2003 NISSAN ALMERA N16 power steering pump

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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ENGINE MECHANICAL
QG
PRECAUTIONS .......................................................... 3
Precautions for Drain Coolant .................................. 3
Precautions for Disconnecting Fuel Piping .............. 3
Precautions for Removal and Disassembly ............. 3
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 3
Precautions for Assembly and Installation ............... 3
Parts Requiring Angular Tightening ......................... 3
Precautions for Liquid Gasket .................................. 4
REMOVAL OF LIQUID GASKET SEALING .......... 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
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 10
DRIVE BELTS ............................................................11
Checking Drive Belts ............................................... 11
Tension Adjustment ................................................ 12
POWER STEERING PUMP AND WATER PUMP
BELT ................................................................... 12
ALTERNATOR AND AIR CONDITIONER COM-
PRESSOR BELT ................................................. 12
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
AIR CLEANER AND AIR DUCT ............................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Changing Air Cleaner Element ............................... 15
INTAKE MANIFOLD ................................................. 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 18EXHAUST MANIFOLD AND CATALYTIC CON-
VERTER .................................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
Disassembly and Assembly .................................... 21
DISASSEMBLY ................................................... 21
ASSEMBLY ......................................................... 21
OIL PAN AND OIL STRAINER ..............................
... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 23
IGNITION COIL ......................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
SPARK PLUG (CONVENTIONAL) ........................... 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 25
INSTALLATION ................................................... 25
FUEL INJECTOR AND FUEL TUBE ........................ 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 28
ROCKER COVER ..................................................... 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 30
CAMSHAFT .............................................................. 32
Removal and Installation ........................................ 32
REMOVAL ........................................................... 32
INSTALLATION ................................................... 35

DRIVE BELTS
EM-11
[QG]
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LPY
●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 contacting surfaces and edge areas.
●When measuring deflection, apply 98 N (10 kg, 22 lb) at the ▼ marked point.
CAUTION:
When measuring belt tension immediately after belt is installed, first set the tension to the standard.
Then, rotate crankshaft for more than two turns in order to eliminate variance in belt deflection
between the pulleys. Re-measure and adjust the tension to the standard.
PBIC0764E
Deflection adjustment Unit: mm (in)
Used belt
New belt
Limit After adjustment
AlternatorWithout air conditioner compressor 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
With air conditioner compressor 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)
Power steering oil pump 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)

EM-12
[QG]
DRIVE BELTS
Tension Adjustment
EBS00LPZ
CAUTION:
●When belt is replaced with a new one, tighten it a little
stronger than current one to accommodate for insufficient
adaptability with pulley grooves.
●When tension of belt being used exceeds “Retightening
limit”, adjust it to value for “Used belt”.
●When installing belt, make sure that it is correctly engaged with pulley groove.
●Keep oil and water away from belt.
●Do not twist or bend belt excessively.
●When adjusting belt, remove snap retainer from adjusting bolt thread (to prevent the retainer from
becoming pinched or missing).
●After adjustment, be sure to install snap retainer to adjusting bolt thread.
NOTE:
Snap retainer can prevent adjusting bolt from dropping due to vibration during driving.
POWER STEERING PUMP AND WATER PUMP BELT
1. Loosen lock nut (A) and power steering pump mounting nut (B).
2. Turn adjusting bolt (C) to adjust. Refer to EM-11, "
Checking
Drive Belts" .
3. Tighten lock nut (A) and power steering pump mounting nut (B)
in this order.
ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
1. Remove RH splash cover (with undercover attached).
2. Loosen lock nut (G).
3. Turn adjusting bolt (H) to adjust.
Refer to EM-11, "
Checking Drive Belts" .
4. Tighten lock nut (G).
Portion Belt tightening method for adjustment
Power steering pump and water pump
beltAdjusting bolt on power steering pump
Alternator and air conditioner compres-
sor beltAdjusting bolt on idler pulley
PBIC0531E
Nut A :
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Nut B :
: 26.5 - 36.3 N·m (2.7 - 3.7 kg-m, 20 - 26 ft-lb)
PBIC0532E
Nut G :
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)

