torque NISSAN ALMERA 2001 Service Manual

RHA143E
+Install the pulley assembly using the installer and a hand
press, and then install the snap ring using snap ring pliers.
RHA127F
+Install the clutch disc on the drive shaft, together with the
original shim(s). Press the clutch disc down by hand.
RHA086E
+Using the holder to prevent clutch disc rotation, tighten the bolt
to 14 N´m (1.4 kg-m, 10 ft-lb) torque.
After tightening the bolt, check that the pulley rotates
smoothly.
RHA087E
+Check clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
Break-in OperationNJHA0214S01When replacing compressor clutch assembly, always carry out the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
transmitted torque.
SERVICE PROCEDURE
Compressor Clutch Ð CSV613 (CALSONIC make) (Cont'd)
HA-87

Seat, rear ................................................... BT-60
Self-diagnostic results ....................... EC-74, 628
Shift control components (M/T) .... MT-32, 56, 94
Shift fork (M/T) .............................. MT-32, 56, 94
Shift lever .................................................. MT-29
Shift lock system ...................................... AT-343
Shift schedule .......................................... AT-470
Shift solenoid valve A (A/T) ..... AT-204, 209, 222
Shift solenoid valve B (A/T) ............. AT-204, 209
Shock absorber (front) .............................. SU-10
Shock absorber (rear) ............................... SU-21
Side air bag ........................................ RS-36, 38
Side trim .................................................... BT-31
Spare tire size ............................................ GI-43
Speedometer ........................................... EL-144
Spiral cable ............................................... RS-29
Spot lamp ................................................ EL-141
Spring (Wheelarch) height .......................... SU-6
Stabilizer bar (front) ................................... SU-11
Stall test (A/T) ............................................ AT-80
Standardized relay ....................................... EL-8
Start signal ...................................... EC-557, 823
Starter ....................................................... SC-18
Starting system ......................................... SC-13
Steering linkage ......................................... ST-16
Steering switch .......................................... EL-59
Steering wheel and column ....................... ST-11
Steering wheel play ..................................... ST-6
Steering wheel turning force ....................... ST-8
Stop lamp .................................................. EL-85
Striking rod (M/T) .......................... MT-32, 56, 94
Strut (front) .................................................. SU-9
Strut (rear) ................................................. SU-20
Sub-gear (M/T) ................................... MT-31, 55
Sunroof, electric ....................................... EL-292
Sunroof ...................................................... BT-63
Super lock ................................................ EL-349
Supplemental Restraint System ............... RS-20
Supplemental restraint system - Wiring
diagram .................................................. RS-53
Swirl control valve control solenoid
valve ............................................ EC-399, 475
Symbols and abbreviations ........................ GI-10
Symptom matrix chart ..................... EC-155, 646
Synchronizer (M/T) ....................... MT-31, 55, 93
System readiness test (SRT) code ........... EC-62
T
TCM circuit diagram ................................... AT-17
TCM inspection table ............................... AT-119
TFTS - Wiring diagram ........................... EC-315
TP/SW - Wiring diagram ................. EC-387, 521
TPS - Wiring diagram ............................. EC-210
TURN - Wiring diagram ........................... EL-103
Tachometer .............................................. EL-144
Tail lamp .................................................... EL-81
Tank fuel temperature sensor ................. EC-313
Thermostat .......................................... LC-15, 41Three way catalyst precautions ................... GI-6
Three way catalyst .................................. EC-359
Throttle position sensor (TPS) ................ EC-207
Throttle position sensor
adjustment ................................... EC-100, 128
Throttle position switch ........... AT-141, 267, 341,
EC-385, 520
Throwout bearing - See Clutch release
bearing ............................................. CL-17, 20
Tie-rod ball joints ....................................... ST-20
Tie-rod ........................................................ ST-16
Tightening torque of standard bolts ........... GI-49
Timing chain ....................................... EM-23, 94
Tire size ...................................................... GI-43
Torque converter installation .................... AT-355
Tow truck towing ........................................ GI-47
Transmission case (M/T) .............. MT-30, 54, 92
Tread-FR&RR (Dimensions) ...................... GI-43
Trim ............................................................ BT-31
Trouble diagnoses ...................................... GI-31
Trunk lid finisher ........................................ BT-45
Trunk lid opener - See Trunk lid ................ BT-10
Trunk lid trim .............................................. BT-45
Trunk lid ..................................................... BT-10
Trunk room lamp ..................................... EL-141
Trunk room trim ......................................... BT-45
Turn signal lamp ........................................ EL-96
Two trip detection logic ............................. EC-59
Two-pole lift ................................................ GI-46
U
Under body ................................................ BT-80
V
VSS - Wiring diagram ..................... EC-372, 701
Vacuum hose (brake system) ................... BR-22
Vacuum hose drawing (Engine control) .... EC-30
Vacuum pump ........................................... BR-23
Valve clearance ................................ EM-44, 133
Valve guide ....................................... EM-39, 124
Valve lifter ................................................. EM-43
Valve seat ......................................... EM-41, 126
Valve spring ...................................... EM-42, 128
Vehicle speed sensor (VSS) ........... EC-370, 701
Viscosity number (SAE) ............................ MA-17
Viscous coupling (FF M/T) ........................ MT-93
W
WARN - Wiring diagram .......................... EL-190
WIP/R - Wiring diagram .................. EL-225, 227
WIPER - Wiring diagram ................. EL-217, 220
Warning chime ......................................... EL-197
Warning lamps ......................................... EL-184
Washer, front ........................................... EL-215
ALPHABETICAL INDEX
IDX-7

