2003 NISSAN ALMERA N16 length

SMA020D
To reinstall the rubber hose securely, make sure of hose inser-
tion length and clamp orientation. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
SMA021D
Hose ClampingNJGI0001S0602If old rubber hose is re-used, install hose clamp in its original
position (at the indentation where the old clamp was). If there
is a trace of tube bulging left on the old rubber hose, align
rubber hose at that position.
Discard old clamps; replace with new ones.
SMA022D
After installing leaf spring clamps, apply force to them in the
direction of the arrow, tightening rubber hose equally all
around.
PRECAUTIONS FOR ENGINE OILSNJGI0001S07Prolonged and repeated contact with used engine oil may cause
skin cancer. Try to avoid direct skin contact with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner
as soon as possible.
Health Protection PrecautionsNJGI0001S0701Avoid prolonged and repeated contact with oils, particularly
used engine oils.
Wear protective clothing, including impervious gloves where
practicable.
Do not put oily rags in pockets.
Avoid contaminating clothes, particularly underclothing, with
oil.
Heavily soiled clothing and oil-impregnated footwear should
not be worn. Overalls must be cleaned regularly.
First Aid treatment should be obtained immediately for open
cuts and wounds.
Use barrier creams, applying them before each work period, to
help the removal of oil from the skin.
Wash with soap and water to ensure all oil is removed (skin
cleansers and nail brushes will help). Preparations containing
lanolin replace the natural skin oils which have been removed.
MA
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PRECAUTIONS
Precautions (Cont’d)
GI-7

Dimensions=NJGI0008S03Unit: mm (in)
Item Sedan HB
Overall length 4,470 (176.0) 4,184 (164.7)
Overall width 1,695 (66.7) 1,710 (67.3)
Overall height 1,440 (56.7) 1,440 (56.7)
Front tread 1,470 (57.9) 1,470 (57.9)
Rear tread 1,450 (57.1) 1,455 (57.3)
Wheelbase 2,535 (99.8) 2,535 (99.8)
Wheels and TiresNJGI0008S04Sedan
Item Except for Europe Europe
Road wheelSteel/offset mm (in)14 x 5J/35 (1.38)
14 x 5-1/2JJ/45 (1.77)
15 x 6JJ/45 (1.77)14 x 5J/35 (1.38)
15 x 6JJ/45 (1.77)
Aluminum/offset mm (in) 14 x 6J (J)*/45 (1.77) 15 x 6J*/45 (1.77)
Tire sizeConventional175/65R14
175/70R14
185/65R14
185/65R15175/70R14
185/65R15
195/60R15
Spare Conventional T135/80D15
*: Option
Hatchback
Item
Road wheelSteel/offset mm (in)
15 x 6JJ/45 (1.77)
16 x 6JJ/45 (1.77)
Aluminum/offset mm (in)
Tire sizeConventional185/65R15
195/55R16
SpareConventional
T135/80/D15*
*: If so equipped (for some of A/T models)
IDENTIFICATION INFORMATION
Dimensions
GI-44

EM-20
[QG]
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
●Using heated oxygen sensor wrench, remove heated oxygen
sensor.
CAUTION:
●Be careful not to damage heated oxygen sensor.
●When using heated oxygen sensor wrench, tighten to the
middle of specified torque because length of tool may
induce sight indication increase. (Do not tighten to the
maximum specified torque)
●Do not over torque the heated oxygen sensor. Doing so
may cause damage to the heated oxygen sensor, result-
ing in the MI coming on.
6. Remove exhaust manifold cover.
7. Loosen mounting nuts in reverse order shown in figure to
remove exhaust manifold and catalytic converter assembly.
INSPECTION AFTER REMOVAL
Surface Distortion
●Use a reliable straightedge and feeler gauge to check the flat-
ness of exhaust manifold fitting surface.
INSTALLATION
●Install in the reverse order of removal after this step.
●Tighten mounting nuts for exhaust manifold and catalytic con-
verter assembly in order shown in figure.
●Before installing exhaust manifold support, apply liquid gasket to
contact surface on engine side.
Use Genuine Liquid Gasket or equivalent.
Installation of Heated Oxygen Sensor
CAUTION:
●Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the MI coming on.
PBIC0541E
PBIC0542E
Limit : 0.3 mm (0.012 in)
PBIC0543E
PBIC0542E

OIL PAN AND OIL STRAINER
EM-23
[QG]
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7. Insert Tool (Seal cutter) between oil pan and cylinder block.
Slide tool by tapping on the side of the tool with a hammer.
Remove oil pan.
8. Remove oil strainer.
INSTALLATION
1. Install oil strainer.
NOTE:
Gasket and O-ring are not used for sealed area with oil pump.
2. Install oil pan drain plug.
●Referring to “Components”, install drain plug washer.
3. Apply a continuous bead of liquid gasket to position shown in figure.
Use Genuine Liquid Gasket or equivalent.
4. Tighten mounting nuts and bolts in order shown in figure.
●Install mounting nuts and bolts as follows.
5. Install center member.
Refer to ENGINE ASSEMBLY, EM-67, "
Removal and Installa-
tion" .
6. Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●Check for leakage of engine oil when engine is warmed.
●Pour engine oil or start engine at least 30 minutes after oil pan is installed.
SEM365EA
PBIC0549E
Mounting bolt:
[Shank length under
head 10 mm (0.39 in)]: Nos. 1 - 10, 13, 14
[Shank length under
head 12 mm (0.47 in)]: Nos. 11, 12
SEM072F

