fuel cap NISSAN ALMERA N16 2003 Electronic Repair Manual

SEF289H
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
SGI233
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
SGI234
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
Arrange the disassembled parts in accordance with their
assembled locations and sequence.
Do not touch the terminals of electrical components which use
microcomputers (such as ECMs).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents
when required.
Use tools and recommended special tools where specified for
safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
MA
EM
LC
EC
FE
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MT
AT
AX
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BR
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RS
BT
HA
SC
EL
IDX
PRECAUTIONS
Precautions (Cont’d)
GI-5

EM-72
[QG]
CYLINDER BLOCK
●A commercial engine stand can be used.
NOTE:
●This example is an engine stand for holding at transaxle
mounting side with the flywheel or drive plate removed.
3. Drain engine oil and coolant from inside of engine.
4. Remove the following components and associated parts.
●Fuel tube and injector assembly; Refer to EM-26, "Removal and Installation" .
●Intake manifold and intake manifold collector assembly; Refer to EM-16, "Removal and Installation" .
●Ignition coil; Refer to EM-24, "Removal and Installation" .
●Rocker cover; Refer to EM-29, "Removal and Installation" .
●Oil pan and oil strainer; Refer to EM-22, "Removal and Installation" .
●Front cover and timing chain; Refer to EM-47, "Removal and Installation" .
●Camshaft; Refer to EM-32, "Removal and Installation" .
●Cylinder head assembly; Refer to EM-58, "Removal and Installation" .
●Auxiliary brackets and oil filter
5. Remove knock sensor.
CAUTION:
Avoid impacts such as a dropping.
6. Remove crankshaft position sensor (POS).
CAUTION:
●Avoid impacts such as a dropping.
●Do not disassemble.
●Keep it away from metal particles.
●Do not place sensor close to magnetic materials.
7. Remove flywheel (M/T models) or drive plate (A/T models). Fix
crankshaft with a ring gear stopper (special service tool), and
remove mounting bolts.
8. Remove rear plate.
9. Remove rear oil seal retainer.
●Insert a flat-bladed screwdriver between main bearing cap
and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.
●Punch out with a flat-bladed screwdriver.
CAUTION:
●Be careful not to damage rear oil seal retainer.
PBIC0085E
PBIC0586E
SEM880F

JEM193G
d. Hoist up engine and install it on the engine stand (SST).
Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
Exhaust manifold
Turbocharger assembly (For Europe)
Injection tube
Intake manifold
Oil pan (upper and lower)
Secondary timing chain
Fuel injection pump
Primary timing chain
Rocker cover
High pressure injection nozzle assembly
Camshaft
Cylinder head
Thermostat, water pipes
Oil cooler
Auxiliary component brackets
5. Remove fuel injection pump bracket.
SEM500G
6. If the replacement of pilot bushing is necessary, remove it with
pilot bushing puller (SST).
7. Remove rear oil seal retainer.
Insert a flat-bladed screwdriver between main bearing cap and
rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
Punch out with a flat-bladed screwdriver.
Be careful not to damage rear oil seal retainer.
JEM195G
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-70, “CONNECT-
ING ROD SIDE CLEARANCE”.
10. Remove connecting rod bearings from connecting rod and
connecting rod cap.
CYLINDER BLOCKYD
Disassembly (Cont’d)
EM-68

PREPARATION
EC-19
[QG (WITH EURO-OBD)]
C
D
E
F
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EC
PREPARATIONPFP:00002
Special Service ToolsEBS00K2Z
Commercial Service ToolsEBS00K30
Tool number
Tool nameDescription
KV10117100
Heated oxygen
sensor wrenchLoosening or tightening heated oxygen sensors
with 22 mm (0.87 in) hexagon nut
KV10114400
Heated oxygen
sensor wrenchLoosening or tightening heated oxygen sensors
a: 22 mm (0.87 in)
KV109E0010
Break-out boxMeasuring the ECM signals with a circuit tester
KV109E0080
Y-cable adapterMeasuring the ECM signals with a circuit tester
S-NT379
S-NT636
S-NT825
S-NT826
Tool name Description
Quick connector
releaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
Fuel filler cap adapter Checking fuel tank vacuum relief valve opening
pressure
PBIC0198E
S-NT653

