2001 NISSAN ALMERA N16 belt

Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year)
=NJMA0043S04QG15DE/QG18DE ENGINESNJMA0043S0401Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis only.km x 1,000
(miles x 1,000)15
(9)30
(18)45
(27)60
(36)75
(45)90
(54)105
(63)120
(72)
Engine compartment and under vehicle
Engine oil (Use recommended oil)HRRRRRRRRLC-8
Engine oil filter (Use NISSAN genuine
part or equivalent)HRRRRRRRRLC-9
Drive beltsIIIIIIIIEM-15
Cooling systemIIIILC-12
Engine anti-freeze coolant (Use genu-
ine NISSAN Anti-Freeze Coolant (L2N)
or equivalent)See NOTE (1) I R I LC-17
Air cleaner filterHR R EM-17
Intake & exhaust valve clearance See NOTE (2) EM-42
Fuel and EVAP vapor lines I IFE-5/
EC-36
Spark plugsRRRREM-18
Fuel filter See NOTE (3) FE-9
Heated oxygen sensorHSee NOTE (4)GI-40/
EC-45
NOTE:
(1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). Perform ªIº (checking the mixture ratio and
correcting the mixture ratio if necessary) at the middle of replacement interval.
(2) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.
(3) Fuel filter is maintenance-free. For service procedures, refer to FE section.
(4) Perform only according to ªMaintenance Under Severe Driving Conditionsº for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.
HMaintenance items with ªHº should be performed more frequently according to ªMaintenance Under Severe Driving Con-
ditionsº.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year)
MA-14

Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year)
=NJMA0043S05YD22DDT ENGINENJMA0043S0501Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference pages
Perform on a kilometer basis
only.km x 1,000
(miles x 1,000)20
(12)40
(24)60
(36)80
(48)100
(60)120
(72)
Engine compartment and under vehicle
Engine oil (Use recommended
oil)HRRRRRRLC-30
Engine oil filter (Use Eco filter or
equivalent)HSee NOTE (1)RRRRRRLC-31
Drive beltsIIIIIIEM-84
Cooling systemIIIIIILC-37
Engine anti-freeze coolant (Use
genuine NISSAN Anti-Freeze
Coolant (L2N) or equivalent)See NOTE (2) I I LC-43
Air cleaner filterHR R EM-87
Intake & exhaust valve clearance See NOTE (3) EM-132
Fuel lines I I FE-16
Injection nozzles See NOTE (4) EC-509
Fuel filterHR R FE-16
NOTE:
(1) Oil filter element assembly and O-ring seal are replacement parts.
(2) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, perform ªIº (check-
ing the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(3) If valve noise increases, check valve clearance.
(4) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and if
necessary, replace injection nozzle assembly.
HMaintenance items with ªHº should be performed more frequently according to ªMaintenance Under Severe Driving Con-
ditionsº.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year)
MA-16

ENGINE MECHANICAL
SECTION
EM
CONTENTS
QG
PRECAUTIONS...............................................................4
Parts Requiring Angular Tightening .............................4
Liquid Gasket Application Procedure ..........................4
PREPARATION...............................................................5
Special Service Tools ..................................................5
Commercial Service Tools ...........................................7
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................9
NVH Troubleshooting - Engine Noise .........................9
OUTER COMPONENT PARTS..................................... 11
Removal and Installation ........................................... 11
MEASUREMENT OF COMPRESSION PRESSURE....14
DRIVE BELTS................................................................15
Checking ....................................................................15
AIR CLEANER...............................................................17
Cleaning and Changing .............................................17
VISCOUS PAPER TYPE...........................................17
SPARK PLUG................................................................18
Checking and Changing ............................................18
OIL PAN.........................................................................19
Components...............................................................19
Removal .....................................................................19
Installation ..................................................................20
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/DRIVE PLATE 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 ..........................................................................66
VALVE....................................................................66
VALVE SPRING.......................................................66
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
YD
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...................................................81
NVH Troubleshooting - Engine Noise .......................81
MEASUREMENT OF COMPRESSION PRESSURE....82
DRIVE BELTS................................................................84
Inspection...................................................................84
Adjustment .................................................................84
AIR CONDITIONER COMPRESSOR BELT................85
ALTERNATOR & WATER PUMP BELT.....................85
Removal .....................................................................85
Installation ..................................................................86
AIR CLEANER...............................................................87
Changing Air Cleaner Filter .......................................87
VISCOUS PAPER TYPE...........................................87
OIL PAN.........................................................................88
Components...............................................................88
Removal .....................................................................88
Installation ..................................................................90
TIMING CHAIN..............................................................93
Secondary Timing Chain ...........................................93
REMOVAL...............................................................93
INSPECTION...........................................................95
INSTALLATION........................................................95
Primary Timing Chain ................................................98
REMOVAL...............................................................99
INSPECTION.........................................................101
INSTALLATION......................................................101
INTAKE MANIFOLD....................................................106
Removal and Installation .........................................106
PREPARATIVE WORK...........................................106
FUEL PIPING........................................................107
INTAKE MANIFOLD...............................................107
EGR VOLUME CONTROL VALVE...........................107
WATER HOSE.......................................................107
Inspection.................................................................108
INTAKE MANIFOLD...............................................108
CATALYST..................................................................109
Removal and Installation .........................................109
PREPARATIVE WORK...........................................109
CATALYST............................................................109
GUSSET............................................................... 110
EXHAUST MANIFOLD, TURBOCHARGER............... 111
Removal and Installation ......................................... 111
PREPARATIVE WORK........................................... 111
EXHAUST MANIFOLD AND TURBOCHARGER....... 111
EXHAUST MANIFOLD GASKET............................. 112
Disassembly and Assembly ..................................... 112
TURBOCHARGER................................................. 112
Inspection................................................................. 113
EXHAUST MANIFOLD........................................... 113
TURBOCHARGER................................................. 113
ROCKER COVER........................................................ 116
Removal and Installation ......................................... 116
PREPARATIVE WORK........................................... 116
ROCKER COVER.................................................. 116
CYLINDER HEAD........................................................ 118
Components............................................................. 118
Removal ................................................................... 119
PREPARATIVE WORK........................................... 119
CAMSHAFT........................................................... 119
CYLINDER HEAD..................................................120
Disassembly.............................................................120
Inspection.................................................................121
CONTENTS(Cont'd)
EM-2

CYLINDER HEAD DISTORTION.............................121
CAMSHAFT VISUAL CHECK..................................122
CAMSHAFT RUNOUT............................................122
CAMSHAFT CAM HEIGHT.....................................122
CAMSHAFT JOURNAL CLEARANCE......................122
CAMSHAFT END PLAY..........................................123
CAMSHAFT SPROCKET RUNOUT.........................123
VALVE GUIDE CLEARANCE..................................123
VALVE GUIDE REPLACEMENT..............................124
VALVE SEATS.......................................................125
REPLACING VALVE SEAT FOR SERVICE PARTS..125
VALVE DIMENSIONS.............................................127
VALVE SPRING.....................................................127
VALVE LIFTER......................................................127
Assembly .................................................................128
Installation ................................................................129
CYLINDER HEAD GASKET SELECTION.................129
CYLINDER HEAD BOLT DEFORMATION CHECK...130
CYLINDER HEAD-TO-BLOCK DIFFERENCE
CHECK
.................................................................130
LIQUID GASKET APPLICATION ON REAR CHAIN
CASE
....................................................................130
CYLINDER HEAD INSTALLATION..........................131
GLOW PLUG INSTALLATION.................................131
CAMSHAFT INSTALLATION...................................131
Valve Clearance.......................................................132
CHECKING...........................................................132
ADJUSTING..........................................................133
ENGINE ASSEMBLY...................................................136
Removal and Installation .........................................136
REMOVAL.............................................................137
INSTALLATION......................................................138
CYLINDER BLOCK.....................................................139
Components.............................................................139
Removal and Installation .........................................140
Disassembly.............................................................140
PISTON AND CRANKSHAFT..................................140
Inspection.................................................................143
CRANKSHAFT END PLAY.....................................143
CONNECTING ROD SIDE CLEARANCE.................143
PISTON AND PISTON PIN CLEARANCE................144
PISTON RING SIDE CLEARANCE..........................144
PISTON RING END GAP........................................145
CONNECTING ROD BEND AND TORSION.............145
CYLINDER BLOCK DISTORTION AND WEAR.........145
PISTON-TO-BORE CLEARANCE............................146
CRANKSHAFT.......................................................148
MAIN BEARING HOUSING INNER DIAMETER........148
BEARING CLEARANCE.........................................148
MAIN BEARING CRUSH HEIGHT...........................152
MAIN BEARING CAP BOLT DEFORMATION...........152
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
........................................................152
CONNECTING ROD BOLT DEFORMATION............153
FLYWHEEL RUNOUT............................................153
OIL JET................................................................153
OIL JET RELIEF VALVE.........................................154
Assembly .................................................................154
PISTON................................................................154
CRANKSHAFT.......................................................154
REPLACEMENT OF PILOT BUSHING.....................157
SERVICE DATA AND SPECIFICATIONS (SDS).......159
General Specifications .............................................159
Compression Pressure ............................................159
Belt Deflection..........................................................159
Cylinder Head ..........................................................159
Valve ........................................................................160
VALVE..................................................................160
VALVE CLEARANCE..............................................160
AVAILABLE SHIMS................................................160
VALVE SPRING.....................................................161
VALVE LIFTER......................................................162
VALVE GUIDE.......................................................162
Valve Seat................................................................163
Camshaft and Camshaft Bearing ............................165
Cylinder Block ..........................................................166
Piston, Piston Ring and Piston Pin .........................167
AVAILABLE PISTON..............................................167
PISTON RING.......................................................167
PISTON PIN..........................................................167
Connecting Rod .......................................................168
Crankshaft................................................................168
Available Main Bearing ............................................169
UNDERSIZE..........................................................169
Available Connecting Rod Bearing..........................169
CONNECTING ROD BEARING...............................169
UNDERSIZE..........................................................169
Miscellaneous Components.....................................169
BEARING CLEARANCE.........................................170
CONTENTS(Cont'd)
EM-3

NJEM0005
NVH Troubleshooting Ð Engine NoiseNJEM0005S01Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
Engine
Rocket
Cover Cyl-
inder HeadTicking or
clickC A Ð A B Ð Tappet
noise+Valve clearance EM-42
Rattle C A Ð A B C Camshaft
bearing
noise+Camshaft journal
clearance
+Camshaft runoutEM-37
Crankshaft
Pulley
Cylinder
block (Side
of Engine)
Oil panSlap or
knockÐ A Ð B B Ð Piston pin
noise+Piston and piston pin
clearance
+Connecting rod bush-
ing clearanceEM-54, 59
Slap or
rapA Ð Ð B B A Piston slap
noise+Piston-to-bore clear-
ance
+Piston ring side clear-
ance
+Piston ring end gap
+Connecting rod bend
and torsionEM-54, 55,
56
Knock A B CB B B Connecting
rod-bearing
noise+Connecting rod bear-
ing clearance (Big
end)
+Connecting rod bush-
ing clearance (Small
end)EM-58, 59
Knock A B Ð A B C Main bear-
ing noise+Main bearing oil clear-
ance
+Crankshaft runoutEM-57
Front of
Engine Tim-
ing Chain
CoverTapping or
tickingAAÐBBBTiming
chain and
chain ten-
sioner noise+Timing chain cracks
and wear
+Timing chain tensioner
operationEM-26
Front of
EngineSqueak or
fizzingA B Ð B Ð C Other drive
belts (stick-
ing or slip-
ping)+Drive belts deflection EM-15
CreakingABABABOther drive
belts (slip-
ping)+Idler pulley bearing
operation
Squall or
creakABÐBABWater pump
noise+Water pump operation LC-14
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGQG
NVH Troubleshooting Ð Engine Noise
EM-9

CheckingNJEM0042
SEM100G
1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,
replace with a new one.
+When replacing belt, make sure the new belt has the same
number of ribs as the old one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
3. Turn crankshaft two revolutions and recheck drive belt deflec-
tion.
+Inspect drive belt deflection when engine is cold.
+Adjust if belt deflections exceed the limit.
DRIVE BELTSQG
Checking
EM-15

Belt deflection:
Unit: mm (in)
Applied engineUsed belt deflection
Deflection
of new belt
LimitDeflection
after
adjustment
AlternatorWith air
conditioner
compressorQG15´18DE 8.1 (0.319)5.3 - 5.7
(0.209 -
0.224)4.5 - 5.0
(0.177 -
0.197)
Without air
conditioner
compressorQG15´18DE10.2
(0.402)6.5 - 7.0
(0.256 -
0.276)5.5 - 6.1
(0.217 -
0.240)
Power steering oil
pumpQG15DE 8.5 (0.335)5.2 - 5.8
(0.205 -
0.228)4.6 - 5.2
(0.181 -
0.205)
QG18DE 7.1 (0.280)4.4 - 4.9
(0.173 -
0.193)3.9 - 4.4
(0.154 -
0.173)
Applied pushing force 98 N (10 kg, 22 lb)
Inspect drive belt deflections when engine is cold.
DRIVE BELTSQG
Checking (Cont'd)
EM-16