engine NISSAN ALMERA 2001 Service Manual

SFA114A
INSTALLATIONNJAX00101. Install knuckle with wheel hub.
When installing knuckle to strut, be sure to hold bolts and
tighten nuts.
: 114 - 133 N´m (11.6 - 13.6 kg-m, 84 - 98 ft-lb)
Before tightening, apply oil to threaded portion of drive shaft.
2. Tighten wheel bearing lock nut.
QG engine (Sedan)
: 197 - 274 N´m (20 - 28 kg-m, 145 - 202 ft-lb)
QG engine (Hatchback)
: 226 - 313 N´m (23 - 32 kg-m, 167 - 231 ft-lb)
YD engine
: 255 - 333 N´m (26 - 34 kg-m, 188 - 245 ft-lb)
3. Check that wheel bearings operate smoothly.
SFA543A
4. Check wheel bearing axial end play.
Axial end play:
0.05 mm (0.0020 in)
SFA116A
DISASSEMBLYNJAX0011CAUTION:
When removing wheel hub or wheel bearing from knuckle,
replace wheel bearing assembly (outer race and inner races)
with a new one.
Wheel HubNJAX0011S01Drive out hub with inner race (outside) from knuckle with a suitable
tool.
SFA654A
Wheel BearingNJAX0011S02When replacing wheel bearing, replace complete wheel bear-
ing assembly (Inner races and outer race).
1. Remove bearing inner race (outside).
FRONT AXLE
Wheel Hub and Knuckle (Cont'd)
AX-7

Service Data and Specifications (SDS)
DRIVE SHAFT=NJAX0020
Applied modelEngine QG15DE QG18DE YD22T
Body Hatchback Sedan All All
Transaxle M/T All M/T
Joint typeTransaxle side GI2000I TS70C TS79C GI2300I DS90 + B
Wheel side AC2000I ZF80 ZF90 AC2300I BF90
Grease Quality Nissan genuine grease or equivalent*2
Capacity
g (oz)Transaxle side 90 (3.17)110 - 120
(3.88 - 4.23)155 - 165
(5.47 - 5.82)125.5 - 135.5
(4.42 - 4.77)145 - 165
(5.11 - 5.82)
Wheel side 118 (4.16)71-81
(2.50 - 2.86)Ð*340-50
(1.41 - 1.76)100 - 120
(3.53 - 4.23)
Boot length
mm (in)Transaxle side ªL
2º 90 (3.54)*195.5 - 97.5
(3.760 - 3.839)101.5 - 103.5
(3.996 - 4.075)98 - 100
(3.86 - 3.94)*197-99
(3.82 - 3.90)
Wheel side ªL
1º 90 (3.54)*190.5 - 92.5
(3.563 - 3.642)Ð*394-96
(3.70 - 3.78)*184.5 - 96.5
(3.327 - 3.799)
SFA961AA
SFA962A
*1: Fit boot to boot groove in bar shaft
*2: Use grease sachet 39209 BM510 in service for wheel side and 39709 BM500 for transaxle side. (Genuine GKN grease for 20001
joints)
*3: ZF90F type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive
shaft boots. If the boot or joint is damaged, replace the drive shaft assembly.
FRONT AXLE
Service Data and Specifications (SDS)
AX-20

DYNAMIC DAMPER (WHERE FITTED)=NJAX0033Unit: mm (in)
Applied
modelEngineQG15DE
QG18DE YD22T
Hatchback Sedan
Drive shaft LH RH LH RH LHRH (TS79C
& ZF90)RH (AC/
GI2300I)LH RH
LengthªAº175 - 185
(6.89 -
7.28)432 - 442
(17.01 -
17.40)175 - 185
(6.89 -
7.28)420 - 430
(16.54 -
16.93)175 - 185
(6.89 -
7.28)420 - 430
(16.54 -
16.93)375 - 381
(14.76 -
15.00)161 - 167
(6.34 -
6.57)200 - 206
(7.87 -
8.11)
ªBº 62 (2.44) 62 (2.44) 70 (2.76) 64 (2.52) 70 (2.76) 64 (2.52) 70 (2.76) 70 (2.76)
SAX015
WHEEL BEARING (FRONT)NJAX0021
Wheel bearing axial end play limit mm (in) 0.05 (0.0020)
Wheel bearing lock nut tightening torque N´m (kg-m,
ft-lb)QG engineSedan 197 - 274 (20 - 28, 145 - 202)
Hatchback 226 - 313 (23 - 32, 167 - 231)
YD engine 255 - 333 (26 - 34, 188 - 245)
FRONT AXLE
Service Data and Specifications (SDS) (Cont'd)
AX-21

