NISSAN ALMERA N15 1995 Service Manual

Valvespring SERVICE
DATAANDSPECIFICATIONS (50S)
Inspection andAdjustment (Cont'd)
Valve seatresurfacing

Unit:mm(in)
Free height mm(in)
Outer
Inner
Assembled height
mm/N (mm/kg, in/lb)
Outer Inner
Out-of-square "S"
mm (in)
Outer
Inner
43.2
(1.701)
38.2 (1.504)

Standard

36.1/164.8 (36.1/16.8,1.421/37.0)
32.6/78.5 (32.6/8.0, 1.283/17.6)
2.1 (0.083)
1.9 (0.075)
Intake
Standard (Original)

1.8:t 0.05
(0.0709:t 0.0020) 38.6-38.8 (1.520 -1.528)
0.5 (0.020)
Oversize
Exhaust

2.1 :to.05
(0.0827 :t0.0020)
Valve
guide

Valve guide
Outer diameter
Valve guide
Inner diameter
(Finished size)
Cylinder headvalve
guide holediameter
Interference fitofvalve
guide
Stem toguide clear-
ance
Intake
Exhaust Standard

11.023 -11.034
(0.4340 -0.4344)
7.000 -7.015
(0.2756 -0.2762)
10.985 -10.996
(0.4325 -0.4329)
0.027 -0.049
(0.0011 -0.0019)

Standard

0.020 -0.050
(0.0008 -0.0020)
0.040 -0.070
(0.0016 -0.0028)
Unit:
mm(in)
Service

11.223 -11.234
(0.4418 -0.4423)
11.185 -11.196
(0.4404 -0.4408)

Max. tolerance

0.10 (0.0039)
0.10 (0.0039) '\
'RO.3 -0.5 (0.012 -0.020)
. '41.4_~- 4!:.,454(1.~312 -16320)
'9.85
- 10.15
(0.3878
- 0.3996)
1.8:t0.05 38.6-38.8 (1.520 -1.528)
(0.0709:t 0.0020)

': Cylinder headmachining data

SEM917-B

Standard (Original)
Valve deflection limit
0.1(0.004) 31.6
-31.8 (1.244 -1.252)
31.6 -31.8 (1.244 -1.252)
0.5
(0.020)
Oversize

,- 'RO.3 -0.5 (0.012 -0.020)

r
'35.432 -35.454 (1.3950 -1.3958)
'10.45
- 10.75
(0.4114 (0.0614)
- 0.4232)
2.1:t0.05
(0.0827 :t0.0020)

Cylinder headmachining data

SEM113FA
EM-172

VALVELIFTER SERVICE
DATAANDSPECIFICATIONS (SDS)
Inspection andAdjustment (Cont'd)
CYLINDER BLOCK
Unit: mm(in) Unit:
mm(in)
Valve lifterouter diameter
Standard
Cylinder headvalve lifterhole
diameter
Clearance
Standard
Limit 34.959
-34.975
(1.3763 -1.3770)
34.998 -35.018
(1.3779 -1.3787)
0.023 -0059
(0.0009 -0.0023)
0.1 (0.004)
•

y
SEM902-A
Standard Limit
Surface flatness Lessthan0.05(0.0020)
0.10(0.0039)
Grade No.1
84.500 -84.510
(3.3268 -3.3272)
Grade NO.2
84.510 -84.520
(3.3272 -3.3276)
Grade No.3
Inner 0.2
diameter 84.520
-84.530
(0.008)
(3.3276 -3.3279)
Cylinder GradeNO.4
bore 84.530-84.540
(3.3279 -3.3283)
Grade NO.5
84.540 -84.550
(3.3283 -3.3287)
Out-of- round Lessthan0.015 (O.0006) 004(0.0016)

(X -Y)

Taper Lessthan0.010 (O.0004) 0.04(0.0016)

(A -B)

Piston tocylinder
0.025-0.045
clearance (0.0010-0.0018)
-

Grade No.0
56.654 -56.663
(2.2305 -2.2308)
Grade NO.1
Main journal inner
56.663-56.672
diameter
-

