FLUID NISSAN ALMERA N16 2003 Electronic Repair Manual

SEF289H
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
SGI233
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
SGI234
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
Arrange the disassembled parts in accordance with their
assembled locations and sequence.
Do not touch the terminals of electrical components which use
microcomputers (such as ECMs).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents
when required.
Use tools and recommended special tools where specified for
safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
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PRECAUTIONS
Precautions (Cont’d)
GI-5

SERVICE DATA AND SPECIFICATIONSare contained at the end of each section for quick reference of
data.
The followingSYMBOLS AND ABBREVIATIONSare used:
SYMBOL ABBREVIATION SYMBOL ABBREVIATION
Tightening torque
2WD2-Wheel Drive
Should be lubricated with grease. Unless oth-
erwise indicated, use recommended multi-pur-
pose grease.A/CAir Conditioner
Should be lubricated with oil. P/S Power Steering
Sealing point SST Special Service Tools
Checking point SAE Society of Automotive Engineers, Inc.
Always replace after every disassembly. ATF Automatic Transmission Fluid
P
Apply petroleum jelly.
D1Drive range 1st gear
Apply ATF. D2Drive range 2nd gear
★Select with proper thickness. D
3Drive range 3rd gear
✩Adjustment is required. D
4Drive range 4th gear
SDS Service Data and Specifications OD Overdrive
LH, RH Left-Hand, Right-Hand 2
22nd range 2nd gear
FR, RR Front, Rear 2
12nd range 1st gear
M/T Manual Transaxle/Transmission 1
21st range 2nd gear
A/T Automatic Transaxle/Transmission 1
11st range 1st gear
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HOW TO USE THIS MANUAL
GI-11

MAINTENANCE
SECTION
MA
CONTENTS
PRE-DELIVERY INSPECTION ITEMS............................2
GENERAL MAINTENANCE............................................3
PERIODIC MAINTENANCE (EXCEPT FOR
EUROPE)<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..........4
Engine and Emission Control Maintenance
(Gasoline engine) ........................................................4
Chassis and Body Maintenance ..................................5
Maintenance Under Severe Driving Conditions ..........6
PERIODIC MAINTENANCE (FOR EUROPE).................7
Maintenance Schedule for Petrol Engines
(Annual Mileage < 30,000 km/year) ............................7
QG15DE/QG18DE ENGINES......................................7
CHASSIS AND BODY MAINTENANCE........................8
Maintenance Schedule for Diesel Engines
(Annual Mileage < 30,000 km/year) ............................9
YD22DDT ENGINE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>9
CHASSIS AND BODY MAINTENANCE......................10
Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year) ............ 11Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year) ..........................13
QG15DE/QG18DE ENGINES....................................13
CHASSIS AND BODY MAINTENANCE......................14
Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year) ..........................15
YD22DDT ENGINE..................................................15
CHASSIS AND BODY MAINTENANCE......................16
Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year) ............17
RECOMMENDED FLUIDS AND LUBRICANTS...........19
Fluids and Lubricants ................................................19
SAE Viscosity Number ..............................................20
GASOLINE ENGINE.................................................20
DIESEL ENGINE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>0
Engine Coolant Mixture Ratio....................................21
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NJMA0036
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard tothe conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION
Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
Inspect for interior and exterior metal and paint damage
Check for spare tire, jack, tools (wheel chock), and literature
Wash, clean interior and exterior
: Not applicable to this model
PRE-DELIVERY INSPECTION ITEMS
MA-2

NJMA0004
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers dothem for a nominal charge.
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified.
Item Reference page
TiresCheck the pressure with a gauge periodically when at a service station,
including the spare, and adjust to the specified pressure if necessary. Check
carefully for damage, cuts or excessive wear.—
Windshield wiper
bladesCheck for cracks or wear if not functioning correctly. —
Doors and engine
hoodCheck that all doors, the engine hood, the trunk lid and back door operate
properly. Also ensure that all latches lock securely. Lubricate if necessary.
Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.BT-7
BT-16
Tire rotationTires should be rotated every 10,000 km (6,000 miles). SU-7
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the
vehicle, etc.
Item Reference page
LampsMake sure that the headlamps, stop lamps, tail lamps, turn signal lamps,
and other lamps are all operating properly and installed securely. Also check
headlamp aim.—
Warning lamps and
chimesMake sure that all warning lamps and buzzers/chimes are operating prop-
erly.—
Steering wheelCheck that it has the specified play.
Check for changes in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)—
Seat beltsCheck that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely.
Check the belt webbing for cuts, fraying, wear or damage.RS-4
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel.
Item Reference page
Windshield washer
fluidCheck that there is adequate fluid in the tank. —
Engine coolant levelCheck the coolant level when the engine is cold. LC-18, LC-43
Engine oil levelCheck the level after parking the vehicle (on level ground) and turning off
the engine.LC-8, LC-30
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the “MAX” and
“MIN” lines on the reservoir.BR-7
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN”
lines.—
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GENERAL MAINTENANCE
MA-3