TIMING CHAIN
EM-47
[QG]
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TIMING CHAINPFP:13028
Removal and InstallationEBS00LQD
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Place vehicle on lift.
PBIC0971E
1. Cylinder head front cover 2. Camshaft sprocket (INT) 3. Washer
4. Camshaft sprocket (EXH) 5. Chain tensioner 6. Chain slack guide
7. O-ring 8. Power steering pump adjusting bar 9. Crankshaft pulley
10. Front oil seal 11. Front cover 12. Chain tension guide
13. Dowel pin 14. Timing chain 15. Oil pump drive spacer
16. Crankshaft sprocket 17. O-ring (with collar) 18. Auxiliary bolt of cylinder head

EM-48
[QG]
TIMING CHAIN
2. Disconnect battery ground cable.
3. Remove undercover, front RH wheel and RH splash cover.
4. Drain engine coolant from radiator and cylinder block. Refer to LC-17, "Changing Engine Coolant".
5. Drain engine oil from oil pan.
6. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
7. Remove power steering pump from adjusting bar.
8. Remove alternator. SC-33, "Removal and Installation".
9. Remove ignition coils. Refer to EM-24, "
IGNITION COIL" .
10. Remove rocker cover. Refer to EM-29, "
Removal and Installation" .
11. Remove oil level gauge.
12. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
13. Remove center member.
14. Remove gusset.
15. Remove rear plate (lower) (A/T models).
16. Remove oil pan and oil strainer. Refer to EM-22, "
Removal and Installation" .
17. For safe operation, and to reduce load to mount insulator, install removed center member again.
18. Remove engine front-side (right side of vehicle) engine mount. Refer to EM-67, "
ENGINE ASSEMBLY" .
a. Remove any parts that cause difficulties for operation around mount, or perform transfer.
b. Support cylinder block bottom surface with a transmission jack.
CAUTION:
●When applying jack, use a wooden block to avoid damage to oil pan mounting surface.
●While performing following operations, support engine front-side with jack.
c. Separate engine mounting insulator and bracket.
d. Remove engine mounting bracket.
19. Remove cylinder head front cover.
●Move harness which was previously fixed on front surface.
20. Remove auxiliary bolts of cylinder head.
21. Set the No. 1 cylinder to the compression TDC.
a. Turn the crankshaft pulley clockwise, and align the timing indica-
tor of the gear case to the timing mark of the crankshaft pulley.
PBIC0557E
PBIC0750E

EM-50
[QG]
TIMING CHAIN
24. Remove front cover with the following procedure:
a. To increase freedom of front cover posture during removal/
installation, pull oil pump drive spacer out through front oil seal.
●Pull it straight out using long-nose priers or two flat-bladed
screwdrivers.
CAUTION:
Be careful not to damage side of oil pump drive spacer and
front oil seal lip.
b. Remove power steering pump adjusting bar.
c. Remove front cover carefully.
●Remove mounting bolts A - E shown in figure.
NOTE:
Bolts C and E have been removed in step b.
CAUTION:
●When removing, be careful not to damage or bend front
end of cylinder head gasket. Also after peeling off con-
tact face between front cover and gasket, their surfaces
shall be smooth.
●If cylinder head gasket is damaged, replace it with new
one.
d. Remove O-rings from front cover and cylinder block.
25. Pull two dowel pins for front cover out of cylinder block.
●Heat them with industrial dryer sufficiently, then pull them out
using locking pliers.
NOTE:
This operation is performed as preparation operation for front
cover installation. This operation can be performed after
removal of timing chain.
26. If front oil seal is need to be replaced, remove it from front cover.
●Insert a flat-bladed screwdriver in notch on oil seal mounting
point, and lift oil seal to remove.
NOTE:
Remove timing chain and its related parts with the following pro-
cedure:
27. Secure intake camshaft sprocket in most advanced position. Refer to EM-32, "
REMOVAL" .
NOTE:
Removal of timing chain and related parts is described in following steps.
28. Remove chain tensioner. Refer to EM-32, "
REMOVAL" .
29. Remove camshaft sprocket. Refer to EM-32, "
REMOVAL" .
CAUTION:
After this step is completed, do not rotate crankshaft and camshaft separately in order to prevent
interference between valve and piston.
PBIC0566E
EMD0850D
PBIC0567E
PBIC0558E

