Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Micra 2003-2006 Approved 03k12e EM
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download EM documenatation <<
Text preview - extract from the document
ENGINE MECHANICAL
B ENGINE
A
EM
SECTION
ENGINE MECHANICAL C
D
E
CONTENTS
CR INTAKE MANIFOLD ................................................ 20 . F
Removal and Installation ....................................... 20 .
PRECAUTIONS ......................................................... 5 . REMOVAL .......................................................... 20 .
Precautions for Draining Coolant ............................ 5 . INSTALLATION .................................................. 21 . G
Precautions for Disconnecting Fuel Piping ............. 5 . EXHAUST MANIFOLD AND THREE WAY CATA-
Precautions for Removal and Disassembly ............ 5 . LYST ......................................................................... 22
.
Precautions for Inspections, Repairs, and Replace- Removal and Installation ....................................... 22 .
ment ........................................................................ 5
. H
REMOVAL .......................................................... 22 .
Precautions for Assembling and Installing .............. 5 . INSPECTION AFTER REMOVAL ...................... 23 .
Parts Requiring Angle Tightening ............................ 5 . INSTALLATION .................................................. 23 .
Precautions for Liquid Gasket ................................. 6 . OIL PAN AND OIL STRAINER ................................ 24 . I
REMOVAL OF LIQUID GASKET SEALING ......... 6 . Removal and Installation ....................................... 24 .
LIQUID GASKET APPLICATION PROCEDURE 6 ..... REMOVAL .......................................................... 24 .
PREPARATION .......................................................... 7 . INSTALLATION .................................................. 25 . J
Special Service Tools .............................................. 7 . INSPECTION AFTER INSTALLATION ............... 26 .
Commercial Service Tools ....................................... 9 . IGNITION COIL ........................................................ 27 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 27 .
TROUBLESHOOTING ............................................. 10 . K
REMOVAL .......................................................... 27 .
NVH Troubleshooting --Engine Noise .................. 10 . INSTALLATION .................................................. 27 .
Use the Chart Below to Help You Find the Cause SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 28 .
of the Symptom. .....................................................11 . Removal and Installation ....................................... 28 . L
DRIVE BELTS .......................................................... 12. REMOVAL .......................................................... 28 .
Checking drive Belts ............................................. 12 . INSPECTION AFTER REMOVAL ...................... 28 .
Tension Adjustment ............................................... 12 . INSTALLATION .................................................. 29 . M
ALTERNATOR AND A/C COMPRESSOR BELT FUEL INJECTOR AND FUEL TUBE ....................... 30 .
(WITH A/C MODELS) ........................................ 13 . Removal and Installation ....................................... 30 .
ALTERNATOR BELT (WITHOUT A/C MODELS).. 13 . REMOVAL .......................................................... 30 .
WATER PUMP BELT ......................................... 14 . INSTALLATION .................................................. 31 .
Removal and Installation ....................................... 14 . INSPECTION AFTER INSTALLATION ............... 32 .
REMOVAL .......................................................... 14 . ROCKER COVER .................................................... 33 .
INSTALLATION .................................................. 14 . Removal and Installation ....................................... 33 .
Removal and Installation of Drive Belt Idler Pulley 14 ... REMOVAL .......................................................... 33 .
REMOVAL .......................................................... 15 . INSTALLATION .................................................. 34 .
INSTALLATION .................................................. 15 . CAMSHAFT ............................................................. 36 .
AIR CLEANER AND AIR DUCT .............................. 16 . Removal and Installation ....................................... 36 .
Removal and Installation ....................................... 16 . REMOVAL .......................................................... 36 .
REMOVAL .......................................................... 16 . INSTALLATION .................................................. 39 .
INSTALLATION .................................................. 17 .
Changing Air Cleaner Filter ................................... 19 .
REMOVAL .......................................................... 19 .
INSTALLATION .................................................. 19 .
EM-1
INSPECTION AFTER REMOVAL ....................... 43 . ING ......................................................................88
.
Valve Clearance ..................................................... 45
. PISTON TO CYLINDER BORE CLEARANCE ...88
INSPECTION ...................................................... 45
. OUTER DIAMETER OF CRANKSHAFT JOUR-
ADJUSTMENT ................................................... 46 . NAL .....................................................................90
.
TIMING CHAIN ......................................................... 48
. OUTER DIAMETER OF CRANKSHAFT PIN .....90 .
Removal and Installation ....................................... 48 . OUT-OF-ROUND AND TEPER OF CRANK-
REMOVAL .......................................................... 49
. SHAFT ................................................................90
.
INSPECTION AFTER REMOVAL ....................... 52 . CRANKSHAFT RUNOUT ...................................90 .
INSTALLATION ................................................... 52. OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER INSTALLATION ............... 55 . BEARING ............................................................91 .
