NISSAN ALMERA N16 2003 Electronic Repair Manual

SFE561AB
SFE658AA
After connecting quick connector, make sure the connection is
firmly made using the following method.
Pull on the fuel tube and connector to make sure they are firmly
connected.
Start the engine, increase engine speed and verify that there
are no leaks.
Fuel Level Sensor UnitNJFE0032
SFE645A
GI
MA
EM
LC
EC
CL
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BR
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EL
IDX
FUEL SYSTEMYD
Fuel Tank (Cont’d)
FE-23

JFE613A
REMOVALNJFE0032S01For SedanNJFE0032S01011. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
4. Remove inspection hole cover under the rear seat.
SFE600A
5. Disconnect electrical connector.
6. Disconnect the quick connectors.
For disconnect of quick connectors, refer to step 7. of “Fuel
Tank Removal”.
7. Remove the six screws.
CAUTION:
Use genuine bolts only when fixing retainer.
8. Remove retainer.
SFE646A
9. Pull out the fuel level sensor unit.
Do not damage the arm of the fuel level sensor unit.
JFE613A
For HatchbackNJFE0032S01021. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap.
3. Remove rear seat cushion. Refer to BT-59, “Removal and
Installation”.
4. Remove inspection hole cover under the rear seat.
SFE639A
5. Disconnect electrical connector.
6. Disconnect the quick connectors.
For disconnect of quick connectors, refer to step 7. of “Fuel
Tank Removal”.
FUEL SYSTEMYD
Fuel Level Sensor Unit (Cont’d)
FE-24

SFE376A
7. Remove lock ring using a lock ring socket (SST).
SFE648AA
8. Pull out the fuel level sensor unit and fuel pump.
Do not damage the arm of the fuel level sensor unit.
INSTALLATIONNJFE0032S02Installation is in reverse order of removal.
GI
MA
EM
LC
EC
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FUEL SYSTEMYD
Fuel Level Sensor Unit (Cont’d)
FE-25

SMA211A
Checking Exhaust SystemNJFE0022Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, chafing or deterioration.
SEF180A
Removal and InstallationNJFE0018CAUTION:
Always replace exhaust gaskets with new ones when
reassembling. If gasket remains on flange surface, scrape
off completely as shown at left.
With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
Check to ensure that mounting brackets and mounting
insulators are installed properly and free from undue
stress. Improper installation could result in excessive
noise or vibration.
Be sure to use genuine exhaust system parts which are
designed especially for heat resistance, corrosion
resistance, and shape.
Perform the operation with the exhaust system fully
cooled down because the system will be heated just after
the engine stops.
Be careful not to cut your hand on the insulator edge.
EXHAUST SYSTEMYD
Checking Exhaust System
FE-26

YFE018
GI
MA
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EC
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EXHAUST SYSTEMYD
Removal and Installation (Cont’d)
FE-27

NOTES

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[2
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............2
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Special Service Tools ..................................................3
Commercial Service Tools ...........................................3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>4
NVH Troubleshooting Chart.........................................4
CLUTCH<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....4
CLUTCH SYSTEM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>5
Components - RHD Model with QG Engine - .............5
Components - LHD Model with QG Engine -..............6
Components - RHD Model with YD Engine -..............7
Components - LHD Model with YD Engine - ..............8
Inspection and Adjustment ..........................................9
CLUTCH PEDAL INSPECTION...................................9
CLUTCH PEDAL ADJUSTMENT...............................10
AIR BLEEDING PROCEDURE..................................10
CLUTCH MASTER CYLINDER..................................... 11
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.......... 11
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............12
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............12
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........12
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............12
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............13
OPERATING CYLINDER...............................................14
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........14
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............14
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........14
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............14
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............15
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............15
PIPING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[............16
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............16Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............16
RS5F30A, RS5F70A
CLUTCH RELEASE MECHANISM...............................17
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........17
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............17
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............17
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............17
RS5F50A
CLUTCH RELEASE MECHANISM...............................20
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........20
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............20
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............20
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............20
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....22
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........22
Inspection and Adjustment ........................................22
CLUTCH DISC<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>2
CLUTCH COVER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>3
FLYWHEEL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>3
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............23
SERVICE DATA AND SPECIFICATIONS (SDS).........24
Clutch Control System ...............................................24
Clutch Master Cylinder ..............................................24
Clutch Operating Cylinder .........................................24
Clutch Disc<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............24
Clutch Cover <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..........24
Clutch Pedal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..........24
GI
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IDX

SBR820BA
PrecautionsNJCL0001Recommended fluid is brake fluid “DOT 3” or “DOT 4”
(Europe). Refer to MA-19, “Fluid and Lubricants”.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
When removing and installing clutch piping, use Tool.
Use new brake fluid to clean or wash all parts of master
cylinder and operating cylinder.
Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
PRECAUTIONS
Precautions
CL-2

Special Service ToolsNJCL0002
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
NT406
Removing and installing clutch piping
a: 10 mm (0.39 in)
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
NT645
Installing clutch cover and clutch disc
(F30A and F70A)
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20630000
Clutch aligning bar
NT405
Installing clutch cover and clutch disc
(F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)
ST20050240
Diaphragm spring adjust-
ing wrench
NT404
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
KV32101000
Pin punch
NT410
Removing and installing spring pin
a: 4 mm (0.16 in) dia.
Commercial Service ToolsNJCL0003
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
GI
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EC
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PREPARATION
Special Service Tools
CL-3

NJCL0004
NVH Troubleshooting Chart
NJCL0004S01
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.CLUTCH
NJCL0004S0101
Reference page
CL-9
CL-10
CL-11
CL-14
Refer to EM-67, “Removal and Installation” (QG engine model) and
EM-63, “Removal and Installation” (YD engine model).
CL-17 (RS5F30A, RS5F70A), CL-20 (RS5F50A)
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-23
CL-23
CL-23
CL-23
SUSPECTED PARTS
(Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters———— 1 —— 2 —— 2 2 2 —— 2 ——
Clutch pedal spongy — 1 2 2 ——————————————
Clutch noisy———— — 1 ————————————
Clutch slips 1 — — — —————— 2 2 —— 3 — 4 5
Clutch does not disen-
gage1234 ——55555——5667—
—: Not applicable
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CL-4