(2.2308 -2.2312)
Grade NO.2
56.672 -56.680
(2.2312 -2.2315)
EM-173

SERVICEDATAANDSPECIFICATIONS (SDS)
Inspection andAdjustment (Cont'd)
PISTON, PISTONRINGANDPISTON PIN Pistonpin
Piston Unit:
mm(in)
Grade NO.2
Grade
NO.1
Measure position(FromTop)
Piston pinhole diameter 24.994
-25.000
(0.9840 -0.9843)
0.025 -0.044
(0.0010 -0.0017)
Unit: mm(in)
-0.004
to0(-0.0002 to0)
Less than0.025 (0.0010)
25.025 -25.038
(0.9852 -0.9857)
Less
than0.025 (0.0010)
Piston
pinouter diameter
Standard
Interference

fit
ofpiston pinto
piston
Piston pintoconnecting rod
clearance
Torsion Bend
[per100mm (3.94 in)]
Standard
Piston pinbore dia.
Big end play
CONNECTING
ROD
Unit:
mm(in)
84.465 -84.475
(3.3254 -3.3258)
84.475 -84.485
(3.3258 -3.3262)
84.485 -84.495
(3.3262 -3.3266)
84.495 -84.505
(3.3266 -3.3270)
84.505 -84.515
(3.3270 -3.3274)
84.715 -84.765
(3.3352 -3.3372)
84.965 -85.015
(3.3451 -3.3470)
62 (2.44)
24.991 -24.999
(0.9839 -0.9842)
Grade
NO.4
Grade NO.5
0.5 (0.020)
0.25
(0.0098)
Oversize
Standard
GradeNO.3
Piston
skirt
diam-
eter
Limit0.3
(0.012)
Piston ring
Unit:mm(in)
Side clearance CRANKSHAFT
Top .Standard
Limit
2nd
StandardLimit

Oil
0.060
-0.095 (0.0024 -0.0037)
0.10 (0.0039)
0.040 -0.075 (0.0016 -0.0030)
0.10 (0.0039) Main
journal dia. Unit:
mm(in)
Grade No.0
52.967 -52.975
(2.0853 -20856)
Grade No.1
52.959 -52.967
(2.0850 -2.0853)
Grade NO.2
52.951 -52.959
(2.0847 -2.0850)
Standard
End gap
Top
StandardBore grade 1,2. 3
Bore grade 4,5
Limit
2nd 0.030
-0.070 (0.0012 -0.0028)
0.20 -0.30 (0.0079 -0.0118)
0.12 -0.22 (0.0047 -0.0087)
1.0 (0.039) Pin
journal dia.
Out-of-round (X-Y) and
taper (A-B) Grade
No.0
49.968 -49.974
(1.9672 -1.9675)
Grade NO.1
49.961 -49.968
(1.9670 -1.9672)
Grade NO.2
49.954 -49.961
(1.9667 -1.9670)
Standard
Limit 0.38
-0.53 (0.0150 -0.0209)
0.7 (0.028) Standard
Runout Less
than0.005 (0.0002)

Oil
StandardLessthan0.05(0.0020)
Standard
Limit 0.30
-0.55 (0.0118 -0.0217)
0.6 (0.024) Free
endplay
Standard Limit 0.05
-0.18 (0.0020 -0.0071)
0.3 (0.012)
EM-174

SERVICEOATAAND SPECIFICATIONS (SOS)
Inspection andAdjustment (Cont'd)
AVAILABLE MAINBEARINGS
No.1, No.2, No.4andNo.5main bearings

Grade number

o

2

3

4

Contacting width Thickness
"T"
mm
(in)

1.816 -1.820 (0.0715 -0.0717)
1.820 -1.824 (0.0717 -0.0718)
1.824 -1.828 (0.0718 -0.0720)
1.828 -1.832 (0.0720 -0.0721)
1.832 -1.836 (0.0721 -0.0723)
Width
"W"
mm
(in)

20.0 (0.787)
17.8 (0.7011'
Identification
color
Yellow
Green
Brown Black Blue
•

No.3 mainbearings

Grade number

o

2

3

4

Contacting width Thickness

"T"
mm
(in)

1.816 -1.820 (0.0715 -0.0717)
1.820 -1.824 (0.0717 -0.0718)
1.824 -1.828 (0.0718 -0.0720)
1828 -1.832 (0.0720 -0.0721)
1.832 -1.836 (0.0721 -0.0723)
Width
"W"
mm
(in)

27.95 (1.1004)
20.8 (0.819)'
Identification
color
Yellow
Green
Brown BlackBlue

Main bearing undersize

Unit:
mm
(in)
Crank journal diameter
Bearing
clearance

Main bearing clearance Unit:

mm
(in)

