spark plugs NISSAN ALMERA TINO 2001 Service Repair Manual

TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
IACV-AAC/V
OPENING+Engine: After warming up, idle
the engine.
+Change the IACV-AAC valve
opening steps using CONSULT-
II.Engine speed changes according
to the opening steps.+Harness and connector
+IACV-AAC valve
POWER BAL-
ANCE+Engine: After warming up, idle
the engine.
+Air conditioner switch ªOFFº
+Shift lever ªNº
+Cut off each injector signal one
at a time using CONSULT-II.Engine runs rough or dies.+Harness and connector
+Compression
+Injectors
+Power transistor
+Spark plugs
+Ignition coils
COOLING FAN+Ignition switch: ON
+Turn the cooling fan ªONº and
ªOFFº using CONSULT-II.Cooling fan moves and stops.+Harness and connector
+Cooling fan motor
ENG COOLANT
TEMP+Engine: Return to the original
trouble condition
+Change the engine coolant tem-
perature indication using CON-
SULT-II.If trouble symptom disappears, see
CHECK ITEM.+Harness and connector
+Engine coolant temperature sen-
sor
+Fuel injectors
FUEL PUMP
RELAY+Ignition switch: ON
(Engine stopped)
+Turn the fuel pump relay ªONº
and ªOFFº using CONSULT-II
and listen to operating sound.Fuel pump relay makes the operat-
ing sound.+Harness and connector
+Fuel pump relay
EGR VOL
CONT/V
(where fitted)+Engine: After warming up, idle
the engine.
+Change the EGR volume control
valve opening step using CON-
SULT-II.Engine speed changes according
to the opening step.+Harness and connector
+EGR volume control valve
VALVE TIMING
SOL+Ignition switch: ON
+Turn intake valve timing control
solenoid valve ªONº and ªOFFº
using CONSULT-II and listen for
operating sound.Intake valve timing control solenoid
valve makes an operating sound.+Harness and connector
+Intake valve timing control sole-
noid valve
SWIRL CONT
S O L VA LV E
(where fitted)+Ignition switch: ON
+Turn solenoid valve ªONº and
ªOFFº with CONSULT-II and lis-
ten for operating sound.Solenoid valve makes an operating
sound.+Harness and connector
+Solenoid valve
PURG VOL
CONT/V+Engine: After warming up, idle
the engine.
+Change the EVAP canister purge
volume control solenoid valve
opening percent using CON-
SULT-II.Engine speed changes according
to the opening percent.+Harness and connector
+EVAP canister purge volume
control solenoid valve
DTC AND SRT CONFIRMATION MODENLEC0034S08This mode is not available for models without Euro-OBD system.
SRT STATUS ModeNLEC0034S0801For details, refer to ªSYSTEM READINESS TEST (SRT) CODEº,
EC-62.
SRT Work Support ModeNLEC0034S0803This mode enables a technician to drive a vehicle to set the SRT
while monitoring the SRT status.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG18DE
CONSULT-II (Cont'd)
EC-90

MEF036D
SEF233G
SEF234G
IntroductionNLEC0036The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
accepts input signals from sensors and instantly drives actuators.
It is essential that both input and output signals are proper and
stable. At the same time, it is important that there are no problems
such as vacuum leaks, fouled spark plugs, or other problems with
the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow the ªWork Flowº on EC-97.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, espe-
cially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A ªDiagnostic Worksheetº like the
example on next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
SEF907L
DIAGNOSTIC WORKSHEETNLEC0036S01There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
trouble-shooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer 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 malfunction indicator lamp to
come on steady or blink and DTC to be detected.
Example:
Vehicle ran out of fuel, which caused the engine to misfire.
TROUBLE DIAGNOSIS Ð INTRODUCTIONQG18DE
EC-95

