maintenance NISSAN ALMERA 2001 Workshop Manual

CHASSIS AND BODY MAINTENANCE=NJMA0043S0502Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis
only.km x 1,000
(miles x
1,000)10
(6)20
(12)30
(18)40
(24)50
(30)60
(36)70
(42)80
(48)90
(54)100
(60)11 0
(66)120
(72)
Underhood and under vehicle
Headlamp aiming I I I EL-65
Wheel alignment (if necessary,
balance & rotate wheels)IIISU-6
SU-18
Brake pads, rotors & other
brake componentsHIIIIIIBR-27
BR-28
Foot brake, parking brake &
clutch (for free play, stroke &
operation)IIIIIIBR-12
BR-48
CL-9
Brake booster vacuum hoses,
connections, check valveI I BR-21
Brake & clutch, systems and
fluid (for level and leaks)IIIIIIBR-8
Brake fluidHR R BR-8
Power steering fluid and lines
(for level and leaks)IIIIIIST-7
Supplemental air bag systemsSee NOTE
(1)RS-25
Ventilation air filterHRRRRRRHA-96
Manual transaxle gear oil
(check for leakage. Use genu-
ine NISSAN XZ gear oil or
exact equivalent)IIIMT-14
MT-15
Steering gear & linkage, axle &
suspension parts, drive shafts,
exhaust systemHIIST-7
SU-6
SU-18
FE-32
Body corrosionSee 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.
HMaintenance items with ªHº should be performed more frequently according to ªMaintenance Under Severe Driving Con-
ditionsº.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) (Cont'd)
MA-13

Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year)
=NJMA0043S06The 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 Ð Driving under dusty conditions
B Ð Driving repeatedly short distances
C Ð Towing a trailer or caravan
D Ð Extensive idling
E Ð Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F Ð Driving in high humidity areas or in mountainous areas
G Ð Driving in areas using salt or other corrosive materials
H Ð Driving on rough and/or muddy roads or in the desert
I Ð Driving with frequent use of braking or in mountainous areas
J Ð Frequent off road use or driving in water
K Ð Sustained high speed driving
L Ð For models without Euro-OBD system
Driving conditionMaintenance
itemMaintenance
operationMaintenance interval
ABCD........Engine oil & engine oil filter
Petrol models Replace Every 7,500 km (4,500 miles)
Diesel models Replace Every 10,000 km (6,000 miles)
A...........Air cleaner filter
Petrol models Replace Every 30,000 km (18,000 miles)
Diesel models Replace Every 30,000 km (18,000 miles)
A...E.......Fuel filter
Diesel models Replace Every 30,000 km (18,000 miles)
...........LHeated Oxygen Sensor 1 (Front)
Petrol models Inspect Every 60,000 km (36,000 miles)
...........LHeated Oxygen Sensor 2 (Rear)
Petrol models Inspect Every 60,000 km (36,000 miles)
A...........Ventilation air filter
Petrol models Replace Every 15,000 km (9,000 miles)
Diesel models Replace Every 10,000 km (6,000 miles)
.....F......Brake fluid
Petrol models Replace Every 30,000 km (18,000 miles)
Diesel models Replace Every 30,000 km (18,000 miles)
..C....H....Automatic transaxle fluid
Petrol models Replace Every 60,000 km (36,000 miles)
A.C...GHI...Brake pads, rotors & other brake system components
Petrol models Inspect Every 15,000 km (9,000 miles)
Diesel models Inspect Every 10,000 km (6,000 miles)
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km/year)
MA-14

Driving conditionMaintenance
itemMaintenance
operationMaintenance interval
......GH....Steering gear & linkage, axle & suspension parts, drive shafts,
exhaust system
Petrol models Inspect Every 30,000 km (18,000 miles)
Diesel models Inspect Every 30,000 km (18,000 miles)
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km/year) (Cont'd)
MA-15