STD
0.25 (0.0098)
undersize
52951
-52.975
(2.0847 -2.0856)
52.701 -52.725
(2.0748 -2.0758)
Standard
Connecting rodbearing clearance
Standard
0.039
-0.065
(0.0015 -0.0026)
0.031 -0.055
(0.0012 -0.0022)
Connecting rodbearing undersize

Unit:
mm
(in)
Crank pindiameter
MISCELLANEOUS
COMPONENTS

Unit:
mm
(in)

0.25 (0.0098)
undersize

0.08
(0.0031)
undersize

0.12 (0.0047)
undersize

STD

Grade
0Black
Grade 1Yellow
Grade 2Blue
49.968
-49.974
(1.9672 -1.9675)
49961 -49.968
(1.9670 -1.9672)
49.954 -49.961
(1.9667 -1.9670)
49.874 -49.894"
(1.9635 -1.9643)
49.834 -49.854"
(1.9620 -1.9628)
49.704 -49.724"
(1.9568 -1.9576)
Flywheel
Runout
[TIR"]

Total indicator reading Less
than
0.15(0.0059)

": Reference value

EM-175

GENERALINFORMATION •
SECTION
G
I

CONTENTS
PRECAUTIONS 2

Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 2
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 2
Precautions forNATS V2.0(ForGasoline
Engine Model) 3
General Precautions 3
Precautions forMultiport FuelInjection
System orECCS Engine 5
Precautions forThree WayCatalyst 5
Engine Oils 5
Precautions forFuel 6

HOW TOUSE THIS
MANUAL 7

HOW TOREAD WIRING DIAGRAMS 9

Sample/Wiring Diagram-EXAMPL - 9
Description 11
Wiring Diagram Codes(CellCodes) 17

HOW TOPERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENT 18

Work Flow 18
Incident Simulation Tests 19
Circuit Inspection 23
HOW
TOFOLLOW FLOWCHART INTROUBLE
DIAGNOSES 29
CONSULT CHECKING SYSTEM
32

Function andSystem Application 32
Lithium BatteryReplacement.. 32
Checking Equipment 32

IDENTIFICATION INFORMATION 33

Model Variation 33
Identification Number 36
Di mens ions 39
Wheels andTires 39

LIFTING POINTSANDTOW TRUCK TOWING ..40

Preparation 40
Board-on
Lift
40
Garage JackandSafety Stand 41
2-pole Lift 42
Tow Truck Towing 43

TIGHTENING TORQUEOFSTANDARD BOLTS
44

SAE J1930 TERMINOLOGY LIST 45

SAE J1930 Terminology List.. 45

PRECAUTIONS

Observe thefollowing precautions toensure safeandproper
servicing.

Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System)

The Supplemental RestraintSystem"AirBag" usedalong with
a seat belt,helps toreduce therisk orseverity ofinjury tothe
driver andfront passenger inafrontal collision. TheSupple-
mental Restraint Systemconsists ofair bag modules (located
in the center ofthe steering wheelandonthe instrument panel
on the passenger side),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoser-
vice thesystem safelyisincluded inthe RSsection ofthis Ser-
vice Manual.
WARNING:
• To avoid rendering theSRS inoperative, whichcould
increase therisk ofpersonal injuryordeath inthe event of
a collision whichwould resultinair bag inflation, allmain-
tenance mustbeperformed byan authorized NISSAN
dealer.
• Improper maintenance, includingincorrectremovaland
installation ofthe SRS, canlead topersonal injurycaused
by unintentional activationofthe system.
• Donot use electrical testequipment onany circuit related
to the SRS unless instructed tointhis Service Manual. SRS
wiring harnesses arecovered withyellow insulation either
just before theharness connectors orfor the complete
harness, foreasy identification.

Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System)

The Supplemental RestraintSystem"AirBag" andused along
with aseat belt, helps toreduce therisk orseverity ofinjury to
the driver inafrontal collision. TheSupplemental Restraint
System consists ofan air bag module (located inthe center of
the steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoser-
vice thesystem safelyisincluded inthe RSsection ofthis Ser-
vice Manual.
WARNING:
• To avoid rendering theSRS inoperative, whichcould
increase therisk ofpersonal injuryordeath inthe event of
a collision whichwould resultinair bag inflation, allmain-
tenance mustbeperformed byan authorized NISSAN
dealer.
• Improper maintenance, includingincorrectremovaland
installation ofthe SRS, canlead topersonal injurycaused
by unintentional activationofthe system.

