wheel bolts NISSAN ALMERA N16 2003 Electronic Repair Manual

TOWING AN AUTOMATIC TRANSAXLE MODEL
WITH REAR WHEELS RAISED (WITH FRONT
WHEELS ON GROUND)
..........................................48
TOWING POINT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>9TIGHTENING TORQUE OF STANDARD BOLTS........50
ISO 15031-2 TERMINOLOGY LIST..............................51
ISO 15031-2 <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.........51
CONTENTS(Cont’d)
GI-2

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-48
[QG]
TIMING CHAIN
2. Disconnect battery ground cable.
3. Remove undercover, front RH wheel and RH splash cover.
4. Drain engine coolant from radiator and cylinder block. Refer to LC-17, "Changing Engine Coolant".
5. Drain engine oil from oil pan.
6. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
7. Remove power steering pump from adjusting bar.
8. Remove alternator. SC-33, "Removal and Installation".
9. Remove ignition coils. Refer to EM-24, "
IGNITION COIL" .
10. Remove rocker cover. Refer to EM-29, "
Removal and Installation" .
11. Remove oil level gauge.
12. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
13. Remove center member.
14. Remove gusset.
15. Remove rear plate (lower) (A/T models).
16. Remove oil pan and oil strainer. Refer to EM-22, "
Removal and Installation" .
17. For safe operation, and to reduce load to mount insulator, install removed center member again.
18. Remove engine front-side (right side of vehicle) engine mount. Refer to EM-67, "
ENGINE ASSEMBLY" .
a. Remove any parts that cause difficulties for operation around mount, or perform transfer.
b. Support cylinder block bottom surface with a transmission jack.
CAUTION:
●When applying jack, use a wooden block to avoid damage to oil pan mounting surface.
●While performing following operations, support engine front-side with jack.
c. Separate engine mounting insulator and bracket.
d. Remove engine mounting bracket.
19. Remove cylinder head front cover.
●Move harness which was previously fixed on front surface.
20. Remove auxiliary bolts of cylinder head.
21. Set the No. 1 cylinder to the compression TDC.
a. Turn the crankshaft pulley clockwise, and align the timing indica-
tor of the gear case to the timing mark of the crankshaft pulley.
PBIC0557E
PBIC0750E

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

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

CYLINDER BLOCK
EM-79
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
18. Install flywheel or drive plate.
●Install drive plate in direction shown in figure.
●Fix crankshaft with ring gear stopper (special service tool).
●Tighten mounting bolts diagonally in several steps.
19. Install oil level gauge guide.
●Press it in with punch mark for installing instruction in direction
shown in figure.
●Apply locking agent to pressed position.
20. Install knock sensor.
●Install sensor with connector facing lower right by 45° as
shown.
CAUTION:
●If any impact by dropping is applied to the knock sensor,
replace it with new one.
●Make sure that there is no foreign material on the cylin-
der block mating surface and the back surface of the
knock sensor.
●Do not tighten the mounting bolts while holding the con-
nector.
●Make sure that the knock sensor does not interfere with other parts.
21. Install crankshaft position sensor (POS).
●Tighten bolt after fully inserting crankshaft position sensor (POS) into cylinder block.
22. Tighten accessory brackets to the following tightening torque.
23. Assemble in the reverse order of disassembly.
PBIC0595E
PBIC0596E
Power steering pump bracket:
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Alternator air conditioner compressor bracket:
: 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 25 - 34 ft-lb)
PBIC0597E

Removal and InstallationNJEM0069
SEM554G
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
For safety during subsequent steps, the tension of wires
should be slackened against the engine.
Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-46, “Garage Jack and Safety Stand”.
Be sure to hoist 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 careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
In hoisting the engine, always use engine slingers in a
safe manner.
In removing drive shaft, be careful not to damage grease
seal of transaxle.
Before separating engine and transaxle, remove the
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ENGINE ASSEMBLYYD
Removal and Installation
EM-63

crankshaft position sensor (TDC sensor) from the assem-
bly.
Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, “Changing Engine Coolant”.
3. Remove the following parts:
Battery
RH and LH front wheels
RH and LH splash covers (combined with undercover)
Auxiliary belts
Alternator
Alternator brackets
Radiator and cooling fan
Engine cover
Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
YEM024
14. Install engine slingers to cylinder head.
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-64

Removal and InstallationNJEM0071CAUTION:
When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
Place removed parts such as bearings and bearing caps
in their proper order and direction.
When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
Do not allow any magnetic materials to contact the signal
plate of flywheel.
Do not remove the signal plate at back.
Do not place the signal plate side facing under.
Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
DisassemblyNJEM0072PISTON AND CRANKSHAFTNJEM0072S011. Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-63.
2. Place engine on a work stand.
a. Remove flywheel.
Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a
pulley holder (SST) to remove the flywheel.
JEM192G
b. Install engine sub-attachment (SST) to rear surface of cylinder
block.
To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
The four sets of bolts and nuts are multi-purpose products.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER BLOCKYD
Removal and Installation
EM-67

JEM220G
CONNECTING ROD BOLT DEFORMATIONNJEM0073S18Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread
on the bolt.
If the nut does not screw in smoothly, measure the outer diam-
eter of the bolt thread at the point specified in the figure.
If a necked point is identified, measure at that point.
Standard: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit: 8.75 mm (0. 3445 in) dia.
If the measurement exceeds the limit, replace connecting rod
bolts and nuts.
AEM100
FLYWHEEL RUNOUTNJEM0073S11Runout (Total indicator reading):
Flywheel★
Less than 0.15 mm (0.0059 in)
CAUTION:
The signal plate is built into the flywheel assembly. Be
careful not to damage the signal plate, especially the
teeth.
Check the signal plate for deformation or cracks.
Never place the flywheel assembly with the signal plate
facing down.
Keep any magnetized objects away from the signal plate.
Do not allow any magnetic materials to contact the signal
plate teeth.
JEM221G
OIL JETNJEM0073S19Check nozzle for deformation or damage.
Check oil passage for obstruction by blowing in air on nozzle
side.
If abnormality is found, clean or replace.
JEM222G
OIL JET RELIEF VALVENJEM0073S20Using a clean resin rod, press down on the check valve inside relief
valve. Check for appropriate bounce/repulsion and smooth
operation.
CYLINDER BLOCKYD
Inspection (Cont’d)
EM-80