steering NISSAN ALMERA 2001 Repair Manual

crankshaft position sensor (TDC sensor) from the assem-
bly.
+Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-44, ªChanging Engine Coolantº.
3. Remove the following parts:
+Battery
+RH and LH front wheels
+RH and LH splash covers (combined with undercover)
+Auxiliary belts
+Alternator
+Alternator brackets
+Radiator and cooling fan
+Engine cover
+Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
+Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
SEM666G
14. Install engine slingers to cylinder head.
: 30 - 37 N´m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
+Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-138

PrecautionsNJGI0001Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
SGI646
PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) ªAIR BAGº AND ªSEAT BELT
PRE-TENSIONERº
NJGI0001S01The 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 passen-
ger for certain types of collision. The SRS system composition
which is available to NISSAN MODEL N16 is as follows (The com-
position varies according to the destination and optional equip-
ment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag
module (located in the center of the steering wheel), front pas-
senger 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 performed by an authorized
NISSAN dealer.
+Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal 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 FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
NJGI0001S02NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
The security indicator is located on the instrument panel or in the
PRECAUTIONS
Precautions
GI-3

+SERVICE DATA AND SPECIFICATIONSare contained at the end of each section for quick reference of
data.
+The followingSYMBOLS AND ABBREVIATIONSare used:
SYMBOL ABBREVIATION SYMBOL ABBREVIATION
Tightening torque
2WD2-Wheel Drive
Should be lubricated with grease. Unless oth-
erwise indicated, use recommended multi-pur-
pose grease.A/CAir Conditioner
Should be lubricated with oil. P/S Power Steering
Sealing point SST Special Service Tools
Checking point SAE Society of Automotive Engineers, Inc.
Always replace after every disassembly. ATF Automatic Transmission Fluid
jP
Apply petroleum jelly.
D1Drive range 1st gear
Apply ATF. D2Drive range 2nd gear
HSelect with proper thickness. D
3Drive range 3rd gear
IAdjustment is required. D
4Drive range 4th gear
SDS Service Data and Specifications OD Overdrive
LH, RH Left-Hand, Right-Hand 2
22nd range 2nd gear
FR, RR Front, Rear 2
12nd range 1st gear
M/T Manual Transaxle/Transmission 1
21st range 2nd gear
A/T Automatic Transaxle/Transmission 1
11st range 1st gear
HOW TO USE THIS MANUAL
GI-10

SGI805
SGI987
Tow Truck TowingNJGI0009S05CAUTION:
+All applicable local laws regarding the towing operation
must be obeyed.
+It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is in accordance with Towing Procedure Manual at
dealer.
+Always attach safety chains before towing.
+When towing, make sure that the transmission, steering
system and power train are in good order. If any unit is
damaged, dollies must be used.
NISSAN recommends that the vehicle be towed with the driving
(front) wheels off the ground as illustrated.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH
FOUR WHEELS ON GROUND
NJGI0009S0502Observe the following restricted towing speeds and distances.
Speed:
Below 50 km/h (30 MPH)
Distance:
Less than 65 km (40 miles)
CAUTION:
Never tow an automatic transaxle model from the rear (i.e.,
backward) with four wheels on the ground as this may cause
serious and expensive damage to the transaxle.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH
REAR WHEELS RAISED (WITH FRONT WHEELS ON
GROUND)
NJGI0009S0503Never tow an automatic transaxle model with rear wheels raised
(with front wheels on ground) as this may cause serious and
expensive damage to the transaxle. If it is necessary to tow it with
rear wheels raised, always use a towing dolly under the front
wheels.
LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing
GI-47

Heater & Cooling Unit (Heater Core)
REMOVALNJHA0193
RHA807H
1. Drain the cooling system. Refer to LC-18 (QG), LC-44 (YD),
ªChanging Engine Coolantº.
2. Discharge the A/C system. Refer to HA-78.
3. Disconnect the two heater hoses from inside the engine com-
partment.
4. Remove the blower unit. Refer to HA-89.
5. Remove the steering member assembly. Refer to BT-25,
ªInstrument Panel Assemblyº.
6. Remove the heater unit.
7. Separate the heater & cooling unit case, and remove the
heater core.
INSTALLATIONNJHA0194Install in the reverse order of removal.
When filling radiator with coolant, refer to LC-19 (QG), LC-45
(YD), ªRefilling Engine Coolantº.
Recharge the A/C system. Refer to HA-78.
RHA673H
A/C Evaporator
REMOVALNJHA02041. Discharge the A/C system. Refer to HA-78.
2. Disconnect the two refrigerant lines from the engine compart-
ment.
Cap the A/C lines to prevent moisture from entering the sys-
tem.
3. Remove the grommet cover, grommet and expansion valve
cover from the engine compartment.
4. Remove the glove box, instrument lower assist panel, instru-
ment lower cover and drink holder. Refer to BT-25.
SERVICE PROCEDURE
Heater & Cooling Unit (Heater Core)
HA-88

