width NISSAN ALMERA N16 2003 Electronic Repair Manual

Dimensions=NJGI0008S03Unit: mm (in)
Item Sedan HB
Overall length 4,470 (176.0) 4,184 (164.7)
Overall width 1,695 (66.7) 1,710 (67.3)
Overall height 1,440 (56.7) 1,440 (56.7)
Front tread 1,470 (57.9) 1,470 (57.9)
Rear tread 1,450 (57.1) 1,455 (57.3)
Wheelbase 2,535 (99.8) 2,535 (99.8)
Wheels and TiresNJGI0008S04Sedan
Item Except for Europe Europe
Road wheelSteel/offset mm (in)14 x 5J/35 (1.38)
14 x 5-1/2JJ/45 (1.77)
15 x 6JJ/45 (1.77)14 x 5J/35 (1.38)
15 x 6JJ/45 (1.77)
Aluminum/offset mm (in) 14 x 6J (J)*/45 (1.77) 15 x 6J*/45 (1.77)
Tire sizeConventional175/65R14
175/70R14
185/65R14
185/65R15175/70R14
185/65R15
195/60R15
Spare Conventional T135/80D15
*: Option
Hatchback
Item
Road wheelSteel/offset mm (in)
15 x 6JJ/45 (1.77)
16 x 6JJ/45 (1.77)
Aluminum/offset mm (in)
Tire sizeConventional185/65R15
195/55R16
SpareConventional
T135/80/D15*
*: If so equipped (for some of A/T models)
IDENTIFICATION INFORMATION
Dimensions
GI-44

CYLINDER BLOCK
EM-91
[QG]
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OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
●Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod bolts to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) – (Outer
diameter of crankshaft pin)
●If clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer to EM-81, "
HOW
TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the method by
calculation.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
●Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
●If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter
and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to EM-82,
"HOW TO SELECT MAIN BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in “the method by calculation.”Standard : 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit : 0.10 mm (0.0039 in)
PBIC0119E
EM142
Standard : 0.020 - 0.044 mm (0.0008 - 0.0017 in)
Limit : 0.1 mm (0.004 in)
EM142

CAUTION:
When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
Attach tags to valve lifters so as not to mix them up.
RemovalNJEM0063PREPARATIVE WORKNJEM0063S011. Drain engine coolant. Refer to LC-43, “Changing Engine Cool-
ant”.
2. Remove exhaust manifold. Refer to EM-38, “Removal”.
3. Remove intake manifold. Refer to EM-34, “Removal”.
Apply paint to camshaft sprockets for alignment during
installation.
JEM152G
CAMSHAFTNJEM0063S021. Remove the following parts:
Rocker cover
Vacuum pump and cylinder head rear cover assembly
Spill tube
High pressure injection nozzle assembly
Secondary timing chain and associated parts
JEM159G
2. Remove camshaft sprockets.
Holding the hexagonal part of the camshaft with a wrench
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket.
JEM160G
3. Remove camshafts.
Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters.
Confirm the correct location of each part removed. Store them
so they do not get mixed up.
For re-installation, be sure to put mark on camshaft
bracket before removal.
CYLINDER HEADYD
Components (Cont’d)
EM-46

Available Main BearingNJEM0085
SEM255G
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717)
19.9 - 20.1 (0.783 - 0.791)Black
1 1.820 - 1.824 (0.0717 - 0.0718) Red or Brown
2 1.824 - 1.828 (0.0718 - 0.0720) Green
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
UNDERSIZENJEM0085S01Unit: mm (in)
Thickness Main journal diameter “Dm”
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)Grind so that bearing clearance is the specified
value.
Available Connecting Rod BearingNJEM0086CONNECTING ROD BEARINGNJEM0086S01
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color (mark)
0 1.492 - 1.496 (0.0587 - 0.0589)
22.9 - 23.1
(0.902 - 0.909)Black
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.504 (0.0591 - 0.0592) Green
UNDERSIZENJEM0086S02Unit: mm (in)
Thickness Crank pin journal diameter “Dp”
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the specified
value. 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous ComponentsNJEM0087Unit: mm (in)
Flywheel runout [TIR]*Less than 0.15 (0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Available Main Bearing
EM-96

