panel NISSAN ALMERA N15 1995 Service Manual
Page 7 of 1701
PREPARATIONANDPRECAUTIONS
Service Notice
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System)
The Supplemental RestraintSystem"AirBag" usedalong withaseat belt, helps toreduce therisk or
severity ofinjury tothe driver andfront passenger inafrontal collision. TheSupplemental Restraint
System consists ofair bag modules (locatedinthe center ofthe steering wheelandonthe instrument
panel onthe passenger side),adiagnosis sensorunit,warning lamp,wiring harness andspiral cable.
Information necessarytoservice thesystem safelyisincluded inthe
RSsection
ofthis Service Manual.
WARNING:
• Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
Ii
Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual. SRSwiring harnesses arecovered withyellow insulation eitherjustbefore the
harness connectors orfor the complete harness,foreasy identification.
•
Before proceeding withdisassembly, thor-
oughly cleantheoutside ofthe transaxle. Itis
important toprevent theinternal partsfrom
becoming contaminated bydirt orother for-
eign matter.
• Disassembly shouldbedone inaclean work
area.
• Use lint-free clothortowels forwiping parts
clean. Common shopragscanleave fibers
that could interfere withtheoperation ofthe
transaxle.
• Place disassembled partsinorder, onaparts
rack, foreasier andproper assembly.
• Allparts should becarefully cleaned-witha
general purpose, non-flammable solvent
before inspection orreassembly.
• Gaskets, sealsandO-rings shouldbe
replaced anytime thetransaxle isdisassem-
bled.
• Itis very important toperform functional tests
whenever theyareindicated. •
The valve bodycontains precision partsand
requires extremecarewhen partsare
removed andserviced. Placedisassembled
valve bodyparts inorder, onaparts rack,for
easier andproper assembly. Carewillalso
prevent springs andsmall partsfrombecom-
ing scattered orlost.
• Properly installedvales,sleeves, plugs,etc.
will slide along theirbores inthe valve body
under theirownweight.
• Before assembly, applyacoat ofrecom-
mended ATFtoall parts. Apply petroleum
jelly toprotect O-ringandseals, orhold bear-
ings andwashers inplace during assembly.
Do not use grease.
• Extremely careshould betaken toavoid dam-
age toO-rings, sealsandgaskets when
assembling.
• After overhaul, refillthetransaxle withnew
ATF.
•
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System)
The Supplemental RestraintSystem"AirBag" andused along withaseat belt,helps toreduce therisk
or severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists of
an air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoservice thesystem safelyisincluded inthe
RS section
ofthis Service Manual.
WARNING:
• Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual.
AT-7
Page 35 of 1701
ON-VEHICLESERVICE
Control CableInstallation andAdjustment
• Move selector leverfromthe"P" range tothe "1" range.
You should beable tofeel thedetents ineach range.
• The control cableneeds adjustment inthe following cases:
1) When thedetents cannotbefelt;
2) When thepointer indicating therange isimproperly
aligned.
• Always adjustcontrol cablewhenitis removed fromselec-
tor lever ormanual shaft.
SEC. 349
Floorpanel
\.~ 4.4-5.9 (0.45 •0.60. 39.1-52.1)
Front
<;:::J
~ 4.4 -5.9 (0.45 -0.60, 39.1-52.1)
Transax1,e
Cable bracket
•
~4.4 -5.9
(0.45 •0.60.
'I
39.1 -52.1)
~ 17.5 -23.7 (1.8•2.4, 13•17)
Sub frame Selector
leverassembly
~ 4.4•5.9 (0.45 -0.60, 39.1-52.1)
AIT control cableassembly
~:N.m (kg-m, in-Ib)
~ :N.m (kg-m, ft-Ib)
SAT499HA
•
SAT230EA
-{'
.~
did
Selector lever
I'y-
Clamp ,I.
'OJ} "
\ '4'i"" \.,)
I
,i
Selector leverbracket
\Vu
7//
;( ( .tll@:::(-c/",/.I
'''J)!I'r.
cY'?1I/'
i
j\\-.. )
~j
'.-It
( t:J-.,'-' ,
'.~/;,J~
A
'j
(,k;;.
l~\.\:\
D
eee:::
Control cable
t;-\
'II
Lock nut
~i'
l~}
I'
I
p
/.f .----
u
/,<\,:.~
4.4•5.9 N.m .."
