2001 NISSAN ALMERA alternator

SYSTEM Ð ENGINE MECHANICAL & OTHERNJEC0041S03
SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA
Fuel Fuel tank
5
5FE section
Fuel piping 5 5 5 5 5 5
Ð Vapor lock
Valve deposit
5 555 55 5
Poor fuel (Heavy weight
gasoline, Low octane)
Air Air duct
55555 5 Air cleaner
Air leakage from air duct
(Mass air flow sensor Ð
throttle body)
5555
Throttle body, Throttle wireFE section
Air leakage from intake
manifold/Collector/GasketÐ
Cranking Battery
111111 11
EL section Alternator circuit
Starter circuit 3
Flywheel/drive plate 6EM section
1 - 6: The numbers refer to the order of inspection.
(continued on next page)
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONQG
Symptom Matrix Chart (Cont'd)
EC-157

On Board Diagnosis LogicNJEC1258The ECM checks if battery voltage is within the tolerance range for the engine control system.
DTC Malfunction is detected when ... Check Items (Possible Cause)
P1660
0502+An abnormally high or low voltage from the battery
is sent to ECM.+Incorrect jump starting
+Battery
+Alternator
+ECM
DTC Confirmation ProcedureNJEC1259With CONSULT-II
1) Check the following.
+Jumper cables are connected for jump starting.
+Battery or alternator has been replaced.
If the result is ªYesº for one item or more, skip the following steps and go to ªDiagnostic Procedureº,
EC-801.
2) Check that the positive battery terminal is connected to battery properly. If NG, reconnect it properly.
3) Check that the alternator functions properly. Refer to SC-30, ªTrouble Diagnosisº.
4) Turn ignition switch ªONº and select ªDATA MONITORº mode with CONSULT-II.
5) Wait one minute.
6) If DTC is detected, go to ªDiagnostic Procedureº, EC-801.
If DTC is not detected, go to next step.
7) Start engine and wait one minute at idle.
8) If DTC is detected, go to ªDiagnostic Procedureº, EC-801.
Without CONSULT-II
1) Check the following.
+Jumper cables are connected for jump starting.
+Battery or alternator has been replaced.
If the result is ªYesº for one item or more, skip the following steps and go to ªDiagnostic Procedureº,
EC-801.
2) Check that the positive battery terminal is connected to battery properly. If NG, reconnect it properly.
3) Check that the alternator functions properly. Refer to SC-30, ªTrouble Diagnosisº.
4) Turn ignition switch ªONº and wait one minute.
5) Turn ignition switch ªOFFº, wait 5 seconds and then turn ªONº.
6) Perform ªDiagnostic Test Mode II (Self-diagnostic result)º with ECM.
7) If DTC is detected, go to ªDiagnostic Procedureº, EC-801.
If DTC is not detected, go to next step.
8) Start engine and wait one minute at idle.
9) Turn ignition switch ªOFFº, wait 5 seconds and then turn ªONº.
10) Perform ªDiagnostic Test Mode II (Self-diagnostic result)º with ECM.
11) If DTC is detected, go to ªDiagnostic Procedureº, EC-801.
Diagnostic ProcedureNJEC1260
1 INSPECTION START
Are jumper cables connected for the jump starting?
YesorNo
Ye s©GO TO 3.
No©GO TO 2.
DTC P1660 BATTERY VOLTAGEYD
On Board Diagnosis Logic
EC-801

2 CHECK BATTERY AND ALTERNATOR
Check that the proper type of battery and alternator is installed.
Refer to SC-38, ªBatteryº and SC-39, ªAlternatorº.
OK or NG
OK©GO TO 5.
NG©Replace with a proper one.
3 CHECK JUMPER CABLES INSTALLATION
Check that the jumper cables are connected in the correct sequence.
SEF439Z
OK or NG
OK©GO TO 4.
NG©Reconnect jumper cables properly.
4 CHECK BATTERY FOR BOOSTER
Check that the battery for the booster is a 12V battery.
OK or NG
OK©GO TO 5.
NG©Change the vehicle for booster.
5 PERFORM DTC CONFIRMATION PROCEDURE AGAIN
Perform ªDTC Confirmation Procedureº, EC-801, again.
OK or NG
OK©GO TO 6.
NG©Replace ECM.
6 CHECK ELECTRICAL PARTS DAMAGE
Check the following for damage.
+Wiring harness and harness connectors for burn
+Fuses for short
OK or NG
OK©INSPECTION END
NG©Repair or replace malfunctioning part.
DTC P1660 BATTERY VOLTAGEYD
Diagnostic Procedure (Cont'd)
EC-802

