Power condition NISSAN ALMERA N16 2003 Electronic Repair Manual

SERVICE DATA AND SPECIFICATIONSare contained at the end of each section for quick reference of
data.
The followingSYMBOLS AND ABBREVIATIONSare used:
SYMBOL ABBREVIATION SYMBOL ABBREVIATION
Tightening torque
2WD2-Wheel Drive
Should be lubricated with grease. Unless oth-
erwise indicated, use recommended multi-pur-
pose grease.A/CAir Conditioner
Should be lubricated with oil. P/S Power Steering
Sealing point SST Special Service Tools
Checking point SAE Society of Automotive Engineers, Inc.
Always replace after every disassembly. ATF Automatic Transmission Fluid
P
Apply petroleum jelly.
D1Drive range 1st gear
Apply ATF. D2Drive range 2nd gear
★Select with proper thickness. D
3Drive range 3rd gear
✩Adjustment is required. D
4Drive range 4th gear
SDS Service Data and Specifications OD Overdrive
LH, RH Left-Hand, Right-Hand 2
22nd range 2nd gear
FR, RR Front, Rear 2
12nd range 1st gear
M/T Manual Transaxle/Transmission 1
21st range 2nd gear
A/T Automatic Transaxle/Transmission 1
11st range 1st gear
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
HOW TO USE THIS MANUAL
GI-11

Description=NJGI0003S02
Number Item Description
1 Power conditionThis shows the condition when the system receives battery positive voltage (can be
operated).
2 Fusible linkThe double line shows that this is a fusible link.
The open circle shows current flow in, and the shaded circle shows current flow out.
3Fusible link/fuse loca-
tionThis shows the location of the fusible link or fuse in the fusible link or fusebox.For
arrangement, refer to EL-12, “POWER SUPPLY ROUTING”.
4FuseThe single line shows that this is a fuse.
The open circle shows current flow in, and the shaded circle shows current flow out.
5 Current rating This shows the current rating of the fusible link or fuse.
6 ConnectorsThis shows that connector E3 is female and connector M1 is male.
The G/R wire is located in the 1A terminal of both connectors.
Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ con-
nector. Refer to GI-20.
7 Optional splice The open circle shows that the splice is optional depending on vehicle application.
8 Splice The shaded circle shows that the splice is always on the vehicle.
9 Page crossingThis arrow shows that the circuit continues to an adjacent page.
The A will match with the A on the preceding or next page.
10 Common connectorThe dotted lines between terminals show that these terminals are part of thesamecon-
nector.
11 Option abbreviation This shows that the circuit is optional depending on vehicle application.
12 RelayThis shows an internal representation of the relay. For details, refer to EL-9, “STAN-
DARDIZED RELAY”.
13 Connectors This shows that the connector is connected to the body or a terminal with bolt or nut.
14 Wire colorThis shows a code for the color of the wire.
B=Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
LG = Light GreenBR = Brown
OR = Orange
P = Pink
PU = Purple
GY = Gray
SB = Sky Blue
CH = Dark Brown
DG=DarkGreen
When the wire color is striped, the base color is given first, followed by the stripe color as
shown below:
Example: L/W = Blue with White Stripe
15 Option description This shows a description of the option abbreviationused on the page.
16 SwitchThis shows that continuity exists between terminals 1 and 2 when the switchis in the A
position. Continuity exists between terminals 1 and 3 when the switch is inthe B posi-
tion.
17 Assembly parts Connector terminal in component shows that it is a harness incorporated assembly.
18 Cell codeThis identifies each page of the wiring diagram by section, system and wiring diagram
page number.
19 Current flow arrowArrow indicates electric current flow, especially where the direction ofstandard flow (ver-
tically downward or horizontally from left to right) is difficult to follow.
A double arrow “
” shows that current can flow in either direction depending on cir-
cuit operation.
HOW TO READ WIRING DIAGRAMS
Description
GI-14

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

TESTING FOR “OPENS” IN THE CIRCUITNJGI0005S0302Before you begin to diagnose and test the system, you should
rough sketch a schematic of the system. This will help you to logi-
cally walk through the diagnoses process. Drawing the sketch will
also reinforce your working knowledge of the system.
SGI846
Continuity Check Method
The continuity check is used to find an open in the circuit. The
Digital Multimeter (DMM) set on the resistance function will indicate
an open circuit as over limit (no beep tone or no ohms symbol).
Make sure to always start with the DMM at the highest resistance
level.
To help in understanding the diagnoses of open circuits please
refer to the schematic above.
1) Disconnect the battery negative cable.
2) Start at one end of the circuit and work your way to the other
end. (At the fuse block in this example)
3) Connect one probe of the DMM to the fuse block terminal on
the load side.
4) Connect the other probe to the fuse block (power) side of SW1.
Little or no resistance will indicate that portion of the circuit has
good continuity. If there were an open in the circuit, the DMM
would indicate an over limit or infinite resistance condition.
(point A)
5) Connect the probes between SW1 and the relay. Little or no
resistance will indicate that portion of the circuit has good con-
tinuity. If there were an open in the circuit, the DMM would
indicate an over limit or infinite resistance condition. (point B)
6) Connect the probes between the relay and the solenoid. Little
or no resistance will indicate that portion of the circuit has good
continuity. If there were an open in the circuit, the DMM would
indicate an over limit or infinite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the above
example.
Voltage Check Method
To help in understanding the diagnoses of open circuits please
refer to the previous schematic.
In any powered circuit, an open can be found by methodically
checking the system for the presence of voltage. This is done by
switching the DMM to the voltage function.
1) Connect one probe of the DMM to a known good ground.
2) Begin probing at one end of the circuit and work your way to
the other end.
3) With SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
4) Close SW1 and probe at relay.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
GI-26