SLC428B
REMOVALNJLC0076S011. Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen the filter body approximately four turns.
JLC291B
2. Drain the oil after matching the “DRAIN” arrow mark at the
bottom of the filter body to the protrusion on the oil filter
bracket.
Catch the oil with a pan or cloth.
CAUTION:
The drained oil flows over the right surface of the filter
body.
Completely wipe clean any engine oil remaining on the
filter body or vehicle.
3. Remove the filter body, then remove the oil filter element.
JLC292B
4. Remove the O-ring from the filter body.
Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the filter body.
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they may
cause damage to the filter body.
INSTALLATIONNJLC0076S021. Completely remove all foreign objects adhering to the inside of
the filter body or O-ring mounting area (body side and bracket
side).
2. Install the oil filter element and O-ring to the filter body.
Push the oil filter element into the filter body completely.
3. Install the filter body to the oil filter bracket.
: 20 - 24 N·m (2.0 - 2.5 kg-m, 15 - 18 ft-lb)
4. After warming up the engine, check for engine oil leakage.
ENGINE LUBRICATION SYSTEMYD
Changing Oil Filter (Cont’d)
LC-32

EC-24
[QG (WITH EURO-OBD)]
ENGINE CONTROL SYSTEM
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), the camshaft
position sensor (PHASE) and the mass air flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operat-
ing conditions as listed below.

●During warm-up
●When starting the engine
●During acceleration
●Hot-engine operation
●When selector lever is changed from “N” to “D” (A/T models)
●High-load, high-speed operation

●During deceleration
●During high engine speed operation
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM
adjusts the injection pulse width according to the sensor voltage signal. For more information about heated
oxygen sensor 1, refer to EC-155
. This maintains the mixture ratio within the range of stoichiometric (ideal air-
fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.
Open Loop Control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
●Deceleration and acceleration
●High-load, high-speed operation
●Malfunction of heated oxygen sensor 1 or its circuit
●Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
●High engine coolant temperature
●During warm-up
●After shifting from “N” to “D” (A/T models)
●When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as orig-
PBIB0121E

ENGINE CONTROL SYSTEM
EC-25
[QG (WITH EURO-OBD)]
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EC
inally designed. Both manufacturing differences (i.e., mass air flow sensor hot film) and characteristic changes
during operation (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.
FUEL INJECTION TIMING
Two types of systems are used.
Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.
Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
Electronic Ignition (EI) SystemEBS00K36
INPUT/OUTPUT SIGNAL CHART
*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.
SEF337W
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)Engine speed
*2 and piston position
Ignition timing control Power transistor Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Throttle position sensor Throttle position
Accelerator pedal position sensor Accelerator pedal position
Knock sensor Engine knocking
Park/neutral position (PNP) switch Gear position
Battery
Battery voltage
*2
Vehicle speed signal*1Vehicle speed

EC-26
[QG (WITH EURO-OBD)]
ENGINE CONTROL SYSTEM
SYSTEM DESCRIPTION
The ignition timing is controlled by the ECM to maintain the best air-
fuel ratio for every running condition of the engine. The ignition tim-
ing data is stored in the ECM. This data forms the map shown.
The ECM receives information such as the injection pulse width and
camshaft position sensor signal. Computing this information, ignition
signals are transmitted to the power transistor.
e.g., N: 1,800 rpm, Tp: 1.50 msec
A°BTDC
During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
●At starting
●During warm-up
●At idle
●At low battery voltage
●During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.
Air Conditioning Cut ControlEBS00K37
INPUT/OUTPUT SIGNAL CHART
*1: These signals are sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.
SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned off.
●When the accelerator pedal is fully depressed.
●When cranking the engine.
●At high engine speeds.
●When the engine coolant temperature becomes excessively high.
●When operating power steering during low engine speed or low vehicle speed.
●When engine speed is excessively low.
●When refrigerant pressure is excessively low or high.
SEF742M
Sensor Input Signal to ECM ECM Function Actuator
Air conditioner switch*
1Air conditioner “ON” signal
Air conditioner
cut controlAir conditioner relay Throttle position sensor Throttle valve opening angle
Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)Engine speed
*2
Engine coolant temperature sensor Engine coolant temperature
Battery
Battery voltage
*2
Refrigerant pressure sensor Refrigerant pressure
Power steering pressure sensor Power steering operation
Vehicle speed signal
*1Vehicle speed

