warning NISSAN ALMERA 2001 Workshop Manual

Service NoticeNJBT0001+When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
+Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to oil
or damage them.
+Apply sealing compound where necessary when installing parts.
+When applying sealing compound, be careful that the sealing compound does not protrude from parts.
+When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-
vention measures.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJBT0002The 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.
PRECAUTIONS
Service Notice
BT-3

SBF034BA
Removal and InstallationNJBT0023REMOVALNJBT0023S01After removing moldings, remove glass using piano wire or power
cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety
glasses and heavy gloves to help prevent glass splinters from
entering your eyes or cutting your hands.
CAUTION:
+Be careful not to scratch the glass when removing.
+Do not set or stand the glass on its edge. Small chips may
develop into cracks.
SBT472
SBT473
INSTALLATIONNJBT0023S02+Use a genuine Nissan Urethane Adhesive Kit or equivalent
and follow the instructions furnished with it.
+While the urethane adhesive is curing, open a door win-
dow. This will prevent the glass from being forced out by
passenger compartment air pressure when a door is
closed.
+The molding must be installed securely so that it is in
position and leaves no gap.
+Inform the customer that the vehicle should remain sta-
tionary until the urethane adhesive has completely cured
(preferably 24 hours). Curing time varies with temperature
and humidity.
WARNING:
+Keep heat and open flames away as primers and adhesive
are flammable.
+The materials contained in the kit are harmful if
swallowed, and may irritate skin and eyes. Avoid contact
with the skin and eyes.
+Use in an open, well ventilated location. Avoid breathing
the vapors. They can be harmful if inhaled. If affected by
vapor inhalation, immediately move to an area with fresh
air.
+Driving the vehicle before the urethane adhesive has com-
pletely cured may affect the performance of the wind-
shield in case of an accident.
CAUTION:
+Do not use an adhesive which is past its usable term.
Shelf life of this product is limited to six months after the
date of manufacture. Carefully adhere to the expiration or
manufacture date printed on the box.
+Keep primers and adhesive in a cool, dry place. Ideally,
they should be stored in a refrigerator.
WINDSHIELD AND WINDOWS
Removal and Installation
BT-71

SBR820BA
PrecautionsNJCL0001+Recommended fluid is brake fluid ªDOT 4º. Refer to
MA-16, ªFluid and Lubricantsº.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+When removing and installing clutch piping, use Tool.
+Use new brake fluid to clean or wash all parts of master
cylinder and operating cylinder.
+Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
PRECAUTIONS
Precautions
CL-2

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

SEF543X
NATS (Nissan Anti-theft System)NJEC0591+If the security indicator lights up with the ignition switch
in the ªONº position or ªNATS MALFUNCTIONº is dis-
played on ªSELF-DIAG RESULTSº screen, perform self-
diagnostic results mode with CONSULT-II using NATS pro-
gram card. Refer to NATS (Nissan Anti-Theft System) in EL
section.
+Confirm no self-diagnostic results of NATS is displayed
before touching ªERASEº in ªSELF-DIAG RESULTSº
mode with CONSULT-II.
+When replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedure of NATS initialization and NATS
ignition key ID registration, refer to CONSULT-II operation
manual, NATS.
Malfunction Indicator (MI)
DESCRIPTIONNJEC0032
SAT652J
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check.
+If the MI does not light up, refer to EL-184, ªWARNING LAMPSº or see EC-591.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has detected an engine system malfunction.
On Board Diagnostic System FunctionNJEC0032S01The on board diagnostic system has the following four functions.
Diagnostic Test Mode I
1. BULB CHECK:
This function checks the MI bulb for damage (blown, open circuit, etc.).
If the MI does not come on, check MI circuit and ECM test mode selector. (See the following page.)
2. MALFUNCTION WARNING:
MI Condition
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
NATS (Nissan Anti-theft System)
EC-74

Diagnostic Test Mode II (If so equipped)
3. SELF-DIAGNOSTIC RESULTS:
This function allows DTCs and 1st trip DTCs to be read.
4. HEATED OXYGEN SENSOR 1 MONITOR (FRONT):
This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1 (front),
to be read.
MI Flashing without DTC
NJEC0032S0101If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM test
mode following ªHow to Switch Diagnostic Test Modesº.
How to switch the diagnostic test (function) modes, and details of the above functions are described later.
(Refer to EC-76.)
Condition Diagnostic Test Mode I Diagnostic Test Mode II
Ignition switch in ªONº position
Engine stopped
BULB CHECK SELF-DIAGNOSTIC RESULTS
Engine running
MALFUNCTION WARNINGHEATED OXYGEN SENSOR 1
MONITOR (FRONT)
The following emission-related diagnostic information is cleared when the ECM memory is erased.
1) Diagnostic trouble codes
2) 1st trip diagnostic trouble codes
3) Freeze frame data
4) 1st trip freeze frame data
5) System readiness test (SRT) codes
6) Test values
7) Distance traveled while MI is activated
8) Others
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
Malfunction Indicator (MI) (Cont'd)
EC-75

