump bracket.
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c. Install rear chain case.
When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20mm(0.79in):BoltNo.3,4,6,9,10,11,13,14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-29

JEM137G
2. Install power steering pump.
3. Install fuel injection pump.
Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM136G
6. Install primary timing chain with fuel injection pump sprocket.
When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
Install fuel injection pump sprocket washer with the surface
marked “F” (front mark) facing the front of the engine.
7. Install timing chain onto power steering pump sprocket and
through chain guide.
JEM135G
8. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt.
Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt.
JEM134G
9. Install timing chain slack guide.
10. Install chain tensioner.
Push the plunger of the chain tensioner. While keeping plunger
pressed down with a push pin, etc., install the chain tensioner.
After installation, pull out the push pin holding the plunger.
Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
JEM142G
11. Install front oil seal to oil pump.
Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-30

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) as shown in the
figure.
Apply liquid gasket on oil pump-side surface.
JEM144G
13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
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b. Install oil pump drive spacer to crankshaft.
Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
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d. Install oil pump.
When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM146G
14. Check gaps on upper oil pan mounting surface.
Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
Rear chain case and cylinder block
–0.25 to 0.13 mm (–0.0098 to 0.0051 in)
If the measured value is out of the above range, install again.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
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JEM147G
15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST).
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with
one of the punched marks on the bolt.
e. Tighten fixing bolt another 60° - 66° [target: 60° (turn by one
notch)].
16. Install secondary timing chain and the associated parts.
Refer to EM-22, “Secondary Timing Chain”, “INSTALLATION”.
17. Install in the reverse order of removal hereafter.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-32

Removal and InstallationNJEM0109
YEM053
SEM565G
PREPARATIVE WORKNJEM0109S011. Drain engine coolant. Refer to LC-43, “Changing engine cool-
ant”.
2. Remove engine cover. Refer to the figure at left.
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
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INTAKE MANIFOLDYD
Removal and Installation
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JEM238G
FUEL PIPINGNJEM0109S02RemovalNJEM0109S0201To prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
Be careful not to spill fuel in the engine compartment.
InstallationNJEM0109S0202After repairing, bleed air in pipes by shifting priming pump up
and down until the touch is heavy.
For further air bleeding, idle at least 1 minute or more.
SEM489G
INTAKE MANIFOLDNJEM0109S03RemovalNJEM0109S0301Loosen bolts and nuts in the reverse order of that shown in the
figure.
InstallationNJEM0109S0302When stud bolts come off, install with the following torque:
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Tighten fixing bolts in the numerical order shown in the figure.
EGR VOLUME CONTROL VALVENJEM0109S04Handle with care avoiding any shocks.
Do not disassemble or adjust.
YEM054
WATER HOSENJEM0109S05InstallationNJEM0109S0501Install water hose by referring to identification marks; avoiding
twisting.
When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end.
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
INTAKE MANIFOLDYD
Removal and Installation (Cont’d)
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SEM491G
InspectionNJEM0110INTAKE MANIFOLDNJEM0110S01Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
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INTAKE MANIFOLDYD
Inspection
EM-35

Removal and InstallationNJEM0101
JEM264G
PREPARATIVE WORKNJEM0101S01Remove the following parts.
Under cover
Engine coolant (drain)
Refer to LC-43, “Changing Engine Coolant”.
Radiator upper hose
Cooling fan
Refer to LC-42, “Radiator”.
Radiator mount bracket
Water inlet pipe
Exhaust front tube (disconnect)
Refer to FE-26, “Removal and Installation”, “EXHAUST SYS-
TEM”.
CATALYSTNJEM0101S02RemovalNJEM0101S0201Remove the catalyst, refer to above illustration.
CAUTION:
Do not disassemble.
InstallationNJEM0101S0202Install two locking pins into both sides of the catalytic converter. Be
careful not to confuse locking pins with insulator mounting bolts.
Catalytic converter locking pin:
Flange bolt (black)
Insulator mounting bolt:
Washer bolt (silver or yellow)
CATALYSTYD
Removal and Installation
EM-36