ABS NISSAN ALMERA 2001 Repair Manual

General SpecificationsNJBR0077Unit: mm (in)
Applied model For Europe
Engine QG15DE Except QG15DE
ABS Without ABS Optional Ð
Front brakeBrake model CL25VG CL25VBG
Cylinder bore
diameter57.2 (2.252)
Pad
Length´width´
thickness113.1´45.5´11.0
(4.45´1.791´0.433)108.8´47.7´11.0 (4.28´1.878´0.433)
Rotor outer diam-
eter´thickness257´22 (10.12´0.87) 280´22 (11.02´0.87)
Unit: mm (in)
Body Sedan Hatchback
Grade LX Except LX
ABS Without ABS With ABS Ð
Rear
brakeBrake model LT20N CL9HC LT20NCL9HCG
(Cam &
strut type)CL11HEG
(Ball &
Ramp
type)
Cylinder bore diam-
eter17.46 (0.6874) 33.9 (1.335)17.46
(0.6874)33.96
(1.3370)38.2
(1.504)
Lining or pad
Length´width´
thickness195´35´4.5 (7.68
´1.38´0.18)89.1´39.5´10.0 (3.508´1.555´0.394)195´35
´4.5
(7.68´
1.38´
0.18)79.8´38.5´9.3
(3.142´1.516´
0.366)
Drum inner diameter
or rotor outer diam-
eter´thickness203.2 (8.00) 258´9 (10.16´0.35)203.2
(8.00)258´9 (10.16´0.35)
Master
cylinderCylinder bore diam-
eter23.81 (15/16)
Control
valveValve modelDual proportioning valve
[Except 4-door Sedan for Europe (RHD with optional ABS, and LHD with gasoline engine and optional ABS)]
Split point
kPa (bar, kg/cm
2,
psi)´reducing ratio3,923 (39.2, 40, 569)´0.4
Unit: mm (in)
Applied model For Europe
Body Sedan Hatchback
Engine QG15DE, QG18DE YD22DDT QG15DE, QG18DE YD22DDT
ABS OptionalWithout
ABSÐ Optional Ð
Brake
boosterBooster model M215T S255 M215T S255, V255
Dia-
phragm
diameterPrimary 230 (9.06) 255 (10.04)230
(9.06)255 (10.04)
Second-
ary205 (8.07) Ð205
(8.07)Ð
Recommended brake fluid DOT 4
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
BR-100

Removal and InstallationNJBT0004+When removing or installing hood, place a cloth or other padding on hood. This prevents vehicle body from
being scratched.
+Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
+Hood adjustment: Adjust at hinge portion.
+Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
+Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.
FRONT BUMPER ASSEMBLYNJBT0004S011. Remove clips securing front grille, then remove front grille.
2. Remove front turn signal lamp, then disconnect harness connectors.
3. Remove clips and screws securing left and right sides of fender protectors.
4. Remove clips and screws securing left and right sides of fender protectors in wheelhoulse.
5. Remove screws securing left and right front fenders to bumper fascia.
6. Remove screws securing left and right radiator core support side to bumper fascia.
7. Remove bolts securing radiator core support lower to bumper fascia.
8. Remove clips securing radiator core support upper to bumper fascia.
9. Extract bumper fascia assembly. Then disconnect harness connectors. (Models with fog lamp assembly)
10. Remove energy absorber. (Where fitted)
11. Remove bolts and hooks securing the headlamp assembly, then disconnect harness connectors.
12. Remove nuts securing bumper reinforcement to left and right bumper stays.(Where fitted)
13. Extract bumper reinforcement. (Where fitted)
14. Remove bolts securing bumper upper retainer, then remove bumper upper retainer.
15. Remove bolts securing bumper stays, then remove the bumper stays.
Fog lamp assembly (Models with fog lamp assembly)
16. Remove bolt securing fog lamp assembly.
17. Extract fog lamp assembly.
NBT182
BODY FRONT END
Removal and Installation
BT-7

NJCL0004
NVH Troubleshooting ChartNJCL0004S01Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
CLUTCHNJCL0004S0101
Reference pageCL-10
CL-10
CL-11
CL-14
Refer to EM-137, ªRemoval and Installationº (QG engine model) and
EM-137, ªRemoval and Installationº (YD engine model).
CL-17 (RS5F30A, RS5F70A), CL-20 (RS5F50A)
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-23
CL-23
CL-23
CL-23
SUSPECTED PARTS
(Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disen-
gage1234 55555 5667
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CL-4

CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc.
These DTCs are prescribed by ISO 15031-6.
(CONSULT-II also displays the malfunctioning component or system.)
+1st trip DTC No. is the same as DTC No.
+Output of a DTC indicates a malfunction. However, Mode II and GST do not indicate whether the
malfunction is still occurring or has occurred in the past and has returned to normal.
CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if avail-
able) is recommended.
A sample of CONSULT-II display for DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed
in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was
driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be ª0º.
If a 1st trip DTC is stored in the ECM, the time data will be ª[1t]º.
SEF698X
Freeze Frame Data and 1st Trip Freeze Frame DataNJEC0031S0102The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant
temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, absolute throttle position,
base fuel schedule and intake air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or
GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
details, see EC-86.
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no prior-
ity for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the fol-
lowing priorities to update the data.
Priority Items
1Freeze frame data Misfire Ð DTC: P0300 - P0304 (0300 - 0304)
Fuel Injection System Function Ð DTC: P0171 (0171), P0172 (0172)
2 Except the above items (Includes A/T related items)
3 1st trip freeze frame data
For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different mal-
function is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or
1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and
freeze frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged
in the ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM
memory is erased. Procedures for clearing the ECM memory are described in ªHow to Erase Emission-related
Diagnostic Informationº. Refer to EC-70.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
Emission-related Diagnostic Information (Cont'd)
EC-61

Freeze frame data
item*Description
S-FUEL TRIM-B1 [%]+ªShort-term fuel trimº at the moment a malfunction is detected is displayed.
+The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.
ENGINE SPEED
[rpm]+The engine speed at the moment a malfunction is detected is displayed.
VEHICL SPEED
[km/h] or [mph]+The vehicle speed at the moment a malfunction is detected is displayed.
ABSOL TH´P/S [%]+The throttle valve opening angle at the moment a malfunction is detected is displayed.
B/FUEL SCHDL
[msec]+The base fuel schedule at the moment a malfunction is detected is displayed.
INT/A TEMP SE [ÉC]
or [ÉF]+The intake air temperature at the moment a malfunction is detected is displayed.
*: The items are the same as those of 1st trip freeze frame data.
DATA MONITOR MODENJEC0034S06
Monitored item [Unit]ECM
input
signalsMain
signalsDescription Remarks
ENG SPEED [rpm]jj+Indicates the engine speed computed from
the POS signal of the crankshaft position
sensor.+Accuracy becomes poor if engine
speed drops below the idle rpm.
+If the signal is interrupted while the
engine is running, an abnormal
value may be indicated.
MAS A/F SE-B1 [V]jj+The signal voltage of the mass air flow sen-
sor is displayed.+When the engine is stopped, a cer-
tain value is indicated.
B/FUEL SCHDL
[msec]+ªBase fuel scheduleº indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correc-
tion.
A/F ALPHA-B1 [%]j+Indicates the mean value of the air-fuel
ratio feedback correction factor per cycle.+When the engine is stopped, a cer-
tain value is indicated.
+This data also includes the data for
the air-fuel ratio learning control.
COOLAN TEMP/S
[ÉC] or [ÉF]jj+The engine coolant temperature (deter-
mined by the signal voltage of the engine
coolant temperature sensor) is displayed.+When the engine coolant tempera-
ture sensor is open or short-
circuited, ECM enters fail-safe
mode. The engine coolant tempera-
ture determined by the ECM is dis-
played.
HO2S1 (B1) [V]jj+The signal voltage of the heated oxygen
sensor 1 (front) is displayed.
HO2S2 (B1) [V]j+The signal voltage of the heated oxygen
sensor 2 (rear) is displayed.
HO2S1 MNTR (B1)
[RICH/LEAN]j+Display of heated oxygen sensor 1 (front)
signal during air-fuel ratio feedback control:
RICH ... means the mixture became ªrichº,
and control is being affected toward a
leaner mixture.
LEAN ... means the mixture became ªleanº,
and control is being affected toward a rich
mixture.+After turning ON the ignition switch,
ªRICHº is displayed until air-fuel
mixture ratio feedback control
begins.
+When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continuously.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
CONSULT-II (Cont'd)
EC-87