NVH troubleshooting (SU) ........................ SU-16
NVH troubleshooting (CL) ........................... CL-4
NVIS (Nissan vehicle immobiliser sys-
tem) precautions ....................................... GI-3
Neutral position switch .................... EC-437, 536
O
Oil pan (engine) .................................. EM-20, 89
Oil pressure (engine) ............................ LC-5, 28
Oil pump (A/T) ......................................... AT-384
Oil pump (engine) ................................. LC-5, 28
Oil pump regulator valve (engine) ......... LC-8, 30
Oil seal replacement (engine) .................. EM-32
On board diagnostic system ............. EC-59, 627
Operating cylinder (clutch) ........................ CL-14
Overdrive control switch .......................... AT-341
Overrun clutch .......................................... AT-412
P
P/ANT - Wiring diagram .......................... EL-282
PCV (positive crankcase
ventilation) ..................................... EC-39, 613
PGC/V - Wiring diagram ................. EC-366, 505
PNP/SW - Wiring diagram ...... EC-439, 537, 826
POWER - Wiring diagram ................... EL-11, 28
PST/SW - Wiring diagram ....................... EC-568
Park/Neutral position switch ... EC-437, 536, 826
Park/neutral position switch (A/T) ............ AT-183
Park/neutral position switch (M/T) ............ MT-21
Parking brake control ................................ BR-47
Parking lamp .............................................. EL-81
Piston assembly ............................... EM-62, 155
Piston pin inspection ........................ EM-56, 145
Piston ring inspection ....................... EM-56, 145
Piston to bore clearance .................. EM-58, 147
Power antenna ........................................ EL-282
Power door lock ....................................... EL-314
Power door mirror .................................... EL-294
Power steering fluid level ............................ ST-7
Power steering gear .................................. ST-16
Power steering hydraulic pressure .............. ST-9
Power steering oil pressure switch ......... EC-567
Power steering oil pump ............................ ST-25
Power steering system bleeding ................. ST-8
Power supply routing ................................. EL-10
Power window ......................................... EL-298
Precautions (General) .................................. GI-4
Pressure plate - See Clutch cover ............ CL-22
Priming pump .................................. EC-625, 641
Q
Quick-glow system .................................. EC-806
R
RR02 - Wiring diagram .......... EC-261, 270, 278,
286, 463
RR02/H - Wiring diagram ............... EC-293, 470
Radiator ............................................... LC-16, 42
Radio - See Audio ................................... EL-258
Rear air spoiler .......................................... BT-47
Rear axle (disc brake type) ....................... AX-24
Rear axle ................................................... AX-22
Rear bumper .............................................. BT-10
Rear combination lamp removal and
installation .............................................. BT-47
Rear disc brake .................................. BR-35, 43
Rear door ................................................... BT-16
Rear drum brake ....................................... BR-31
Rear heated oxygen sensor (HO2S)
heater .......................................... EC-291, 469
Rear heated oxygen sensor (HO2S) ..... EC-258,
267, 275, 284, 462
Rear seat belt ............................................ RS-11
Rear seat ................................................... BT-60
Rear suspension ....................................... SU-16
Rear window defogger ............................ EL-240
Rear window .............................................. BT-71
Refrigerant connection precaution .............. HA-3
Refrigerant general precaution ................... HA-2
Refrigerant lines ........................................ HA-91
Refrigeration cycle .................................... HA-13
Release bearing (clutch) ..................... CL-17, 20
Removal and installation (A/T) ................ AT-354
Reverse clutch ......................................... AT-403
Reverse idler shaft (M/T) .............. MT-30, 54, 93
Reverse lamp switch (M/T) - See
Back-up lamp switch (M/T) ................... MT-21
Reverse main gear (M/T) ............. MT-31, 55, 93
Road wheel size ......................................... GI-43
Roof trim .................................................... BT-43
Room lamp - See Interior lamp ............... EL-115
S
S/LOCK - Wiring diagram ............... EL-318, 335,
352, 372
S/SIG - Wiring diagram ........................... EC-558
SAE J1930 terminology list ........................ GI-50
SHIFT - Wiring diagram ........................... AT-344
SROOF - Wiring diagram ........................ EL-292
SRS - See Supplemental Restraint
System ................................................... RS-20
START - Wiring diagram ........................... SC-14
STOP/L - Wiring diagram .................... EL-85, 86
SWL/V - Wiring diagram ................. EC-399, 475
Seal - See Exterior .................................... BT-47
Seat belt pre-tensioner disposal ............... RS-40
Seat belt pre-tensioner ............................... RS-3
Seat belt, front ............................................ RS-5
Seat belt, rear ............................................ RS-11
Seat, front .................................................. BT-56
ALPHABETICAL INDEX
IDX-6