OIL SEAL ................................................................. 56
. OIL CLEARANCE OF MAIN BEARING ..............91 .
Removal and Installation of Valve Oil Seal ............ 56 . CRUSH HEIGHT OF MAIN BEARING OR CON-
REMOVAL .......................................................... 56
. NECTING ROD BEARING ..................................92 .
INSTALLATION ................................................... 56. FLYWHEEL RUNOUT ........................................92 .
Removal and Installation of Front Oil Seal ............ 56 . SERVICE DATA AND SPECIFICATIONS (SDS) .....93 .
REMOVAL .......................................................... 56
. Standard and Limit .................................................93 .
INSTALLATION ................................................... 57. GENERAL SPECIFICATIONS ............................93 .
Removal and Installation of Rear Oil Seal ............. 57 . INTAKE MANIFOLD AND EXHAUST MANI-
REMOVAL .......................................................... 57
. FOLD ..................................................................93
.
INSTALLATION ................................................... 57. DRIVE BELTS .....................................................94 .
CYLINDER HEAD .................................................... 59 . SPARK PLUG .....................................................94 .
On Vehicle Inspection ............................................ 59. CYLINDER HEAD ...............................................94 .
COMPRESSION PRESSURE INSPECTION ..... 59 . VALVE .................................................................95
.
Removal and Installation ....................................... 60 . CAMSHAFT AND CAMSHAFT BEARING ..........98 .
REMOVAL .......................................................... 60
. CYLINDER BLOCK .............................................98 .
INSPECTION AFTER REMOVAL ....................... 61 . PISTON, PISTON RING AND PISTON PIN ..... 100 .
INSTALLATION ................................................... 61. CONNECTING ROD ......................................... 100 .
Disassembly and Assembly ................................... 62 . CRANKSHAFT .................................................. 101 .
DISASSEMBLY .................................................. 63 . MAIN BEARING ................................................ 101 .
ASSEMBLY ........................................................ 63
. CONNECTING ROD BEARING ........................ 102 .
INSPECTION AFTER DISASSEMBLY ............... 64 . MISCELLANEOUS COMPONENTS ................. 102 .
ENGINE ASSEMBLY ............................................... 69 . Tightening Torque ................................................ 103 .
Removal and Installation ....................................... 69 .
REMOVAL .......................................................... 70
. K9K
INSTALLATION ................................................... 72.
INSPECTION AFTER INSTALLATION ............... 72 . PRECAUTIONS ...................................................... 105 .
CYLINDER BLOCK .................................................. 73 . Precautions for Drain Coolant .............................. 105 .
Disassembly and Assembly ................................... 73 . Precautions for Disconnecting Fuel Piping .......... 105 .
DISASSEMBLY .................................................. 74 . Precautions for Removal and Disassembly ......... 105 .
ASSEMBLY ........................................................ 76
. Precautions for Inspection, Repair and Replace-
How to Select Piston and Bearing ......................... 82 . ment ..................................................................... 105
.
DESCRIPTION ................................................... 82 . Precautions for Assembly and Installation ........... 105 .
HOW TO SELECT PISTON ................................ 82 . Parts Requiring Angular Tightening ..................... 105 .
HOW TO SELECT MAIN BEARING ................... 83 . Precautions For Liquid Gasket ............................. 106 .
Inspection After Disassembly ................................ 84 . REMOVAL OF LIQUID GASKET ...................... 106 .
CRANKSHAFT SIDE CLEARANCE ................... 84 . LIQUID GASKET APPLICATION PROCEDURE.106
CONNECTING ROD SIDE CLEARANCE .......... 85 . Cleanliness Instructions Which Must Be Followed
PISTON AND PISTON PIN CLEARANCE ......... 85 . When Working On The High Pressure Direct Injec-
PISTON RING SIDE CLEARANCE .................... 85 . tion System .......................................................... 106
.
PISTON RING END GAP ................................... 86 . RISKS RELATING TO CONTAMINATION ........ 106 .
CONNECTING ROD BEND AND TORSION ...... 86 . The Sources Of Contamination ............................ 107 .
CONNECTING ROD BEARING HOUSING Precautions To Be Followed Before Any Work Is
DIAMETER (BIG END) ....................................... 87 . Carried Out On The Injection System .................. 107 .
CONNECTING ROD BUSHING OIL CLEAR- Cleaning Precautions To Be Followed Before Car-
ANCE DIAMETER (SMALL END) ...................... 87 . rying Out Any Work On The Fuel System ............ 107 .
CYLINDER BLOCK DISTORTION ..................... 88 . Precautions To Be Followed During The Operation.107
INNER DIAMETER OF MAIN BEARING HOUS- Instructions For Fitting The Plugs ........................ 109 .
