service NISSAN ALMERA 2001 Service Manual

Trouble Diagnoses IntroductionNJRS0043CAUTION:
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
+Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
+Keep ground portion clean.
DIAGNOSIS FUNCTIONNJRS0043S01The SRS self-diagnosis results can be read by using ªAIR BAGº warning lamp and/or CONSULT-II. The read-
ing of these results is accomplished using one of two modes Ð ªUser modeº and ªDiagnosis modeº.
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system
malfunction through the operation of the ªAIR BAGº warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the ªAIR BAGº warning lamp and CONSULT-II are as follows:
User mode Diagnosis mode Display type
ªAIR BAGº warning lamp X X ON-OFF operation
CONSULT-II Ð X Monitoring
NOTE:
Seat belt pre-tensioner malfunction is indicated by ªAIR BAGº warning lamp.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Trouble Diagnoses Introduction
RS-47

STARTING & CHARGING SYSTEMS
SECTION
SC
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
Wiring Diagrams and Trouble Diagnoses....................2
BATTERY.........................................................................3
How to Handle Battery ................................................3
METHODS OF PREVENTING OVER-DISCHARGE......3
CHECKING ELECTROLYTE LEVEL............................3
SPECIFIC GRAVITY CHECK......................................4
Battery Test and Charging Chart .................................6
CHART I...................................................................6
CHART II..................................................................7
A: SLOW CHARGE....................................................8
B: STANDARD CHARGE..........................................10
C: QUICK CHARGE................................................. 11
STARTING SYSTEM.....................................................13
System Description ....................................................13
M/T MODELS..........................................................13
A/T MODELS...........................................................13
Wiring Diagram - START -/Sedan .............................14
M/T MODELS..........................................................14
A/T MODELS...........................................................15
Wiring Diagram - START -/Hatchback.......................16
Trouble Diagnoses.....................................................17
Construction ...............................................................18
Removal and Installation ...........................................21
REMOVAL...............................................................21
INSTALLATION........................................................21
Inspection...................................................................21
MAGNETIC SWITCH CHECK...................................21
PINION/CLUTCH CHECK.........................................21
BRUSH CHECK.......................................................22
YOKE CHECK.........................................................23
ARMATURE CHECK................................................23
Assembly ...................................................................24
PINION PROTRUSION LENGTH ADJUSTMENT........24
CHARGING SYSTEM....................................................26
System Description ....................................................26
SEDAN...................................................................26
HATCHBACK...........................................................26
Wiring Diagram - CHARGE -/Sedan .........................27
GASOLINE ENGINE MODELS..................................27
DIESEL ENGINE MODELS.......................................28
Wiring Diagram - CHARGE -/Hatchback...................29
Trouble Diagnoses.....................................................30
WITH IC REGULATOR.............................................30
MALFUNCTION INDICATOR....................................30
Construction ...............................................................31
Removal and Installation ...........................................34
REMOVAL (QG ENGINE).........................................34
REMOVAL (YD ENGINE)..........................................34
INSTALLATION........................................................35
Disassembly...............................................................35
REAR COVER.........................................................35
REAR BEARING......................................................35
Inspection...................................................................35
ROTOR CHECK......................................................35
BRUSH CHECK.......................................................36
STATOR CHECK.....................................................36
Assembly ...................................................................36
RING FITTING IN REAR BEARING...........................36
REAR COVER INSTALLATION.................................37
SERVICE DATA AND SPECIFICATIONS (SDS).........38
Battery........................................................................38
Starter ........................................................................38
Alternator ...................................................................39

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJSC0001The 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 diagnosis 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, diagnosis 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 harnesses can be identified by yellow harness connector.
Wiring Diagrams and Trouble DiagnosesNJSC0002When you read wiring diagrams, refer to the following:
+GI-11, ªHOW TO READ WIRING DIAGRAMSº
+EL-10, ªPOWER SUPPLY ROUTINGº for power distribution circuit
When you perform trouble diagnoses, refer to the following:
+GI-32, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSESº
+GI-21, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
SC-2