RESTRAINT SYSTEM
SECTION
RS
CONTENTS
SEAT BELTS...................................................................3
Precautions ..................................................................3
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
²AIR BAG²AND²SEAT BELT PRE-TENSIONER²
........3
PRECAUTION FOR SEAT BELT SERVICE..................3
Maintenance ................................................................4
Front Seat Belt.............................................................5
REMOVAL AND INSTALLATION/4-DOOR SEDAN.......5
REMOVAL AND INSTALLATION/5-DOOR
HATCHBACK
.............................................................7
REMOVAL AND INSTALLATION/3-DOOR
HATCHBACK
.............................................................9
Rear Seat Belt ........................................................... 11
REMOVAL AND INSTALLATION/4-DOOR SEDAN
WITH 2-POINT TYPE REAR CENTER SEAT BELT
.... 11
REMOVAL AND INSTALLATION/4-DOOR SEDAN
WITH 3-POINT TYPE REAR CENTER SEAT BELT
....13
REMOVAL AND INSTALLATION/HATCHBACK..........15
ISO Fix Child Restraint Anchor .................................18
REMOVAL AND INSTALLATION...............................18
Tether Anchor Plate ...................................................19
REMOVAL AND INSTALLATION...............................19
SUPPLEMENTAL RESTRAINT SYSTEM (SRS).........20
Precautions ................................................................20
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
²AIR BAG²AND²SEAT BELT PRE-TENSIONER²
......20
PRECAUTIONS FOR SRS²AIR BAG²AND²SEAT
BELT PRE-TENSIONER²SERVICE
...........................20
WIRING DIAGRAMS AND TROUBLE DIAGNOSIS.....20
Preparation ................................................................21
SPECIAL SERVICE TOOLS......................................21
COMMERCIAL SERVICE TOOL................................22
SRS Configuration .....................................................22
Seat Belt Pre-tensioner with Load Limiter.................23
Built-in Type Side Air Bag..........................................23
SRS Component Parts Location ...............................24
Maintenance Items ....................................................25
Diagnosis Sensor Unit ...............................................26
REMOVAL AND INSTALLATION...............................26
Front Seat Belt Pre-tensioner ....................................27
REMOVAL AND INSTALLATION...............................27Side Air Bag (Satellite) Sensor ..................................27
REMOVAL AND INSTALLATION...............................27
Driver Air Bag Module and Spiral Cable ...................29
REMOVAL AND INSTALLATION/WITH 4-SPOKE
STEERING WHEEL
.................................................29
REMOVAL...............................................................29
INSTALLATION........................................................31
REMOVAL AND INSTALLATION/WITH 3-SPOKE
STEERING WHEEL
.................................................32
REMOVAL...............................................................32
INSTALLATION........................................................34
Front Passenger Air Bag Module ..............................35
REMOVAL...............................................................35
INSTALLATION........................................................36
Front Side Air Bag Module/4-door Sedan .................36
REMOVAL...............................................................36
INSTALLATION........................................................37
Front Side Air Bag Module/Hatchback ......................38
REMOVAL...............................................................38
INSTALLATION........................................................39
Disposal of Air Bag Module and Seat Belt Pre-
tensioner ....................................................................40
CHECKING DEPLOYMENT TOOL.............................40
DEPLOYMENT PROCEDURES FOR AIR BAG
MODULE (OUTSIDE OF VEHICLE)
...........................41
DEPLOYMENT PROCEDURES FOR SEAT BELT
PRE-TENSIONER (OUTSIDE OF VEHICLE)
..............45
DEPLOYMENT OF AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER WHILE MOUNTED IN
VEHICLE
.................................................................46
DISPOSING OF AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER
...........................................46
Trouble Diagnoses Introduction.................................47
DIAGNOSIS FUNCTION...........................................47
DIAGNOSIS MODE FOR CONSULT-II.......................48
HOW TO CHANGE SELF-DIAGNOSIS MODE
WITH CONSULT-II
...................................................49
HOW TO CHANGE SELF-DIAGNOSIS MODE
WITHOUT CONSULT-II
............................................49
HOW TO ERASE SELF-DIAGNOSIS RESULTS.........49