Monitored item [Unit]ECM
input
signalsMain
signalsDescription Remarks
IGN TIMING [BTDC]j+Indicates the ignition timing computed by
ECM according to the input signals.
CAL/LD VALUE [%]+ªCalculated load valueº indicates the value
of the current airflow divided by peak air-
flow.
ABSOL TH.P/S [%]+ªAbsolute throttle position sensorº indicates
the throttle opening computed by ECM
according to the signal voltage of the
throttle position sensor.
MASS AIRFLOW
[gm/s]+Indicates the mass airflow computed by
ECM according to the signal voltage of the
mass air flow sensor.
IACV-AAC/V [step]j+Indicates the IACV-AAC valve control value
computed by ECM according to the input
signals.
PURG VOL C/V [%]+Indicates the EVAP canister purge volume
control solenoid valve computed by the
ECM according to the inpuct signals.
+The opening becomes larger as the value
increases.
EGR VOL CON/V
[step]*j+Indicates the EGR volume control valve
computed by the ECM according to the
input signals.
+The opening becomes larger as the value
increases.
SWRL CONT S/V
[ON/OFF]*+The control condition of the swirl control
valve control solenoid valve (determined by
ECM according to the input signals) is indi-
cated.
+ON ... Swirl control valve is closed.
OFF ... Swirl control valve is opened.
INT/V SOL-B1
[ON/OFF]+The control condition of the valve timing
solenoid valve (determined by ECM accord-
ing to the input signal) is indicated.
ON ... Intake valve timing control operating
OFF ... Intake valve timing control not oper-
ating
AIR COND RLY
[ON/OFF]j+Indicates the air conditioner relay control
condition determined by ECM according to
the input signals.
FUEL PUMP RLY
[ON/OFF]j+Indicates the fuel pump relay control condi-
tion determined by ECM according to the
input signals.
COOLING FAN
[ON/OFF]j+Indicates [ON/OFF] control condition of the
cooling fan determined by ECM according
to the input signals.
HO2S1 HTR (B1)
[ON/OFF]+Indicates [ON/OFF] condition of heated oxy-
gen sensor 1 heater (front) determined by
ECM according to the input signals.
HO2S2 HTR (B1)
[ON/OFF]+Indicates [ON/OFF] condition of heated oxy-
gen sensor 2 heater (rear) determined by
ECM according to the input signals.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG
CONSULT-II (Cont'd)
EC-89

MONITOR ITEM CONDITION SPECIFICATION
PW/ST SIGNAL+Engine: After warming up, idle
the engineSteering wheel in neutral position
(forward direction)OFF
The steering wheel is turned ON
LOAD SIGNAL+Engine: runningRear window defogger or headlamp
ªONºON
Except the above OFF
IGNITION SW+Ignition switch: ON®OFF ON®OFF
HEATER FAN SW+Heater fan switch is ªONº ON
+Heater fan switch is ªOFFº OFF
INJ PULSE-B1+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: ªNº
+No-loadIdle 2.0 - 3.5 msec
2,000 rpm 1.5 - 3.5 msec
IGN TIMING+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: ªNº
+No-loadIdleM/T: 8ɱ5É BTDC
A/T: 10ɱ5É BTDC
2,000 rpm Approx. 30É BTDC
CAL/LD VALUE+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: ªNº
+No-loadIdle Not used
2,500 rpm Not used
ABSOL TH´P/S+Engine: Idle Throttle valve fully closed 0.0É
+Ignition switch: ON
(Engine stopped)Throttle valve fully opened Approx. 80É
MASS AIRFLOW+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: N
+No-loadIdle 1.0 - 4.0 g´m/s
2,500 rpm 5.0 - 10.0 g´m/s
IACV-AAC/V+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: ªNº
+No-loadIdle 5 - 25 steps
2,000 rpm Ð
PURG VOL C/V+Engine: After warming up
+No-loadIdle 0%
Revving engine Ð
EGR VOL CON/V*+Engine: After warming up
+Shift lever: ªNº
+No-loadIdle 0 step
Revving engine up to 3,000 rpm
quickly1 - 10 steps
SWRL CONT S/V*+Engine speed: IdleEngine coolant temperature is
between 15ÉC (59ÉF) to 40ÉC
(104ÉF)ON
Engine coolant temperature is above
40ÉC (104ÉF)OFF
INT/V SOL-B1+Engine: After warming up
+Lift up drive wheelsIdle OFF
Suitable gear position except ªPº or
ªNº and revving engineON (Momentarily)
AIR COND RLY+Air conditioner switch: OFF®ON OFF®ON
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONQG
CONSULT-II Reference Value in Data Monitor Mode (Cont'd)
EC-160

