check engine NISSAN ALMERA 2001 Service Manual

CHASSIS AND BODY MAINTENANCE=NJMA0043S0402Abbreviations: 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)15
(9)30
(18)45
(27)60
(36)75
(45)90
(54)105
(63)120
(72)
Underhood and under vehicle
Headlamp aimingIIIIEL-65
Wheel alignment (if necessary, balance
& rotate wheels)IIIISU-6/
SU-18
Brake pads, rotors & other brake com-
ponentsHIIIIBR-27
BR-28
Foot brake, parking brake & clutch (for
free play, stroke & operation)IIIIBR-12/
BR-48/
CL-9
Brake booster vacuum hoses,
connections, check valveI I BR-21
Brake & clutch, systems and fluid (for
level and leaks)IIIIBR-8
Brake fluidHR R BR-8
Power steering fluid and lines (for level
and leaks)IIIIST-7
Supplemental air bag systems See NOTE (1) RS-25
Ventilation air filterHRRRRHA-96
Manual transaxle gear oil (check for
leakage. Use genuine NISSAN XZ
gear oil or exact equivalent)IIIIMT-14
MT-15
Automatic transaxle fluid (for level and
leaks)HIIIIAT-80
Steering gear and linkage, axle & sus-
pension parts, drive shafts, exhaust
systemHIIST-7/
SU-6/
SU-18/
FE-15
Body corrosion See 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 Petrol Engines (Annual Mileage > 30,000 km/year) (Cont'd)
MA-11

Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year)
=NJMA0043S05YD22DDT ENGINENJMA0043S0501Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference pages
Perform on a kilometer basis
only.km x 1,000
(miles x 1,000)20
(12)40
(24)60
(36)80
(48)100
(60)120
(72)
Engine compartment and under vehicle
Engine oil (Use recommended
oil)HRRRRRRLC-31
Engine oil filter (Use Eco filter or
equivalent)HSee NOTE (1)RRRRRRLC-32
Drive beltsIIIIIIEM-85
Cooling systemIIIIIILC-38
Engine anti-freeze coolant (Use
genuine NISSAN Anti-Freeze
Coolant (L2N) or equivalent)See NOTE (2) I I LC-44
Air cleaner filterHR R EM-88
Intake & exhaust valve clearance See NOTE (3) EM-133
Fuel lines I I FE-20
Injection nozzles See NOTE (4) EC-614
Fuel filterHR R FE-20
NOTE:
(1) Oil filter element assembly and O-ring seal are replacement parts.
(2) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, perform ªIº (check-
ing the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(3) If valve noise increases, check valve clearance.
(4) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and if
necessary, replace injection nozzle assembly.
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)
MA-12

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

SMA089D
Engine Coolant Mixture Ratio=NJMA0006S03The engine cooling system is filled at the factory with a high-quality,
year-round and extended life engine coolant. The high quality
engine coolant contains the specific solutions effective for the anti-
corrosion and the anti-freeze function. Therefore, additional cool-
ing system additives are not necessary.
CAUTION:
When adding or replacing coolant, be sure to use only Genu-
ine NISSAN Anti-freeze Coolant (L2N) or equivalent. Because
L2N is premixed type coolant.
The use of other types of engine coolant may damage your
cooling system.
+When checking the engine coolant mixture ratio by the coolant
hydrometer, use the chart below to correct your hydrometer
reading (specific gravity) according to coolant temperature.
Mixed coolant specific gravity
Unit: specific gravity
Engine coolant mixture
ratioCoolant temperature ÉC (ÉF)
15 (59) 25 (77) 35 (95) 45 (113)
30% 1.046 - 1.050 1.042 - 1.046 1.038 - 1.042 1.033 - 1.038
50% 1.076 - 1.080 1.070 - 1.076 1.065 - 1.071 1.059 - 1.065
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator. Wait until the engine and radiator cool down.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine Coolant Mixture Ratio
MA-18