INSPECTION...........................................................37
ASSEMBLY.............................................................37
Mainshaft and Gears .................................................39
DISASSEMBLY........................................................39
INSPECTION...........................................................41
ASSEMBLY.............................................................42
Final Drive..................................................................44
DISASSEMBLY........................................................44
INSPECTION...........................................................44
ASSEMBLY.............................................................45
Shift Control Components .........................................46
INSPECTION...........................................................46
Case Components .....................................................46
DISASSEMBLY AND ASSEMBLY..............................46
ADJUSTMENT...............................................................49
Differential Side Bearing Preload ..............................49
Mainshaft Bearing Preload ........................................50
ASSEMBLY....................................................................51
RS5F70A
OVERHAUL...................................................................54
Case Components .....................................................54
Gear Components .....................................................55
Shift Control Components .........................................56
Final Drive Components ............................................57
DISASSEMBLY..............................................................58
Transaxle Case ..........................................................58
Clutch Housing ..........................................................60
REPAIR FOR COMPONENT PARTS...........................64
Input Shaft and Gears ...............................................64
DISASSEMBLY........................................................64
INSPECTION...........................................................65
ASSEMBLY.............................................................66
Mainshaft and Gears .................................................69
DISASSEMBLY........................................................69
INSPECTION...........................................................70
ASSEMBLY.............................................................72
Final Drive..................................................................77
PRE-INSPECTION...................................................77
DISASSEMBLY........................................................78
INSPECTION...........................................................79
ASSEMBLY.............................................................79
Shift Control Components .........................................81
INSPECTION...........................................................81
ASSEMBLY....................................................................82
Clutch Housing ..........................................................82
Transaxle Case ..........................................................86
RS5F50A
OVERHAUL...................................................................92
Case Components .....................................................92
Gear Components .....................................................93
Shift Control Components .........................................94DISASSEMBLY..............................................................95
REPAIR FOR COMPONENT PARTS...........................98
Input Shaft and Gears ...............................................98
DISASSEMBLY........................................................98
INSPECTION...........................................................99
ASSEMBLY...........................................................100
Mainshaft and Gears ...............................................103
DISASSEMBLY......................................................103
INSPECTION.........................................................104
ASSEMBLY...........................................................105
Final Drive................................................................107
DISASSEMBLY......................................................107
INSPECTION.........................................................107
ASSEMBLY...........................................................108
Shift Control Components .......................................109
INSPECTION.........................................................109
Case Components ...................................................109
REMOVAL AND INSTALLATION.............................109
ADJUSTMENT............................................................. 111
Input Shaft End Play and Differential Side
Bearing Preload ....................................................... 111
DIFFERENTIAL SIDE............................................. 111
INPUT SHAFT SIDE............................................... 112
Mainshaft Bearing Preload ...................................... 112
ASSEMBLY.................................................................. 114
RS5F30A
SERVICE DATA AND SPECIFICATIONS (SDS)....... 118
General Specifications ............................................. 118
TRANSAXLE......................................................... 118
FINAL GEAR......................................................... 118
Gear End Play ......................................................... 119
Clearance Between Baulk Ring and Gear .............. 119
1ST, 2ND, 3RD, 4TH & 5TH BAULK RING............... 119
1ST AND 2ND DOUBLE BAULK RING (WHERE
FITTED)
................................................................ 119
Available Check Plugs ............................................. 119
REVERSE CHECK PLUGS..................................... 119
Available Snap Rings ..............................................120
INPUT SHAFT FRONT BEARING...........................120
INPUT SHAFT 5TH SYNCHRONIZER HUB.............120
INPUT SHAFT REAR BEARING..............................120
Available C-rings......................................................120
MAINSHAFT C-RING.............................................120
Available Washers ...................................................121
DIFFERENTIAL SIDE GEAR THRUST WASHER......121
Available Shims - Mainshaft and Differential Side
Bearing Preload and Adjusting Shim.......................121
BEARING PRELOAD (REUSED BEARING).............121
TURNING TORQUE (NEW BEARING).....................121
MAINSHAFT REAR BEARING ADJUSTING SHIMS..121
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS
..................................................................122
CONTENTS(Cont'd)
MT-2

RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS).......123
General Specifications .............................................123
TRANSAXLE.........................................................123
FINAL GEAR.........................................................123
Gear End Play .........................................................124
Clearance Coupling Sleeve .....................................124
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE
COUPLING SLEEVE
..............................................124
Clearance Between Baulk Ring and Gear ..............124
3RD, 4TH, 5TH, REVERSE BAULK RING................124
1ST AND 2ND DOUBLE BAULK RING....................124
Available Snap Rings ..............................................125
SNAP RING...........................................................125
Available C-rings......................................................125
4TH INPUT GEAR C-RING.....................................125
5TH INPUT GEAR REAR C-RING...........................125
MAINSHAFT C-RING.............................................126
Available Adjusting Shims .......................................127
INPUT SHAFT REAR BEARING ADJUSTING
SHIM
....................................................................127
MAINSHAFT ADJUSTING SHIM..............................128
MAINSHAFT REAR BEARING ADJUSTING SHIM....128
Available Thrust Washer..........................................129
MAINSHAFT THRUST WASHER.............................129
Available Washers ...................................................129
DIFFERENTIAL SIDE GEAR THRUST WASHER......129
Available Shims - Differential Side Bearing
Preload and Adjusting Shim ....................................130
BEARING PRELOAD.............................................130
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS
..................................................................130RS5F50A
SERVICE DATA AND SPECIFICATIONS (SDS).......131
General Specifications .............................................131
TRANSAXLE.........................................................131
FINAL GEAR.........................................................131
Gear End Play .........................................................132
Clearance Between Baulk Ring and Gear ..............132
3RD, 4TH & 5TH BAULK RING...............................132
1ST AND 2ND DOUBLE BAULK RING....................132
REVERSE BAULK RING........................................132
Available Snap Rings ..............................................133
1ST & 2ND SYNCHRONIZER HUB (AT
MAINSHAFT)
.........................................................133
3RD & 4TH SYNCHRONIZER HUB (AT INPUT
SHAFT)
.................................................................133
5TH MAIN GEAR (AT MAINSHAFT)........................133
Available Thrust Washer..........................................133
4TH INPUT GEAR (AT INPUT SHAFT)....................133
DIFFERENTIAL SIDE GEAR THRUST WASHER......133
Available Shims .......................................................134
BEARING PRELOAD AND END PLAY....................134
TOTAL TURNING TORQUE (NEW BEARING)..........134
MAINSHAFT BEARING ADJUSTING SHIM..............134
TABLE FOR SELECTING MAINSHAFT BEARING
ADJUSTING SHIM(S)
.............................................134
INPUT SHAFT BEARING ADJUSTING SHIM...........135
TABLE FOR SELECTING INPUT SHAFT BEARING
ADJUSTING SHIM(S)
.............................................135
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM
....................................................................135
TABLE FOR SELECTING DIFFERENTIAL SIDE
BEARING ADJUSTING SHIM(S)
.............................136
CONTENTS(Cont'd)
MT-3

Special Service ToolsNJMT0030
Tool number
Tool nameDescription
KV38105900
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bear-
ing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38105900.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
ST22730000
Puller
NT411
Removing mainshaft front and rear bearing inner
race
Removing 5th main gear
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
ST30031000
Puller
NT411
Removing differential side bearing inner race
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing 5th synchronizer
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
PREPARATIONRS5F30A
Special Service Tools
MT-4

