radiator NISSAN ALMERA N15 1995 Service Manual

SAT620EDISASSEMBL
Y

5. Set manual shaftto"P" position.
6. Remove inhibitorswitch.

Waste material

Oil
pan
SAT013D
7.
Remove oilpan andoilpan gasket.

• Donot reuse oilpan bolts.

8. Check foreign materials inoil pan tohelp determine cause•
of malfunction. Ifthe fluid isvery dark, smells burned, or
contains foreignparticles, thefrictional material(clutches,
band) mayneed replacement. Atacky filmthat willnotwipe
clean indicates varnishbuildup.Varnish cancause valves,
servo andclutches tostick andcaninhibit pumppressure.

• Iffrictional materialisdetected, replaceradiator afterrepair
of AlT. Refer toLC section ("Radiator", "ENGINECOOLING
SYSTEM").
SAT711D
9.
Remove controlvalveassembly according tothe following
procedures.
a. Remove controlvalveassembly mountingbolts@,
CID,
@

and @.

AT-51

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

REPLACEMENTOPERATIONS
Front SideMember (PartialReplacement)
(Work afterradiator coresupport hasbeen removed.) ________
CORROSIONPROTECTION _
Stone Guard Coat
SectionB-B
Section
A-A
--r':":'

To
prevent damage causedbystones, thelower outerbodypanels (fender, door,etc.)have anadditional layer
of Stone Guard CoatovertheEDprimer coating. Thus,when replacing orrepairing thesepanels, apply
undercoat tothe same portions asbefore. Useacoat which isrust preventive, durable,shockresistant andhas
a long shelf life.

~mm1111i :
Indicates stoneguard coated portions

114

Patch

118

111

115
114

hoodledge
panel

117

111

Unit:mm

8

Patch

""

"
"

(Thickness: 1mm)

-\

Service
Joint

(This figure showrightfront sidemember)
2-spot welds 3-spotwelds M.1.
Gplug weld MIG seam weld/
(For 3panels plugweld method )P1ID.~irit
F
weld

• rr=
.A=-= .B~
G1J --- ~
Section
C-C

-35- -10-

BODYCONSTRUCTION _

------------

BodyConsb"uction. REPLACEMENT
OPERATIONS _

------------

Hoodledge(PartialReplacement)
(Work afterradiator coresupport hasbeen removed.)
114AUnit:mm
Before
installing
hoodledge reinforcement.
117

Service
Joint

(This figure showrightsidehoodledge)
Sedan
3-d oar Hatchback
5-door Hatchback 2-spot
welds 3-spotwelds

M.1.
Gplug weld )
M.I.
Gseam weld/
(For 3panels plugweld method. Pointweld

· r
.A~ .B~
.an.F

-34-
-11-

REPLACEMENTOPERATIONS _

------------

RadiatorCoreSupport (PartialReplacement) BODY
CONSTRUCTION _

-----------

BodyConstruction

\

Section
L-L:
Section P-P:
Section
D-D:
Section H-H:
Section K-K:
Section
C-C:
Section G-G:
Section 0-0:
Section

J-J:

Section
F-F:
Section
8-8:
. Section N-N:
Section
I-I:
Section
E-E:
Section
A-A:
Section M-M:

_1

FR

(

e
4orll3 *
indicates thatthere isan equivalent wel~ing.portion
with thesame dimensions onthe opposite Side.

o

*
e
3
or 112

FR

Service
Joint

Section
0-0:
Section
R-R:

2-spot welds 3-spotwelds
M.1.Gplug weld )M.I.Gseam weld/
(Point weld
For 3panels plugweld m.ethod

· r ·
A
=='*= •
B
===:=
.an
F

-33- -12-

Description
_________
BODYALIGNMENT _
Body Center Marks ________
REPLACEMENTOPERATIONS _

SYMBOLS FORCUITING AND
WELDING/BRAZING OPERATIONS

..J

3-spot welds

(3-panel overlapping portions)

2-SDOt

welds

(2-panel overlapping portions)

••••

2-spot
welds

0000

3-spot
welds
Spot
weld
Brazing
Soldering
(ItIlI)

M.LG. seamweld/
Point weld
Saw
cutor
air chisel cut

•
•
•

M.LG. plugweld

-

The
indentification ofthe cutting andthewelding/brazing symbolsusedthroughout thisguide isgiven inthe
following pages

Portion F
Portion
C
Unit:
mm

Porton
H
3-Door Hatchback
and 5-Door Hatchback

• Front roof
• Second crossmember

Portion
D-Sedan
Portion E
-Sedan
Portion F

Portion E
Portion
8
Portion
G

~

Slot(7X 11)

/~/

• Rear waist panelslot
•
Cowl top

Portion
BPortion
C

Hole(4
dial

Portion
A
Portion D

Portion
A

• Rear roof
•
Upper radiator coresupport

A
mark hasbeen placed oneach partofthe body toindicate thevehicle center.Whenrepairing partsdamaged
by an accident whichmightaffectthevehicle frame(members, pillars,etc.)more accurate, effectiverepairwill
be possible byusing these marks together withbody alignment data.