Precautions
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ªAIR BAGº AND ªSEAT BELT
PRE-TENSIONERº
NJRS0001The 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 composition which is available to NISSAN MODEL N16 is as follows (The composition
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).
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.
+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.
PRECAUTION FOR SEAT BELT SERVICENJRS0002CAUTION:
+Before removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect both
battery cables and wait at least 3 minutes.
+Do not use electrical test equipment for seat belt pre-tensioner connector.
+After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-ten-
sioner connector, check the system function. Refer to ªSRS Operation Checkº for details. (RS-59)
+Do not use disassemble buckle or seat belt assembly.
+Replace anchor bolts if they are deformed or worn out.
+Never oil tongue and buckle.
+If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt
assembly.
+If webbing is cut, frayed, or damaged, replace seat belt assembly.
+When replacing seat belt assembly, use a genuine seat belt assembly.
After A CollisionNJRS0002S01WARNING:
Inspect all seat belt assemblies including retractors and attaching hardware after any collision.
NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the
collision was minor and the belts show no damage and continue to operate properly. Failure to do so
could result in serious personal injury in an accident. Seat belt assemblies not in use during a colli-
sion should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner
should be replaced even if the seat belts are not in use during a frontal collision in which the air bags
are deployed.
Replace any seat belt assembly (including anchor bolts) if:
+The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and
buckles show no damage and continue to operate properly).
+The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.)
+The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for dam-
age or distortion and repair as necessary before installing a new seat belt assembly.
+Anchor bolts are deformed or worn out.
+The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in
which the air bags are deployed.
SEAT BELTS
Precautions
RS-3

MaintenanceNJRS0055
SRS888
SEAT BELTS
Maintenance
RS-4

Precautions
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ªAIR BAGº AND ªSEAT BELT
PRE-TENSIONERº
NJRS0006The 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 composition which is available to NISSAN MODEL N16 is as follows (The composition
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).
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.
+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.
PRECAUTIONS FOR SRS ªAIR BAGº AND ªSEAT BELT PRE-TENSIONERº SERVICENJRS0007+Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual.
+Before servicing the SRS, turn ignition switch ªOFFº, disconnect both battery cables and wait at least 3
minutes.
For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt
pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes
have passed.
+Diagnosis sensor unit must always be installed with their arrow marks ªÜº pointing towards the front of
the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before
installation and replace as required.
+The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to
turn steering wheel or column after removal of steering gear.
+Handle air bag module carefully. Always place driver and front passenger air bag modules with the pad
side facing upward and place front side air bag module standing with stud bolt side setting bottom.
+Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
+After air bag inflates, the front instrument panel assembly should be replaced if damaged.
WIRING DIAGRAMS AND TROUBLE DIAGNOSISNJRS0008When 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 diagnosis, refer to the following:
+GI-32, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSESº
+GI-21, ªHOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENTº
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions
RS-20

SRS797-A
Maintenance ItemsNJRS0012CAUTION:
Do not use electrical test equipment to check SRS circuit.
1. Check operation of ªAIR BAGº warning lamp.
After turning ignition key to ªONº position, ªAIR BAGº warning
lamp illuminates. The ªAIR BAGº warning lamp will go off after
about 7 seconds if no malfunction is detected. If any of the fol-
lowing ªAIR BAGº warning lamp conditions occur, immediately
check the air bag system. Refer to RS-59 for details.
+The ªAIR BAGº warning lamp does not illuminate when the
ignition switch is turned ªONº.
+The ªAIR BAGº warning lamp does not go off about 7 seconds
after the ignition switch is turned ªONº.
+The ªAIR BAGº warning lamp blinks after about 7 seconds after
the ignition switch is turned ªONº.
2. Visually check SRS components.
1) Diagnosis sensor unit
+Check diagnosis sensor unit and bracket for dents, cracks and
deformities.
+Check connectors for damage, and terminals for deformities.
2) Air bag module and steering wheel
+Remove air bag module from steering wheel, instrument panel
or seatback. Check harness cover and connectors for damage,
terminals for deformities, and harness for binding.
+Install driver air bag module to steering wheel to check fit or
alignment with the wheel.
+Check steering wheel for excessive free play.
+Install front passenger air bag module to instrument panel to
check fit or alignment with the instrument panel.
+Install front side air bag module to seatback to check fit and
alignment with the seat.
3) Spiral cable
+Check spiral cable for dents, cracks, or deformities.
+Check connectors and protective tape for damage.
+Check steering wheel for noise, binding or heavy operation.
4) Main harness, body harness, side air bag module sub-harness
+Check connectors for poor connections, damage, and termi-
nals for deformities.
+Check harnesses for binding, chafing or cut.
5) Front seat belt pre-tensioner
+Check harness cover and connectors for damage, terminals
for deformities, and harness for binding.
+Check belts for damage and anchors for loose mounting.
+Check retractor for smooth operation.
+Perform self-diagnosis for seat belt pre-tensioner using ªAIR
BAGº warning lamp or CONSULT-II.
Refer to ªSRS Operation Checkº for details. (RS-59)
6) Side air bag (satellite) sensor
+Check side air bag (satellite) sensor (including bracket portion)
for dents, cracks or deformities.
+Check connectors for damage, and terminals for deformities.
CAUTION:
Replace previously used special bolts, hex bolts and ground
bolt with new ones.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items
RS-25

