Engine harness NISSAN ALMERA N16 2003 Electronic Repair Manual

GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............3
PRECAUTIONS FOR SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)″AIR BAG″AND
″SEAT BELT PRE-TENSIONER″
.................................3
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...3
GENERAL PRECAUTIONS.........................................4
PRECAUTIONS FOR MULTIPORT FUEL
INJECTION SYSTEM OR ENGINE CONTROL
SYSTEM
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....6
PRECAUTIONS FOR THREE WAY CATALYST...........6
PRECAUTIONS FOR HOSES.....................................6
PRECAUTIONS FOR ENGINE OILS...........................7
PRECAUTIONS FOR FUEL........................................8
PRECAUTIONS FOR AIR CONDITIONING..................9
HOW TO USE THIS MANUAL......................................10
HOW TO READ WIRING DIAGRAMS..........................12
Sample/Wiring Diagram - EXAMPL - ........................12
OPTIONAL SPLICE..................................................13
Description <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[.............14
CONNECTOR SYMBOLS.........................................16
HARNESS INDICATION...........................................17
COMPONENT INDICATION......................................17
SWITCH POSITIONS...............................................17
DETECTABLE LINES AND NON-DETECTABLE
LINES
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......18
MULTIPLE SWITCH.................................................19
REFERENCE AREA.................................................20
HOW TO PERFORM EFFICIENT DIAGNOSES
FOR AN ELECTRICAL INCIDENT...............................22
Work Flow <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[...........22
Incident Simulation Tests ...........................................23
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>3
VEHICLE VIBRATION..............................................23
HEAT SENSITIVE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>4
FREEZING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>24
WATER INTRUSION................................................25
ELECTRICAL LOAD.................................................25
COLD OR HOT START UP.......................................25
Circuit Inspection .......................................................25
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>5
TESTING FOR″OPENS″IN THE CIRCUIT................26
TESTING FOR″SHORTS″IN THE CIRCUIT..............27
GROUND INSPECTION...........................................28
VOLTAGE DROP TESTS..........................................28
CONTROL UNIT CIRCUIT TEST...............................30
HOW TO FOLLOW TROUBLE DIAGNOSES...............32
How to Follow Test Groups in Trouble Diagnoses ....33
Key to Symbols Signifying Measurements or
Procedures<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............34
CONSULT-II CHECKING SYSTEM...............................36
Function and System Application ..............................36
Nickel Metal Hydride Battery Replacement...............37
Checking Equipment..................................................37
CONSULT-II Data Link Connector (DLC) Circuit ......38
INSPECTION PROCEDURE.....................................38
IDENTIFICATION INFORMATION................................39
Model Variation ..........................................................39
FOR EUROPE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>9
FOR AUSTRALIA, NEW ZEALAND AND SOUTH
AFRICA
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....39
PREFIX AND SUFFIX DESIGNATIONS.....................40
Identification Number .................................................40
VEHICLE IDENTIFICATION NUMBER
ARRANGEMENT
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>1
IDENTIFICATION PLATE..........................................41
ENGINE SERIAL NUMBER.......................................42
AUTOMATIC TRANSAXLE NUMBER........................42
MANUAL TRANSAXLE NUMBER..............................43
Dimensions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[...........44
Wheels and Tires .......................................................44
LIFTING POINTS AND TOW TRUCK TOWING...........45
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............45
SPECIAL SERVICE TOOLS......................................45
Board-on Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...........45
Garage Jack and Safety Stand .................................46
2-pole Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............47
Tow Truck Towing ......................................................48
TOWING AN AUTOMATIC TRANSAXLE MODEL
WITH FOUR WHEELS ON GROUND
........................48
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX

PrecautionsNJGI0001Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
SGI646
PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) “AIR BAG” AND “SEAT BELT
PRE-TENSIONER”
NJGI0001S01The Supplemental Restraint System such as “AIR BAG” and “SEAT
BELT PRE-TENSIONER” used along with a seat belt, helps to
reduce the risk or severity of injury to the driver and front passen-
ger for certain types of collision. The SRS system composition
which is available to NISSAN MODEL N16 is as follows (The com-
position varies according to the destination and optional equip-
ment.):
For a frontal collision
The Supplemental Restraint System consists of driver air bag
module (located in the center of the steering wheel), front pas-
senger air bag module (located on the instrument panel on
passenger side), front seat belt pre-tensioners, a diagnoses
sensor unit, warning lamp, wiring harness and spiral cable.
For a side collision
The Supplemental Restraint System consists of front side air
bag module (located in the outer side of front seat), side air bag
(satellite) sensor, diagnoses sensor unit (one of components of
air bags for a frontal collision), wiring harness, warning lamp
(one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in
theRS sectionof this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance should be performed by an authorized
NISSAN dealer.
Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system. For removal of
Spiral Cable and Air Bag Module, see the RS section.
Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses can be identified by yellow and/or
orange harness connector.
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
NJGI0001S02NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PRECAUTIONS
Precautions
GI-3

Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically. Continued refueling may cause fuel
overflow, resulting in fuel spray and possibly a fire.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do
not carelessly disconnect the harness connectors which are
related to the engine control system and TCM (Transmission
Control Module) system. The connectors should be discon-
nected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
SGI787
PRECAUTIONS FOR MULTIPORT FUEL INJECTION
SYSTEM OR ENGINE CONTROL SYSTEM
NJGI0001S04Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air
flow sensor.
PRECAUTIONS FOR THREE WAY CATALYSTNJGI0001S05If a large amount of unburned fuel flows into the catalyst, the cata-
lyst temperature will be excessively high. To prevent this, follow the
instructions below:
Use unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
Do not run engine when the fuel tank level is low, otherwise the
engine may misfire, causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flammable
material off the exhaust pipe and the three way catalyst.
SMA019D
PRECAUTIONS FOR HOSESNJGI0001S06Hose Removal and InstallationNJGI0001S0601To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
PRECAUTIONS
Precautions (Cont’d)
GI-6

