wheel NISSAN ALMERA 2001 Repair Manual

Inspection and AdjustmentNJCL0006CLUTCH PEDAL INSPECTIONNJCL0006S03Pedal StrokeNJCL0006S0301Check clutch pedal stroke by using a 1±meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver's seat to set a ref-
erence point, ensure the book/clipboard does not move during
pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the
reference point on the book/clipboard. Measure the distance
between the marks (A and B), this is the actual pedal stroke (S).
Check the specified pedal stroke in the table, adjust actual pedal
stroke if necessary (refer toªCLUTCH PEDAL ADJUSTMENTº).
NOTE:
+Do not use steering wheel as a reference point, angle gives
incorrect reading.
+Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.
NCL058
SCL702
Pedal Free PlayNJCL0006S0302Check pedal free play, if out of specification refer toªCLUTCH
PEDAL ADJUSTMENTº
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
CLUTCH SYSTEM
Inspection and Adjustment
CL-9

ComponentsNJCL0044
SCL819
SCL820
RemovalNJCL00451. Remove manual transaxle from vehicle. Refer to MT-24,
ªRemovalº.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch lever.
3. Support clutch lever claws with an appropriate wood block,
align retaining pin with A in the figure, and drive out spring pin
using a pin punch.
4. Pull out withdrawal lever and remove clutch lever.
SCL733
InspectionNJCL0046+Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
+Replace the withdrawal lever if its contact surface is worn
abnormally.
+Replace the clutch lever if its contact surface is worn abnor-
mally.
+Replace the dust seal if it is deformed or cracked.
InstallationNJCL0047CAUTION:
+Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
+Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
+Clean old grease and abrasive materials off the grease
application area.
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Components
CL-17

ComponentsNJCL0027
SCL842
RemovalNJCL00281. Remove manual transaxle from vehicle. Refer to MT-27,
ªRemovalº.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch withdrawal lever.
3. Remove dust cover.
4. Remove retainer spring from withdrawal lever.
SCL733
InspectionNJCL0029+Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
+Replace the withdrawal lever if its contact surface is worn
abnormally.
+Replace the dust cover if it is deformed or cracked.
InstallationNJCL00301. Apply a coat of grease to parts as instructed in the following
cautions and notes before installation.
CAUTION:
+Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
+Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
CLUTCH RELEASE MECHANISMRS5F50A
Components
CL-20

ComponentsNJCL0031
SCL816-C
SCL229
Inspection and AdjustmentNJCL0032CLUTCH DISCNJCL0032S01+Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
MODEL 240, MODEL 200, MODEL 215 (Part number
30100-2F205)
0.3 mm (0.012 in)
Wearing thickness of facing:
MODEL 215 (Part number 30100-2F215)
1.3 mm (0.051 in)
SCL221
+Check clutch disc for backlash of spline and runout of facing.
Maximum spline backlash (at outer edge of disc):
MODEL 200 0.8 mm (0.031 in)
MODEL 215 0.9 mm (0.035 in)
MODEL 240 1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
MODEL 200 95 mm (3.74 in)
MODEL 215 102.5 mm (4.04 in)
MODEL 240 115 mm (4.53 in)
+Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Components
CL-22

SCL466-C
CLUTCH COVERNJCL0032S02+Check clutch cover installed on vehicle for unevenness of dia-
phragm spring toe height.
Uneven limit:
MODEL 200, 215 0.8 mm (0.031 in)
MODEL 240 0.7 mm (0.028 in)
+If out of limit, adjust the height with Tool.
AEM100
FLYWHEELNJCL0032S03+Check contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
+Check flywheel runout.
Maximum allowable runout:
Refer to EM-62, ªFlywheel/Drive Plate Runoutº (QG
engine models), and EM-154, ªFlywheel Runout (YD
engine models)º.
SCL616-B
SCL600-F
InstallationNJCL0033+Insert Tool into clutch disc hub when installing clutch cover and
disc.
+Be careful not to allow grease to contaminate clutch fac-
ing.
+Tighten bolts in numerical order.
First step:
: 10 - 20 N´m (1 - 2 kg-m,7-14ft-lb)
Final step:
QG engine models (200, 215)
: 22 - 29 N´m (2.2 - 3.0 kg-m, 15 - 21 ft-lb)
YD22DDT engine model (240)
: 35 - 44 N´m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Inspection and Adjustment (Cont'd)
CL-23

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

h)Fuel pressure
i)Engine compression
j)EGR valve operation
k)Throttle valve
l)EVAP system
+On models equipped with air conditioner, checks should
be carried out while the air conditioner is ªOFFº.
+When checking idle speed on models equipped with A/T,
ignition timing and mixture ratio, checks should be carried
out while shift lever is in ªPº or ªNº position.
+When measuring ªCOº percentage, insert probe more
than 40 cm (15.7 in) into tail pipe.
+Turn off headlamps, heater blower, rear window defogger.
+On vehicles equipped with daytime light systems, set
lighting switch to the 1st position to light only small
lamps.
+Keep front wheels pointed straight ahead.
+If engine stops immediately after starting or idle condition
is unstable, perform the following to initialize IACV-AAC
valve:
a)Stop engine and wait 9 seconds.
b)Turn ignition ªONº and wait 1 second.
c)Turn ignition ªOFFº and wait 9 seconds.
+Make sure the cooling fan has stopped.
BASIC SERVICE PROCEDUREQG
Preparation (Cont'd)
EC-45

