flow 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
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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

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

Number Item Description
20 System branchThis shows that the system branches to another system identified by cell code (section
and system).
21 Page crossingThis arrow shows that the circuit continues to another page identified by cell code.
The C will match with the C on another page within the system other than the next or
preceding pages.
22 Shielded line The line enclosed by broken line circle shows shield wire.
23Component box in
wave lineThis shows that another part of the component is also shown on another page (indicated
by wave line) within the system.
24 Component name This shows the name of a component.
25 Connector numberThis shows the connector number.
The letter shows which harness the connector is located in.
Example:M: main harness. For detail and to locate the connector, refer to EL-556, “Main
Harness”. A coordinate grid is included for complex harnesses to aid in locating connec-
tors.
26 Ground (GND)The line spliced and grounded under wire color shows that ground line is spliced at the
grounded connector.
27 Ground (GND)This shows the ground connection. For detailed ground distribution information, refer to
EL-24, “GROUND DISTRIBUTION”.
28 Connector viewsThis area shows the connector faces of the components in the wiring diagramon the
page.
29 Common componentConnectors enclosed in broken line show that these connectors belong to thesamecom-
ponent.
30 Connector colorThis shows a code for the color of the connector. For code meaning, refer to wire color
codes, Number 14 of this chart.
31Fusible link and fuse
boxThis shows the arrangement of fusible link(s) and fuse(s), used for connector views of
“POWER SUPPLY ROUTING” in EL section.
The open square shows current flow in, and the shaded square shows current flow out.
32 Reference areaThis shows that more information on the Super Multiple Junction (SMJ), Electrical Units,
exists at the end of the manual. Refer to GI-20 for details.
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HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
GI-15

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

NJGI0006
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1)Before performing trouble diagnoses, read the “Prelimi-
nary Check”, the “Symptom Chart” or the “Work Flow”.
2)After repairs, re-check that the problem has been com-
pletely eliminated.
3)Refer to Component Parts and Harness Connector Loca-
tion for the Systems described in each section for
identification/location of components and harness con-
nectors.
4)Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness
connectors in more detail, such as when a sub-harness is
used, refer to Wiring Diagram in each individual section
and Harness Layout in EL section for identification of har-
ness connectors.
5)When checking circuit continuity, ignition switch should
be OFF.
6)Before checking voltage at connectors, check battery volt-
age.
7)After accomplishing the Diagnostic Procedures and Elec-
trical Components Inspection, make sure that all harness
connectors are reconnected as they were.
HOW TO FOLLOW TROUBLE DIAGNOSES
GI-32

NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Malfunction indicator MI Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection system MFI system Fuel injection control
Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnoses
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
Park/neutral position switch PNP switch Park/neutral switch
Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system ***
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control
solenoid valvePAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
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ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 (Cont’d)
GI-53

NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Simultaneous multiport fuel injection sys-
tem*** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter
systemTWC + OC system ***
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancelsolenoid
Lock-up solenoid
Transmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
temWU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter
systemWU-TWC system ***
Wide open throttle position switch WOTP switch Full switch
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 (Cont’d)
GI-54

EM-14
[QG]
AIR CLEANER AND AIR DUCT
AIR CLEANER AND AIR DUCT
PFP:16500
Removal and InstallationEBS00LQ1
REMOVAL
1. Remove air cleaner case assembly, air duct and resonator.
●Add marks as necessary for easier installation.
2. Remove harness connector from mass air flow sensor.
3. Remove mass air flow sensor.
CAUTION:
Handle mass air flow sensor with following cares.
●Do not shock it.
●Do not disassembly it.
●Do not touch its sensor.
●Do not deform mass air flow sensor's wire mesh.
4. Remove left fender protector and resonator.
INSTALLATION
1. Attach each joint aligning marks put at removal. Screw clamps firmly.
2. Install in the reverse order of removal.
PBIC0533E
1. Air cleaner case (upper) 2. Resonator 3. Air duct
4. Mass air flow sensor 5. O-ring 6. Air cleaner case (lower)
7. Grommet 8. Air cleaner element 9. Bracket

EM-104
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
CONNECTING ROD BEARING
Standard Size
Unit: mm (in)
Undersize
Unit: mm (in)
Bearing Clearance
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
*: Total indicator reading
Tightening TorqueEBS00LQQ
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb) / Unit: N·m (kg-m, in-lb)*2
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) Block
1 1.506 - 1.509 (0.0593 - 0.0594) Red
2 1.509 - 1.512 (0.0594 - 0.0595) Green
Grade No. Thickness Identification color or number
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) —
0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) —
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) —
Connecting rod bearing clear-
anceStandard 0.014 - 0.039 (0.0006 - 0.0015)
Limit 0.1 (0.004)
Flywheel runout [TIR*] Less than 0.1 (0.004)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
Mass air flow sensor
8.4 - 10.8 (0.9 - 1.1, 75 - 95)*2
Resonator
3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2
Air cleaner case lower
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*2
Intake manifold16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Intake manifold collector
7.0 - 9.5 (0.71 - 0.97, 62 - 84)*
2
Intake manifold support 16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Electric throttle control actuator 17.7 - 21.6 (1.8 - 2.2, 13 - 15)
Exhaust manifold25.5 - 29.4 (2.6 - 2.9, 19 - 21)
Exhaust manifold cover
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*
2
Heated oxygen sensor 58.8 - 78.4 (6.0 - 7.9, 44 - 57)
Ground nut79.4 (8.1, 59)
Oil pan
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Oil pan drain plug29.4 - 39.2 ( 3.0 - 3.9, 22 - 28)
Oil strainer
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Ignition coil
3.8 - 5.0 (0.38 - 0.51, 33 - 44)*2
Spark plug19.6 - 29.4 (2.0 - 3.0, 15 - 21)
*1 Fuel tube1) 11.8 - 13.8 (1.2 - 1.4, 9 - 10 )
2) 17 - 23 (1.7 - 2.4, 13 - 17)
Rocker cover
6.9 - 9.5 (0.70 - 0.97, 61 - 84)*
2