2003 NISSAN ALMERA N16 height adjustment

EM-94
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in) 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)Deflection adjustment
Used belt
New belt
Limit After adjustment
Make NGK Champion
Ty p eStandard LFR5A-11 REC10YC4
Hot LFR4A-11 —
Cold LFR6A-11 —
Plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.9 (4.642) —
QG15DE QG18DE
Valve head diameter “D”Intake 28.9 - 29.2 (1.138 - 1.150) 29.9 - 30.2 (1.177 - 1.189)
Exhaust 23.9 - 24.2 (0.941 - 0.953) 24.9 - 25.2 (0.980 - 0.992)
Valve length “L”Intake 92.00 - 92.50 (3.6220 - 3.6417)
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter “d”Intake 5.465 - 5.480 (0.2152 - 0.2157)
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve seat angle “α”44°15′ - 44°45′
Valve margin “T” 0.8 - 0.14 (0.031 - 0.055)
Valve margin “T” limit More than 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
SEM188
For adjusting For checking
Hot Cold* (reference data) Hot

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

SCL466-C
CLUTCH COVERNJCL0032S02Check clutch cover installed on vehicle for unevenness of dia-
phragm spring toe height.
Uneven limit:
MODEL 200, 215 0.8 mm (0.031 in)
MODEL 240 0.7 mm (0.028 in)
If out of limit, adjust the height with Tool.
AEM100
FLYWHEELNJCL0032S03Check contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
Check flywheel runout.
Maximum allowable runout:
Refer to EM-92, “FLYWHEEL RUNOUT” (QG engine
models), and EM-80, “Flywheel Runout (YD engine
models)”.
SCL616-B
SCL600-F
InstallationNJCL0033Insert Tool into clutch disc hub when installing clutch cover and
disc.
Be careful not to allow grease to contaminate clutch fac-
ing.
Tighten bolts in numerical order.
First step:
: 10 - 20 N·m (1 - 2 kg-m, 7 - 14 ft-lb)
Final step:
QG, engine models (200, 215)
: 22 - 29 N·m (2.2 - 3.0 kg-m, 15 - 21 ft-lb)
YD22DDT engine model (240)
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Inspection and Adjustment (Cont’d)
CL-23

Removal and InstallationNJBR0015
JBR752E
SBR997
InspectionNJBR0016Check brake pedal for following items.
Brake pedal bend
Clevis pin deformation
Crack of any welded portion
Crack or deformation of clevis pin stopper
SBR657EA
AdjustmentNJBR0017Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height
Refer to SDS, BR-73.
C
1,C2: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch
0.74 - 1.96 mm (0.0291 - 0.0772 in)
D: Depressed height
LHD (M/T): More than 90 mm (3.54 in)
LHD (A/T): More than 95 mm (3.74 in)
RHD (M/T): More than 90 mm (3.54 in)
RHD (A/T): More than 95 mm (3.74 in)
Under force of 490 N (50 kg, 110 lb) with engine run-
ning
A: Pedal free play at pedal pad
1.0-3.0mm(0.039-0.118in)
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-12

SBR229E
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal’s depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)
BR-13

ADJUSTMENTNJBT0022S03
SBT004A
If any height difference between glass lid and roof is found, check
glass lid fit and adjust as follows:
Height Difference AdjustmentNJBT0022S03021. Tilt glass lid up and down.
2. Check height difference between roof panel and glass lid to
see if it is as “A-A” as shown in the figure above.
3. If necessary, adjust it by using one of following procedures.
Adjust by adding or removing adjustment shim(s) between
glass lid and link assembly.
If glass lid protrudes above roof panel, add shim(s) or plain
washer(s) at sunroof mounting bracket or stud bolt locations to
adjust sunroof installation as required.
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
HA
SC
EL
IDX
SUNROOF
Trouble Diagnoses (Cont’d)
BT-65

YEL812D
Aiming Adjustment=NJEL0029Before performing aiming adjustment, make sure of the following.
1) Keep all tires inflated to correct pressure.
2) Place vehicle on level ground.
3) See that vehicle is unloaded (except for full levels of coolant,
engine oil and fuel, and spare tire, jack, and tools). Have the
driver or equivalent weight placed in driver’s seat.
Adjust aiming in the vertical direction by turning the adjusting
screw.
MEL327G
1. Set the distance between the screen and the center of the fog
lamp lens as shown at left.
2. Remove front fog lamp rim. For detail, refer to “BODY END” in
BT section.
3. Turn front fog lamps ON.
NEL794
4. Adjust front fog lamps so that the top edge of the high inten-
sity zone is 152 mm (6.0 in) (Sedan) or 91 to 136 mm (3.58 to
5.35 in) (Hatchback) below the height of the fog lamp centers
as shown at left.
When performing adjustment, if necessary, cover the head-
lamps and opposite fog lamp.
FRONT FOG LAMP
Aiming Adjustment
EL-64

SEL026Z
PINION PROTRUSION LENGTH ADJUSTMENTNJSC0020S01Clearance (QG engine models)NJSC0020S0101With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “” between the front edge
of the pinion and the pinion stopper.
Clearance “”:
Refer to SDS (SC-37).
MEL140L
Movement (YD engine models)NJSC0020S0102Compare movement “” in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement “”:
Refer to SDS (SC-37).
SEL633BA
Not in the specified value ... Adjust by adjusting plate.
STARTING SYSTEM
Assembly (Cont’d)
SC-26