EM-2
PREPARATION ....................................................... 111 . GLOW PLUG ......................................................... 136 .
Special Service Tools ........................................... 111 . Removal and Installation ..................................... 136 . A
Commercial Service Tools ....................................114 . REMOVAL ........................................................ 136.
IDENTIFICATION INFORMATION ..........................116 . INSTALLATION ................................................ 136 .
Engine Identification .............................................116 . VACUUM PUMP ..................................................... 137 . EM
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ..................................... 137 .
TROUBLESHOOTING ............................................117 . REMOVAL ........................................................ 137.
NVH Troubleshooting --Engine Noise .................117 . INSTALLATION ................................................ 137 .
Use the Chart Below to Help You Find the Cause ROCKER COVER .................................................. 138 . C
of the Symptom. ...................................................118 . Removal and Installation ..................................... 138 .
ENGINE ROOM COVER ........................................119 . REMOVAL ........................................................ 138.
Removal and Installation ......................................119 . INSTALLATION ................................................ 139 . D
REMOVAL ........................................................ 120 . TIMING BELT ......................................................... 140
.
INSTALLATION ................................................ 120 . Removal and Installation ..................................... 140 .
DRIVE BELTS ........................................................ 121 . REMOVAL ........................................................ 140. E
Checking Drive Belts ........................................... 121 . INSTALLATION ................................................ 143 .
Tension Adjustment ............................................. 121 . CYLINDER HEAD .................................................. 144 .
MODELS WITH A/C COMPRESSOR .............. 121 . Removal and Installation ..................................... 144 .
MODELS WITHOUT A/C COMPRESSOR ...... 121 . REMOVAL ........................................................ 144. F
Removal and Installation ..................................... 121 . INSTALLATION ................................................ 145 .
REMOVAL ........................................................ 121 . Disassembly and Assembly ................................. 145 .
INSTALLATION ................................................ 122 . DISASSEMBLY ................................................ 145 . G
AIR CLEANER AND AIR DUCT ............................ 123 . INSPECTION AFTER DISASSEMBLY ............. 145 .
Removal and Installation ..................................... 123 . ASSEMBLY ...................................................... 146 .
REMOVAL ........................................................ 123 . ENGINE ASSEMBLY ............................................. 147 . H
INSTALLATION ................................................ 123 . Removal and Installation ..................................... 147 .
Changing Air Cleaner Filter ................................. 124 . REMOVAL ........................................................ 147.
REMOVAL ........................................................ 124 . INSTALLATION ................................................ 149 .
I
INSTALLATION ................................................ 124 . INSPECTION AFTER INSTALLATION ............. 149 .
CHARGE AIR COOLER ........................................ 125 . OVERHAUL ........................................................... 151.
Removal and Installation ..................................... 125 . Tightening Torques .............................................. 151 .
REMOVAL ........................................................ 125 . UPPER ENGINE .............................................. 151 . J
INSPECTION AFTER REMOVAL .................... 126 . BOTTOM ENGINE ........................................... 151 .
INSTALLATION ................................................ 126 . Standard Replacement ........................................ 152 .
EGR UNIT .............................................................. 127
. PREPARING USED ENGINE ........................... 152 . K
Removal and Installation ..................................... 127 . Disassembly ........................................................ 153
.
REMOVAL ........................................................ 127 . REMOVING THE UPPER ENGINE .................. 153 .
INSTALLATION ................................................ 128 . POSITIONING THE BELT AT THE TIMING L
EXHAUST MANIFOLD, TURBOCHARGER, CATA- POINT .............................................................. 154
.
LYST ...................................................................... 129
. DISASSEMBLY OF THE CYLINDER HEAD .... 158 .
Removal and Installation ..................................... 129 . Cleaning .............................................................. 160
.
REMOVAL ........................................................ 129 . Inspection ............................................................ 160
. M
INSTALLATION ................................................ 130 . GASKET FACE ................................................ 160 .
INSPECTION AFTER INSTALLATION ............ 130 . CAMSHAFT END PLAY ................................... 161 .
Disassembly and Assembly ................................ 131 . Valve Clearance .................................................. 161.
DISASSEMBLY ................................................ 131 . CHECKING AND ADJUSTING THE VALVE
INSPECTION AFTER DISASSEMBLY ............ 131 . CLEARANCE ................................................... 161 .
ASSEMBLY ...................................................... 132 . Assembly ............................................................. 162
.
OIL PAN ................................................................. 133
. ASSEMBLY OF THE CYLINDER HEAD .......... 162 .
Removal and Installation ..................................... 133 . Disassembly of The Bottom Engine .................... 167 .
REMOVAL ........................................................ 133 . REMOVAL ........................................................ 167.
INSPECTION AFTER REMOVAL .................... 135 . Assembly ............................................................. 170
.