ROCKER COVER
EM-31
[QG]
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d. Tighten mounting screws to specified torque in 2 or more steps
in numerical order shown in figure.
3. Install intake valve timing control solenoid valve and camshaft position sensor (PHASE).
●Tighten bolt after fully inserting it into rocker cover.
4. Install PCV valve.
●Insert until flange contacts grommet tightly.
5. Install remaining parts in the reverse order of removal.Bolt length: Bolt position
25 mm (0.98 in) : 1
65 mm (2.56 in) : 2
20 mm (0.79 in) : Except the above (all circumference)
KBIA1376E

EM-34
[QG]
CAMSHAFT
c. Slowly turn intake camshaft in direction A (counterclockwise:
intake manifold side).
●Perform while applying air pressure.
CAUTION:
Be careful not to dislocate camshaft retaining spanner.
d. During above step, operating click (a sound indicating internal
lock pin is disengaged) is heard from inside of intake camshaft
sprocket. After hearing it, slowly turn intake camshaft in direction
B (clockwise: exhaust manifold side), and set to most advanced
position.
●Perform while applying air pressure.
●When vane rotates solely against sprocket, lock pin is disengaged even if operating click is not heard.
●If lock pin is not disengaged, apply vibration by jiggling the camshaft with a spanner.
●If lock pin is not disengaged with above step, hit intake camshaft in front by using plastic hammer.
e. The following status indicates that most advanced position is
achieved: vane starts rotating on its own, then sprocket also
starts rotating when camshaft is turned. When above status is
achieved, this step is complete.
●Most advanced position is confirmed when stopper pin groove
and lock pin breathing groove are aligned.
f. Stop air, insert stopper pin [approximately 3 mm (0.12 in) dia.,
length of inserted part is approximately 15 mm (0.59 in)] into
pinhole on camshaft sprocket to fix most advanced position.
NOTE:
In the figure, an Allen wrench [a/f 2.5 mm (0.091 in), short part:
approximately 20 mm (0.79 in), long part: approximately 50 mm
(1.97 in)] is used for stopper pin as an example.
CAUTION:
Load (spring reaction force) is not applied to stopper pin.
Pin is easily detached. Therefore, secure it with vinyl tape to
prevent detachment.
5. Remove chain tensioner.
●Remove in the following order.
a. Press plate down, and release stopper tab.
b. Insert plunger into tensioner body until it stops.
c. Secure plate by passing stopper pin (such as a hard wire)
through plate hole and body hole. (Plunger is also secured.)
d. Remove mounting bolts, and remove chain tensioner.
KBIA1414J
MBIB0198E
PBIC0966E
MBIB0201E

EM-60
[QG]
CYLINDER HEAD
3. Tighten cylinder auxiliary bolts (11) to (14) in numerical order
shown in figure.
●Pay attention to shank length under bolt head. [11: 20 mm
(0.79 in), 12 - 14: 25 mm (0.98 in)]
Disassembly and AssemblyEBS00LQJ
CAUTION:
●When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surface with new engine oil.
●Apply new engine oil to threads and seat surface when installing cylinder head, camshaft
sprocket, crankshaft pulley and camshaft bracket.
●Attach tags to valve lifters so as not to mix them up.
DISASSEMBLY
1. Remove adjusting shim (if so equipped) and valve lifter.
●Confirm installation point.
SEM900F
PBIC0973E
1. Cylinder head 2. Valve (INT) 3. Valve (EXH)
4. Valve seat 5. Engine coolant temperature sensor 6. Copper washer
7. Spark plug tube 8. Spark plug

EM-76
[QG]
CYLINDER BLOCK
5. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
●Dowel pins of crankshaft and signal plate are provided as a
set for each.
●If dowel pin is not available (when crankshaft and signal plate
are reused), use M6 bolt [length under head: 10 mm (0.39 in)
or longer] as its substitute.
6. Install the crankshaft to the cylinder block.
●While turning the crankshaft by hand, check that it turns smoothly.
7. Install main bearing cap.
●Main bearing cap is identified by identification paint No. made
on it before it is removed.
●Install it with arrow facing to front.
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
8. Tighten main bearing bolts in several steps in numerical order
shown in the figure.
●Apply engine oil onto thread and seat of mounting bolt.
●After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
●Check crankshaft side clearance. Refer to EM-84, "CRANK-
SHAFT SIDE CLEARANCE" .
9. Install piston to connecting rod.
a. Using snap ring pliers, install snap ring to groove of piston rear side.
●Install with chamfered side facing piston pin side. Refer to EM-70, "Disassembly and Assembly" .
b. Install piston to connecting rod.
●Using hot-air blower, heat piston to 60 to 70°C (140 to 158°F) so that piston pin can be easily inserted
by hand. Insert piston pin into piston and connecting rod from front side of piston.
●Assemble so that front mark on piston head and oil hole in
connecting rod are positioned as shown in the figure.
c. Install snap ring to front side of piston.
●Refer to step “a” to install snap ring.
●After installation, make sure that connecting rod moves
smoothly.
PBIC0265E
SEM420C
SEM933F
PBIC0591E