NISSAN ALMERA TINO 2001 Service Repair Manual

RH SIDE (MODELS WITH ECM IN CABIN)NLEL0349S05
YEL542C
HARNESS LAYOUT
Front Door Harness/RHD Models (Cont'd)
EL-520

Rear Door HarnessNLEL0416LH SIDENLEL0416S01
YEL045C
HARNESS LAYOUT
Rear Door Harness
EL-521

RH SIDENLEL0416S02
YEL046C
HARNESS LAYOUT
Rear Door Harness (Cont'd)
EL-522

Back Door HarnessNLEL0492
YEL047C
HARNESS LAYOUT
Back Door Harness
EL-523

NLEL0144
HeadlampNLEL0144S03
Item Wattage (Bulb type)
High/Low (Semi-sealed beam)55 (H7)/55 (H7)
Exterior LampNLEL0144S01
Item Wattage (Bulb type)
Front fog lamp51 (HB4)
Front turn signal lamp21
Side turn signal lamp5
Parking lamp5
Rear combination lampTurn signal 16
Stop/Tail 21/5
Back-up 18
Rear fog lamp 21
Rear side marker lamp3.8
License lamp5
High-mounted stop lampLED (Not serviceable)
Interior LampNLEL0144S02
Item Wattage (Bulb type)
Interior room lamp5
Map lamp5
Rear personal lamp5
Luggage room lamp5
BULB SPECIFICATIONS
Headlamp
EL-524

NLEL0311
Use the chart below to find out what each wiring
diagram code stands for.
Refer to the wiring diagram code in the alphabetical
index to find the location (page number) of each
wiring diagram.
Code Section Wiring Diagram Name
A/C, M HA Manual Air Conditioner
A/CCUT EC Air Conditioner Control
AAC/V EC IDLE AIR CONTROL VALVE (IACV)
Ð AUXIUARY AIR CONTROL
(AAC) VALVE
AACVLV EC Idle Air Control Valve (IACV) Ð
Auxiuary Air Control (AAC) Valve
ABS BR Anti-lock Brake System
APS EC Accelerator Position Sensor
ATCONT EC A/T Control line
ATDIAG EC A/T Diagnosis Communication Line
AUDIO EL Audio
BACK/L EL Back-up Lamp
BRK/SW EC Brake Switch
CHARGE SC Charging System
CHIME EL Warning Chime
CIGAR EL Cigarette Lighter
CKPS EC Crankshaft Position Sensor
CLOCK EL Clock
CMPS EC Camshaft Position Sensor (CMPS)
COOL/F EC Cooling Fan Motor
D/LOCK EL Power Door Lock
DEF EL Rear Window Defogger
DTRL EL Headlamp Ð Daytime Light System
ECMRLY EC ECM Relay
ECTS EC Engine Coolant Temperature Sensor
(ECTS)
EGR/TS EC EGR Temperature Sensor
EGRC/V EC EGR Volume Control Valve
EGRC1 EC EGR Function (Close)
EGRSYS EC EGR Function
EGVC/V EC EGR Volume Control Valve
ENGSS AT Engine Speed Signal
F/FOG EL Front Fog Lamp
F/PUMP EC Fuel Pump
FPS AT CVT Fluid Pressure Sensor
Code Section Wiring Diagram Name
FRO2 EC Heated Oxygen Sensor 1 (Front)
FRO2/H EC Heated Oxygen Sensor 1 Heater
(Front)
FTS AT CVT Fluid Temperature Sensor
FUEL EC Fuel Injection System Function
GLOW EC Glow Control System
H/AIM EL Headlamp Ð Headlamp Aiming
Control Ð
H/LAMP EL Headlamp
H/SEAT EL Heated Seat
HEATER HA Heater System
HLC EL Headlamp Washer
HORN EL Horn
IATS EC Intake Air Temperature Sensor
IATSEN EC Intake Air Temperature Sensor
IGN/SG EC Ignition Signal
IGNSYS EC Ignition Signal
ILL EL Illumination
INJECT EC Injector
INJPMP EC Injection Pump (Fuel Temperature
Sensor)
INT/L EL Spot and Laggage Room Lamps
IVC EC Intake Valve Timing Control Sole-
noid Valve
IVC/V EC Intake Valve Timing Control Sole-
noid Valve
KS EC Knock Sensor (KS)
LOAD EC Electrical Load Signal
LPS AT Line Pressure Sensor
LPSV AT Line Pressure Solenoid Valve
MAFS EC Mass Air Flow Sensor (MAFS)
MAIN AT Main Power Supply and Ground Cir-
cuit
MAIN EC Main Power Supply and Ground Cir-
cuit
METER EL Meter and Gauges
MIL/DL EC MIL and Data Link Connectors
MIRROR EL Door Mirror
MULTI EL Multi-remote Control System
NATS EL NATS (Nissan Anti-Theft System)
NAVI EL Navigation System
WIRING DIAGRAM CODES (CELL CODES)
EL-525