Seat, rear ................................................... BT-60
Self-diagnostic results ....................... EC-74, 628
Shift control components (M/T) .... MT-32, 56, 94
Shift fork (M/T) .............................. MT-32, 56, 94
Shift lever .................................................. MT-29
Shift lock system ...................................... AT-343
Shift schedule .......................................... AT-470
Shift solenoid valve A (A/T) ..... AT-204, 209, 222
Shift solenoid valve B (A/T) ............. AT-204, 209
Shock absorber (front) .............................. SU-10
Shock absorber (rear) ............................... SU-21
Side air bag ........................................ RS-36, 38
Side trim .................................................... BT-31
Spare tire size ............................................ GI-43
Speedometer ........................................... EL-144
Spiral cable ............................................... RS-29
Spot lamp ................................................ EL-141
Spring (Wheelarch) height .......................... SU-6
Stabilizer bar (front) ................................... SU-11
Stall test (A/T) ............................................ AT-80
Standardized relay ....................................... EL-8
Start signal ...................................... EC-557, 823
Starter ....................................................... SC-18
Starting system ......................................... SC-13
Steering linkage ......................................... ST-16
Steering switch .......................................... EL-59
Steering wheel and column ....................... ST-11
Steering wheel play ..................................... ST-6
Steering wheel turning force ....................... ST-8
Stop lamp .................................................. EL-85
Striking rod (M/T) .......................... MT-32, 56, 94
Strut (front) .................................................. SU-9
Strut (rear) ................................................. SU-20
Sub-gear (M/T) ................................... MT-31, 55
Sunroof, electric ....................................... EL-292
Sunroof ...................................................... BT-63
Super lock ................................................ EL-349
Supplemental Restraint System ............... RS-20
Supplemental restraint system - Wiring
diagram .................................................. RS-53
Swirl control valve control solenoid
valve ............................................ EC-399, 475
Symbols and abbreviations ........................ GI-10
Symptom matrix chart ..................... EC-155, 646
Synchronizer (M/T) ....................... MT-31, 55, 93
System readiness test (SRT) code ........... EC-62
T
TCM circuit diagram ................................... AT-17
TCM inspection table ............................... AT-119
TFTS - Wiring diagram ........................... EC-315
TP/SW - Wiring diagram ................. EC-387, 521
TPS - Wiring diagram ............................. EC-210
TURN - Wiring diagram ........................... EL-103
Tachometer .............................................. EL-144
Tail lamp .................................................... EL-81
Tank fuel temperature sensor ................. EC-313
Thermostat .......................................... LC-15, 41Three way catalyst precautions ................... GI-6
Three way catalyst .................................. EC-359
Throttle position sensor (TPS) ................ EC-207
Throttle position sensor
adjustment ................................... EC-100, 128
Throttle position switch ........... AT-141, 267, 341,
EC-385, 520
Throwout bearing - See Clutch release
bearing ............................................. CL-17, 20
Tie-rod ball joints ....................................... ST-20
Tie-rod ........................................................ ST-16
Tightening torque of standard bolts ........... GI-49
Timing chain ....................................... EM-23, 94
Tire size ...................................................... GI-43
Torque converter installation .................... AT-355
Tow truck towing ........................................ GI-47
Transmission case (M/T) .............. MT-30, 54, 92
Tread-FR&RR (Dimensions) ...................... GI-43
Trim ............................................................ BT-31
Trouble diagnoses ...................................... GI-31
Trunk lid finisher ........................................ BT-45
Trunk lid opener - See Trunk lid ................ BT-10
Trunk lid trim .............................................. BT-45
Trunk lid ..................................................... BT-10
Trunk room lamp ..................................... EL-141
Trunk room trim ......................................... BT-45
Turn signal lamp ........................................ EL-96
Two trip detection logic ............................. EC-59
Two-pole lift ................................................ GI-46
U
Under body ................................................ BT-80
V
VSS - Wiring diagram ..................... EC-372, 701
Vacuum hose (brake system) ................... BR-22
Vacuum hose drawing (Engine control) .... EC-30
Vacuum pump ........................................... BR-23
Valve clearance ................................ EM-44, 133
Valve guide ....................................... EM-39, 124
Valve lifter ................................................. EM-43
Valve seat ......................................... EM-41, 126
Valve spring ...................................... EM-42, 128
Vehicle speed sensor (VSS) ........... EC-370, 701
Viscosity number (SAE) ............................ MA-17
Viscous coupling (FF M/T) ........................ MT-93
W
WARN - Wiring diagram .......................... EL-190
WIP/R - Wiring diagram .................. EL-225, 227
WIPER - Wiring diagram ................. EL-217, 220
Warning chime ......................................... EL-197
Warning lamps ......................................... EL-184
Washer, front ........................................... EL-215
ALPHABETICAL INDEX
IDX-7