BatteryNJSC0014
Applied
modelQG engine YD engine
Type 34B19L 46B24L 55D23L 65D26LYUASA type code YUASA type code
110D26L
025 027 063 065 075 096L 010S 067 096
Capac-
ity V-AH12-27 12-36 12-48 12-52 12-47 12-55 12-50 12-65 12-60 12-64 12-70
StarterNJSC0015
Type0 001 116 006 D7E31 S114-570B S114-800B M2T48681 M0T83581A M8T71371
BOSCH VALEO make HITACHI make MITSUBISHI make
Non-reduction Non-reduction Non-reduction Reduction Non-reduction Reduction Reduction
Applied model QG engine YD engine
System voltage V12
No-loadTerminal voltage V 11.5 11.0 11.5 11.0 11.5 11.0 11.0
Current A Less than 48 45 Less than 60 Less than 90 Less than 53 Less than 90 Less than 145
Revolution rpmMore than
5,80012,000More than
6,000More than
2,750More than
6,000More than
2,750More than
3,400
Minimum diameter of commutator
mm (in)33.5 (1.319) 28.2 (1.110) 28.0 (1.102) 31.4 (1.236) 28.8 (1.134) 31.4 (1.236)
Minimum length of brush mm (in) 3.5 (0.138) 6.15 (0.242) 9.0 (0.354) 10.5 (0.413) 11.5 (0.453) 7.0 (0.276) 11.0 (0.433)
Brush spring tension N (kg, lb)5.2 (0.53,
1.17) at 7.5
mm (0.295 in)
brush length16.2 - 19.8
(1.65 - 2.02,
3.46 - 4.45)9.8 - 13.7
(1.0 - 1.4,
2.2 - 3.1)12.7 - 17.7
(1.3 - 1.8,
2.9 - 4.0)13.7 - 25.5
(1.4 - 2.6,
3.1 - 5.7)15.0 - 20.4
(1.5 - 2.1,
3.4 - 4.6)26.5 - 36.3
(2.7 - 3.7,
6.0 - 8.2)
Clearance between bearing metal
and armature shaft mm (in)Ð 0.05 (0.0020) Less than 0.2 (0.008) Ð
Clearance ª!º between pinion
front edge and pinion stopper mm
(in)0.0 - 3.9
(0 - 0.154)Max. 1
(0.039)0.3 - 2.5 (0.012 - 0.098)0.5 - 2.0
(0.020 - 0.079)Ð
Movement ª!º in height of pinion
assembly mm (in)ÐMax. 12.2
(0.480)Ð0.5 - 2.0
(0.020 -
0.079)
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
SC-38

AlternatorNJSC0016
TypeLR180-762 LR180-757 LR1100-724 A2TB3191 A3TB0771
HITACHI make MITSUBISHI make
Applied model QG engine YD engine QG engine YD engine
Nominal rating V-A 12-80 12-80 12-100 12-80 12-90
Ground polarityNegative
Minimum revolutions under no-load
(When 13.5V is applied) rpmLess than 1,000 Less than 1,100 Less than 1,000 Less than 1,300
Hot output current (When 13.5V is
applied) A/rpmMore than
23/1,300
More than
65/2,500
More than
77/5,000More than
17/1,300
More than
63/2,500
More than
76/5,000More than
34/1,300
Morethan
80/2,500
More than
91/5,000More than
23/1,300
More than
62/2,500
More than
72/5,000More than
29/1,300
More than
76/2,500
More than
88/5,000
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) More than 6.0 (0.236) More than 5.0 (0.197)
Brush spring pressure N (g, oz) 1.0 - 3.43 (102 - 350, 3.60 - 12.34) 4.8 - 6.0 (490 - 610, 17.28 - 21.51)
Slip ring minimum diameter mm (in) More than 26.0 (1.024) More than 22.1 (0.870)
Rotor coil resistance at 20É (68ÉF)W2.67 2.31 2.2 - 2.6 2.1 - 2.5
SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator
SC-39

SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator (Cont'd)
SC-40

STEERING SYSTEM
SECTION
ST
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
Precautions for Steering System .................................2
PREPARATION...............................................................3
Special Service Tools ..................................................3
Commercial Service Tool .............................................4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................5
NVH Troubleshooting Chart.........................................5
ON-VEHICLE SERVICE..................................................6
Checking Steering Wheel Play ....................................6
Checking Neutral Position on Steering Wheel ............6
PRE-CHECKING........................................................6
CHECKING...............................................................6
Front Wheel Turning Angle ..........................................6
Checking Gear Housing Movement ............................6
Checking and Adjusting Drive Belts ............................7
Checking Steering Gear and Linkage .........................7
STEERING GEAR......................................................7
STEERING LINKAGE.................................................7
Checking Fluid Level ...................................................7
Checking Fluid Leakage ..............................................7
Bleeding Hydraulic System..........................................8
Checking Steering Wheel Turning Force ....................8
Checking Hydraulic System.........................................9
STEERING WHEEL AND STEERING COLUMN......... 11
Components............................................................... 11
Removal and Installation ........................................... 11
STEERING WHEEL................................................. 11
STEERING COLUMN...............................................12
Disassembly and Assembly .......................................14
Inspection...................................................................15
TILT MECHANISM...................................................15
POWER STEERING GEAR AND LINKAGE................16
Components...............................................................16
Removal and Installation ...........................................17
Disassembly...............................................................18
Inspection...................................................................19
BOOT.....................................................................19
RACK.....................................................................19
GEAR SUB-ASSEMBLY...........................................19
GEAR HOUSING CYLINDER....................................19
TIE-ROD OUTER AND INNER SOCKETS..................20
Assembly ...................................................................20
Adjustment .................................................................23
POWER STEERING OIL PUMP (QG ENGINE)...........25
Components...............................................................25
Pre-disassembly Inspection .......................................25
Disassembly...............................................................26
Inspection...................................................................27
Assembly ...................................................................27
POWER STEERING OIL PUMP (YD ENGINE)............29
Components...............................................................29
Pre-disassembly Inspection .......................................29
Removal and Installation ...........................................30
Disassembly...............................................................30
Inspection...................................................................31
Assembly ...................................................................32
SERVICE DATA AND SPECIFICATIONS (SDS).........33
General Specifications ...............................................33
Steering Wheel ..........................................................33
Steering Column ........................................................33
Steering Gear and Linkage .......................................34
Power Steering ..........................................................35

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJST0044The 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 diagnosis 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, diagnosis 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 harnesses (except ªSEAT BELT PRE-TENSIONERº connector) can be
identified by yellow harness connector.
Precautions for Steering SystemNJST0003+Before disassembly, thoroughly clean the outside of the unit.
+Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
+Place disassembled parts in order, on a parts rack, for easier and proper assembly.
+Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
+Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
+Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Vaseline
may be applied to O-rings and seals. Do not use any grease.
+Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRON
TMIII or equivalent. Refer to MA-16, ªFluids and Lubricantsº.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
ST-2

Special Service ToolsNJST0004
Tool number
Tool nameDescription
KV48100700
Torque adapter
NT169
Measuring pinion rotating torque
KV48102500
Pressure gauge adapter
NT542
Measuring oil pressure
ST27180001
Steering wheel puller
NT544
Removing steering wheel
HT72520000
Ball joint remover
NT546
Removing ball joint
a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)
KV48103500
Pressure gauge
NT547
Measuring oil pressure
KV48104400
Rack seal ring reformer
NT550
Reforming teflon ring
a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in)
ST3127S000
1 GG91030000
Torque wrench
2 HT62940000
Socket adapter
3 HT62900000
Socket adapter
NT541
Measuring turning torque
PREPARATION
Special Service Tools
ST-3

Commercial Service ToolNJST0005
Tool number Description
Oil pump attachment
NT774
Disassembling and assembling oil pump
Unit: mm (in)
KV48105210
Sprocket holder
NT809
Removing and Installing power steering oil pump
PREPARATION
Commercial Service Tool
ST-4