engine NISSAN ALMERA 2001 Service Manual

SEL022Z
5. Check depth of insulating mold from commutator surface.
+Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
AssemblyNJSC0020Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
SEL026Z
PINION PROTRUSION LENGTH ADJUSTMENTNJSC0020S01Clearance (QG engine models)NJSC0020S0101With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance ª!º between the front edge
of the pinion and the pinion stopper.
Clearance ª!º:
Refer to SDS (SC-38).
MEL140L
Movement (YD engine models)NJSC0020S0102Compare movement ª!º 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 ª!º:
Refer to SDS (SC-38).
STARTING SYSTEM
Inspection (Cont'd)
SC-24

System DescriptionNJSC0009SEDANNJSC0009S01The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 4 (S) through:
+10A fuse (No. 33, located in the fuse and fusible link box).
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage
is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected
by the 80A (A/T models with QG13DE engine and M/T models with gasoline engine) or 100A (A/T models
except QG13DE engine and diesel engine models) fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
+through 10A fuse [No. 30, located in the fuse block (J/B)]
+to combination meter terminal 17 (Models with tachometer) or 22 (Models without tachometer) for the
charge warning lamp.
Ground is supplied to terminal 62 (Models with tachometer) or 61 (Models without tachometer) of the combi-
nation meter through terminal 3 (L) of the alternator. With power and ground supplied, the charge warning lamp
will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened
and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
HATCHBACKNJSC0009S02The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 4 (S) through:
+10A fuse (No. 33, located in the fuse and fusible link box).
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage
is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected
by the 80A (Gasoline engine models without daytime light system) or 100A (A/T models, diesel engine mod-
els and gasoline engine models with daytime light system) fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
+through 10A fuse [No. 30, located in the fuse block (J/B)]
+to combination meter terminal 40 or 1
Ground is supplied to terminal 1 or 28 of the combination meter through terminal 3 (L) of the alternator. With
power and ground supplied, the charge warning lamp will illuminate. When the alternator is providing suffi-
cient voltage with the engine running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
CHARGING SYSTEM
System Description
SC-26

Wiring Diagram Ð CHARGE Ð/SedanNJSC0010GASOLINE ENGINE MODELSNJSC0010S02
HSC014
CHARGING SYSTEM
Wiring Diagram Ð CHARGE Ð/Sedan
SC-27

DIESEL ENGINE MODELSNJSC0010S03
HSC015
CHARGING SYSTEM
Wiring Diagram Ð CHARGE Ð/Sedan (Cont'd)
SC-28

MEL497L
MEL145L
Removal and InstallationNJSC0013REMOVAL (QG ENGINE)NJSC0013S011. Loosen drive belt idler pulley.
2. Remove drive belt idler pulley (include tightening screw).
3. Remove alternator harness.
4. Remove alternator upper bolt and lower bolt.
5. Remove alternator.
MEL948N
REMOVAL (YD ENGINE)NJSC0013S031. Remove alternator harness.
2. Loosen alternator upper nut and lower bolt.
3. Loosen drive belt.
4. Remove alternator bracket bolts (two).
5. Remove alternator upper nut and lower bolt.
6. Remove alternator.
CHARGING SYSTEM
Construction (Cont'd)
SC-34

