air bleeding NISSAN ALMERA N16 2003 Electronic Repair Manual

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)
EM-34

While filling, if coolant from engine side spills out, be sure to
reconnect the heater hose.
Fill coolant to the level of the radiator cap at a rate of 2(1-3/4
Imp qt)/min or lower.
(Close the air relief plugs in order starting with the location from
where the coolant began spilling out.)
CAUTION:
If the filling rate is too fast, this could lead to air being mixed
in the coolant. Be sure to fill the coolant slowly according to
the rate indicated above.
Replace the copper washer of the air bleeding plug.
Air relief plug:
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
Use genuine Nissan anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).
SMA182B
SMA412B
Refer to MA-19, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
8.7(7-5/8 Imp qt)
Reservoir tank capacity:
0.7(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
4. Fill radiator and reservoir tank to specified level.
5. Warm up engine to normal operating temperature without
radiator cap installed.
If coolant overflows radiator filler hole, install radiator cap.
6. Run engine at 3,000 rpm for 10 seconds and return to idle
speed with radiator cap installed.
Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
7. Stop engine and cool it down.
Cool down using a fan to reduce the time.
If necessary, refill radiator up to filler neck with coolant.
8. Refill reservoir tank to MAX level line with coolant.
9. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
10. Check cooling system for leaks with engine running.
11. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 3,000 rpm with heater tempera-
ture controller set at several positions between COOL and
HOT.
Sound may be noticeable at heater water cock.
12. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until coolant level no longer drops
Clean excess coolant from engine.
ENGINE COOLING SYSTEMYD
Changing Engine Coolant (Cont’d)
LC-44

JEF346Y
Inspection for Spill Tube AirtightnessNJEC0619S01Before the rocker cover is installed, perform the inspection as fol-
lows.
1. Connect the handy vacuum pump to the spill hose.
2. Check that the airtightness is maintained after the negative
pressure shown below is applied.
Standard:
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –500
mmHg, –15.75 to –19.69 inHg)
JEF347Y
Air Bleeding of Fuel PipingNJEC0619S02After the repair, bleed air in the piping by pumping the priming
pump up and down until it becomes heavy.
JEF348Y
Injection Pressure TestNJEC0619S031. Install injection nozzle assembly to injection nozzle tester and
bleed air from flare nut.
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
New
21,476 - 22,457 kPa (214.7 - 224.5 bar, 219 - 229
kg/cm
2, 3,114 - 3,256 psi)
Limit
18,275 kPa (182.7 bar, 186 kg/cm
2, 2,650 psi)
The injection nozzle assembly has a 2-stage pressure injection
function. However, the judgement should be made at the first
stage of the valve opening pressure.
Always check initial injection pressure using a new nozzle.
BASIC SERVICE PROCEDUREYD
Injection Tube and Injection Nozzle (Cont’d)
EC-24

Fuel Filter
DESCRIPTIONNJEC0623A water draining cock is on the lower side and a priming pump for
bleeding air is on the upper side.
SEF375Y
AIR BLEEDINGNJEC06241. After the repair, bleed air from the piping by pumping the prim-
ing pump up and down until it becomes heavy.
2. To start the engine, rotate the starter for a maximum of 30
seconds. To start the engine more quickly, crank the engine
while pumping the priming pump (requires two workers).
3. If the engine does not start after rotating the starter for a maxi-
mum of 30 seconds, stop it once, and pump the priming pump
again until it becomes heavy.
4. Rotate the starter again until the engine starts running.
5. After the engine starts, let it idle for at least 1 minute to stabi-
lize the behavior.
When air is bled completely, the pumping of the priming
pump suddenly becomes heavy. Stop the operation at that
time.
If it is difficult to bleed air by the pumping of the priming
pump (the pumping of the priming pump does not become
heavy), disconnect the fuel supply hose between the fuel
filter and the injection pump. Then, perform the operation
described above, and make sure that fuel comes out. (Use
a pan, etc. so as not to spill fuel. Do not let fuel get on
engine and other parts.) After that, connect the hose, then
bleed air again.
Start engine and let it idle for at least one minute after
performing air bleeding.
WATER DRAININGNJEC06251. Remove the fuel filter, filter bracket, protector assembly from
the dash panel as follows.
a. Remove the air cleaner case (upper), air duct assembly, and
vacuum hose for brake booster (between the vacuum pump
and vacuum pipe).
CAUTION:
After the duct is removed, cover the opening with gum tape,
etc. to prevent foreign object from getting into the engine
during the operation.
b. Disconnect the water level warning sensor harness connector.
c. Remove the mounting nuts on the dash panel, then remove the
fuel filter, filter bracket, and protector assembly from the dash
panel.
It is not necessary to disconnect the fuel hose.
2. Using a tool such as a pliers, loosen the water draining cock
at the bottom of the water level warning sensor located under
the fuel filter.
BASIC SERVICE PROCEDUREYD
Fuel Filter
EC-32

3. Install the fuel filter, filter bracket, and protector assembly tem-
porarily. Then, drain the water by pumping the priming pump
with the filter standing straight.
Extend the drain hose if necessary.
Water amount when the MI lights up:
65 - 100 m(2.3 - 3.5 Imp fl oz)
CAUTION:
When the water is drained, the fuel is also drained. Use a pan,
etc. to avoid fuel adherence to the rubber parts such as the
engine mount insulator.
4. Tighten the water draining cock, then install the fuel filter, filter
bracket, protector assembly in the reverse order of removal.
CAUTION:
Do not over-tighten the water draining cock. This will damage
the cock thread, resulting in water or fuel leak.
5. Bleed air of the fuel filter. Refer to EC-32.
Start engine and let it idle for at least one minute after
performing air bleeding.
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BASIC SERVICE PROCEDUREYD
Fuel Filter (Cont’d)
EC-33