Code Section Wiring Diagram Name
NONDTC AT Non-detectable Items
O2H1B1 EC Heated Oxygen Sensor 1 Heater
(Front)
O2H2B1 EC Heated Oxygen Sensor 2 Heater
(Rear)
O2S1B1 EC Heated Oxygen Sensor 1 (Front)
O2S2B1 EC Heated Oxygen Sensor Heater 2
(Rear)
PGC/V EC EVAP Canister Purge Volume Con-
trol Solenoid Valve
PHASE EC Camshaft Position Sensor (PHASE)
PNP/SW EC Park/Neutral Position (PNP) Switch
PNP/SW AT Park/Neutral Position (PNP) Switch
PNPSW1 EC Park/Neutral Position (PNP) Switch
POS EC Crankshaft Position Sensor (POS)
POWER EL Power Supply Routing
PRGVLV EC EVAP Canister Purge Volume Con-
trol Solenoid Valve
PSSAT AT Primary Speed Sensor
PST/SW EC Power Steering Oil Pressure Switch
R/FOG EL Rear Fog Lamp
ROOM/L EL Interior Room Lamp
RP/SEN EC Referigerant Pressure Sensor
RRO2 EC Heated Oxygen Sensor 2 (Rear)
RRO2/H EC Heated Oxygen Sensor 2 Heater
(Rear)
S/SIG EC Start Signal
SHIFT AT Shift Lock System
S/LOCK EL Power Door Lock Ð Super Lock Ð
SROOF EL Power Sunroof
SRS RS Supplemental Restraint System
(SRS)
START SC Starting System
STM AT Step Motor
STOP/L EL Stop Lamp
S/VCSW EC Swirl Control Valve Control Vacuum
check Switch
SWL/C EC Swirl Control Valve Control System
SWL/V EC Swirl Control Valve Control Solenoid
Valve
TAIL/L EL Parking, License and Tail LampsCode Section Wiring Diagram Name
TCV AT Torque Converter Clutch Solenoid
Valve
TP/SW EC Closed Throttle Position Switch
TPS AT Throttle Position Sensor
TPS EC Throttle Position Sensor
TURN EL Turn Signal and Hazard Warning
Lamps
VSS EC Vehicle Speed Sensor (VSS)
VSSAT AT Secondary Speed Sensor
WARN EL Warning Lamps
WINDOW EL Power Window
WIP/R EL Rear Wiper and Washer
WIPER EL Front Wiper and Washer
WIRING DIAGRAM CODES (CELL CODES)
EL-526

ENGINE MECHANICAL
SECTION
EM
CONTENTS
QG
PRECAUTIONS...............................................................5
Parts Requiring Angular Tightening .............................5
Liquid Gasket Application Procedure ..........................5
PREPARATION...............................................................6
Special Service Tools ..................................................6
Commercial Service Tools ...........................................8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................10
NVH Troubleshooting - Engine Noise .......................10
OUTER COMPONENT PARTS.....................................12
Removal and Installation ...........................................12
MEASUREMENT OF COMPRESSION PRESSURE....16
DRIVE BELTS................................................................17
Checking ....................................................................17
AIR CLEANER...............................................................18
Changing Air Cleaner Filter .......................................18
VISCOUS PAPER TYPE...........................................18
SPARK PLUG................................................................19
Checking and Changing ............................................19
OIL PAN.........................................................................20
Components...............................................................20
Removal .....................................................................20
Installation ..................................................................21
TIMING CHAIN..............................................................22
Components...............................................................22
Removal .....................................................................23
Inspection...................................................................26
Installation ..................................................................27
OIL SEAL.......................................................................31
Replacement ..............................................................31
VALVE OIL SEAL.....................................................31
FRONT OIL SEAL....................................................31
REAR OIL SEAL......................................................32
CYLINDER HEAD..........................................................33
Components...............................................................33
Removal .....................................................................34
Disassembly...............................................................36Inspection...................................................................36
CYLINDER HEAD DISTORTION...............................36
CAMSHAFT VISUAL CHECK....................................36
CAMSHAFT RUNOUT..............................................37
CAMSHAFT CAM HEIGHT.......................................37
CAMSHAFT JOURNAL CLEARANCE........................37
CAMSHAFT END PLAY............................................38
CAMSHAFT SPROCKET RUNOUT...........................38
VALVE GUIDE CLEARANCE....................................38
VALVE GUIDE REPLACEMENT................................39
VALVE SEATS.........................................................40
REPLACING VALVE SEAT FOR SERVICE PARTS....40
VALVE DIMENSIONS...............................................41
VALVE SPRING.......................................................41
VALVE LIFTER AND VALVE SHIM............................41
Valve Clearance.........................................................42
CHECKING.............................................................42
ADJUSTING............................................................43
Assembly ...................................................................45
Installation ..................................................................45
ENGINE ASSEMBLY.....................................................49
Removal and Installation ...........................................49
REMOVAL...............................................................50
INSTALLATION........................................................51
CYLINDER BLOCK.......................................................52
Components...............................................................52
Removal and Installation ...........................................53
Disassembly...............................................................53
PISTON AND CRANKSHAFT....................................53
Inspection...................................................................54
PISTON AND PISTON PIN CLEARANCE..................54
PISTON RING SIDE CLEARANCE............................54
PISTON RING END GAP..........................................54
CONNECTING ROD BEND AND TORSION...............55
CYLINDER BLOCK DISTORTION AND WEAR...........55
PISTON-TO-BORE CLEARANCE..............................56
CRANKSHAFT.........................................................57
BEARING CLEARANCE...........................................57
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
..........................................................59

REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
..........................................60
FLYWHEEL RUNOUT..............................................60
Assembly ...................................................................60
PISTON..................................................................60
CRANKSHAFT.........................................................61
SERVICE DATA AND SPECIFICATIONS (SDS).........64
General Specifications ...............................................64
Compression Pressure ..............................................64
Belt Deflection............................................................64
Spark Plug .................................................................65
Cylinder Head ............................................................65
Valve ..........................................................................65
VALVE....................................................................65
VALVE SPRING.......................................................65
VALVE LIFTER........................................................66
VALVE CLEARANCE................................................67
VALVE GUIDE.........................................................67
AVAILABLE SHIMS..................................................67
VALVE SEAT...........................................................70
VALVE SEAT RESURFACE LIMIT.............................71
Camshaft and Camshaft Bearing ..............................71
Cylinder Block ............................................................72
Piston, Piston Ring and Piston Pin ...........................73
PISTON..................................................................73
PISTON RING.........................................................73
PISTON PIN............................................................73
Connecting Rod .........................................................74
Crankshaft..................................................................74
Main Bearing..............................................................74
STANDARD.............................................................74
UNDERSIZE............................................................74
Connecting Rod Bearing ...........................................75
STANDARD SIZE....................................................75
UNDERSIZE............................................................75
Bearing Clearance .....................................................75
Miscellaneous Components.......................................75
SR
PRECAUTIONS.............................................................76
Parts Requiring Angular Tightening ...........................76
Liquid Gasket Application Procedure ........................76
PREPARATION.............................................................77
Special Service Tools ................................................77
Commercial Service Tools .........................................79
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................80
NVH Troubleshooting - Engine Noise .......................81
OUTER COMPONENT PARTS.....................................82
Removal and Installation ...........................................82
MEASUREMENT OF COMPRESSION PRESSURE....85
DRIVE BELTS................................................................86
Checking ....................................................................86AIR CLEANER...............................................................88
Changing Air Cleaner Filter .......................................88
VISCOUS PAPER TYPE...........................................88
SPARK PLUG................................................................89
Checking and Changing Spark Plugs .......................89
Checking Ignition Leads ............................................90
OIL PAN.........................................................................91
Components...............................................................91
Removal .....................................................................91
Installation ..................................................................93
TIMING CHAIN..............................................................96
Components...............................................................96
Removal .....................................................................97
Inspection.................................................................100
Installation ................................................................100
OIL SEAL.....................................................................105
Replacement ............................................................105
VALVE OIL SEAL...................................................105
FRONT OIL SEAL..................................................105
REAR OIL SEAL....................................................107
CYLINDER HEAD........................................................108
Components.............................................................108
Removal ...................................................................109
Disassembly............................................................. 111
Inspection................................................................. 113
CYLINDER HEAD DISTORTION............................. 113
CAMSHAFT VISUAL CHECK.................................. 114
CAMSHAFT RUNOUT............................................ 114
CAMSHAFT CAM HEIGHT..................................... 114
CAMSHAFT JOURNAL CLEARANCE...................... 115
CAMSHAFT END PLAY.......................................... 115
CAMSHAFT SPROCKET RUNOUT......................... 116
VALVE GUIDE CLEARANCE.................................. 116
VALVE GUIDE REPLACEMENT.............................. 116
VALVE SEATS....................................................... 117
REPLACING VALVE SEAT FOR SERVICE PARTS.. 118
VALVE DIMENSIONS............................................. 119
VALVE SPRING..................................................... 119
HYDRAULIC LASH ADJUSTER.............................. 119
ROCKER ARM, SHIM AND ROCKER ARM GUIDE...120
Assembly .................................................................120
Installation ................................................................123
ENGINE ASSEMBLY...................................................130
Removal and Installation .........................................130
REMOVAL.............................................................131
INSTALLATION......................................................132
CYLINDER BLOCK.....................................................133
Components.............................................................133
Removal and Installation .........................................134
Disassembly.............................................................134
PISTON AND CRANKSHAFT..................................134
Inspection.................................................................134
PISTON AND PISTON PIN CLEARANCE................134
PISTON RING SIDE CLEARANCE..........................135
CONTENTS(Cont'd)
EM-2