Portion G

3-door and5-door Hatchback

Lozenge
mark
Portion
H

3-door and5-door Hatchback Sealing
• Rear roof •
Rear panel

-13- -32-

__________ PRECAUTIONS ___________
BODYALIGNMENT _
Precautions ForHandling HighStregth Steel Engine
Compartment

__ MEASURMENT POINTS__

Unit:mm

Front side

SBT088

Traction direction: ...
Not
recommended

• The repair ofreinforcements (suchasside
members) byheating isnot recommended
since itinvolves theriskoflowering strength.
When heating isunavoidable, donot heat
such parts attemperatures above550°C (1,

022°F)

Heating temperature shouldbeverified with
a thermometer. (Acrayon-type andother
thermometer areavailable.)
• When straightening bodypanels, usecaution
in pulling anyHSS panel. Because itis very
strong, thismay cause deformation inadja-
cent portions ofthe body. Inthis case,
increase thenumber ofmeasuring points,
and carefully pulltheHSS panel.
Special
consideration forHSS must begiven tothe following points:
1 .Additional pointstoconsider
• Incutting HSSpanel, avoidgascutting if
possible. Instead,useanairsaw orahand
cutter toavoid decreasing thestrength of
surrounding portionsduetothe influence of
heat. Incase gascutting isinevitable, a
minimum allowance of50 mm (1.97 in)
must begiven.

SBT090
Radiator
coresupport lower

•
(b)

11
dia.

SBT094

• Inwelding HSSpanel, usespot welding
whenever possibleinorder tominimize any
decrease instrength ofsurrounding portions
due tothe influence ofheat.
If spot welding isimpossible, useM.LG.
welding. Donotuseacetylene gaswelding
because itis inferior inwelding strength.
GOOD

-================
N.G.

Never useacetylene .gas
welding.
Radiator
coresupport uppercenter

SBT091

-29-
-16-

__________ BODYALIGNMENT _
_HANDLINGPRECAUTIONS FORPLASTICS _
Passenger Compartment Sedan
5-door Hatchback Location
OfPlastic Parts

Side turnsignal lamplens
(Lens: AS)
Housing: ASS
Wind-shield molding
(Upper: PVC )
Side:Stainless+PVC
Doorout-side molding
(Stainless+PVC)
Wheel cover
(Full cover: PP+PA6 )
Half cover: PA66+PPO
Center cap:PA6
Door
mirror
(Housing: AAS)
Garnish: ASS
Front turnsignal lamp
(Lens: PMMA)
Housing: PP
Fog
lamp
(Lens: Glass)
Housing: PP
Head
lamp
(Lens: Glass)
Housing: pp
Radiator grille

(ABS)

Fog lamp finisher
(PM MA)
Front
bumper fascia

(PP)

Front airspoiler

(PP)

Point
Dimension

@-@
1228

CB-<f)
1374

@-@
1366

(8)-{6)
1159

CD--cD
1387
Q)-{J) 1367

@--@
1156

(b)--{[)
1385

~-4iV
1370

@~
1364

@~
1364

C&#39;e)--@
1598

@--@
989*

@-{E)
918*

@~
1156*

@--{[)
917*

@~@
975*

@~(b)
757*

@~
1004*

@--@
723*

,
... ._MEASURMENT _

Figures marked witha
*
show symmetrically identical
dimensions onboth right andlefthand sides ofthe
vehicle.
Unit:
mm

@ :
Cowl tophole center (5dia.)
CB>
:
Front roofflange endatcenter
Positioning mark ~~
~}Outer frontpillarjoggle
Sideguard molding (PVC)
Rear combination lamp
(Lens: PMMA)
Housing: PP
Door
outside handle
(Handle: POM )
Escutcheon: POM
Mud guard (TPR)
Rear
Windowmolding
(PVC)
-for Sedan
Rear bumper fascia

(PP)

License
lamp
(Lens: PC)
Housing: PP
Trunk
lidfinisher(pp)
-for Sedan
Rear
spoiler(PPO)
-for Sedan
High mounted stoplamp
(In Rear SpoilerType)
(Lens: PMMA)-for Sedan
Housing: ASS
(Fixed Trunk LidTipe)
(Lens: PC)-for Sedan
Housing: PP

