2003 NISSAN ALMERA N16 ECU

REMOVALNJEM0094S011. Remove engine and transaxle assembly. Refer to EM-63,
“ENGINE ASSEMBLY”.
2. Remove transaxle from engine. Place engine onto engine
stand (SST). Refer to EM-67, “CYLINDER BLOCK”, “Disas-
sembly”.
3. Remove the following parts:
Oil pan (upper and lower)
Refer to EM-15, “OIL PAN”.
Oil filter bracket
Refer to LC-31, “Oil Filter Bracket”.
Injection tube
Refer to EC-21, “Injection Tube and Injection Nozzle”.
4. Remove secondary timing chain and associated parts.
Refer to EM-20, “Secondary Timing Chain”.
5. When removing rear chain case, remove camshaft sprockets.
Refer to EM-46, “CAMSHAFT”.
JEM131G
6. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
JEM132G
c. Using pulley puller (SST), remove crankshaft pulley.
Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM133G
7. Remove oil pump.
Loosen bolts in the reverse order of that shown in the figure
and remove them.
Use seal cutter (SST) etc. for removal.
8. Remove front oil seal from oil pump.
Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
Be careful not to damage the oil pump.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-26

JEM158G
SEM301G
3. Heat cylinder head to 110 to 120°C (230 to 248°F) by soaking
in heated oil.
4. Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.
WARNING:
Do not touch cold valve seat with your bare hands.
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-90).
CAUTION:
Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-52, “Valve Seats”.
JEM253G
8. Use a depth gauge to measure the distance between the
mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit “L”:
Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)
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CYLINDER HEADYD
Inspection (Cont’d)
EM-53

JEM175G
3. Install camshaft brackets.
Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N·m (0.2 kg-m, 17 in-lb).
Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N·m (0.6 kg-m, 52 in-lb).
c. Tightento12to13N·m(1.2to1.4kg-m,9to10ft-lb).
5. Install camshaft sprockets.
Camshaft sprockets are commonly used for RH and LH.
Align camshaft sprocket and dowel pin on camshaft, and
install.
Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-59,
“Valve Clearance”.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
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CYLINDER HEADYD
Installation (Cont’d)
EM-59

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

SEM189G
Make sure that support is stable with the use of safety
blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
JEM190G
20. Carefully lower transmission jacks in accordance with the low-
ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
shift.
21. Remove center member.
Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATIONNJEM0069S02Install in the reverse order of removal, observing the following:
While installing, be careful to keep mount insulators free of oil
smear and damage.
When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
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ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-65

Removal and InstallationNJEM0071CAUTION:
When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
Place removed parts such as bearings and bearing caps
in their proper order and direction.
When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
Do not allow any magnetic materials to contact the signal
plate of flywheel.
Do not remove the signal plate at back.
Do not place the signal plate side facing under.
Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
DisassemblyNJEM0072PISTON AND CRANKSHAFTNJEM0072S011. Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-63.
2. Place engine on a work stand.
a. Remove flywheel.
Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a
pulley holder (SST) to remove the flywheel.
JEM192G
b. Install engine sub-attachment (SST) to rear surface of cylinder
block.
To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
The four sets of bolts and nuts are multi-purpose products.
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CYLINDER BLOCKYD
Removal and Installation
EM-67

AssemblyNJEM0074PISTONNJEM0074S011. With using snap ring pliers, install snap rings to grooves at the
rear side of the piston.
Install securely to fully fit into the groove.
2. Install piston to the connecting rod.
Heat the piston with an industrial drier to 60 to 70°C (140 to
158°F) so that the piston pin can be easily inserted by finger.
Then, insert the piston pin from the front of the piston into the
piston and into the connecting rod.
JEM227G
Assemble so that the front mark on the piston top surface and
cylinder No. stamped on connecting rod are positioned as
shown in the figure.
3. Install snap ring on piston front.
Refer to step 1. above for notes for installation.
After installing, check that the connecting rod moves smoothly.
4. Install piston rings using piston ring expander (Commercial
Service Tool).
Be extremely careful to avoid any damage to the piston.
JEM228G
Install top ring and second ring with the punched surface fac-
ing upward.
Identification mark:
Top ring AE
Second ring AE2
Install rings so that three closed gap position 120° apart one
another.
Closed gaps do not need to face in a specific directions, as
long as each are positioned 120° apart.
JEM223G
CRANKSHAFTNJEM0074S021. Blow air sufficiently into the coolant passage, oil passage in the
cylinder block, inside of crankshaft case, and inside of cylinder
bores to remove any foreign materials.
2. Install oil jet relief valves.
3. Install oil jets.
JEM224G
4. Install main bearings and thrust bearings.
a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
Install thrust bearings with oil groove facing in the direction of
the crankshaft arm (outside).
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CYLINDER BLOCKYD
Assembly
EM-81

JEM233G
16. Install rear oil seal retainer.
Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
JEM234G
17. Install pilot bushing.
Force fit with the drift [approx. 19 mm (0.75 in) dia.].
SEM513G
18. Install fuel injection pump bracket.
Install insulator according to the shape of the block, and secure
by placing the bracket against the insulator. (Not installed on
some models)
Align the bracket with the dowel pins on the block to install.
The two bolts used for dowel pins have a longer shanks than
the other two.
Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
19. Install parts to the engine in the reverse order of disassembly.
Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque.
: 57 - 65 N·m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel.
Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
Tighten bolts uniformly in a crisscross manner.
SEM500GA
REPLACEMENT OF PILOT BUSHINGNJEM0074S031. Remove pilot bushing using tool or suitable tool.
CYLINDER BLOCKYD
Assembly (Cont’d)
EM-84