PISTON RING END GAP........................................135
CONNECTING ROD BEND AND TORSION.............136
CYLINDER BLOCK DISTORTION AND WEAR.........136
PISTON-TO-BORE CLEARANCE............................137
CRANKSHAFT.......................................................138
BEARING CLEARANCE.........................................138
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
........................................................141
REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
........................................141
REPLACEMENT OF PILOT CONVERTER (CVT).....141
DRIVE PLATE RUNOUT........................................142
Assembly .................................................................142
PISTON................................................................142
CRANKSHAFT.......................................................143
SERVICE DATA AND SPECIFICATIONS (SDS).......146
General Specifications .............................................146
Compression Pressure ............................................146
Cylinder Head ..........................................................146
Valve ........................................................................147
VALVE..................................................................147
VALVE SPRING.....................................................147
HYDRAULIC LASH ADJUSTER (HLA).....................147
VALVE GUIDE.......................................................148
VALVE SHIM CLEARANCE ADJUSTMENT..............148
AVAILABLE SHIM..................................................149
VALVE SEAT.........................................................150
Camshaft and Camshaft Bearing ............................151
Cylinder Block ..........................................................152
Piston, Piston Ring and Piston Pin .........................153
PISTON................................................................153
PISTON RING.......................................................153
PISTON PIN..........................................................153
Connecting Rod .......................................................154
Crankshaft................................................................155
Main Bearing............................................................156
STANDARD...........................................................156
UNDERSIZE..........................................................156
Connecting Rod Bearing .........................................156
STANDARD SIZE..................................................156
UNDERSIZE..........................................................156
Bearing Clearance ...................................................157
Miscellaneous Components.....................................157
YD
PRECAUTIONS...........................................................158
Parts Requiring Angular Tightening .........................158
Liquid Gasket Application Procedure ......................158
PREPARATION...........................................................159
Special Service Tools ..............................................159
Commercial Service Tools .......................................161
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.................................................163
NVH Troubleshooting - Engine Noise .....................163MEASUREMENT OF COMPRESSION PRESSURE..164
DRIVE BELTS..............................................................166
Inspection.................................................................166
Adjustment ...............................................................166
AIR CONDITIONER COMPRESSOR BELT..............167
ALTERNATOR & WATER PUMP BELT...................167
Removal ...................................................................167
Installation ................................................................168
AIR CLEANER.............................................................169
Changing Air Cleaner Filter .....................................169
VISCOUS PAPER TYPE.........................................169
OIL PAN.......................................................................170
Components.............................................................170
Removal ...................................................................170
Installation ................................................................172
TIMING CHAIN............................................................175
Secondary Timing Chain .........................................175
REMOVAL.............................................................175
INSPECTION.........................................................177
INSTALLATION......................................................177
Primary Timing Chain ..............................................180
REMOVAL.............................................................181
INSPECTION.........................................................183
INSTALLATION......................................................183
INTAKE MANIFOLD....................................................188
Removal and Installation .........................................188
PREPARATIVE WORK...........................................188
FUEL PIPING........................................................189
INTAKE MANIFOLD...............................................189
EGR VOLUME CONTROL VALVE...........................189
WATER HOSE.......................................................189
Inspection.................................................................190
INTAKE MANIFOLD...............................................190
SWIRL CONTROL VALVE......................................190
CATALYST..................................................................191
Removal and Installation .........................................191
PREPARATIVE WORK...........................................191
THREE WAY CATALYST.......................................191
GUSSET...............................................................192
EXHAUST MANIFOLD, TURBOCHARGER...............193
Removal and Installation .........................................193
PREPARATIVE WORK...........................................193
EXHAUST MANIFOLD AND TURBOCHARGER.......193
EXHAUST MANIFOLD GASKET.............................194
Disassembly and Assembly .....................................194
TURBOCHARGER.................................................194
Inspection.................................................................195
EXHAUST MANIFOLD...........................................195
TURBOCHARGER.................................................195
ROCKER COVER........................................................198
Removal and Installation .........................................198
PREPARATIVE WORK...........................................198
ROCKER COVER..................................................198
CYLINDER HEAD........................................................200
CONTENTS(Cont'd)
EM-3