System DescriptionNJEL0351The headlamp system on vehicles for North Europe contains a daytime light unit. The unit activates the fol-
lowing whenever the engine is running with the lighting switch in the OFF position:
+Low beam headlamps
+Parking, license, tail and illumination lamps
Power is supplied at all times
+through 10A fuse (No. 38, located in the fusible link and fuse box)
+to daytime light unit terminal 1 and
+to lighting switch terminal 11.
Power is also supplied at all times
+through 15A fuse (No. 39, located in the fusible link and fuse box)
+to daytime light unit terminal 3 and
+to lighting switch terminal 5.
Power is also supplied at all times
+through 15A fuse (No. 40, located in the fusible link and fuse box)
+to daytime light unit terminal 2 and
+to lighting switch terminal 8.
With the ignition switch in the ON or START position, power is supplied
+through 10A fuse [No. 20, located in the fuse block (J/B)]
+to daytime light unit terminal 7.
With the ignition switch in the START position, power is supplied
+through 10A fuse [No. 21, located in the fuse block (J/B)]
+to daytime light unit terminal 6.
Ground is supplied to daytime light unit terminal 9 through body grounds E30 and E73.
HEADLAMP OPERATION (DAYTIME LIGHT CANCEL OPERATION)NJEL0351S01When the lighting switch is turned to the 1st or 2nd position, power is supplied
+through lighting switch terminal 12,
+to daytime light unit terminal 11.
Then daytime light will be canceled. And the lighting system operation will be the same as no daytime light
system.
DAYTIME LIGHT OPERATIONNJEL0351S02With the engine running and the lighting switch in the OFF position, power is supplied
+from alternator terminal 3
+to daytime light unit terminal 8,
+through daytime light unit terminal 5
+to terminal 3 of headlamp LH,
+through daytime light unit terminal 4
+to terminal 3 of headlamp RH and
+through daytime light unit terminal 10
+to tail lamp and illumination.
Ground is supplied to terminal 2 of each headlamp through body grounds E30 and E73.
HEADLAMP Ð DAYTIME LIGHT SYSTEM Ð
System Description
EL-67

Trouble DiagnosesNJEL0354DAYTIME LIGHT UNIT INSPECTION TABLENJEL0354S01
Terminal No. ConnectionsINPUT (I)/ OUT-
PUT (O)Operated conditionVoltage (V)
(Approximate val-
ues)
1Power source for illumina-
tion & tail lampÐÐ12
2Power source for headlamp
LHÐÐ12
3Power source for headlamp
RHÐÐ12
4 Headlamp RH OON (daytime light operating*) 12
OFF 0
5 Headlamp LH OON (daytime light operating*) 12
OFF 0
6 Start signal I Ignition switchSTART 12
ON, ACC or OFF 0
7 Power source Ð Ignition switchON or START 12
ACC or OFF 0
8 Alternator ªLº terminal I EngineRunning 12
Stopped 0
9 Ground Ð Ð Ð
10 Illumination & tail lamp OON (daytime light operating*) 12
OFF 0
11 Lighting switch I1ST´2ND position 12
OFF 0
*: Daytime light operating: Lighting switch in ªOFFº position with engine running.
Bulb ReplacementNJEL0355Refer to ªHEADLAMPº (EL-64).
HEADLAMP Ð DAYTIME LIGHT SYSTEM Ð
Trouble Diagnoses
EL-76

REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
..........................................62
FLYWHEEL/DRIVE PLATE RUNOUT........................62
Assembly ...................................................................62
PISTON..................................................................62
CRANKSHAFT.........................................................63
SERVICE DATA AND SPECIFICATIONS (SDS).........66
General Specifications ...............................................66
Compression Pressure ..............................................66
Belt Deflection............................................................67
Spark Plug .................................................................67
Cylinder Head ............................................................67
Valve ..........................................................................68
VALVE....................................................................68
VALVE SPRING.......................................................68
VALVE LIFTER........................................................68
VALVE CLEARANCE................................................69
VALVE GUIDE.........................................................69
AVAILABLE SHIMS..................................................69
VALVE SEAT...........................................................71
VALVE SEAT RESURFACE LIMIT.............................72
Camshaft and Camshaft Bearing ..............................72
Cylinder Block ............................................................73
Piston, Piston Ring and Piston Pin ...........................74
PISTON..................................................................74
PISTON RING.........................................................74
PISTON PIN............................................................74
Connecting Rod .........................................................75
Crankshaft..................................................................75
Main Bearing..............................................................75
STANDARD.............................................................75
UNDERSIZE............................................................75
Connecting Rod Bearing ...........................................76
STANDARD SIZE....................................................76
UNDERSIZE............................................................76
Bearing Clearance .....................................................76
Miscellaneous Components.......................................76
YD
PRECAUTIONS.............................................................77
Parts Requiring Angular Tightening ...........................77
Liquid Gasket Application Procedure ........................77
PREPARATION.............................................................78
Special Service Tools ................................................78
Commercial Service Tools .........................................80
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................82
NVH Troubleshooting - Engine Noise .......................82
MEASUREMENT OF COMPRESSION PRESSURE....83
DRIVE BELTS................................................................85
Inspection...................................................................85
Adjustment .................................................................85
AIR CONDITIONER COMPRESSOR BELT................86
ALTERNATOR & WATER PUMP BELT.....................86
Removal .....................................................................86
Installation ..................................................................87
AIR CLEANER...............................................................88
Changing Air Cleaner Filter .......................................88
VISCOUS PAPER TYPE...........................................88
OIL PAN.........................................................................89
Components...............................................................89
Removal .....................................................................89
Installation ..................................................................91
TIMING CHAIN..............................................................94
Secondary Timing Chain ...........................................94
REMOVAL...............................................................94
INSPECTION...........................................................96
INSTALLATION........................................................96
Primary Timing Chain ................................................99
REMOVAL.............................................................100
INSPECTION.........................................................102
INSTALLATION......................................................102
INTAKE MANIFOLD....................................................107
Removal and Installation .........................................107
PREPARATIVE WORK...........................................107
FUEL PIPING........................................................108
INTAKE MANIFOLD...............................................108
EGR VOLUME CONTROL VALVE...........................108
WATER HOSE.......................................................108
Inspection.................................................................109
INTAKE MANIFOLD...............................................109
CATALYST.................................................................. 110
Removal and Installation ......................................... 110
PREPARATIVE WORK........................................... 110
CATALYST............................................................ 110
GUSSET............................................................... 111
EXHAUST MANIFOLD, TURBOCHARGER............... 112
Removal and Installation ......................................... 112
PREPARATIVE WORK........................................... 112
EXHAUST MANIFOLD AND TURBOCHARGER....... 112
EXHAUST MANIFOLD GASKET............................. 113
Disassembly and Assembly ..................................... 113
TURBOCHARGER................................................. 113
Inspection................................................................. 114
EXHAUST MANIFOLD........................................... 114
TURBOCHARGER................................................. 114
ROCKER COVER........................................................ 117
Removal and Installation ......................................... 117
PREPARATIVE WORK........................................... 117
ROCKER COVER.................................................. 117
CYLINDER HEAD........................................................ 119
Components............................................................. 119
Removal ...................................................................120
PREPARATIVE WORK...........................................120
CAMSHAFT...........................................................120
CYLINDER HEAD..................................................121
Disassembly.............................................................121
Inspection.................................................................122
CONTENTS(Cont'd)
EM-2

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
pumpSedan with
QG15DE8.5 (0.335)5.2 - 5.8
(0.205 -
0.228)4.6 - 5.2
(0.181 -
0.205)
Except for
Sedan with
QG15DE7.1 (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-17

CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing chain tensioner, oil seats, 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
RemovalNJEM01051. 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-40, 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-24