2003 NISSAN ALMERA N16 flow

EM-14
[QG]
AIR CLEANER AND AIR DUCT
AIR CLEANER AND AIR DUCT
PFP:16500
Removal and InstallationEBS00LQ1
REMOVAL
1. Remove air cleaner case assembly, air duct and resonator.
●Add marks as necessary for easier installation.
2. Remove harness connector from mass air flow sensor.
3. Remove mass air flow sensor.
CAUTION:
Handle mass air flow sensor with following cares.
●Do not shock it.
●Do not disassembly it.
●Do not touch its sensor.
●Do not deform mass air flow sensor's wire mesh.
4. Remove left fender protector and resonator.
INSTALLATION
1. Attach each joint aligning marks put at removal. Screw clamps firmly.
2. Install in the reverse order of removal.
PBIC0533E
1. Air cleaner case (upper) 2. Resonator 3. Air duct
4. Mass air flow sensor 5. O-ring 6. Air cleaner case (lower)
7. Grommet 8. Air cleaner element 9. Bracket

EM-104
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
CONNECTING ROD BEARING
Standard Size
Unit: mm (in)
Undersize
Unit: mm (in)
Bearing Clearance
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
*: Total indicator reading
Tightening TorqueEBS00LQQ
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb) / Unit: N·m (kg-m, in-lb)*2
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) Block
1 1.506 - 1.509 (0.0593 - 0.0594) Red
2 1.509 - 1.512 (0.0594 - 0.0595) Green
Grade No. Thickness Identification color or number
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) —
0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) —
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) —
Connecting rod bearing clear-
anceStandard 0.014 - 0.039 (0.0006 - 0.0015)
Limit 0.1 (0.004)
Flywheel runout [TIR*] Less than 0.1 (0.004)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
Mass air flow sensor
8.4 - 10.8 (0.9 - 1.1, 75 - 95)*2
Resonator
3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2
Air cleaner case lower
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*2
Intake manifold16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Intake manifold collector
7.0 - 9.5 (0.71 - 0.97, 62 - 84)*
2
Intake manifold support 16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Electric throttle control actuator 17.7 - 21.6 (1.8 - 2.2, 13 - 15)
Exhaust manifold25.5 - 29.4 (2.6 - 2.9, 19 - 21)
Exhaust manifold cover
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*
2
Heated oxygen sensor 58.8 - 78.4 (6.0 - 7.9, 44 - 57)
Ground nut79.4 (8.1, 59)
Oil pan
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Oil pan drain plug29.4 - 39.2 ( 3.0 - 3.9, 22 - 28)
Oil strainer
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Ignition coil
3.8 - 5.0 (0.38 - 0.51, 33 - 44)*2
Spark plug19.6 - 29.4 (2.0 - 3.0, 15 - 21)
*1 Fuel tube1) 11.8 - 13.8 (1.2 - 1.4, 9 - 10 )
2) 17 - 23 (1.7 - 2.4, 13 - 17)
Rocker cover
6.9 - 9.5 (0.70 - 0.97, 61 - 84)*
2

JEM238G
FUEL PIPINGNJEM0109S02RemovalNJEM0109S0201To prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
Be careful not to spill fuel in the engine compartment.
InstallationNJEM0109S0202After repairing, bleed air in pipes by shifting priming pump up
and down until the touch is heavy.
For further air bleeding, idle at least 1 minute or more.
SEM489G
INTAKE MANIFOLDNJEM0109S03RemovalNJEM0109S0301Loosen bolts and nuts in the reverse order of that shown in the
figure.
InstallationNJEM0109S0302When stud bolts come off, install with the following torque:
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Tighten fixing bolts in the numerical order shown in the figure.
EGR VOLUME CONTROL VALVENJEM0109S04Handle with care avoiding any shocks.
Do not disassemble or adjust.
YEM054
WATER HOSENJEM0109S05InstallationNJEM0109S0501Install water hose by referring to identification marks; avoiding
twisting.
When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end.
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
INTAKE MANIFOLDYD
Removal and Installation (Cont’d)
EM-34

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.
Carbon is accumulated.
Friction with housing.
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contami-
nated by oil.
Friction with housing.
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.
The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing.
Oil return portCarbon or sludge is accumulated in the
waste oil hole.
: Large possibility
: Medium possibility
: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont’d)
EM-42

crankshaft position sensor (TDC sensor) from the assem-
bly.
Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, “Changing Engine Coolant”.
3. Remove the following parts:
Battery
RH and LH front wheels
RH and LH splash covers (combined with undercover)
Auxiliary belts
Alternator
Alternator brackets
Radiator and cooling fan
Engine cover
Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
YEM024
14. Install engine slingers to cylinder head.
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-64

YLC044
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
ALC094
Changing Oil FilterNJLC0010The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
Use Tool KV10115801 for removing oil filter.
SLC275B
1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
SMA010
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
SMA229B
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
Clean excess oil from engine.
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ENGINE LUBRICATION SYSTEMQG
Changing Engine Oil (Cont’d)
LC-9

CHECKING RADIATORNJLC0017S04Check radiator for mud or clogging. If necessary, clean radiator as
follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically download.
Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm
2,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
SLC613-A
CHECKING RADIATOR CAPNJLC0017S03To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2,9-14psi)
SMA967B
Pull the negative pressure valve to open it.
Check that it closes completely when released.
SLC756AA
CHECKING COOLING SYSTEM FOR LEAKSNJLC0017S02To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2,23psi)
CAUTION:
Higher pressure than specified may cause radiator damage.
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ENGINE COOLING SYSTEMQG
System Check (Cont’d)
LC-13

SMA182B
SMA412B
Refer to MA-19, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Coolant capacity (With reservoir tank):
Unit:(Imp qt)
M/T 6.7 (5-7/8)
A/TFor Sedan 6.6 (5-7/8)
For Hatchback 6.7 (5-7/8)
Reservoir tank capacity:
0.7(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
3. Fill radiator and reservoir tank to specified level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
If coolant overflows radiator filler hole, install filler cap.
5. Run engine at 2,500 rpm for 10 seconds and return to idle
speed with radiator cap installed.
Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool it down.
Cool down using a fan to reduce the time.
If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 3,000 rpm with heater tempera-
ture controller set at several positions between COOL and
HOT.
Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until coolant level no longer drops
Clean excess coolant from engine.
— FLUSHING COOLING SYSTEM —NJLC0037S031. Open air relief plug.
2. Fill radiator with water until water spills from the air relief hole,
then close air relief plug. Fill radiator and reservoir tank with
water and reinstall radiator cap.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from
radiator.
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ENGINE COOLING SYSTEMQG
Changing Engine Coolant (Cont’d)
LC-19