BatteryNJSC0014
Applied
modelQG engine YD engine
Type 34B19L 46B24L 55D23L 65D26LYUASA type code YUASA type code
110D26L
025 027 063 065 075 096L 010S 067 096
Capac-
ity V-AH12-27 12-36 12-48 12-52 12-47 12-55 12-50 12-65 12-60 12-64 12-70
StarterNJSC0015
Type0 001 116 006 D7E31 S114-570B S114-800B M2T48681 M0T83581A M8T71371
BOSCH VALEO make HITACHI make MITSUBISHI make
Non-reduction Non-reduction Non-reduction Reduction Non-reduction Reduction Reduction
Applied model QG engine YD engine
System voltage V12
No-loadTerminal voltage V 11.5 11.0 11.5 11.0 11.5 11.0 11.0
Current A Less than 48 45 Less than 60 Less than 90 Less than 53 Less than 90 Less than 145
Revolution rpmMore than
5,80012,000More than
6,000More than
2,750More than
6,000More than
2,750More than
3,400
Minimum diameter of commutator
mm (in)33.5 (1.319) 28.2 (1.110) 28.0 (1.102) 31.4 (1.236) 28.8 (1.134) 31.4 (1.236)
Minimum length of brush mm (in) 3.5 (0.138) 6.15 (0.242) 9.0 (0.354) 10.5 (0.413) 11.5 (0.453) 7.0 (0.276) 11.0 (0.433)
Brush spring tension N (kg, lb)5.2 (0.53,
1.17) at 7.5
mm (0.295 in)
brush length16.2 - 19.8
(1.65 - 2.02,
3.46 - 4.45)9.8 - 13.7
(1.0 - 1.4,
2.2 - 3.1)12.7 - 17.7
(1.3 - 1.8,
2.9 - 4.0)13.7 - 25.5
(1.4 - 2.6,
3.1 - 5.7)15.0 - 20.4
(1.5 - 2.1,
3.4 - 4.6)26.5 - 36.3
(2.7 - 3.7,
6.0 - 8.2)
Clearance between bearing metal
and armature shaft mm (in)Ð 0.05 (0.0020) Less than 0.2 (0.008) Ð
Clearance ª!º between pinion
front edge and pinion stopper mm
(in)0.0 - 3.9
(0 - 0.154)Max. 1
(0.039)0.3 - 2.5 (0.012 - 0.098)0.5 - 2.0
(0.020 - 0.079)Ð
Movement ª!º in height of pinion
assembly mm (in)ÐMax. 12.2
(0.480)Ð0.5 - 2.0
(0.020 -
0.079)
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
SC-38

AlternatorNJSC0016
TypeLR180-762 LR180-757 LR1100-724 A2TB3191 A3TB0771
HITACHI make MITSUBISHI make
Applied model QG engine YD engine QG engine YD engine
Nominal rating V-A 12-80 12-80 12-100 12-80 12-90
Ground polarityNegative
Minimum revolutions under no-load
(When 13.5V is applied) rpmLess than 1,000 Less than 1,100 Less than 1,000 Less than 1,300
Hot output current (When 13.5V is
applied) A/rpmMore than
23/1,300
More than
65/2,500
More than
77/5,000More than
17/1,300
More than
63/2,500
More than
76/5,000More than
34/1,300
Morethan
80/2,500
More than
91/5,000More than
23/1,300
More than
62/2,500
More than
72/5,000More than
29/1,300
More than
76/2,500
More than
88/5,000
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) More than 6.0 (0.236) More than 5.0 (0.197)
Brush spring pressure N (g, oz) 1.0 - 3.43 (102 - 350, 3.60 - 12.34) 4.8 - 6.0 (490 - 610, 17.28 - 21.51)
Slip ring minimum diameter mm (in) More than 26.0 (1.024) More than 22.1 (0.870)
Rotor coil resistance at 20É (68ÉF)W2.67 2.31 2.2 - 2.6 2.1 - 2.5
SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator
SC-39