SGI854
CONTROL UNIT CIRCUIT TESTNJGI0005S0306System Description: When the switch is ON, the control unit lights
up the lamp.
MGI034A
Input-output voltage chart
Pin No. Item ConditionVoltage
value VIn case of high resistance such as single strand V *
1 Switch Switch ON Battery voltage Lower than battery voltage Approx. 8 (Example)
Switch OFF Approx. 0 Approx. 0
2 Lamp Switch ON Battery voltage Approx. 0 (Inoperative lamp)
Switch OFF Approx. 0 Approx. 0
The voltage value is based on the body ground.
* : If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit
does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the
lamp.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
GI-30

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

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION
A
EM
ENGINE MECHANICAL
QG
PRECAUTIONS .......................................................... 3
Precautions for Drain Coolant .................................. 3
Precautions for Disconnecting Fuel Piping .............. 3
Precautions for Removal and Disassembly ............. 3
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 3
Precautions for Assembly and Installation ............... 3
Parts Requiring Angular Tightening ......................... 3
Precautions for Liquid Gasket .................................. 4
REMOVAL OF LIQUID GASKET SEALING .......... 4
LIQUID GASKET APPLICATION PROCEDURE ..... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 9
NVH Troubleshooting —Engine Noise ..................... 9
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 10
DRIVE BELTS ............................................................11
Checking Drive Belts ............................................... 11
Tension Adjustment ................................................ 12
POWER STEERING PUMP AND WATER PUMP
BELT ................................................................... 12
ALTERNATOR AND AIR CONDITIONER COM-
PRESSOR BELT ................................................. 12
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
AIR CLEANER AND AIR DUCT ............................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Changing Air Cleaner Element ............................... 15
INTAKE MANIFOLD ................................................. 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 18EXHAUST MANIFOLD AND CATALYTIC CON-
VERTER .................................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
Disassembly and Assembly .................................... 21
DISASSEMBLY ................................................... 21
ASSEMBLY ......................................................... 21
OIL PAN AND OIL STRAINER ..............................
... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 23
IGNITION COIL ......................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
SPARK PLUG (CONVENTIONAL) ........................... 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 25
INSTALLATION ................................................... 25
FUEL INJECTOR AND FUEL TUBE ........................ 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 28
ROCKER COVER ..................................................... 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 30
CAMSHAFT .............................................................. 32
Removal and Installation ........................................ 32
REMOVAL ........................................................... 32
INSTALLATION ................................................... 35

DRIVE BELTS
EM-11
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LPY
●Before 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 contacting surfaces and edge areas.
●When measuring deflection, apply 98 N (10 kg, 22 lb) at the ▼ marked point.
CAUTION:
When measuring belt tension immediately after belt is installed, first set the tension to the standard.
Then, rotate crankshaft for more than two turns in order to eliminate variance in belt deflection
between the pulleys. Re-measure and adjust the tension to the standard.
PBIC0764E
Deflection adjustment Unit: mm (in)
Used belt
New belt
Limit After adjustment
AlternatorWithout air conditioner compressor 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
With air conditioner compressor 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)
Power steering oil pump 7.1 (0.280)4.4 - 4.9
(0.173 - 0.193)3.9 - 4.4
(0.154 - 0.173)
Applied pushing force 98 N (10 kg, 22 lb)

EM-12
[QG]
DRIVE BELTS
Tension Adjustment
EBS00LPZ
CAUTION:
●When belt is replaced with a new one, tighten it a little
stronger than current one to accommodate for insufficient
adaptability with pulley grooves.
●When tension of belt being used exceeds “Retightening
limit”, adjust it to value for “Used belt”.
●When installing belt, make sure that it is correctly engaged with pulley groove.
●Keep oil and water away from belt.
●Do not twist or bend belt excessively.
●When adjusting belt, remove snap retainer from adjusting bolt thread (to prevent the retainer from
becoming pinched or missing).
●After adjustment, be sure to install snap retainer to adjusting bolt thread.
NOTE:
Snap retainer can prevent adjusting bolt from dropping due to vibration during driving.
POWER STEERING PUMP AND WATER PUMP BELT
1. Loosen lock nut (A) and power steering pump mounting nut (B).
2. Turn adjusting bolt (C) to adjust. Refer to EM-11, "
Checking
Drive Belts" .
3. Tighten lock nut (A) and power steering pump mounting nut (B)
in this order.
ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
1. Remove RH splash cover (with undercover attached).
2. Loosen lock nut (G).
3. Turn adjusting bolt (H) to adjust.
Refer to EM-11, "
Checking Drive Belts" .
4. Tighten lock nut (G).
Portion Belt tightening method for adjustment
Power steering pump and water pump
beltAdjusting bolt on power steering pump
Alternator and air conditioner compres-
sor beltAdjusting bolt on idler pulley
PBIC0531E
Nut A :
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Nut B :
: 26.5 - 36.3 N·m (2.7 - 3.7 kg-m, 20 - 26 ft-lb)
PBIC0532E
Nut G :
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)

EM-68
[QG]
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