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

Monitored item [Unit]ECM
input
signalsMain
signalsDescription Remarks
A/F ALPHA-B1 [%]j+Indicates the mean value of the air-fuel ratio
feedback correction factor per cycle.+When the engine is running, specifi-
cation range is indicated.
+This data also includes the data for
the air-fuel ratio learning control.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
ACTIVE TEST MODENLEC1365S08
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
FUEL INJEC-
TION+Engine: Return to the original
trouble condition
+Change the amount of fuel injec-
tion using CONSULT-II.If trouble symptom disappears, see
CHECK ITEM.+Harness and connector
+Fuel injectors
+Heated oxygen sensor 1 (front)
IGNITION TIM-
ING+Engine: Return to the original
trouble condition
+Timing light: Set
+Retard the ignition timing using
CONSULT-II.If trouble symptom disappears, see
CHECK ITEM.+Adjust initial ignition timing.
IACV-AAC/V
OPENING+Engine: After warming up, idle
the engine.
+Change the IACV-AAC valve
opening steps using CONSULT-
II.Engine speed changes according
to the opening steps.+Harness and connector
+IACV-AAC valve
POWER BAL-
ANCE+Engine: After warming up, idle
the engine.
+Air conditioner switch ªOFFº
+Shift lever ªNº
+Cut off each injector signal one
at a time using CONSULT-II.Engine runs rough or dies.+Harness and connector
+Compression
+Injectors
+Power transistor
+Spark plugs
+Ignition coil
+Ignition wires
COOLING FAN+Ignition switch: ON
+Turn the cooling fan ªHIGHº,
ªLOWº and ªOFFº using CON-
SULT-II.Cooling fan moves at high speed or
low speed and stops.+Harness and connector
+Cooling fan motors
+Cooling fan relays
ENG COOLANT
TEMP+Engine: Return to the original
trouble condition
+Change the engine coolant tem-
perature indication using CON-
SULT-II.If trouble symptom disappears, see
CHECK ITEM.+Harness and connector
+Engine coolant temperature sen-
sor
+Fuel injectors
FUEL PUMP
RELAY+Ignition switch: ON
(Engine stopped)
+Turn the fuel pump relay ªONº
and ªOFFº using CONSULT-II
and listen to operating sound.Fuel pump relay makes the operat-
ing sound.+Harness and connector
+Fuel pump relay
EGR VOL
CONT/V
(where fitted)+Engine: After warming up, idle
the engine.
+Change the EGR volume control
valve opening step using CON-
SULT-II.EGR volume control valve maks an
operating sound.+Harness and connector
+EGR volume control valve
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONSR20DE
CONSULT-II (Cont'd)
EC-614

MEF036D
SEF233G
SEF234G
IntroductionNLEC1367The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
accepts input signals from sensors and instantly drives actuators.
It is essential that both input and output signals are proper and
stable. At the same time, it is important that there are no problems
such as vacuum leaks, fouled spark plugs, or other problems with
the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow the ªWork Flowº on EC-621.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, espe-
cially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A ªDiagnostic Worksheetº like the
example on next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
SEF907L
DIAGNOSTIC WORKSHEETNLEC1367S01There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
trouble-shooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer 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 malfunction indicator lamp to
come on steady or blink and DTC to be detected.
Example:
Vehicle ran out of fuel, which caused the engine to misfire.
TROUBLE DIAGNOSIS Ð INTRODUCTIONSR20DE
EC-619

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

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

NLEM0007
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC-43, ªReleasing Fuel Pressureº.
4. Remove ignition coils.
5. Remove spark plugs.
+Clean area around plug with compressed air before removing
the spark plug.
SEM973E
AEM308
6. Attach a compression tester to No. 1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
+Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure: kPa (bar, kg/cm
2, psi)/rpm
Standard
1,324 (13.24, 13.5, 192)/350
Minimum
1,128 (11.28, 11.5, 164)/350
Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
10. If cylinder compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder through the spark
plug hole and retest compression.
+If adding oil improves cylinder compression, piston rings
may be worn or damaged. If so, replace piston rings after
checking piston.
+If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to SDS, EM-70. If valve or valve seat is damaged
excessively, replace them.
+If compression in any two adjacent cylinders is low and if add-
ing oil does not improve compression, there is leakage past the
gasket surface. If so, replace cylinder head gasket.
11. Reinstall spark plugs, ignition coils and fuel pump fuse.
12. Perform ªSelf-diagnosis Procedureº referring to EC-69, ªHow
to Erase DTCº if any DTC appears.
MEASUREMENT OF COMPRESSION PRESSUREQG
EM-16

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

CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing chain tensioner, oil seals, or other sliding
parts, lubricate contacting surfaces with new engine oil.
+Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
+When removing oil pump assembly, remove camshaft
position sensor (PHASE), then remove timing chain from
engine.
+Be careful not to damage sensor edges.
SEM869F
RemovalNLEM01051. Drain engine coolant from radiator and cylinder block.
Be careful not to spill coolant on drive belts.
2. Remove reservoir tank.
3. Release fuel pressure.
Refer to EC-43, ªFuel Pressure Releaseº.
4. Remove the following belts.
+Power steering pump drive belt
+Alternator drive belt
5. Remove front right-side wheel.
6. Remove front/right splash undercover.
7. Remove front exhaust tube.
SEM870F
8. Remove vacuum hoses, fuel hoses, and so on.
9. Remove ignition coils.
10. Remove spark plugs.
SEM102G
11. Remove rocker cover bolts in numerical order as shown in the
figure.
TIMING CHAINQG
Components (Cont'd)
EM-23