MONITOR ITEM CONDITION SPECIFICATION
FUEL PUMP RLY+Ignition switch is turned to ON (Operates for 1 second)
+Engine running and cranking
+When engine is stopped (stops in 1.5 seconds)ON
+Except as shown above OFF
COOLING FAN+After warming up engine, idle
the engine.
+Air conditioner switch: OFFEngine coolant temperature is 99ÉC
(210ÉF) or lessOFF
Engine coolant temperature is 100ÉC
(212ÉF) or moreON
HO2S1 HTR (B1)+Engine speed: Below 3,200 rpm ON
+Engine speed: Above 3,200 rpm OFF
HO2S2 HTR (B1)+Engine speedBelow 3,600 rpm [After driving for 2
minutes at a speed of 70 km/h (43
MPH) or more]ON
Above 3,600 rpm OFF
+Ignition switch ON (Engine stopped) OFF
TRVL AFTER MI+Ignition switch: ONVehicle has traveled after MI has
turned ON.0 - 65,535 km
(0 - 40,723 mile)
*: If so equipped
Major Sensor Reference Graph in Data Monitor
Mode
NJEC0043The following are the major sensor reference graphs in ªDATA MONITORº mode.
THRTL POS SEN, ABSOL TH´P/S, CLSD THL/P SWNJEC0043S01Below is the data for ªTHRTL POS SENº, ªABSOL TH´P/Sº and ªCLSD THL/P SWº when depressing the
accelerator pedal with the ignition switch ªONº.
The signal of ªTHRTL POS SENº and ªABSOL TH´P/Sº should rise gradually without any intermittent drop or
rise after ªCLSD THL/P SWº is changed from ªONº to ªOFFº.
SEF240Y
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONQG
CONSULT-II Reference Value in Data Monitor Mode (Cont'd)
EC-161

Component DescriptionNJEC0079NOTE:
If DTC P0120 (0120) is displayed with DTC P0510 (0510), first perform trouble diagnosis for DTC P0510,
EC-385.
The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiom-
eter which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In
addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal
to the ECM.
Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sen-
sor. This sensor controls engine operation such as fuel cut. On the other hand, the ªWide open and closed
throttle position switchº, which is built into the throttle position sensor unit, is not used for engine control.
NEF308A
CONSULT-II Reference Value in Data Monitor
Mode
NJEC0080Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
THRTL POS SEN+Engine: Idle Throttle valve: fully closed 0.15 - 0.85V
+Ignition switch: ON
(Engine stopped)Throttle valve: fully opened 3.5 - 4.7V
ABSOL TH´P/S+Engine: Idle Throttle valve: fully closed 0.0É
+Ignition switch: ON
(Engine stopped)Throttle valve: fully opened Approx. 80É
DTC P0120 THROTTLE POSITION SENSORQG
Component Description
EC-207

SEF552W
COMPONENT DESCRIPTIONNJEC0227S02EGR Volume Control ValveNJEC0227S0201The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the
ECM. Two windings are turned ON and OFF in sequence. Each
time an ON pulse is issued, the valve opens or closes, changing
the flow rate. When no change in the flow rate is needed, the ECM
does not issue the pulse signal. A certain voltage signal is issued
so that the valve remains at that particular opening.
CONSULT-II Reference Value in Data Monitor
Mode
NJEC0502Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
EGR TEMP SEN+Engine: After warming up Less than 4.5V
EGR VOL CON/V+Engine: After warming up
+Air conditioner switch: ªOFFº
+Shift lever: ªNº
+No-loadIdle 0 step
Revving engine up to 3,000 rpm
quickly10 - 55 step
ECM Terminals and Reference ValueNJEC0503Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
NAL NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
8
9
17
18SB
W/B
R/Y
BR/REGR volume control valve[Engine is running]
+Idle speed0 - 14V
58 B Sensor's ground[Engine is running]
+Warm-up condition
+Idle speed0V
72 P/B EGR temperature sensor[Engine is running]
+Warm-up condition
+Idle speedLess than 4.5V
[Engine is running]
+Warm-up condition
+EGR system is operating.0-1V
SEF073P
On Board Diagnosis LogicNJEC0228If the absence of EGR flow is detected by EGR temperature sen-
sor under the condition that calls for EGR, a low-flow malfunction
is diagnosed.
DTC P0400 EGR FUNCTION (CLOSED) (WHERE FITTED)QG
Description (Cont'd)
EC-344