- (0.45 -0.6
kg-m,
'~-39.1 -52.1 in-Ib)
INSTALLATION
1. Place selector leverandmanual shaftat"P" position.
2. Connect controlcabletoselector leverandtighten control
cable locknut.Clamp control cabletoselector lever
bracket.
AT-35
Page 175 of 1701
CONTENTS
G EN ERAL IN FORMATION 1
Identification Number 2
BODY COMPONENT PARTS 3
U nderbody Component Parts 3
Body Component Parts 4
CO RROSlO NPR OTECTI 0N 7
Description 7
Anti -Co rrosive Wax 8
Undercoating 9
Stone Guard Coat 10
BODY CONSTRUCTION 11
Body Construction .~ 11
BODY ALIGNM ENT 13
Body Center Marks 13
Panel PartsMatching Marks 14
Description 15
Engine Compartment 16
Underbody 17
Passenger Compartment (Sedan-5-door Hatchback) 19
Rear Body (Sedan) 21
Passenger Compartment (3-doorHatchback) 22
Rear Body (3-door Hatchback-5-door Hatchback) 24
HANDLING PRECAUTIONS FORPLASTICS 25
Handling Precautions forPlastics
>-•••••••••••••••••••••••••••••••••••••••••••••••••••••
25
Location ofPlastic Parts - 26
PR ECAUTIONS 28
Precautions ForHandling HighStrength Steel(HSS) 28
R EPLACEM ENTOPERATIONS 32
Description 32
Radiator CoreSupport (PartialReplacement) 33
Hoodledge (PartialReplacement) 34
Front SideMember (PartialReplacement) 35
Front Pillar..~ 36
Center Pillar(Sedan -5-door Hatchback) 37
Outer Sill(Sedan -5-door Hatchback) 38
Outer Sill(3-door Hatchback) 39
Rear Fender (Sedan) 40
Rear Fender (5-door Hatchback) 41
Rear Fender (3-door Hatchback) 42
Rear Floor Rear 43
Rear SideMember Extension (Sedan) 44
Rear SideMember Extension (3-doorand5-door Hatchback) 45
Page 176 of 1701
~~~~~~~~_GENERALJNFORM~ION~~~~~~~~_
IdentificationNumber _
REPLACEMENTOPERATIONS
Rear SideMember Extension
Sedan
-------
/
/\
---
/ \ -
'------- /~ ,,\I
c-
~ ~>~
111
114
Service
Joint
SGI908
Vehicle
identification plate
A
A
Vehicle
identification number
N15 U
0
xxxxxx.
T
T
---c::
serialnumber
0:
Stopgap (nomeaning)
Destination
U: Europe
Model
A: 2-wheel drive
Engine type
A: GA 14DE engine
C: GA 16DE engine
E: SR20DE engine
F: CD20 engine
Body type
B: 4-door Sedan
F: 5-door Hatchback
E: 3-door Hatchback
Manufacturer
J
N 1: Nissan, Passenger vehicle
Emission
controlinformation label
VEHICLE IDENTIFICATION NUMBERARRANGEMENT
For Europe
• JN1 B
2-spotwelds 3-spotwelds M.I.G plug weld
(For 3panels plugweld method )
d
r;==
dA~ dB~
GTJ ~
M.
I.G seam weld/
Point weld
-1-
-44-
Page 177 of 1701
REPLACEMENTOPERATIONS
Rear Floor Rear ________
GENERALINFORMATION _
Identification Number(Cont'd)
(Work afterrearpanel havebeen removed.)
ExceptforEurope
IN 1 .B CAN 15A
0
XXXXXX
T
T
--c:::
serialnumber
0:
Stopgap (nomeaning)
Destination
A: Australia andNew Zealand
Z: Except forEurope, Australia, andNew Zealand
Model
A: 2-wheel drive
Engine type
B: GA 15DE engine
C: GA 16DE engine
E: SR20DE engine-For AustraliaandNew Zealand only
Body type
B: 4-door Sedan
F: 5-door Hatchback
Manufacturer
IN 1:Nissan, Passenger vehicle
VEHICLE IDENTIFICATION PLATE
1Type approval number
2 Vehicle identification
number(Chassis number)
3 Gross vehicle weight
4 Gross combination weight
Gross vehicle weight
+
Gross trailing capacity
(Weight)