Chassis and Body MaintenanceNJMA0005S05Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference page Perform either at number of kilome-
ters (miles) or months, whichever
comes first.kmx1,000
(Miles x
1,000)
Months1
(0.6)
—10
(6)
620
(12)
1230
(18)
1840
(24)
2450
(30)
3060
(36)
3670
(42)
4280
(48)
48
Underhood and under vehicle
Brake, clutch & automatic transaxle
fluid (For level & leaks)★IIIIIIII BR-7,AT-13
Brake fluid★R R BR-18
Brake booster vacuum hoses, con-
nections & check valveI I BR-22
Power steering fluid & lines (For
level & leaks)I*1 I I*1 I I*1 I I*1 I ST-7
Brake, clutch & exhaust systemsIIIIIIIIBR-7, FE-10,
FE-26
Manual transaxle gear oil (For level
& leaks)I*1 I I*1 I I*1 I I*1 I MT-15, MT-14
Steering gear & linkage, axle & sus-
pension parts & drive shafts★I*2IIIIST-7,SU-6,SU-7
Outside and inside
Wheel alignment (If necessary,
rotate & balance wheels)IIIISU-7,SU-14
Brake pads, rotors & other brake
components★IIIIIIII BR-27,BR-31
Brake linings, drums & other brake
components★IIIIBR-7
Lock, hinges & hood latch★L*1 L L*1 L L*1 L L*1 L BT-7, BT-16
Seat belts, buckles, retractors,
anchors & adjusterIIIIRS-4
Foot brake, parking brake & clutch
(For free play, stroke & operation)I*1 I I*1 I I*1 I I*1 I BR-12, BR-43, CL-5
Ventilation air filter★Replace every 12,000 km (7,500 miles) or 12 months HA-95 or ATC-128
Supplemental air bag systemsSee NOTE
(1)RS-25
NOTE:
(1) Inspect at the first 10 years, and then every 2 years.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
*1: Models except for Australia
*2: Models without three way catalystGI
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PERIODIC MAINTENANCE (EXCEPT FOR EUROPE)
Chassis and Body Maintenance
MA-5

Maintenance Under Severe Driving Conditions=NJMA0005S06The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving condition Maintenance itemMaintenance
operationMaintenance intervalReference
page
A........Aircleaner filter Replace More frequently EM-14
ABCD.....Engine oil & oil filter (Gaso-
line engine)ReplaceEvery 5,000 km (3,000
miles) or 3 monthsLC-8, LC-9
.....F...Brakefluid ReplaceEvery 20,000 km (12,000
miles) or 12 monthsBR-7
..C....H.Automatictransaxlefluid ReplaceEvery 40,000 km (24,000
miles) or 24 monthsAT-13
......GH.Steering gear & linkage, axle
& suspension parts & drive
shaftsCheckEvery 10,000 km (6,000
miles) or 6 monthsST-7, SU-6,
SU-18
A.C...GHIBrake pads, rotors & other
brake componentsCheckEvery 5,000 km (3,000
miles) or 3 monthsBR-27,
BR-31
A.C...GHIBrake linings, drums & other
brake componentsCheckEvery 10,000 km (6,000
miles) or 6 monthsBR-7
......G..Lock,hinges & hood latch LubricateEvery 5,000 km (3,000
miles) or 3 monthsBT-16, BT-7
A........Ventilation air filter Replace More frequentlyHA-95 or
ATC-128
PERIODIC MAINTENANCE (EXCEPT FOR EUROPE)
Maintenance Under Severe Driving Conditions
MA-6