SBR686C
Precautions
PRECAUTIONSNJAX0022+When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
+Use flare nut wrench when removing or installing brake
tubes.
+After installing removed suspension parts, check wheel
alignment.
+Do not jack up at the trailing arm and lateral link.
+Always torque brake lines when installing.
Preparation
SPECIAL SERVICE TOOLSNJAX0032
Tool number
Tool nameDescription
KV40104710
Drift
NT474
Install ABS sensor rotor
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
ST3072000
Drift
NT115
Install ABS sensor rotor
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
COMMERCIAL SERVICE TOOLSNJAX0024
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing brake piping
a: 10 mm (0.39 in)
REAR AXLE
Precautions
AX-22

SBR451D
Checking Brake Fluid LevelNJBR0006+Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
+If fluid level is extremely low, check brake system for leaks.
+Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake LineNJBR0007CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake FluidNJBR0008CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Always keep fluid level higher than minimum line on res-
ervoir tank.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal while keeping reservoir level higher than minimum
line by adding new brake fluid.
4. Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ªBleeding Brake Systemº, BR-9.
Brake Burnishing ProcedureNJBR0036Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-8

Removal and InstallationNJBR0015
JBR752E
SBR997
InspectionNJBR0016Check brake pedal for following items.
+Brake pedal bend
+Clevis pin deformation
+Crack of any welded portion
+Crack or deformation of clevis pin stopper
SBR657EA
AdjustmentNJBR0017Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height
Refer to SDS, BR-101.
C
1,C2: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch
0.74 - 1.96 mm (0.0291 - 0.0772 in)
D: Depressed height
LHD (M/T): More than 90 mm (3.54 in)
LHD (A/T): More than 95 mm (3.74 in)
RHD (M/T): More than 90 mm (3.54 in)
RHD (A/T): More than 95 mm (3.74 in)
Under force of 490 N (50 kg, 110 lb) with engine run-
ning
A: Pedal free play at pedal pad
1.0 - 3.0 mm (0.039 - 0.118 in)
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-12

SBR229E
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
BRAKE PEDAL AND BRACKET
Adjustment (Cont'd)
BR-13

SBR002A
SBR365AA
On-vehicle ServiceNJBR0023OPERATING CHECKNJBR0023S011. Stop engine and depress brake pedal several times. Check
that pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECKNJBR0023S021. Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
down the first time, and then it should gradually rise thereaf-
ter.
2. Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change
after holding pedal down for30 seconds.
SBR232CB
RemovalNJBR0024CAUTION:
+Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+Be careful not to deform or bend brake pipes, during
removal of booster.
SBR208E
InspectionNJBR0025OUTPUT ROD LENGTH CHECKNJBR0025S011. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg, þ19.69
inHg) to brake booster with a handy vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
BRAKE BOOSTER
On-vehicle Service
BR-20

SBR225B
Removal and InstallationNJBR0027CAUTION:
When installing vacuum hoses, pay attention to the following
points.
+Do not apply any oil or lubricants to vacuum hose and
check valve.
+Insert vacuum tube into vacuum hose as shown.
+Install check valve, paying attention to its direction.
InspectionNJBR0028HOSES AND CONNECTORSNJBR0028S01Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.
SBR844B
CHECK VALVENJBR0028S02Check vacuum with a vacuum pump.
Connect to booster side Vacuum should exist.
Connect to engine side Vacuum should not exist.
VACUUM HOSE
Removal and Installation
BR-22

RemovalNJBR0123
SBR631E
1. Remove parts shown below.
+Air duct, air cleaner case (upper)
+Engine cover
+Rocker cover
+Exhaust manifold cover
+EGR tube
2. Disconnect vacuum hose from vacuum pump.
3. Remove cylinder head rear cover plate.
+Use a tool such as seal cutter (SST) to remove.
4. Loosen and remove rear cam sprocket installation bolts.
+Camshaft should not be attached. Using engine inner
resistance, loosen installation bolts.
SBR632E
5. Remove vacuum pump and cylinder head rear cover assem-
bly.
+Remove and install vacuum pump, sprocket, drive chain, and
chain guide as an assembly.
+Loosen mounting bolts in the reverse order of the numbers
shown in the figure to the left.
+Remove only bolts that are shown in the figure. (Be especially
careful not to remove M6 bolts on the vacuum pump.)
+Use a tool such as a seal cutter (SST).
VACUUM PUMP
Removal
BR-23