NJMA0036
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION
Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
Inspect for interior and exterior metal and paint damage
Check for spare tire, jack, tools (wheel chock), and literature
Wash, clean interior and exterior
: Not applicable to this model
PRE-DELIVERY INSPECTION ITEMS
MA-2

NJMA0004
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge.
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified.
Item Reference page
TiresCheck the pressure with a gauge periodically when at a service station,
including the spare, and adjust to the specified pressure if necessary. Check
carefully for damage, cuts or excessive wear.Ð
Windshield wiper
bladesCheck for cracks or wear if not functioning correctly. Ð
Doors and engine
hoodCheck that all doors, the engine hood, the trunk lid and back door operate
properly. Also ensure that all latches lock securely. Lubricate if necessary.
Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.BT-7
BT-16
Tire rotationTires should be rotated every 10,000 km (6,000 miles). SU-7
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the
vehicle, etc.
Item Reference page
LampsMake sure that the headlamps, stop lamps, tail lamps, turn signal lamps,
and other lamps are all operating properly and installed securely. Also check
headlamp aim.Ð
Warning lamps and
chimesMake sure that all warning lamps and buzzers/chimes are operating prop-
erly.Ð
Steering wheelCheck that it has the specified play.
Check for changes in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)Ð
Seat beltsCheck that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely.
Check the belt webbing for cuts, fraying, wear or damage.RS-4
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel.
Item Reference page
Windshield washer
fluidCheck that there is adequate fluid in the tank. Ð
Engine coolant levelCheck the coolant level when the engine is cold. LC-19, LC-45
Engine oil levelCheck the level after parking the vehicle (on level ground) and turning off
the engine.LC-8, LC-31
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the ªMAXº and
ªMINº lines on the reservoir.BR-8
BatteryCheck the fluid level in each cell. It should be between the ªMAXº and ªMINº
lines.Ð
GENERAL MAINTENANCE
MA-3

CHASSIS AND BODY MAINTENANCE=NJMA0043S0102Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis, but on
an annual basis when driving less than
15,000 km (9,000 miles) in a year.km x 1,000
(miles x 1,000)
Months15
(9)
1230
(18)
2445
(27)
3660
(36)
4875
(45)
6090
(54)
72105
(63)
84120
(72)
96
Underhood and under vehicle
Headlamp aimingIIIIIIIIEL-65
Wheel alignment (if necessary, balance
& rotate wheels)IIIIIIIISU-6/
SU-18
Brake pads, rotors & other brake com-
ponentsHIIIIIIIIBR-27/
BR-28
Foot brake, parking brake & clutch (for
free play, stroke & operation)IIIIIIIIBR-12/
BR-48/
CL-9
Brake booster vacuum hoses,
connections, check valveIIIIBR-21
Brake & clutch, systems and fluid (for
level and leaks)IIIIIIIIBR-8
Brake fluidHRRRRBR-8
Power steering fluid and lines (for level
and leaks)IIIIIIIIST-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)IIIIIIIIMT-14
MT-15
Automatic transaxle fluid (for level and
leaks)HIIIIIIIIAT-80
Steering gear & linkage, axle & sus-
pension parts, drive shafts, exhaust
systemHIIIIST-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-5