(f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

Outer center pillarindention

CDCD :
Outer center pillarstandard hole
center

CBCD:
}

~@:
Outerfrontpillar indention

@@
:
Dash upper flange endcorner

-19- -26-

__________ BODYALIGNMENT _
_HANDLINGPRECAUTIONS FORPLASTICS _
Passenger Compartment Sedan
5-door Hatchback Location
OfPlastic Parts

Side turnsignal lamplens
(Lens: AS)
Housing: ASS
Wind-shield molding
(Upper: PVC )
Side:Stainless+PVC
Doorout-side molding
(Stainless+PVC)
Wheel cover
(Full cover: PP+PA6 )
Half cover: PA66+PPO
Center cap:PA6
Door
mirror
(Housing: AAS)
Garnish: ASS
Front turnsignal lamp
(Lens: PMMA)
Housing: PP
Fog
lamp
(Lens: Glass)
Housing: PP
Head
lamp
(Lens: Glass)
Housing: pp
Radiator grille

(ABS)

Fog lamp finisher
(PM MA)
Front
bumper fascia

(PP)

Front airspoiler

(PP)

Point
Dimension

@-@
1228

CB-<f)
1374

@-@
1366

(8)-{6)
1159

CD--cD
1387
Q)-{J) 1367

@--@
1156

(b)--{[)
1385

~-4iV
1370

@~
1364

@~
1364

C&#39;e)--@
1598

@--@
989*

@-{E)
918*

@~
1156*

@--{[)
917*

@~@
975*

@~(b)
757*

@~
1004*

@--@
723*

,
... ._MEASURMENT _

Figures marked witha
*
show symmetrically identical
dimensions onboth right andlefthand sides ofthe
vehicle.
Unit:
mm

@ :
Cowl tophole center (5dia.)
CB>
:
Front roofflange endatcenter
Positioning mark ~~
~}Outer frontpillarjoggle
Sideguard molding (PVC)
Rear combination lamp
(Lens: PMMA)
Housing: PP
Door
outside handle
(Handle: POM )
Escutcheon: POM
Mud guard (TPR)
Rear
Windowmolding
(PVC)
-for Sedan
Rear bumper fascia

(PP)

License
lamp
(Lens: PC)
Housing: PP
Trunk
lidfinisher(pp)
-for Sedan
Rear
spoiler(PPO)
-for Sedan
High mounted stoplamp
(In Rear SpoilerType)
(Lens: PMMA)-for Sedan
Housing: ASS
(Fixed Trunk LidTipe)
(Lens: PC)-for Sedan
Housing: PP

(f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

Outer center pillarindention

CDCD :
Outer center pillarstandard hole
center

CBCD:
}

~@:
Outerfrontpillar indention

@@
:
Dash upper flange endcorner

-19- -26-

__________ PRECAUTIONS ___________
BODYALIGNMENT _
Precautions ForHandling HighStregth Steel Engine
Compartment

__ MEASURMENT POINTS__

Unit:mm

Front side

SBT088

Traction direction: ...
Not
recommended

• The repair ofreinforcements (suchasside
members) byheating isnot recommended
since itinvolves theriskoflowering strength.
When heating isunavoidable, donot heat
such parts attemperatures above550°C (1,

022°F)

Heating temperature shouldbeverified with
a thermometer. (Acrayon-type andother
thermometer areavailable.)
• When straightening bodypanels, usecaution
in pulling anyHSS panel. Because itis very
strong, thismay cause deformation inadja-
cent portions ofthe body. Inthis case,
increase thenumber ofmeasuring points,
and carefully pulltheHSS panel.
Special
consideration forHSS must begiven tothe following points:
1 .Additional pointstoconsider
• Incutting HSSpanel, avoidgascutting if
possible. Instead,useanairsaw orahand
cutter toavoid decreasing thestrength of
surrounding portionsduetothe influence of
heat. Incase gascutting isinevitable, a
minimum allowance of50 mm (1.97 in)
must begiven.

SBT090
Radiator
coresupport lower

•
(b)

11
dia.

SBT094

• Inwelding HSSpanel, usespot welding
whenever possibleinorder tominimize any
decrease instrength ofsurrounding portions
due tothe influence ofheat.
If spot welding isimpossible, useM.LG.
welding. Donotuseacetylene gaswelding
because itis inferior inwelding strength.
GOOD

-================
N.G.

Never useacetylene .gas
welding.
Radiator
coresupport uppercenter

SBT091

-29-
-16-