front NISSAN ALMERA N16 2003 Electronic Owner's Guide

TIMING CHAIN
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TIMING CHAINPFP:13028
Removal and InstallationEBS00LQD
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Place vehicle on lift.
PBIC0971E
1. Cylinder head front cover 2. Camshaft sprocket (INT) 3. Washer
4. Camshaft sprocket (EXH) 5. Chain tensioner 6. Chain slack guide
7. O-ring 8. Power steering pump adjusting bar 9. Crankshaft pulley
10. Front oil seal 11. Front cover 12. Chain tension guide
13. Dowel pin 14. Timing chain 15. Oil pump drive spacer
16. Crankshaft sprocket 17. O-ring (with collar) 18. Auxiliary bolt of cylinder head

EM-48
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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

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

TIMING CHAIN
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30. Remove timing chain, timing chain slack guide and tension guide.
31. Remove crankshaft sprocket.
INSPECTION AFTER REMOVAL
Timing Chain
Check timing chain for cracks or serious wear. If a malfunction is
detected, replace it.
INSTALLATION
CAUTION:
●Use a scraper to completely remove all liquid gasket adhering to mounting surface. De-grease and
clean with white gasoline.
●After installation, wipe off any protruding liquid gasket.
1. Install timing chain and its related parts with the following procedure:
●For aligning positions for each sprocket and timing chain, and
installed condition of their related parts, refer to figure.
●Install each sprocket with its mating mark facing engine front
side.
a. Install timing chain and crankshaft sprocket.
●Make sure that crankshaft key points straight up (No.1 cylin-
der is at TDC).
●Hook timing chain on front end of camshaft so that it will not
fall off.
b. Install timing chain slack guide and tension guide.
c. Install camshaft sprocket. Refer to EM-35, "
INSTALLATION" .
d. Install chain tensioner. Refer to EM-35, "
INSTALLATION" .
e. Make sure again that mating marks are properly aligned.
f. Temporarily install oil pump drive spacer, crankshaft pulley, and crankshaft pulley mounting bolt so that
crankshaft can be rotated.
g. Rotate crankshaft clockwise several times to make sure it rotates normally. Refer to EM-35, "
INSTALLA-
TION" .
h. Rotate crankshaft clockwise several times, and check that there is no unusual condition.
i. Remove parts temporarily installed in step f.
PBIC0282E
KBIA1398E

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
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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

EM-54
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OIL SEAL
OIL SEAL
PFP:00100
Removal and Installation of Valve Oil SealEBS00LQE
REMOVAL
1. Remove camshaft. Refer to EM-32, "CAMSHAFT" .
2. Remove adjusting shim (if so equipped) and valve lifters. Refer
to EM-32, "
CAMSHAFT" .
3. To prevent valve from falling inside cylinder, turn crankshaft until
cylinder with oil seal to be removed is at top dead center.
CAUTION:
When rotating crankshaft, be careful that timing chain is not
caught by front cover.
4. Using valve spring compressor (special service tool), remove valve collet. Then remove valve spring and
valve spring retainer.
5. Remove valve oil seal using valve oil seal puller (special service
tool).
INSTALLATION
1. Apply engine oil on new valve oil seal joint and seal lip.
2. Using valve oil seal drift (special service tool), press fit valve oil
seal to height shown in figure.
3. Perform steps in the reverse order of removal for the following
operations.
SEM914F
SEM909F
SEM910F

OIL SEAL
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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

ENGINE ASSEMBLY
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ENGINE ASSEMBLYPFP:10001
Removal and InstallationEBS00LQY
YEM017
1. RH engine mounting 2. RH engine mounting bracket 3. LH engine mounting
4. Rear engine mounting bracket 5. Rear engine mounting 6.Dynamic damper (Specific models
only)
7. Center member 8. Front engine mounting bracket 9. Front engine mounting

EM-68
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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