2003 NISSAN ALMERA N16 Changing MT Oil

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION
A
EM
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

EM-6
[QG]
PREPARATION
KV101151S0
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopperChanging shims
EM03470000
Piston ring compressorPiston assembly into cylinder bore
1. ST15243000
Valve seat drift
2. KV11103710
Adapter
3. KV11103720
AdapterInstalling valve seat drift
KV10111100
Seal cutterRemoving oil pan
WS39930000
Tube presserPressing the tube of liquid gasket
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc. in angle Tool number
Tool nameDescription
NT041
NT044
PBIC1120E
NT046
NT052
NT014

EM-22
[QG]
OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER
P F P : 1111 0
Removal and InstallationEBS00LQ6
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove undercover.
2. Drain engine oil. Refer to LC-8, "Changing Engine Oil".
3. Remove exhaust front tube. Refer to FE-10, "Removal and Installation".
4. Using a transmission jack, be sure to support the bottom of tran-
saxle oil pan, and remove center member.
5. Remove gusset and engine rear plate (lower) [A/T vehicle].
6. Loosen and remove mounting nuts and bolts in reverse order
shown in figure.
PBIC0548E
1. Oil strainer 2. Washer 3. Drain plug
4. Oil pan
SEM067F
SEM072F

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-58
[QG]
CYLINDER HEAD
8. Install spark plug, ignition coil and harness connectors.
Removal and InstallationEBS00LQI
REMOVAL
1. Release fuel pressure. Refer to EC-34, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-427,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove undercover.
3. Drain engine coolant. Refer to LC-17, "Changing Engine Coolant".
4. Remove the following components and related parts:
●Intake manifold and intake manifold collector. Refer to EM-16, "INTAKE MANIFOLD" .
●Exhaust manifold and catalytic converter. Refer to EM-19, "EXHAUST MANIFOLD AND CATALYTIC
CONVERTER" .
●Ignition coil. Refer to EM-24, "IGNITION COIL" .
●Rocker cover. Refer to EM-29, "ROCKER COVER" .
●Camshaft. Refer to EM-32, "CAMSHAFT" .
●Alternator bracket. Refer to SC-33, "Removal and Installation".
PBIC0972E
1. Rear engine slinger 2. Cylinder head bolt 3. Washer
4. Auxiliary bolt of cylinder head 5. Cylinder head gasket 6. Cylinder head assembly

ENGINE MECHANICAL
SECTION
EM
CONTENTS
YD
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Parts Requiring Angular Tightening .............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>8
NVH Troubleshooting - Engine Noise .........................8
MEASUREMENT OF COMPRESSION PRESSURE......9
DRIVE BELTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.11
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.............. 11
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............ 11
AIR CONDITIONER COMPRESSOR BELT................12
ALTERNATOR & WATER PUMP BELT.....................12
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............12
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............13
AIR CLEANER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[14
Changing Air Cleaner Filter .......................................14
VISCOUS PAPER TYPE...........................................14
OIL PAN<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..........15
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........15
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............15
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............17
TIMING CHAIN<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>20
Secondary Timing Chain ...........................................20
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[20
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>2
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
Primary Timing Chain ................................................25
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[26
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>8
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>8
INTAKE MANIFOLD<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>3
Removal and Installation ...........................................33
PREPARATIVE WORK.............................................33
FUEL PIPING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>4
INTAKE MANIFOLD.................................................34
EGR VOLUME CONTROL VALVE.............................34
WATER HOSE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>4
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............35
INTAKE MANIFOLD.................................................35
CATALYST<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....36
Removal and Installation ...........................................36
PREPARATIVE WORK.............................................36
CATALYST<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>36
GUSSET<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..37
EXHAUST MANIFOLD, TURBOCHARGER.................38
Removal and Installation ...........................................38
PREPARATIVE WORK.............................................38
EXHAUST MANIFOLD AND TURBOCHARGER.........38
EXHAUST MANIFOLD GASKET...............................39
Disassembly and Assembly .......................................39
TURBOCHARGER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>9
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............40
EXHAUST MANIFOLD.............................................40
TURBOCHARGER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>0
ROCKER COVER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>3
Removal and Installation ...........................................43
PREPARATIVE WORK.............................................43
ROCKER COVER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>3
CYLINDER HEAD<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>5
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........45
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............46
PREPARATIVE WORK.............................................46
CAMSHAFT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>6
CYLINDER HEAD<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>7
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........47
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............48
CYLINDER HEAD DISTORTION...............................48
CAMSHAFT VISUAL CHECK....................................49
CAMSHAFT RUNOUT..............................................49
CAMSHAFT CAM HEIGHT.......................................49
CAMSHAFT JOURNAL CLEARANCE........................49
CAMSHAFT END PLAY............................................50
CAMSHAFT SPROCKET RUNOUT...........................50
VALVE GUIDE CLEARANCE....................................50
VALVE GUIDE REPLACEMENT................................51
VALVE SEATS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>2
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX

Tool number
Tool nameDescription
KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate
NT617
Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
NT041
Changing shims
ST16610001
Pilot bushing puller
NT045
Removing crankshaft pilot bushing
KV10111100
Seal cutter
NT046
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder
head, etc.
KV10109300
Pulley holder
NT628
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATIONYD
Special Service Tools (Cont’d)
EM-5

Secondary Timing ChainNJEM0093CAUTION:
After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
When removing the oil pans, oil pump assembly and tim-
ing chain from engine, first remove the crankshaft posi-
tion sensor (TDC sensor).
Be careful not to damage sensor edges.
Do not spill engine coolant on drive belts.
JEM120G
REMOVALNJEM0093S01For preparative work for removing/installing secondary timing
chain to remove/install fuel injection pump, refer to EC-25,
“Electronic control fuel injection pump”.
To prepare for removing/installing secondary timing chain to
remove/install camshaft, refer to EM-46, “CAMSHAFT”.
1. Drain engine oil.
2. Drain coolant by removing cylinder block drain plugs. Refer to
LC-43, “Changing Engine Coolant”.
TIMING CHAINYD
Secondary Timing Chain
EM-20