STEERING SYSTEM
SECTION
ST
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
Precautions for Steering System .................................2
PREPARATION...............................................................3
Special Service Tools ..................................................3
Commercial Service Tool .............................................4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................5
NVH Troubleshooting Chart.........................................5
ON-VEHICLE SERVICE..................................................6
Checking Steering Wheel Play ....................................6
Checking Neutral Position on Steering Wheel ............6
PRE-CHECKING........................................................6
CHECKING...............................................................6
Front Wheel Turning Angle ..........................................6
Checking Gear Housing Movement ............................6
Checking and Adjusting Drive Belts ............................7
Checking Steering Gear and Linkage .........................7
STEERING GEAR......................................................7
STEERING LINKAGE.................................................7
Checking Fluid Level ...................................................7
Checking Fluid Leakage ..............................................7
Bleeding Hydraulic System..........................................8
Checking Steering Wheel Turning Force ....................8
Checking Hydraulic System.........................................9
STEERING WHEEL AND STEERING COLUMN......... 11
Components............................................................... 11
Removal and Installation ........................................... 11
STEERING WHEEL................................................. 11
STEERING COLUMN...............................................12
Disassembly and Assembly .......................................14
Inspection...................................................................15
TILT MECHANISM...................................................15
POWER STEERING GEAR AND LINKAGE................16
Components...............................................................16
Removal and Installation ...........................................17
Disassembly...............................................................18
Inspection...................................................................19
BOOT.....................................................................19
RACK.....................................................................19
GEAR SUB-ASSEMBLY...........................................19
GEAR HOUSING CYLINDER....................................19
TIE-ROD OUTER AND INNER SOCKETS..................20
Assembly ...................................................................20
Adjustment .................................................................23
POWER STEERING OIL PUMP (QG ENGINE)...........25
Components...............................................................25
Pre-disassembly Inspection .......................................25
Disassembly...............................................................26
Inspection...................................................................27
Assembly ...................................................................27
POWER STEERING OIL PUMP (YD ENGINE)............29
Components...............................................................29
Pre-disassembly Inspection .......................................29
Removal and Installation ...........................................30
Disassembly...............................................................30
Inspection...................................................................31
Assembly ...................................................................32
SERVICE DATA AND SPECIFICATIONS (SDS).........33
General Specifications ...............................................33
Steering Wheel ..........................................................33
Steering Column ........................................................33
Steering Gear and Linkage .......................................34
Power Steering ..........................................................35

Checking and Adjusting Drive BeltsNJST0011Refer to EM-16, ªChecking Drive Beltsº.
SMA851B
Checking Steering Gear and LinkageNJST0037STEERING GEARNJST0037S01+Check gear housing and boots for looseness, damage or
grease leakage.
+Check connection with steering column for looseness.
STEERING LINKAGENJST0037S02+Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.
YST003
Checking Fluid LevelNJST0012Check fluid level, referring to the scale on reservoir tank.
Use ªHOTº range for fluid temperatures of 50 to 80ÉC (122 to
176ÉF).
Use ªCOLDº range for fluid temperatures of 0 to 30ÉC (32 to 86ÉF).
CAUTION:
+Do not overfill.
+Recommended fluid is DEXRON
TMIII or equivalent. Refer
to MA-16, ªFluids and Lubricantsº.
YST006
YST007
Checking Fluid LeakageNJST0013Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
1. Run engine between idle speed and 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80ÉC
(140 to 176ÉF).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each ªlockº position for five seconds
and carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
5. If fluid leakage from power steering pump is noticed, check
power steering pump. Refer to ST-25.
6. Check rack boots for accumulation of power steering fluid.
ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts
ST-7

Bleeding Hydraulic SystemNJST00141. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Then quickly turn steer-
ing wheel fully to right and left and lightly touch steering stop-
pers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2. above.
+Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a) Air bubbles in reservoir tank
b) Clicking noise in oil pump
c) Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning the steering wheel
slowly. This does not affect the performance or durability of the
system.
SST491B
SST090B
Checking Steering Wheel Turning ForceNJST00151. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-
ture. [Make sure temperature of fluid is approximately 60 to
80ÉC (140 to 176ÉF).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360É from the neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
5. If steering wheel turning force is out of specification, check
rack sliding force.
a. Disconnect steering column lower joint and knuckle arms from
the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. Pull tie-rod slowly to move it from neutral position to±11.5 mm
(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack
sliding force is within specification.
Average rack sliding force:
Sedan
152 - 240 N (15.5 - 24.5 kg, 34 - 54 lb)
Hatchback
132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)
Maximum force deviation:
Sedan
98 N (10 kg, 22 lb)
Hatchback
176 N (17.9 kg, 39 lb)
d. Check sliding force outside the above range at rack speed of
40 mm (1.75 in)/s.
ON-VEHICLE SERVICE
Bleeding Hydraulic System
ST-8