TROUBLE DIAGNOSIS
EC-91
[QG (WITH EURO-OBD)]
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EC
DATA MONITOR MODE
Monitored Item
×: Applicable
Monitored item
[Unit]ECM
INPUT
SIG-
NALSMAIN
SIG-
NALSCAN
DIAG
SUP-
PORT
MNTRDescription Remarks
ENG SPEED [rpm]××
●Indicates the engine speed computed
from the signals of the crankshaft posi-
tion sensor (POS) and camshaft posi-
tion sensor (PHASE).●Accuracy becomes poor if engine
speed drops below the idle rpm.
●If the signal is interrupted while the
engine is running, an abnormal
value may be indicated.
MAS A/F SE-B1 [V]××
●The signal voltage of the mass air flow
sensor is displayed.●When the engine is stopped, a
certain value is indicated.
B/FUEL SCHDL
[msec]×
●“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board cor-
rection.
A/F ALPHA-B1 [%]×
●The mean value of the air-fuel ratio
feedback correction factor per cycle is
indicated.
●When the engine is stopped, a
certain value is indicated.
●This data also includes the data
for the air-fuel ratio learning con-
trol.
COOLAN TEMP/S
[°C] or [°F]××
●The engine coolant temperature (deter-
mined by the signal voltage of the
engine coolant temperature sensor) is
displayed.
●When the engine coolant tempera-
ture sensor is open or short-cir-
cuited, ECM enters fail-safe mode.
The engine coolant temperature
determined by the ECM is dis-
played.
HO2S1 (B1) [V]××
●The signal voltage of the heated oxygen
sensor 1 is displayed.
HO2S2 (B1) [V]×
●The signal voltage of the heated oxygen
sensor 2 is displayed.
HO2S1 MNTR (B1)
[RICH/LEAN]××
●Display of heated oxygen sensor 1 sig-
nal during air-fuel ratio feedback control:
RICH ... means the mixture became
“rich”, and control is being affected
toward a leaner mixture.
LEAN ... means the mixture became
“lean”, and control is being affected
toward a rich mixture.●After turning ON the ignition
switch, “RICH” is displayed until
air-fuel mixture ratio feedback
control begins.
●When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continu-
ously.
HO2S2 MNTR (B1)
[RICH/LEAN]×
●Display of heated oxygen sensor 2 sig-
nal:
RICH ... means the amount of oxygen
after three way catalyst is relatively
small.
LEAN ... means the amount of oxygen
after three way catalyst is relatively
large.
●When the engine is stopped, a
certain value is indicated.
VHCL SPEED SE
[km/h] or [mph]××
●The vehicle speed computed from the
vehicle speed signal is displayed.
BATTERY VOLT
[V]××
●The power supply voltage of ECM is dis-
played.
ACCEL SEN 1 [V]××
●The accelerator pedal position sensor
signal voltage is displayed.
ACCEL SEN 2 [V]×

EC-92
[QG (WITH EURO-OBD)]
TROUBLE DIAGNOSIS
THRTL SEN 1 [V]××●The throttle position sensor signal volt-
age is displayed.
THRTL SEN 2 [V]×
INT/A TEMP SE
[°C] or [°F]××
●The intake air temperature (determined
by the signal voltage of the intake air
temperature sensor) is indicated.
START SIGNAL
[ON/OFF]××
●Indicates [ON/OFF] condition of the
starter signal computed from the signals
of the crankshaft position sensor (POS),
camshaft position sensor (PHASE) and
battery voltage.
●After starting the engine, [OFF] is
displayed regardless of the starter
signal.
CLSD THL POS
[ON/OFF]××
●Indicates idle position [ON/OFF] com-
puted by ECM according to the acceler-
ator pedal position sensor signal.
AIR COND SIG
[ON/OFF]××
●Indicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
P/N POSI SW
[ON/OFF]××
●Indicates [ON/OFF] condition from the
park/neutral position (PNP) switch sig-
nal.
PW/ST SIGNAL
[ON/OFF]××
●[ON/OFF] condition of the power steer-
ing oil pressure switch as determined by
the power steering oil pressure signal is
indicated.
LOAD SIGNAL
[ON/OFF]××
●Indicates [ON/OFF] condition from the
electrical load signal.
ON ... Rear window defogger switch is
ON and/or lighting switch is in 2nd posi-
tion.
OFF ... Both rear window defogger
switch and lighting switch are OFF.
IGNITION SW
[ON/OFF]×
●Indicates [ON/OFF] condition from igni-
tion switch.
HEATER FAN SW
[ON/OFF]×
●Indicates [ON/OFF] condition from the
heater fan switch signal.
BRAKE SW
[ON/OFF]×
●Indicates [ON/OFF] condition from the
stop lamp switch signal.
INJ PULSE-B1
[msec]×
●Indicates the actual fuel injection pulse
width compensated by ECM according
to the input signals.●When the engine is stopped, a
certain computed value is indi-
cated.
IGN TIMING
[BTDC]×
●Indicates the ignition timing computed
by ECM according to the input signals.●When the engine is stopped, a
certain value is indicated.
CAL/LD VALUE [%]
●“Calculated load value” indicates the
value of the current airflow divided by
peak airflow.
MASS AIRFLOW
[g·m/s]
●Indicates the mass airflow computed by
ECM according to the signal voltage of
the mass air flow sensor. Monitored item
[Unit]ECM
INPUT
SIG-
NALSMAIN
SIG-
NALSCAN
DIAG
SUP-
PORT
MNTRDescription Remarks