CHASSIS AND BODY MAINTENANCE=NJMA0043S0102Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis, but on
an annual basis when driving less than
15,000 km (9,000 miles) in a year.kmx1,000
(miles x 1,000)
Months15
(9)
1230
(18)
2445
(27)
3660
(36)
4875
(45)
6090
(54)
72105
(63)
84120
(72)
96
Underhood and under vehicle
Headlamp aimingIIIIIIIIEL-44
Wheel alignment (if necessary, balance
& rotate wheels)IIIIIIIISU-6/
SU-18
Brake pads, rotors & other brake com-
ponents★IIIIIIIIBR-27/
BR-28
Foot brake, parking brake & clutch (for
free play, stroke & operation)IIIIIIIIBR-12/
BR-44/
CL-9
Brake booster vacuum hoses,
connections, check valveIIIIBR-21
Brake & clutch, systems and fluid (for
level and leaks)IIIIIIIIBR-7
Brake fluid★RRRRBR-7
Power steering fluid and lines (for level
and leaks)IIIIIIIIST-7
Supplemental air bag systems See NOTE (1) RS-25
Ventilation air filter★RRRRHA-95 or
AT C - 1 2 8
Manual transaxle gear oil (check for
leakage. Use genuine NISSAN XZ
gear oil or exact equivalent)IIIIIIIIMT-14
MT-15
Automatic transaxle fluid (for level and
leaks)★IIIIIIIIAT-13
Steering gear & linkage, axle & sus-
pension parts, drive shafts, exhaust
system★IIIIST-7/
SU-6/
SU-18/
FE-10
NISSAN Mobility System See NOTE (2)IIIIIII —
Body corrosion See NOTE (3) BT-6
NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Check expiration date of the tyre sealant bottle. Replace if necessary.
(3) Inspect once per year.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) (Cont’d)
MA-8

CHASSIS AND BODY MAINTENANCE=NJMA0043S0202Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference pages Perform on a kilometer basis, but on
an annual basis when driving less
than 20,000 km (12,000 miles) per
year.kmx1,000
(miles x 1,000)
Months20
(12)
1240
(24)
2460
(36)
3680
(48)
48100
(60)
60120
(72)
72
Underhood and under vehicle
Headlamp aimingIIIIII EL-44
Wheel alignment (if necessary, bal-
ance & rotate wheels)IIIIIISU-14
SU-7
Brake pads, rotors & other brake
components★IIIIIIBR-27
BR-28
Foot brake, parking brake & clutch
(for free play, stroke & operation)IIIIIIBR-12
BR-44
CL-9
Brake booster vacuum hoses,
connections, check valveI I I BR-21
Brake & clutch, systems and fluid
(for level and leaks)IIIIII BR-7
Brake fluid★R R R BR-7
Power steering fluid and lines (for
level and leaks)IIIIII ST-7
Supplemental air bag systems See NOTE (1) RS-25
Ventilation air filter★RRRRRR HA-95orATC-128
Manual transaxle gear oil (check for
leakage. Use genuine NISSAN XZ
gear oil or exact equivalent)IIIIIIMT-14
MT-15
Steering gear & linkage, axle & sus-
pension parts, drive shafts, exhaust
system★IIIST-7
SU-6
SU-18
FE-26
NISSAN Mobility System See NOTE (2)IIIII —
Body corrosion See NOTE (3) BT-6
NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Check expiration date of the tyre sealant bottle. Replace if necessary.
(3) Inspect once per year.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Diesel Engines (Annual Mileage < 30,000 km/year) (Cont’d)
MA-10

Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year)
=NJMA0043S03The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K — Sustained high speed driving
L — For models without Euro-OBD system
Driving conditionMaintenance
itemMaintenance
operationMaintenance interval
ABCD........Engine oil & engine oil filter
Petrol models ReplaceEvery 7,500 km (4,500 miles) or 6
months
Diesel models ReplaceEvery 10,000 km (6,000 miles) or 6
months
A...........Air cleaner filter
Petrol models ReplaceEvery 30,000 km (18,000 miles) or
24 months
Diesel models ReplaceEvery 30,000 km (18,000 miles) or
18 months
A...E.......Fuel filter
Diesel models ReplaceEvery 20,000 km (12,000 miles) or
12 months
...........LHeated Oxygen Sensor 1 (Front)
Petrol models InspectEvery 30,000 km (18,000 miles) or
24 months
...........LHeated Oxygen Sensor 2 (Rear)
Petrol models InspectEvery 30,000 km (18,000 miles) or
24 months
A...........Ventilation air filter
Petrol models ReplaceEvery 15,000 km (9,000 miles) or
12 months
Diesel models ReplaceEvery 10,000 km (6,000 miles) or 6
months
.....F......Brake fluid
Petrol models ReplaceEvery 15,000 km (9,000 miles) or
12 months
Diesel models ReplaceEvery 20,000 km (12,000 miles) or
12 months
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PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year)
MA-11