light NISSAN ALMERA 2001 Owner's Manual

Support BearingNJAX0018S05Make sure wheel bearing rolls freely and is free from noise, cracks,
pitting or wear.
Support Bearing BracketNJAX0018S06Check support bearing bracket for cracks with a magnetic explora-
tion or dyeing test.
ASSEMBLYNJAX0019+After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
+Use NISSAN GENUINE GREASE or equivalent after every
overhaul.
SFA800
Wheel SideNJAX0019S011. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA942A
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring marks which were
made during disassembly are properly aligned.
SFA592B
3. Pack drive shaft with specified amount of grease.
Specified amount of grease:
AC2300I type 40 - 50 g (1.41 - 1.76 oz)
AC2000I type 118 g (4.16 oz)
ZF80 type 75 - 85 g (2.65 - 3.00 oz)
BF83 type 80 - 100 g (2.82 - 3.53 oz)
BF90 type 100 - 120 g (3.53 - 4.23 oz)
4. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is ªL
1º.
FRONT AXLE
Drive Shaft (Cont'd)
AX-16

SBR222B
5. Install valve stopper while piston is pushed into cylinder.
SBR704C
InstallationNJBR0116CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to ªBleeding Brake
Systemº, BR-9.
MASTER CYLINDER (TOKICO)
Assembly (Cont'd)
BR-16

SBR236E
InstallationNJBR0121CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 13 - 15 N´m (1.3 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system.
MASTER CYLINDER [BOSCH (NABCO)]
Installation
BR-19

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

InstallationNJBR0026CAUTION:
+Be careful not to deform or bend brake pipes, during
installation of booster.
+Replace clevis pin if damaged.
+Refill with new brake fluid ªDOT 3 or DOT 4º.
+Never reuse drained brake fluid.
+Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
SBR237EA
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ªInstallationº in ªMASTER
CYLINDERº, BR-16, 19.
6. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
BRAKE BOOSTER
Installation
BR-21

lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].
6. Remove thickness gauges (2).
+Leave sprocket retaining bolts (M6) until installation.
VACUUM PUMP
Assembly (Cont'd)
BR-26

System ComponentsNJBR0086
SBR758E
SBR124B
System DescriptionNJBR0087SENSORNJBR0087S01The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating
speed increases.
SBR759E
CONTROL UNITNJBR0087S02The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp
to light up. In this condition, the ABS will be deactivated by the
control unit, and the vehicle's brake system reverts to normal
operation.
SBR176E
ABS ACTUATOR AND ELECTRIC UNITNJBR0087S03The ABS actuator and electric unit contains:
+An electric motor and pump
+Two relays
+Eight solenoid valves, each inlet and outlet for
Ð LH front
Ð RH front
Ð LH rear
Ð RH rear
+ABS control unit
DESCRIPTIONABS
System Components
BR-50

YCL004
+Apply approximately 1 mm (0.04 in)-thick clutch sleeve
grease evenly on the sliding part of the clutch lever and
the release bearing spring.
+Apply just enough clutch sleeve grease to fill up the
release bearing inner groove.
+Apply the clutch grease to the clutch disc and the input
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove
the clutch disc.
+Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing, install the release
bearing, remove the excess grease around the bearing,
and remove the release bearing.
SCL822
1. Assemble clutch lever to clutch housing, and insert withdrawal
lever.
2. Support clutch lever claws with an appropriate wood block, and
install a new spring pin using a pin punch.
CAUTION:
Spring pin cannot be reused.
SCL736
3. Install release bearing spring to release bearing as shown in
the figure.
SCL823
4. Operate withdrawal lever manually, press clutch spring from
both sides, and install release bearing to clutch lever securely.
5. Make sure a click is heard when release bearing spring is
pressed from both sides.
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Installation (Cont'd)
CL-18

SCL466-C
CLUTCH COVERNJCL0032S02+Check clutch cover installed on vehicle for unevenness of dia-
phragm spring toe height.
Uneven limit:
MODEL 200, 215 0.8 mm (0.031 in)
MODEL 240 0.7 mm (0.028 in)
+If out of limit, adjust the height with Tool.
AEM100
FLYWHEELNJCL0032S03+Check contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
+Check flywheel runout.
Maximum allowable runout:
Refer to EM-62, ªFlywheel/Drive Plate Runoutº (QG
engine models), and EM-154, ªFlywheel Runout (YD
engine models)º.
SCL616-B
SCL600-F
InstallationNJCL0033+Insert Tool into clutch disc hub when installing clutch cover and
disc.
+Be careful not to allow grease to contaminate clutch fac-
ing.
+Tighten bolts in numerical order.
First step:
: 10 - 20 N´m (1 - 2 kg-m,7-14ft-lb)
Final step:
QG engine models (200, 215)
: 22 - 29 N´m (2.2 - 3.0 kg-m, 15 - 21 ft-lb)
YD22DDT engine model (240)
: 35 - 44 N´m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Inspection and Adjustment (Cont'd)
CL-23

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEC0002The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnoses sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnoses sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harness can be identified by yellow harness connector.
Precautions for On Board Diagnostic (OBD)
System of Engine and A/T
NJEC0003The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
+Be sure to turn the ignition switch ªOFFº and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause the MI to light up.
+Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
+Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector.
For description and how to disconnect, refer to EL section, ªDescriptionº, ªHARNESS CONNEC-
TORº.
+Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause the MI to light up due to the short circuit.
+Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of fuel injection system, etc.
+Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission Control Module) before returning the vehicle to the customer.
PRECAUTIONSQG
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EC-16