Special Service ToolsNJMT0032
Tool number
Tool nameDescription
KV38107700
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bearing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38107700.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
KV31100300
Pin punch
NT410
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
ST30031000
Puller
NT411
Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchronizer
hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and
4th main gear
Removing and installing differential side bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and 4th
main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-
chronizer hub
Installing 2nd gear bush, 5th gear bush, Rev gear
bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
PREPARATIONRS5F70A
Special Service Tools
MT-7

Special Service ToolsNJMT0001
Tool number
Tool nameDescription
KV38105210
Preload adapter
NT075
Measuring turning torque of final drive assembly
Measuring total turning torque
KV32101000
Pin punch
NT410
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
ST22730000
Puller
NT411
Removing mainshaft front and rear bearing inner
race
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
ST30031000
Puller
NT411
Removing input shaft front and rear bearing
Removing 4th & 5th main gear
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing 5th synchronizer
Removing 3rd & 4th synchronizer
Removing 2nd & 3rd main gear
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
ST3306S001
Differential side bearing
puller set
1 ST33051001
Puller
2 ST33061000
Adapter
NT675
Removing differential side bearing inner race
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in)
PREPARATIONRS5F50A
Special Service Tools
MT-10

Tool number
Tool nameDescription
ST33290001
Puller
NT414
Removing differential oil seal
Removing mainshaft rear bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33400001
Drift
NT086
Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST30600000
Drift
NT065
Installing input shaft front bearing
a: 36 mm (1.42 in) dia.
b: 31 mm (1.22 in) dia.
ST22452000
Drift
NT065
Installing 3rd, 4th and 5th main gear
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST30621000
Drift
NT073
Installing mainshaft rear bearing outer race
(Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
ST30611000
NT419
(Use with ST30621000.)
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
KV38107700
Preload adapter
NT087
Measuring clearance between side gear and differ-
ential case with washer
KV38106500
Preload adapter
NT087
Measuring turning torque of final drive assembly
PREPARATIONRS5F50A
Special Service Tools (Cont'd)
MT-11

SMT652C
15. Lower transaxle while supporting it with a jack.
InstallationNJMT0008S02+Tighten LH mount, rear side mount and center member bolts.
Refer to EM-137, ªRemoval and Installationº.
+Tighten clutch operating cylinder bolts. Refer to CL-15, ªInstal-
lationº.
+Tighten starter motor bolts. Refer to SC-21, ªRemoval and
Installationº.
+Install drive shafts. Refer to AX-12, ªInstallationº.
+Tighten all transaxle bolts and any part removed.
SMT930D
MODEL QG15DE ENGINENJMT0008S0201
Bolt No. Tightening torque N´m (kg-m, ft-lb) ª!º mm (in)
130 - 40 (3.1 - 4.1, 22 - 30) 70 (2.76)
230 - 40 (3.1 - 4.1, 22 - 30) 80 (3.15)
330 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18)
4*1 16 - 21 (1.6 - 2.1, 12 - 15) 25 (0.98)
Front gusset A to
engine30 - 40 (3.1 - 4.1, 22 - 30) 20 (0.79)
Rear gusset B to
engine16 - 21 (1.6 - 2.1, 12 - 15) 16 (0.63)
*1: With gussets
REMOVAL AND INSTALLATIONRS5F30A, RS5F70A
Removal (Cont'd)
MT-24

SMT931D
MODEL QG18DE ENGINE=NJMT0008S0202
Bolt No. Tightening torque N´m (kg-m, ft-lb) ª!º mm (in)
131 - 40 (3.1 - 4.1, 23 - 29) 70 (2.76)
231 - 40 (3.1 - 4.1, 23 - 29) 80 (3.15)
316 - 21 (1.6 - 2.2, 12 - 15) 25 (0.98)
431 - 40 (3.1 - 4.1, 23 - 29) 30 (1.18)
A31 - 40 (3.1 - 4.1, 23 - 29) 20 (0.79)
B31 - 40 (3.1 - 4.1, 23 - 29) 20 (0.79)
C15 - 20 (1.5 - 2.1, 11 - 15) 17.5 (0.69)
REMOVAL AND INSTALLATIONRS5F30A, RS5F70A
Installation (Cont'd)
MT-25