2003 NISSAN ALMERA N16 torque

15 CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND SHORT
1. Disconnect glow plug harness connector.
2. Check harness continuity between glow relay terminal 3 and glow plug harness connector. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK GO TO 16.
NG Repair open circuit or short to ground or short to power in harness or connectors.
16 CHECK GLOW RELAY
Check continuity between glow relay terminals 3 and 5 under the following conditions.
SEF433Y
OK or NG
OK GO TO 17.
NG Replace glow relay.
17 CHECK GLOW PLUG
1. Remove glow plug connecting plate.
2. Check glow plug resistance.
SEF434Y
NOTE:
Do not bump glow plug heating element. If it is bumped, replace glow plug withanewone.
If glow plug is dropped from a height of 10 cm (3.94 in) or higher, replace with a new one.
If glow plug installation hole is contaminated with carbon, remove it witha reamer or suitable tool.
Hand-tighten glow plug by turning it two or three times, then tighten usinga tool to specified torque.
: 17.7 - 22.5 N·m (1.8 - 2.3 kg-m, 13 - 16 ft-lb)
OK or NG
OK GO TO 18.
NG Replace glow plug.
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GLOW CONTROL SYSTEMYD
Diagnostic Procedure (Cont’d)
EC-195

SMA803A
Checking Fuel LinesNJFE0009Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
Removal and InstallationNJFE0004WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a “CAUTION: FLAMMABLE” sign in workshop.
Be sure to furnish workshop with a CO
2fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
a) Put drained fuel in an explosion-proof container and put the lid on securely.
b) Release fuel pressure from fuel line. Refer to EC-34, “Fuel Pressure Release”.
c) Disconnect battery ground cable.
Always replace O-ring and clamps with new ones.
Do not kink or twist tubes when they are being installed.
Do not tighten hose clamps excessively to avoid damaging hoses.
After installing tubes, run engine and check for fuel leaks at connections.
FUEL SYSTEMQG
Checking Fuel Lines
FE-4

SMA211A
Checking Exhaust SystemNJFE0010Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.
Removal and InstallationNJFE0005CAUTION:
Always replace exhaust gaskets with new ones when
reassembling.
With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
Check to ensure that mounting brackets and mounting
insulators are installed properly and free from undue
stress. Improper installation could result in excessive
noise or vibration.
Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; use a new one.
Before installing a new oxygen sensor, clean exhaust sys-
tem threads using oxygen sensor thread cleaner tool and
apply anti-seize lubricant.
Do not overtorque the oxygen sensor. Doing so may
cause damage to the oxygen sensor, resuiting in the MIL
coming on.
Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
Be careful not to cut your hand on the insulator edge.
EXHAUST SYSTEMQG
Checking Exhaust System
FE-10

SMA803A
Checking Fuel LinesNJFE0019Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.
If necessary, repair or replace.
MMA104A
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
SMA794C
Water Draining from Fuel FilterNJFE0028DRAINING WATERNJFE0028S01Open drain valve at the bottom of fuel filter.
FUEL FILTER CHECKNJFE0028S02Check fuel filter for fuel leakage, damage and other abnormal
things.
JFE598A
Changing Fuel FilterNJFE0021REMOVALNJFE0021S011. Take out air duct and upper air cleaner case.
2. Remove fuel filter using a fuel filter wrench (commercial ser-
vice tool).
CAUTION:
Do not spill the fuel during removal. If the fuel is spilt, imme-
diately wipe it off. Be especially careful to prevent the fuel
from adhering to the insulators of the engine mounts.
3. Remove fuel-level warning sensor from fuel filter.
YFE008
INSTALLATIONNJFE0021S02Install in the reverse order of removal.
Tighten the fuel filter so that the sealing face contacts the
packing, then retighten it manually by approximately 2/3 turn.
After installation, operate the priming pump vertically to per-
form air bleeding.
Refer to FE-16, “Bleeding Fuel Filter”.
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FUEL SYSTEMYD
Checking Fuel Lines
FE-15

Special Service ToolsNJCL0002
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
NT406
Removing and installing clutch piping
a: 10 mm (0.39 in)
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
NT645
Installing clutch cover and clutch disc
(F30A and F70A)
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20630000
Clutch aligning bar
NT405
Installing clutch cover and clutch disc
(F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)
ST20050240
Diaphragm spring adjust-
ing wrench
NT404
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
KV32101000
Pin punch
NT410
Removing and installing spring pin
a: 4 mm (0.16 in) dia.
Commercial Service ToolsNJCL0003
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
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PREPARATION
Special Service Tools
CL-3

CLUTCH PEDAL ADJUSTMENTNJCL0006S04Pedal StrokeNJCL0006S04011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free
play.
Pedal stroke “S”.
Refer to “SDS”, CL-24.
Pedal Free PlayNJCL0006S04021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
Pedal free play “A”.
Refer to “SDS”, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENJCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
Carefully monitor fluid level at master cylinder during
bleeding operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, then air bubbles
will no longer appear at the damper in the brake fluid.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont’d)
CL-10

RemovalNJCL00081. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
InstallationNJCL00091. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
: 11 - 14 N·m (1.1 - 1.5 kg-m, 8 - 10 ft-lb)
3. Tighten clutch tube flare nut using a flare nut torque wrench.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. After installing clevis pin, install snap pin to connect clutch
pedal to push rod.
5. After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to “Air Bleeding
Procedure”, CL-10.)
SCL725
DisassemblyNJCL00101. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
InspectionNJCL0011Check the following items, and replace if necessary.
Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
Piston with piston cup, for wear or damage
Return spring, for wear or damage
Dust cover, for cracks, deformation or damage
Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Removal
CL-12

AssemblyNJCL00121. Apply rubber lubricant to the sliding part of piston assembly,
and insert piston assembly.
2. After installing stopper to push rod, install stopper ring while
keeping piston assembly depressed by hand, so that piston
assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring
for assembly.
3. Install dust cover.
4. Install clevis to push rod, and tighten lock nut A to the speci-
fied torque.
: 8 - 10 N·m (0.8 - 1.1 kg-m, 70 - 95 in-lb)
5. Install spring pin using a pin punch.
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CLUTCH MASTER CYLINDER
Assembly
CL-13