SEF217Z
SEF454Y
SEF455Y
Idle Air Volume LearningNJEC0562DESCRIPTIONNJEC0562S01ªIdle Air Volume Learningº is an operation to learn the idle air vol-
ume that keeps each engine within the specific range. It must be
performed under any of the following conditions:
+Each time IACV-AAC valve, throttle body or ECM is replaced.
+Idle speed or ignition timing is out of specification.
PRE-CONDITIONINGNJEC0562S02Before performing ªIdle Air Volume Learningº, make sure that all of
the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are
missed for even a moment.
+Battery voltage: More than 12.9V (At idle)
+Engine coolant temperature: 70 - 99ÉC (158 - 210ÉF)
+PNP switch: ON
+Electric load switch: OFF
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting
switch to the 1st position to light only small lamps.
+Cooling fan motor: Not operating
+Steering wheel: Neutral (Straight-ahead position)
+Vehicle speed: Stopped
+Transmission: Warmed-up
For A/T models with CONSULT-II, drive vehicle until ªFLUID
TEMP SEº in ªDATA MONITORº mode of ªA/Tº system indi-
cates less than 0.9V.
For A/T models without CONSULT-II and M/T models, drive
vehicle for 10 minutes.
OPERATION PROCEDURENJEC0562S03With CONSULT-IINJEC0562S03011. Turn ignition switch ªONº and wait at least 1 second.
2. Turn ignition switch ªOFFº and wait at least 10 seconds.
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic ªPRE-CONDITION-
INGº (previously mentioned) are in good order.
5. Turn ignition switch ªOFFº and wait at least 9 seconds.
6. Start the engine and let it idle for at least 28 seconds.
7. Select ªIDLE AIR VOL LEARNº in ªWORK SUPPORTº mode.
8. Touch ªSTARTº and wait 20 seconds.
9. Make sure that ªCMPLTº is displayed on CONSULT-II screen.
If ªINCMPº is displayed, ªIdle Air Volume Learningº will not be
carried out successfully. In this case, find the cause of the
problem by referring to the NOTE below.
10. Rev up the engine two or three times. Make sure that idle
speed and ignition timing are within specifications.
ITEM SPECIFICATION
Idle speed M/T: 700±50 rpm
A/T: 800±50 rpm (in ªPº or ªNº position)
Ignition timing M/T: 8±5É BTDC
A/T: 10±5É BTDC (in ªPº or ªNº position)
Without CONSULT-IINJEC0562S03021. Turn ignition switch ªONº and wait at least 1 second.
BASIC SERVICE PROCEDUREQG
Inspection Procedure (Cont'd)
EC-57

Basic Inspection/SedanNJEC1736Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+Headlamp switch is OFF,
On vehicle equipped with daytime light systems, set lighting
switch to the 1st position to light only small lamps.
+Air conditioner switch is OFF,
+Rear window defogger switch is OFF,
+Steering wheel is in the straight-ahead position, etc.
MODELS WITH THROTTLE POSITION SWITCHNJEC1736S01
1 INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem, or a current need for scheduled
maintenance.
2. Open engine hood and check the following:
+Harness connectors for improper connections
+Vacuum hoses for splits, kinks and improper connections
+Wiring for improper connections, pinches and cuts
+Air cleaner clogging
+Hoses and ducts for leaks
SEF983U
©GO TO 2.
2 CHECK THROTTLE OPENER OPERATION-I
Confirm that there is a clearance between throttle drum and stopper.
SEF850Y
OK or NG
OK©GO TO 4.
NG©GO TO 3.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONQG
Basic Inspection/Sedan
EC-100

36 ERASE UNNECESSARY DTC
After this inspection, unnecessary DTC No. might be displayed.
Erase the stored memory in ECM and TCM (Transmission control module).
Refer to ªHow to Erase Emission-Related Diagnostic Informationº, EC-70 and AT-52, ªHOW TO ERASE DTCº.
©INSPECTION END
Basic Inspection/HatchbackNJEC1785MODELS WITH THROTTLE POSITION SWITCHNJEC1785S01Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+Headlamp switch is OFF,
On vehicle equipped with daytime light systems, set lighting
switch to the 1st position to light only small lamps.
+Air conditioner switch is OFF,
+Rear window defogger switch is OFF,
+Steering wheel is in the straight-ahead position, etc.
1 INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem, or a current need for scheduled
maintenance.
2. Open engine hood and check the following:
+Harness connectors for improper connections
+Vacuum hoses for splits, kinks and improper connections
+Wiring for improper connections, pinches and cuts
+Air cleaner clogging
+Hoses and ducts for leaks
SEF983U
©GO TO 2.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONQG
Basic Inspection/Sedan (Cont'd)
EC-128