3 CHECK IDLE SPEED
With CONSULT-II
1. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
2. Read idle speed.
SEF817Y
Without CONSULT-II
Check idle speed.
725±25 rpm
OK or NG
OKINSPECTION END
NG GO TO 4.
4 CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK GO TO 5.
NG Repair or replace.
5 BLEED AIR FROM FUEL SYSTEM
1. Stop engine.
2. Use priming pump to bleed air from fuel system. Refer to “AIR BLEEDING”, EC-32.
GO TO 6.
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TROUBLE DIAGNOSIS — BASIC INSPECTIONYD
Basic Inspection (Cont’d)
EC-49

SMA803A
Checking Fuel LinesNJFE0019Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.
If necessary, repair or replace.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
SMA794C
Water Draining from Fuel FilterNJFE0028DRAINING WATERNJFE0028S01Open drain valve at the bottom of fuel filter.
FUEL FILTER CHECKNJFE0028S02Check fuel filter for fuel leakage, damage and other abnormal
things.
JFE598A
Changing Fuel FilterNJFE0021REMOVALNJFE0021S011. Take out air duct and upper air cleaner case.
2. Remove fuel filter using a fuel filter wrench (commercial ser-
vice tool).
CAUTION:
Do not spill the fuel during removal. If the fuel is spilt, imme-
diately wipe it off. Be especially careful to prevent the fuel
from adhering to the insulators of the engine mounts.
3. Remove fuel-level warning sensor from fuel filter.
YFE008
INSTALLATIONNJFE0021S02Install in the reverse order of removal.
Tighten the fuel filter so that the sealing face contacts the
packing, then retighten it manually by approximately 2/3 turn.
After installation, operate the priming pump vertically to per-
form air bleeding.
Refer to FE-16, “Bleeding Fuel Filter”.
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FUEL SYSTEMYD
Checking Fuel Lines
FE-15

JEM238G
Bleeding Fuel FilterNJFE00231. After the repair, bleed air from the piping by pumping the prim-
ing pump up and down until it becomes heavy.
2. To start the engine, rotate the starter for a maximum of 30
seconds.
To start the engine more quickly, crank the engine while pump-
ing the priming pump (requires two workers).
3. If the engine does not start after rotating the starter for a maxi-
mum of 30 seconds, stop it once, and pump the priming pump
again until it becomes heavy.
4. Rotate the starter again until the engine starts running.
5. After the engine starts, let it idle for at least 1 minute to stabi-
lize the behavior.
NOTE:
When air is bled completely, pumping the priming pump sud-
denly becomes heavy.
Stop the operation at that time.
If it is difficult to bleed air by pumping the priming pump (the
priming pump does not become heavy during pumping), dis-
connect the fuel supply hose between the fuel filter and the
injection pump. Then, pump the priming pump up and down,
and make sure that fuel comes out. (Use a pan and be care-
ful not to spill fuel. Keep fuel clear of the engine.) After that,
connect the hose, then bleed air again.
DEF017
Checking Priming PumpNJFE0024Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from the
hose end. If not, replace priming pump.
Removal and InstallationNJFE0015WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a “CAUTION: FLAMMABLE” sign in workshop.
Be sure to furnish workshop with a CO
2fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
a) Put drained fuel in an explosion-proof container and put the lid on securely.
b) Disconnect battery ground cable.
FUEL SYSTEMYD
Bleeding Fuel Filter
FE-16

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[2
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............2
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Special Service Tools ..................................................3
Commercial Service Tools ...........................................3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>4
NVH Troubleshooting Chart.........................................4
CLUTCH<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....4
CLUTCH SYSTEM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>5
Components - RHD Model with QG Engine - .............5
Components - LHD Model with QG Engine -..............6
Components - RHD Model with YD Engine -..............7
Components - LHD Model with YD Engine - ..............8
Inspection and Adjustment ..........................................9
CLUTCH PEDAL INSPECTION...................................9
CLUTCH PEDAL ADJUSTMENT...............................10
AIR BLEEDING PROCEDURE..................................10
CLUTCH MASTER CYLINDER..................................... 11
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.......... 11
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............12
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............12
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........12
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............12
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............13
OPERATING CYLINDER...............................................14
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........14
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............14
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........14
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............14
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............15
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............15
PIPING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[............16
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............16Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............16
RS5F30A, RS5F70A
CLUTCH RELEASE MECHANISM...............................17
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........17
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............17
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............17
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............17
RS5F50A
CLUTCH RELEASE MECHANISM...............................20
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........20
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............20
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............20
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............20
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....22
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........22
Inspection and Adjustment ........................................22
CLUTCH DISC<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>2
CLUTCH COVER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>3
FLYWHEEL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>3
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............23
SERVICE DATA AND SPECIFICATIONS (SDS).........24
Clutch Control System ...............................................24
Clutch Master Cylinder ..............................................24
Clutch Operating Cylinder .........................................24
Clutch Disc<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............24
Clutch Cover <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..........24
Clutch Pedal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..........24
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CLUTCH PEDAL ADJUSTMENTNJCL0006S04Pedal StrokeNJCL0006S04011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free
play.
Pedal stroke “S”.
Refer to “SDS”, CL-24.
Pedal Free PlayNJCL0006S04021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
Pedal free play “A”.
Refer to “SDS”, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENJCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
Carefully monitor fluid level at master cylinder during
bleeding operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, then air bubbles
will no longer appear at the damper in the brake fluid.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont’d)
CL-10