Diagnostic Test Mode I Ð Bulb CheckNJEC0032S03In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the MI bulb. Refer to
EL-184, ªWARNING LAMPSº or see EC-591.
Diagnostic Test Mode I Ð Malfunction WarningNJEC0032S04
MI Condition
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.
+These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS).
Diagnostic Test Mode II Ð Self-diagnostic Results (If so equipped)NJEC0032S05In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illu-
minates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are
displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These uni-
dentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how
to read a code.
SEF952W
A particular trouble code can be identified by the number of four-digit numeral flashes. The ªzeroº is indicated
by the number of ten flashes. The length of time the 1000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second)-OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0 second OFF. In other words, the lat-
ter numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8 second off.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC ª0000º refers to no
malfunction. (See TROUBLE DIAGNOSIS Ð INDEX, EC-10.)
How to Erase Diagnostic Test Mode II (Self-diagnostic results)
NJEC0032S0501The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from
Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to ªHow To Switch Diagnostic Test Modesº, EC-76.)
+If the battery is disconnected, the DTC will be lost from the backup memory after approx. 24 hours.
+Be careful not to erase the stored memory before starting trouble diagnoses.
Diagnostic Test Mode II Ð Heated Oxygen Sensor 1 Monitor (Front) (If so equipped)NJEC0032S06In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1 (front).
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
Malfunction Indicator (MI) (Cont'd)
EC-77

SEF621WA
SEF646X
SEC163BA
Overall Function CheckNJEC0489Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by
turning it a quarter turn to allow built-up pressure to escape.
Then turn the cap all the way off.
With CONSULT-II
1) Check the coolant level and mixture ratio (using coolant tester)
in the reservoir tank and radiator.
Allow engine to cool before checking coolant level and
mixture ratio.
+If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-410.
+If the coolant mixture ratio is out of the range of 45 to 55%,
replace the coolant in the following procedure LC-18, ªChang-
ing Engine Coolantº.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-410.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with CON-
SULT-II.
5) If the results are NG, go to ªDiagnostic Procedureº, EC-410.
Without CONSULT-II
1) Check the coolant level and mixture ratio (using coolant tester)
in the reservoir tank and radiator.
Allow engine to cool before checking coolant level and
mixture ratio.
+If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-410.
+If the coolant mixture ratio is out of the range of 45 to 55%,
replace the coolant in the following procedure LC-18, ªChang-
ing Engine Coolantº.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-410.
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control lever to full cold position.
5) Turn air conditioner switch ªONº.
6) Turn blower fan switch ªONº.
7) Run engine at idle for a few minutes with air conditioner oper-
ating.
Be careful not to overheat engine.
8) Make sure that cooling fan operates. Refer to ªOPERATIONº
table for cooling fan, EC-406.
If NG, go to ªDiagnostic Procedureº, EC-410.
DTC P1217 OVERHEAT (COOLING SYSTEM)QG
On Board Diagnosis Logic (Cont'd)
EC-408

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEC0601The 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 harness can be identified by yellow harness connector.
PRECAUTIONSYD
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EC-598

JEF344Y
Spill TubeNJEC0618S03RemovalNJEC0618S0301Loosen and remove the mounting bolts and flare nuts in the
reverse order of the numbers in the figure.
+When the flare nuts are loosened, hold the head of hexagonal
retaining bolts (head inside) using a wrench.
Installation
NJEC0618S03021. Tighten the flare nuts and mounting bolts in the numerical
order shown in the figure.
+When the flare nuts are tightened, hold the head of the hex-
agonal retaining bolts (head inside) using a wrench.
2. To prevent interference with the rocker cover, place the spill
gasket joint within the range shown by the arrow, then tighten
the mounting bolts. (Be especially careful about No. 2 and 4
cylinders.)
+After the spill tube is installed, check the airtightness of
the spill tube.
+After the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.
JEF345Y
High Pressure Injection Nozzle AssemblyNJEC0618S04RemovalNJEC0618S04011. Remove the nozzle support, then pull out the high-pressure
injection nozzle assembly by turning it clockwise/
counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the cop-
per washer inside the cylinder head.
CAUTION:
Do not disassemble the high-pressure injection nozzle.
Installation
NJEC0618S04021. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.
TEST AND ADJUSTMENTNJEC0619WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
BASIC SERVICE PROCEDUREYD
Injection Tube and Injection Nozzle (Cont'd)
EC-616