INSTALLATION ................................................ 135 . INSTALLATION OF OIL JETS .......................... 170 .
INSPECTION AFTER INSTALLATION ............ 135 . METHOD FOR INSTALLING THE OIL COOLER
EM-3
AND OIL FILTER .............................................. 172 . VALVE SPRING ................................................ 194 .
Removing The Piston Pins .................................. 172 . PISTON ............................................................. 194
.
CONNECTING ROD BEARING ....................... 172 . INSPECTION OF VALVE CLEARANCE ........... 194 .
ON THE CONNECTING ROD BODY ............... 173 . CAMSHAFT ...................................................... 195 .
ON THE CONNECTING ROD CAP ................. 174 . Piston ................................................................... 196
.
INSTALLATION OF MAIN BEARING ............... 175 . PISTON MARKING ........................................... 196 .
ON THE CYLINDER BLOCK ............................ 176 . TABLE OF PISTON PIN HEIGHT ..................... 196 .
ON THE BEARING CAPS ................................ 176 . MEASURING THE PISTON DIAMETER .......... 196 .
INSTALLATION OF NO. 1 BEARING ............... 177 . PISTON RING ................................................... 197 .
CONNECTING RODS / PISTON ASSEMBLY .. 177 . PISTON RING END GAP ................................. 197 .
DIRECTION FOR INSTALLATION THE SNAP Connecting Rod ................................................... 197 .
RINGS ON THE PISTON ................................. 178 . DIRECTION OF INSTALLATION OF THE CON-
INSTALLATION OF THE SNAP RINGS ........... 178 . NECTING ROD IN RELATION TO THE PISTON.198
CHECKING PISTON PROTRUSION ............... 178 . DIRECTION FOR INSTALLATION THE SNAP
INSTALLATION OF REAR OIL SEAL RETAINER RINGS ON THE PISTON .................................. 198 .
AND OIL PUMP ................................................ 179 . Crankshaft ............................................................ 198
.
INSTALLATION OF THE CRANKSHAFT SEAL WORKING OUT THE CLASS OF MAIN BEAR-
GASKETS ......................................................... 181 . ING (ORIGINAL FITMENT) .............................. 199 .
INSTALLATION OF THE CYLINDER HEAD .... 184 . Cylinder Block ...................................................... 199.
TIMING ADJUSTMENT .................................... 186 . TABLE OF CYLINDER BLOCK MAIN BEARING
BASIC INSPECTION .............................................. 191 . HOUSING INNER DIAMETERS ....................... 199 .
Cylinder Head ...................................................... 191
. MATCHING THE MAIN BEARING .................... 200 .
CYLINDER HEAD TIGHTENING PROCEDURE 191 . Main Bearing and Cap ......................................... 200 .
THICKNESS OF THE CYLINDER HEAD GAS- MAIN BEARING ................................................ 200 .
KET ................................................................... 191
. CONNECTING ROD BEARING ........................ 201 .
INSPECTION OF THE PISTON PROTRUSION. 191 Preparing the engine to be on the stand .............. 201 .
VALVE ............................................................... 192
. Parts To Be Replaced After Removal .................. 202 .
VALVE SEAT .................................................... 192 . Installation of Thread Inserts ................................ 203 .
VALVE GUIDE .................................................. 192 .
EM-4
PRECAUTIONS
[CR]
PRECAUTIONS
[CR] PFP:00001
A
Precautions for Draining Coolant EBS00OEB
q Drain coolant only after the engine has cooled down.
EM
Precautions for Disconnecting Fuel Piping EBS00OHR
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disassembly. C
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00OED
D
q Use correct special service tool in the specified position. Always pay attention to safety.
q Be careful not to damage surface accuracy of mating or sliding surfaces.
q To prevent foreign material from entering the engine, close openings with appropriate tape as necessary. E
q Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or
excessive wear and to insure correct reassembly.
q The removal order of nuts and bolts should in principle move diagonally from the outside. Locations for F
which order is stipulated should follow that order.
Precautions for Inspections, Repairs, and Replacement EBS00OEE
G
q Thoroughly inspect each part following inspection procedure, then correct or replace as necessary.
Inspect new parts in the same way, and replace if necessary.
Precautions for Assembling and Installing EBS00OEF H
q Always use a torque wrench when tightening nuts and bolts.
q Unless otherwise specified, tighten nuts and bolts from inside to outside in crisscross pattern. Tighten
them gradually and evenly in two to three steps. I
q Always replace gasket, packing, oil seals, and O-rings with new ones.
q Thoroughly wash, clean, and blow dry each part. Be sure that engine oil and coolant passages are free of
clogs. J
q Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine
oil to sliding surfaces.
q If coolant was drained, bleed air from the system. K
q Follow the procedure below to make sure there are no fuel leaks.
◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo