2001 NISSAN ALMERA N16 check engine

SEM904F
+Apply new engine oil to bolt threads and seat surface.
+Tighten camshaft bracket bolts in the following steps.
a. Tighten bolts9-12,then1-8.
2.0 N´m (0.204 kg-m, 17.7 in-lb)
b. Tighten bolts1-12.
5.9 N´m (0.60 kg-m, 52.2 in-lb)
c. Tighten bolts1-12.
9.0 - 11.8 N´m (0.92 - 1.20 kg-m, 80 - 104 in-lb)
+If any part of valve assembly or camshaft is replaced,
check valve clearance according to reference data.
After completing assembly check valve clearance. Refer
to ªCheckingº and ªAdjustingº in ªVALVE CLEARANCEº
(EM-42).
Reference data valve clearance (Cold):
Intake
0.25 - 0.33 mm (0.010 - 0.013 in)
Exhaust
0.32 - 0.40 mm (0.013 - 0.016 in)
SEM905F
6. Install camshaft sprocket.
+Set timing chain by aligning mating marks with those of
camshaft sprockets.
SEM906F
7. Install camshaft sprocket bolts to correct torque.
+Apply new engine oil to bolt threads and seat surface.
SEM907F
8. Install chain tensioner.
+Before installing chain tensioner, insert a suitable pin into
pin hole of chain tensioner.
+After installing chain tensioner, remove the pin.
9. Install timing chain guide.
CYLINDER HEADQG
Installation (Cont'd)
EM-47

NJEM0051
NVH Troubleshooting Ð Engine NoiseNJEM0051S01Use 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
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingC AÐA BÐTappet
noise+Valve clearance EM-133
Rattle C A Ð A B CCamshaft
bearing
noise+Camshaft journal
clearance
+Camshaft runoutEM-122,
122
Crankshaft
pulley
Cylinder
block
(Side of
engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noise+Piston and piston
pin clearance
+Connecting rod
bushing clearanceEM-144,
152
Slap or
rapAÐÐB B APiston slap
noise+Piston-to-bore
clearance
+Piston ring side
clearance
+Piston ring end
gap
+Connecting rod
bend and torsionEM-144,
145, 145,
146
Knock A B C B B BConnect-
ing rod
bearing
noise+Connecting rod
bushing clearance
(Small end)
+Connecting rod
bearing clearance
(Big end)EM-152,
150
Knock A B Ð A B CMain bear-
ing noise+Main bearing oil
clearance
+Crankshaft runoutEM-148,
148
Front of
engine
Timing
chain
coverTapping or
tickingAAÐBBBTiming
chain and
chain ten-
sioner
noise+Timing chain
cracks and wear
+Timing chain ten-
sioner operationEM-95, 93
Front of
engineSqueaking
or fizzingA BÐBÐCOther
drive belts
(Sticking
or slipping)+Drive belts deflec-
tion
EM-84
CreakingABABABOther
drive belts
(Slipping)+Idler pulley bearing
operation
Squall
CreakABÐBABWater
pump
noise+Water pump opera-
tionLC-39
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGYD
NVH Troubleshooting Ð Engine Noise
EM-81

NJEM0053
JEM111G
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-492, ªTrouble Diagnosis Ð
INDEXº.
+Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
+Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
+Carefully remove glow plugs to prevent any damage or
breakage.
+Handle with care to avoid applying any shock to glow
plugs.
SEM112G
7. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
+Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
3,138 (31.38, 32.0, 455)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
+When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
+If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin-
der block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Install glow plugs.
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-82

JEM249G
InspectionNJEM0088+Before inspecting the engine, make sure the engine has
cooled down; wait approximately 30 minutes after the engine
has been stopped.
+Visually inspect all belts for wear, damage, or cracks on con-
tacting surfaces and edge areas.
+When measuring deflection, apply 98 N (10 kg, 22 lb) at the.
marked point.
+When checking belt deflection immediately after
installation, first adjust it to the specified value. Then,
after turning the crankshaft two turns or more, re-adjust to
the specified value to avoid variation in deflection
between pulleys.
+Tighten idler pulley lock nut by hand and measure deflec-
tion without looseness.
Belt Deflection:
Applied beltBelt specifica-
tionBelt deflection with 98 N (10 kg, 22 lb) force
applied* mm (in)
New AdjustedLimit for re-
tightening
Air conditioner
compressor
beltHA type low
edge belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator &
water pump
beltHA type low-
edge wide
angle belt9.0 - 10.5
(0.354 -
0.413)11.0 - 12.5
(0.433 -
0.492)16.5 (0.650)
*: When engine is cold.
AdjustmentNJEM0089+Adjust belts with the parts shown below.
Applied belt Belt tightening method for adjustment
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator
CAUTION:
+When a new belt is installed as a replacement, adjust it to
the value specified under ªNewº accommodations
because of insufficient adaptability with pulley grooves.
DRIVE BELTSYD
Inspection
EM-84

JEM137G
2. Install power steering pump.
3. Install fuel injection pump.
+Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM136G
6. Install primary timing chain with fuel injection pump sprocket.
+When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
+Install fuel injection pump sprocket washer with the surface
marked ªFº (front mark) facing the front of the engine.
7. Install timing chain onto power steering pump sprocket and
through chain guide.
JEM135G
8. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt.
+Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt.
JEM134G
9. Install timing chain slack guide.
10. Install chain tensioner.
+Push the plunger of the chain tensioner. While keeping plunger
pressed down with a push pin, etc., install the chain tensioner.
+After installation, pull out the push pin holding the plunger.
+Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
JEM142G
11. Install front oil seal to oil pump.
+Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
+Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-103

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-76, ªLiquid Gasket Application Procedureº.) as shown in
the figure.
+Apply liquid gasket on oil pump-side surface.
JEM144G
13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-76, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM145G
b. Install oil pump drive spacer to crankshaft.
+Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
JEM133G
d. Install oil pump.
+When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
+When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM146G
14. Check gaps on upper oil pan mounting surface.
+Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
±0.14 to 0.14 mm (±0.0055 to 0.0055 in)
Rear chain case and cylinder block
±0.25 to 0.13 mm (±0.0098 to 0.0051 in)
+If the measured value is out of the above range, install again.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-104

Trouble Diagnosis of Turbocharger=NJEM0104S0206Preliminary check:
+Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection
item meets each inspection result)
Oil
leakageSmoke NoiseInsuffi-
cient
power/
accel-
eration
failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contami-
nated by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor shaft
is rotated by your fingertips.nnj
The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing.nnjn
Oil return portCarbon or sludge is accumulated in the
waste oil hole.n
nn
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-115

Piston protrusion mm (in)Gasket thickness*
mm (in)Identification
Number of holes
Less than 0.255 (0.0100) 0.900 (0.0354) 1
Less than 0.255 - 0.280
(0.0100 - 0.0110)0.925 (0.0364) 2
Less than 0.280 - 0.305
(0.0110 - 0.0120)0.950 (0.0374) 3
Less than 0.305 - 0.330
(0.0120 - 0.0130)0.975 (0.0384) 4
Less than 0.330 - 0.355
(0.0130 - 0.0140)1.000 (0.0394) 5
More than 0.355 (0.0140) 1.025 (0.0404) 6
*: Measured with head bolts tightened
JEM171G
CYLINDER HEAD BOLT DEFORMATION CHECKNJEM0067S02+Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
+When the necked point is identified at a point other than speci-
fied points, measure at the point as d1.
+Calculate the difference between d1 and d2. If the value
exceeds the limit, replace with new ones.
Limit: 0.15 mm (0.0059 in)
JEM172G
CYLINDER HEAD-TO-BLOCK DIFFERENCE CHECKNJEM0067S03+After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.
Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
+If the difference is out of the range, check fitting of dowel pins
and cylinder head.
JEM167G
LIQUID GASKET APPLICATION ON REAR CHAIN CASENJEM0067S04Apply a continuous bead of specified liquid gasket (Refer to EM-76,
ªLiquid Gasket Application Procedureº.) on the surface shown in
the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with 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 is assembled.
CYLINDER HEADYD
Installation (Cont'd)
EM-130