TROUBLE DIAGNOSIS
EC-61
[QG (WITH EURO-OBD)]
C
D
E
F
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EC
DIAGNOSTIC WORKSHEET
Description
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make trou-
bleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
●Vehicle ran out of fuel, which caused the engine to misfire.
●Fuel filler cap was left off or incorrectly screwed on, allowing fuel
to evaporate into the atmosphere.
SEF907L

TROUBLE DIAGNOSIS
EC-73
[QG (WITH EURO-OBD)]
C
D
E
F
G
H
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J
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EC
1 - 6: The numbers refer to the order of inspection.Cooling Radiator/Hose/Radiator filler cap
55555 55 25LC-12
Thermostat 5 LC-15
Water pumpLC-14
Water galleryLC-12
Cooling fan 5 LC-17
Coolant level (low)/Contaminated
coolantLC-17
NATS (Nissan Anti-Theft System) 1 1EC-49
or
EL-386 SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA

EC-172
[QG (WITH EURO-OBD)]
DTC P0138 HO2S2
DTC P0138 HO2S2
PFP:226A0
Component DescriptionEBS00K69
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS00K6A
Specification data are reference values.
On Board Diagnosis LogicEBS00K6B
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.LEAN ←→ RICH
SEF305UA
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0138
0138Heated oxygen sensor 2
circuit high voltageAn excessively high voltage from the sensor
is sent to ECM.
●Harness or connectors
(The sensor circuit is open or shorted.)
●Heated oxygen sensor 2

EC-178
[QG (WITH EURO-OBD)]
DTC P0139 HO2S2
DTC P0139 HO2S2
PFP:226A0
Component DescriptionEBS00K6H
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS00K6I
Specification data are reference values.
On Board Diagnosis LogicEBS00K6J
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst causes the longer
switching time. To judge the malfunctions of heated oxygen sensor
2, ECM monitors whether the switching response of the sensor's
voltage is faster than specified during the various driving condition
such as fuel-cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.LEAN ←→ RICH
SEF302U
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0139
0139Heated oxygen sensor 2
circuit slow responseIt takes more time for the sensor to respond
between rich and lean than the specified time.
●Harness or connectors
(The sensor circuit is open or shorted.)
●Heated oxygen sensor 2
●Fuel pressure
●Injectors
●Intake air leaks

EC-246
[QG (WITH EURO-OBD)]
DTC P0420 THREE WAY CATALYST FUNCTION
DTC P0420 THREE WAY CATALYST FUNCTION
PFP:20905
On Board Diagnosis LogicEBS00K8J
The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 and 2.
A three way catalyst (Manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (Manifold)
malfunction is diagnosed.
DTC Confirmation ProcedureEBS00K8K
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:
●Open engine hood before conducting the following procedure.
●Do not hold engine speed for more than the specified minutes below.
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch ″OFF″ and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no
load.
4. Let engine idle for one minute.
5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUP-
PORT” mode with CONSULT-II.
6. Rev engine up to 2,500 to 3,500 rpm and hold it for 3 consecu-
tive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 9
7. Wait 5 seconds at idle.
SEF484YF
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0420
0420Catalyst system efficiency
below threshold
●Three way catalyst (Manifold) does not operate
properly.
●Three way catalyst (Manifold) does not have
enough oxygen storage capacity.
●Three way catalyst (Manifold)
●Exhaust tube
●Intake air leaks
●Fuel injectors
●Fuel injector leaks
●Spark plug
●Improper ignition timing
PBIB0566E

EC-308
[QG (WITH EURO-OBD)]
DTC P1146 HO2S2
DTC P1146 HO2S2
PFP:226A0
Component DescriptionEBS00KAU
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS00KAV
Specification data are reference values.
On Board Diagnosis LogicEBS00KAW
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the minimum voltage of sensor is
sufficiently low during the various driving condition such as fuel-cut.
DTC Confirmation ProcedureEBS00KAX
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)
●Engine: After warming up
●Keeping the engine speed
between 3,500 and 4,000 rpm
for one minute and at idle for
one minute under no loadRevving engine from idle to 3,000
rpm quickly.LEAN ←→ RICH
SEF258VA
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P1146
1146Heated oxygen sensor 2
minimum voltage monitoringThe minimum voltage from the sensor is not
reached to the specified voltage.
●Harness or connectors
(The sensor circuit is open or shorted.)
●Heated oxygen sensor 2
●Fuel pressure
●Injectors