NJGI0005
Work FlowNJGI0005S01
SGI838
STEP DESCRIPTION
STEP 1 Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHATVehicle Model, Engine, Transmission and the System (i.e. Radio).
WHENDate, Time of Day, Weather Conditions, Frequency.
WHERERoad Conditions, Altitude and Traffic Situation.
HOWSystem Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem can not be duplicated, refer to “Incident Simulation Tests”next page.
STEP 3 Get the proper diagnoses materials together including:
POWER SUPPLY ROUTING
System Operation Descriptions
Applicable Service Manual Sections
Check for any Service Bulletin.
Identify where to begin diagnoses based upon your knowledge of the system operation and the cus-
tomer comments.
STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing
and Harness Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6 Operate the system in all modes. Verify the system works properly under all conditions. Make sure you
have not inadvertently created a new incident during your diagnoses or repair steps.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Work Flow
GI-22

Incident Simulation TestsNJGI0005S02INTRODUCTIONNJGI0005S0201Sometimes the symptom is not present when the vehicle is brought
in for service. If possible, re-create the conditions present at the
time of the incident. Doing so may help avoid a No Trouble Found
Diagnoses. The following section illustrates ways to simulate the
conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:
Vehicle vibration
Heat sensitive
Freezing
Water intrusion
Electrical load
Cold or hot start up
Get a thorough description of the incident from the customer. It is
important for simulating the conditions of the problem.
VEHICLE VIBRATIONNJGI0005S0202The problem may occur or become worse while driving on a rough
road or when engine is vibrating (idle with A/C on). In such a case,
you will want to check for a vibration related condition. Refer to the
illustration below.
Connectors & Harness
Determine which connectors and wiring harness would affect the
electrical system you are inspecting.Gentlyshake each connec-
tor and harness while monitoring the system for the incident you
are trying to duplicate. This test may indicate a loose or poor elec-
trical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin
film of corrosion on the connector terminals. A visual inspection
may not reveal this without disconnecting the connector. If the
problem occurs intermittently, perhaps the problem is caused by
corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensors & Relays
Gentlyapply a slight vibration to sensors and relays in the system
you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests
GI-23

Engine Compartment
There are several reasons a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for are:
Connectors not fully seated.
Wiring harness not long enough and is being stressed due to
engine vibrations or rocking.
Wires laying across brackets or moving components.
Loose, dirty or corroded ground wires.
Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integ-
rity of ground connections. (Refer to GROUND INSPECTION
described later.) First check that the system is properly grounded.
Then check for loose connection bygently shakingthe wiring or
components as previously explained. Using the wiring diagrams
inspect the wiring for continuity.
Behind The Instrument Panel
An improperly routed or improperly clamped harness can become
pinched during accessory installation. Vehicle vibration can aggra-
vate a harness which is routed along a bracket or near a screw.
Under Seating Areas
An unclamped or loose harness can cause wiring to be pinched by
seat components (such as slide guides) during vehicle vibration. If
the wiring runs under seating areas, inspect wire routing for pos-
sible damage or pinching.
SGI842
HEAT SENSITIVENJGI0005S0203The owner’s problem may occur during hot weather or after car has
sat for a short time. In such cases you will want to check for a heat
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
Do not heat components above 60°C (140°F).If incident occurs
while heating the unit, either replace or properly insulate the com-
ponent.
SGI843
FREEZINGNJGI0005S0204The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez-
ing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnoses
of those electrical components which could be affected.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont’d)
GI-24

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

EM-26
[QG]
FUEL INJECTOR AND FUEL TUBE
FUEL INJECTOR AND FUEL TUBE
PFP:16600
Removal and InstallationEBS00LQ9
CAUTION:
●Apply new engine oil when installing the parts that specified to do so in the figure.
●Do not remove or disassembly parts unless instructed as shown in the figure.
REMOVAL
1. Release fuel pressure. Refer to EC-34, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-427,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Disconnect harness for fuel injector, and move it aside.
3. Remove fuel hose.
CAUTION:
After removal, install blind plug to fuel hose to prevent the fuel from draining.
4. Remove fuel tube and injector assembly with the following pro-
cedure:
a. Loosen mounting bolts in reverse order shown in figure.
b. Pull out fuel injector/fuel tube assembly toward engine rear side.
YEM051
1. Fuel tube 2. Fuel feed hose 3. O-ring
4. Clip 5. Fuel injector 6. Intake manifold
PBIC0617E

ROCKER COVER
EM-29
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
ROCKER COVERPFP:13264
Removal and InstallationEBS00LQA
CAUTION:
Apply new engine oil when installing the parts that specified to do so in the figure.
REMOVAL
1. Move harnesses on top surface and right side of rocker cover, and move them aside.
2. Remove ignition coil. Refer to EM-24, "
Removal and Installation" .
3. Disconnect PCV hoses on rocker cover side.
4. If necessary, remove PCV control valve.
5. If necessary, remove intake valve timing control solenoid valve and camshaft position sensor (PHASE).
CAUTION:
●Do not shock it.
●Do not disassemble it.
●Tip of camshaft position sensor (PHASE) generates strong magnetic fields. Keep it away from
metal particles or objects affected by magnetic fields.
KBIA1375E
1. PCV hose 2. Rocker cover 3. Grommet
4. PCV control valve 5. PCV hose 6.Intake valve timing control solenoid
valve
7. O-ring 8. Oil filter cap 9. Gasket
10. Gasket 11. Rocker cover oil seal 12. Gasket
13. O-ring 14. Camshaft position sensor (PHASE)