SRS702
10. Check that no malfunction is detected on ªSELF-DIAG
[PAST]º.
11. Touch ªBACKº key of CONSULT-II until ªSELECT SYSTEMº
appears in order to return to User mode from Diagnosis mode.
12. Turn ignition switch ªOFFº, then turn off and disconnect CON-
SULT-II.
13. Go to ªSRS Operation Checkº, page RS-59 to check SRS
operation by using ªAIR BAGº warning lamp with User mode.
DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM
DIAGNOSTIC PROCEDURE 2)
NJRS0048S03Inspecting SRS malfunctioning record
1 CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING
Is it the first time for maintenance of SRS?
YesorNo
Ye s©Go to DIAGNOSTIC PROCEDURE 5 (RS-68).
No©Self-diagnostic result ªSELF-DIAG [PAST]º (previously stored in the memory) might not
be erased after repair. Go to DIAGNOSTIC PROCEDURE 3, step 8 (RS-66).
SRS834-A
SRS872
DIAGNOSTIC PROCEDURE 5NJRS0048S04Inspecting SRS intermittent malfunction by using CONSULT-II
Ð Diagnosis mode
1. Turn ignition switch ªOFFº.
2. Connect CONSULT-II to data link connector.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Trouble Diagnoses with CONSULT-II (Cont'd)
RS-68

ªAIR BAGº warning lamp operation Ð User mode Ð SRS condition Reference item
MRS095A
No malfunction is
detected.
No further action is neces-
sary.Ð
MRS096A
The system is malfunc-
tioning and needs to be
repaired as indicated.Go to DIAGNOSTIC PRO-
CEDURE 6 (RS-74).
MRS097A
Air bag is deployed.
Seat belt pre-tensioner is
deployed.Go to COLLISION DIAG-
NOSIS (RS-85).
Air bag fuse, diagnosis
sensor unit or harness is
malfunctioning and needs
to be repaired.Go to DIAGNOSTIC PRO-
CEDURE 9 (RS-82).
MRS098A
One of the following has
occurred and needs to be
repaired.
+Meter fuse is blown.
+ªAIR BAGº warning
lamp circuit has open
or short.
+Diagnosis sensor unit is
malfunctioning.Go to DIAGNOSTIC PRO-
CEDURE 10 (RS-84).
DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM
DIAGNOSTIC PROCEDURE 6)
NJRS0049S03Inspecting SRS malfunctioning record
1 CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING
Is it the first time for maintenance of SRS?
YesorNo
Ye s©Go to DIAGNOSTIC PROCEDURE 5 (RS-68). (Further inspection cannot be performed
without CONSULT-II.)
No©Diagnosis results (previously stored in the memory) might not be erased after repair. Go
to DIAGNOSTIC PROCEDURE 7, step 5 (RS-79).
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Trouble Diagnoses without CONSULT-II (Cont'd)
RS-81