5 Gross axleweight(Front)
6 Gross axleweight(Rear)
7 Type approval number
8 Body colorcode
9 Trim color code
10 Model Specification No.
11 Engine model
12 Engine displacement
13 Transaxle model
14 Axle model
cc
o
PLANT
PlANTA
El
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MADEINJAPAN
NISSAN
MOTORCO.,LTD. APAN
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Expect
Europe
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FARBE. POlST
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NISSAN
MOTORCO.,LTD. JAPAN
I ~ I
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TYPE
TTP
Europe
FR
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3D
HI
B:3door hatchback
5D
HI
B:5door hatchback
Service
Joint
111
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2-spot welds 3-spotwelds M.
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(For 3panels plugweld method )P:
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weld
• rr=- •
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===-=
.'S~
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GTJ --- ~
-43-
-2-
Page 178 of 1701
UnderbodyComponent Parts REPLACEMENT'
OPERATIONS
Rear Fender
3-doorhatchback
@
1
or
11 1
@
1
or
11 1
112
111
112
114
113
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Unit:mm
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-3-
-42-
Page 179 of 1701
________BODYCOMPONENT PARTS _
___________ REPLACEMENTOPERATIONS
Rear Fender
5-doorhatchback
BodyComponent Parts Sedan
5-door Hatchback
~
o
o
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iD
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Point weld
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_ 7orll5
Rear pillar inner
reinforcement
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M.1. Gplug wel(d For3panels plugweld method )
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@ 5orll 4
Unit:mm
2-spot welds 3-spotwelds
Service
Joint
-41-
-4-
Page 180 of 1701
~~~~~~~_BODYCOMPONENTPAR~~~~~~~~_
BodyComponent Parts Sedan
5-door Hatchback REPLACEMENT
OPERATIONS
Rear Fender
Sedan
@ 1orll 1
o~
( \ FR
..an
(length :10mm)
114
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(For 3panels plugweld method )P..an.~i~t (Fweld
• rr=
.A=-= .B~
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@
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Unit:mm
e
12 orll 9
Service
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-5-
-40-
Page 181 of 1701
REPLACEMENTOPERATIONS
Outer Sill
3-doorhatchback Body
Component Parts 3-doorHatchback
Service Joint
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-39-
-6-
Page 182 of 1701
Description REPLACEMENT
OPERATIONS
Outer Sill
Sedan
5-door hatchback
FR
_4A
.cm
(OIerlap cutting)
_4
117
Unit:mm
119
112A 111A
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Service
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One-side precoated
Steel
sheet
~ Outside
Two-side precoated
Zn-Ni
alloy
Cationic electrodeposition primer
PHOSPHATE
COATINGTREATMENT AND
CATIONIC ELECTRODEPOSITION PRIMER
ANTI-CORROSIVE
PRECOATEDSTEEL
(DURASTEEL)
To
provide improved corrosion prevention, thefollowing anti-corrosive measureshavebeen implemented in
our production plants.Whenrepairing orreplacing bodypanels, itis necessary touse these sameanti-corrosive
measures.
Nissan Genuine ServicePartsalsoaretreated inthe same manner. Therefore, itis recommended tbat
GENUINE NISSANPARTSbeused forpanel replacement tomaintain anti-corrosive performancebuilt
into thevehicle atthe factory.
A
phosphate coatingtreatment andacationic electrodeposition primer,whichprovide anexcellent anti-
corrosion effect,areemployed onallbody components.
Caution:
Confine paintremoval inthe welding operation tothe absolute minimum.
Durasteel
isclassified aseither one-side precoated
steel ortwo-side precoated steel.Thetwo side
precoated steelprovides excellent corrosion resis-
tance. To
improve repairability andcorrosion resistance, a
new type ofanti-corrosive precoatedsteelsheets have
been adopted takingtheplace ofconventional zinc-
coated steelsheets.
This durasteel iselectroplated, zinc-nickelalloyunder
organic film,which provides excellent corrosion resis-
tance.
Nissan Genuine ServicePartsarefabricated fromdurasteel sheets.Therefore, itis recommended that
GENUINE NISSANPARTSbeused forpanel replacement tomaintain theanti-corrosive performance
built intothevehicle atthe factory.
-7-
-38-