gas type NISSAN ALMERA TINO 2001 Service Repair Manual

Supplemental Restraint System (SRS)“AIR
BAG”and“SEAT BELT PRE-TENSIONER”
NLBR0081The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL V10 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
SBR686C
Precautions for Brake SystemNLBR0002+Recommended fluid is brake fluid“DOT 4”.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
+Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
+Use flare nut wrench when removing and installing brake
tube.
+Always torque brake lines when installing.
+Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to“Brake Burnishing Procedure”,“ON-VEHICLE
SERVICE”, BR-7.
WARNING:
+Clean brake pads with a waste cloth, then wipe with a dust
collector.
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
BR-3

6 CHECK IGNITION SPARK
1. Turn Ignition switch ªOFFº.
2. Disconnect ignition coil assembly from rocker cover.
3. Connect a known good spark plug to the ignition coil assembly.
4. Place end of spark plug against a suitable ground and crank engine.
5. Check for spark.
SEF575Q
OK or NG
OK©GO TO 7.
NG©Check ignition coil, power transistor and their circuits. Refer to EC-500.
7 CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG
OK©GO TO 8.
NG©Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to
EM-19, ªChecking and changingº.
8 CHECK COMPRESSION PRESSURE
Refer to EM section.
+Check compression pressure.
Standard:
1,324 kPa (13.24 bar, 13.5 kg/cm
2, 192 psi)/350 rpm
Minimum:
1,128 kPa (11.28 bar, 11.5 kg/cm
2, 164 psi)/350 rpm
Difference between each cylinder:
98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)/350 rpm
OK or NG
OK©GO TO 9.
NG©Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
DTC P0300 - P0304 NO.4-1CYLINDER MISFIRE, MULTIPLE CYLINDER
MISFIRE
QG18DE
Diagnostic Procedure (Cont'd)
EC-288

9 CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG
OK©GO TO 10.
NG©Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to
EM-19, ªChecking and changingº.
10 CHECK COMPRESSION PRESSURE
Refer to EM section.
+Check compression pressure.
Standard:
1,125 kPa (12.75 bar, 13.0 kg/cm
2, 185 psi)/300 rpm
Minimum:
1,079 kPa (10.79 bar, 11.0 kg/cm
2, 156 psi)/300 rpm
Difference between each cylinder:
98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)/300 rpm
OK or NG
OK©GO TO 11.
NG©Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
11 CHECK FUEL PRESSURE
1. Install any parts removed.
2. Release fuel pressure to zero. Refer to EC-577.
3. Install fuel pressure gauge and check fuel pressure.
SEF775Z
At idle: Approx. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi)
OK or NG
OK©GO TO 13.
NG©GO TO 12.
DTC P0300 - P0304 NO.4-1CYLINDER MISFIRE, MULTIPLE CYLINDER
MISFIRE
SR20DE
Diagnostic Procedure (Cont'd)
EC-812

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

SEM870F
Checking and ChangingNLEM00441. Disconnect ignition coil harness connectors.
2. Remove ignition coils.
SMA294A
3. Remove spark plugs with spark plug wrench.
4. Clean plugs in sand blast cleaner.
5. Check insulator for cracks or chips, gasket for damage or dete-
rioration and electrode for wear and burning. If they are exces-
sively worn away, replace with new spark plugs.
6. Check spark plug gap.
Spark plug
NGK Champion
TypeStandard BKR5E-11 RC10YC4
Hot BKR4E-11 Ð
Cold BKR6E-11 Ð
Plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
SMA476
7. Install spark plugs.
Spark plug:
: 20 - 29 N´m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
8. Install ignition coils.
9. Connect ignition coil harness connectors.
SPARK PLUGQG
Checking and Changing
EM-19

SMA273C
Checking and Changing Spark PlugsNLEM01211. Disconnect ignition wires from spark plugs at boot. Do not pull
on the wire.
SMA294A
2. Remove spark plugs with spark plug wrench.
3. Check insulator for cracks or chips, gasket for damage or dete-
rioration and electrode for wear and burning. If they are exces-
sively worn away, replace with new spark plugs.
Spark plug
MakeNGK
Models with EGR Models without EGR
Standard type PFR6G-11 BKR6EY-11
Hot type PFR5G-11 Ð
Cold type PFR7G-11 Ð
Use standard type spark plug for normal condition.
The cold type spark plug is suitable when spark knock may occur
with the standard type spark plug such as:
+extended highway driving
+frequent high engine revolution
SMA673B
+Do not use a wire brush for cleaning.
+If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:
Less than 588 kPa (6 kg/cm
2, 85 psi)
Cleaning time:
Less than 20 seconds
SMA806C
+Adjusting plug gap is not required.
4. Check spark plug gap.
Gap: 1.0 - 1.1 mm (0.039 - 0.043 in)
SPARK PLUGSR
Checking and Changing Spark Plugs
EM-89

JEM140G
1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-158, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM141G
b. Install four O-rings to the grooves of the cylinder block, fuel
injection pump bracket.
JEM138G
c. Install rear chain case.
+When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
+Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in): Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
+The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-184

+Do not use gasoline, kerosine, diesel fuel, gas oil, thinners or
solvents for cleaning skin.
+If skin disorders develop, obtain medical advice without delay.
+Where practicable, degrease components prior to handling.
+Where there is a risk of eye contact, eye protection should be
worn, for example, chemical goggles or face shields; in addi-
tion an eye wash facility should be provided.
Environmental Protection PrecautionsNLGI0001S0702Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating sys-
tem must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt, check with the
appropriate local authority and/or manufacturer of the approved
appliance.
Dispose of used oil and used oil filters through authorized waste
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local authority
for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains,
or into water courses.
The regulations concerning the pollution vary between
regions.
PRECAUTIONS FOR FUELNLGI0001S08Gasoline EngineNLGI0001S0804Models with three way catalyst
Unleaded premium gasoline of at least 95 octane (RON)
If premium gasoline is not available, unleaded regular gaso-
line with an octane rating of 91 (RON) may be temporarily
used, but only under the following precautions:
+Have the fuel tank filled only partially with unleaded regu-
lar gasoline, and fill up with premium unleaded gasoline
as soon as possible.
+Avoid full throttle driving and abrupt acceleration.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will dam-
age the three way catalyst.
Diesel Engine*:NLGI0001S0805Diesel fuel of at least 50 cetane
* If two types of diesel fuel are available, use summer or winter
fuel properly according to the following temperature conditions.
+Above 7°C (20°F) ... Summer type diesel fuel.
+Below 7°C (20°F) ... Winter type diesel fuel.
CAUTION:
+Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
+Do not use summer fuel at temperatures below 7°C
(20°F). The cold temperatures will cause wax to form in the
fuel. As a result, it may prevent the engine from running
smoothly.
+Do not add gasoline or other alternate fuels to diesel fuel.
PRECAUTIONS FOR AIR CONDITIONINGNLGI0001S09Use an approved refrigerant recovery unit any time the air condi-
tioning system must be discharged. Refer to HA-85, “HFC-134a
(R-134a) Service Procedure” for specific instructions.
PRECAUTIONS
Precautions (Cont’d)
GI-8