TIMING CHAIN
EM-53
[QG]
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h. Install front cover with mounting bolts temporarily so that front
cover will not move.
i. Press fit dowel pin into cylinder block through front cover.
j. Tighten front cover mounting bolts temporarily.
●A [M6 x 20 mm (0.79 in)], B [M6 x 40 mm (1.57 in)], C [M8 x
70 mm (2.76 in)], D [M6 x 73 mm (2.87 in)]
●Bolt C also secures power steering pump adjusting bar.
●Bolt E [M6 x 12 mm (0.47 in)] is for installing power steering
pump adjusting bar.
k. Tighten cylinder head auxiliary bolts (M6) temporarily.
l. Tighten front cover mounting bolts and cylinder head auxiliary
bolts to specified torque.
4. Install oil pump drive spacer.
●When installing, align with flat of oil pump inner rotor.
●If they are not aligned, rotate inner rotor with a flat-bladed
screwdriver to align them.
CAUTION:
Be careful not to damage oil seal lips.
5. Install water pump pulley and idler pulley bracket assembly.
6. Install crankshaft pulley.
●When installing it, make sure that front oil seal lip is not inverted and garter spring is in position.
●For direction of mounting bolt washer, refer to “Component Parts Location”.
●With same procedure as “removal”, secure crankshaft, and tighten mounting bolts.
7. Install cylinder head front cover.
●Apply liquid gasket to cylinder head front cover.
●Use Genuine Liquid Gasket or equivalent.
8. Install engine front mounting bracket.
9. Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●In order to allow liquid gasket to be cured, perform inspection at least 30 minutes after the last step in
which parts sealed with liquid gasket are installed.
●With engine warmed up, check each part for engine oil leakage.
PBIC0564E
EMD0850D
PBIC0566E
PBIC0968E

EM-68
[QG]
ENGINE ASSEMBLY
WARNING:
●Position vehicle on a flat and solid surface.
●Place chocks at front and back of rear wheels.
●Do not remove engine until exhaust system has completely cooled off, otherwise, you may burn
yourself and/or fire may break out in fuel line.
●Before disconnecting fuel hose, release pressure.
Refer to EC-34 (WITH EURO-OBD), EC-428 (WITHOUT EURO-OBD).
●Be sure to lift engine and transaxle in a safe manner.
●For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
●When lifting engine, be sure to clear surrounding parts. Use special care near accelerator wire
casing, brake lines and brake master cylinder.
●When lifting the engine, always use engine slingers in a safe manner.
●When removing drive shaft, be careful not to damage grease seal of transaxle.
●Before separating engine and transaxle, remove crankshaft position sensor (POS) from the cylin-
der block assembly.
●Always be extra careful not to damage edge of crankshaft position sensor (POS), or signal plate
teeth.
Engine cannot be removed separately from transaxle. Remove engine with transaxle as an assembly.
REMOVAL
1. Drain coolant from radiator and cylinder block. Refer to LC-17, "Chacking Engine Coolant".
2. Remove coolant reservoir tank and bracket.
3. Drain engine oil.
4. Remove battery and battery tray.
5. Remove air cleaner and air duct.
6. Remove drive belts.
7. Remove alternator and air conditioner compressor from engine.
8. Remove power steering oil pump from engine and position aside.
Power steering oil pump does not need to be disconnected from power steering tubes.
9. Remove the following parts:
●RH and LH front tires
●Splash covers
●RH and LH brake caliper assemblies
Refer to BR-28,"Removal".
Brake hose does not need to be disconnected from brake
caliper assembly. Never depress brake pedal.
●RH & LH drive shaft. Refer to AX-11, "Removal".
When removing drive shaft, be careful not to damage
transaxle side grease seal.
●Disconnect control rod and support rod from transaxle. (M/T
models.)
Refer to MT-26, "Removal".
●Disconnect control cable from transaxle. (A/T models.)
Refer to AT-411, "Removal".
SEM174D
SEM109G