MANUAL TRANSAXLE
SECTION
MT
CONTENTS
RS5F30A
PREPARATION...............................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
RS5F70A
PREPARATION...............................................................7
Special Service Tools ..................................................7
Commercial Service Tools ...........................................9
RS5F50A
PREPARATION.............................................................10
Special Service Tools ................................................10
Commercial Service Tools .........................................12
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................13
NVH Troubleshooting Chart.......................................13
MANUAL TRANSAXLE.............................................13
RS5F30A, RS5F70A
M/T OIL..........................................................................14
Changing M/T Oil.......................................................14
Checking ....................................................................14
OIL LEAK AND OIL LEVEL.......................................14
RS5F50A
M/T OIL..........................................................................15
Changing M/T Oil.......................................................15
Checking ....................................................................15
OIL LEAK AND OIL LEVEL.......................................15
DESCRIPTION...............................................................16
Cross-sectional View - RS5F30A ..............................16Cross-sectional View - RS5F70A ..............................17
Cross-sectional View - RS5F50A ..............................18
DOUBLE-CONE SYNCHRONIZER............................19
ON-VEHICLE SERVICE................................................20
Replacing Oil Seal .....................................................20
DIFFERENTIAL OIL SEAL........................................20
STRIKING ROD OIL SEAL.......................................21
Position Switch Check ...............................................21
BACK-UP LAMP SWITCH........................................21
PNP SWITCH..........................................................22
BACK-UP LAMP SWITCH AND PNP SWITCH...........22
RS5F30A, RS5F70A
REMOVAL AND INSTALLATION.................................23
Removal .....................................................................23
Installation ..................................................................24
MODEL QG15DE ENGINE.......................................24
MODEL QG18DE ENGINE.......................................25
RS5F50A
REMOVAL AND INSTALLATION.................................26
Removal .....................................................................26
Installation ..................................................................28
MODEL YD ENGINE................................................28
TRANSAXLE GEAR CONTROL...................................29
Components...............................................................29
RS5F30A
OVERHAUL...................................................................30
Case Components .....................................................30
Gear Components .....................................................31
Shift Control Components .........................................32
DISASSEMBLY..............................................................33
REPAIR FOR COMPONENT PARTS...........................36
Input Shaft and Gears ...............................................36
DISASSEMBLY........................................................36

SMA145AA
SMT512C
Changing M/T OilNJMT00861. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-16, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F30A 2.8 - 3.0!(4-7/8 - 5-1/4 Imp pt)
RS5F70A 3.0!(5-1/4 Imp pt)
Oil level (Reference data):
RS5F30A 58 - 66 mm (2.28 - 2.60 in)
RS5F70A 75.5 - 80.5 mm (2.224 - 2.402 in)
Drain plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA066C
CheckingNJMT0087OIL LEAK AND OIL LEVELNJMT0087S011. Check that oil is not leaking from transaxle or around it.
2. Check oil level.
Never start engine while checking oil level.
Filler plug:
: 10 - 19 N´m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
M/T OILRS5F30A, RS5F70A
Changing M/T Oil
MT-14

SMA067C
Changing M/T OilNJMT00881. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-16, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F50A 4.5 - 4.8!(7-7/8 - 8-1/2 Imp pt)
Drain plug:
: 15 - 20 N´m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SMA066C
CheckingNJMT0089OIL LEAK AND OIL LEVELNJMT0089S01Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
M/T OILRS5F50A
Changing M/T Oil
MT-15

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

How to Handle BatteryNJSC0003CAUTION:
If it becomes necessary to start the engine with a booster
battery and jumper cables,
1) Use a 12-volt booster battery.
2) After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
MEL040F
METHODS OF PREVENTING OVER-DISCHARGENJSC0003S01The following precautions must be taken to prevent over-discharg-
ing a battery.
+The battery surface (particularly its top) should always be kept
clean and dry.
+The terminal connections should be clean and tight.
+At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as ªlow maintenanceº
and ªmaintenance-freeº.
MEL041F
+When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal.
MEL042F
+Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVELNJSC0003S02WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.
BATTERY
How to Handle Battery
SC-3

SEL022Z
5. Check depth of insulating mold from commutator surface.
+Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
AssemblyNJSC0020Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
SEL026Z
PINION PROTRUSION LENGTH ADJUSTMENTNJSC0020S01Clearance (QG engine models)NJSC0020S0101With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance ª!º between the front edge
of the pinion and the pinion stopper.
Clearance ª!º:
Refer to SDS (SC-38).
MEL140L
Movement (YD engine models)NJSC0020S0102Compare movement ª!º in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement ª!º:
Refer to SDS (SC-38).
STARTING SYSTEM
Inspection (Cont'd)
SC-24