GI-2

SGI916PRECAUTIONS

• Donot use electrical testequipment onany circuit related •
to the SRS unless instructed tointhis Service Manual.

Precautions forNATS V2.0(ForGasoline Engine
Model)
NATS (Nissan Anti-Theft System)

NATS V2.0willimmobilize theengine ifsomeone triestostart
it without theregistered keyofNATS V2.0.
Both ofthe originally suppliedignitionkeyIDshave been NATS
registered.
The NATS security indicator islocated onthe instrument panel.
The indicator blinkswhentheignition switchisin "OFF" or
"ACC" position. Therefore, NATSwarns outsiders thatthevehi-
cle isequipped withtheanti-theft system.
• When NATSdetects trouble, themalfunction indicatorlamp
(MIL) blinks.
This blinking indicates thattheanti-theft isnot functioning,
so prompt service isrequired.
• When servicing NATS(trouble diagnoses, systeminitialisa-
tion andadditional registration ofother NATS ignition key
IDs), CONSULT hardwareandCONSULT NATSsoftware is
necessary.
Regarding theprocedures ofNATS initialisation andNATS
ignition key
10
registration, refertoCONSULT operation
manual, NATSV2.0.

Therefore, CONSULTNATSsoftware (program cardandoper-
ation manual) mustbekept strictly confidential tomaintain the
integrity ofthe anti-theft function.

• When servicing NATSV2.0(trouble diagnoses, systemini-
tial isation andadditional registration ofother NATS ignition
key IDs),
it
may benecessary tore-register originalkey
identification. Therefore,besure toreceive allkeys from
vehicle owner.
A maximum offour keyIDscan beregistered intoNATS.
• When failing tostart theengine first-time usingthekey of
NATS V2.0,startasfollows.
(1) Turn ignition keyto"OFF".
(2) Wait approx. 5seconds.
(3) Turn ignition keyto"START" againwhilekeeping the
key apart fromanyothers onkey-chain.

SGI285 General
Precautions

• Donot operate theengine foranextended periodoftime
without properexhaust ventilation.
Keep thework areawellventilated andfree ofany flamma-
ble materials. Specialcareshould betaken whenhandling
any flammable orpoisonous materials,suchasgasoline,
refrigerant gas,etc.When working inapit orother enclosed
area, besure toproperly ventilate thearea before working
with hazardous materials.
Do not smoke whileworking onthe vehicle.

GI-3

SEF289HSGI233
SGI234 PRECAUTIONS
General Precautions (Cont'd)

• Before jacking upthe vehicle, applywheel chocks orother
tire blocks tothe wheels toprevent thevehicle frommov-
ing. After jacking upthe vehicle, supportthevehicle weight
with safety stands atthe points designated forproper lifting
before working onthe vehicle.
These operations shouldbedone onalevel surface.
• When removing aheavy component suchasthe engine or
transaxle/transmission, becareful nottolose your balance
and drop them. Also,donot allow themtostrike adjacent
parts, especially thebrake tubesandmaster cylinder.
• Before starting repairswhichdonot require batterypower:
Turn offignition switch.
Disconnect thenegative batteryterminal.
• Toprevent seriousburns:
Avoid contact withhotmetal parts.
Do not remove theradiator capwhen theengine ishot.
• Before servicing thevehicle:
Protect fenders, upholstery andcarpeting withappropriate
covers.
Take caution thatkeys, buckles orbuttons donot scratch
paint.
• Clean alldisassembled partsinthe designated liquidor
solvent priortoinspection orassembly.
• Replace oilseals, gaskets, packings, O-rings,locking
washers, cotterpins,self-locking nuts,etc.with newones.
• Replace innerandouter races oftapered rollerbearings
and needle bearings asaset.
• Arrange thedisassembled partsinaccordance withtheir
assembled locationsandsequence.
• Donot touch theterminals ofelectrical components which
use microcomputers (suchasECMs).
Static electricity maydamage internalelectronic compo-
nents.

GI-4

PRECAUTIONS
General Precautions (Cont'd)

• After disconnecting vacuumorair hoses, attachatag to
indicate theproper connection.
• Use only thefluids andlubricants specifiedinthis manual.
• Use approved bondingagent,sealants ortheir equivalents
when required.
• Use tools andrecommended specialtoolswhere specified
for safe andefficient servicerepairs.
• When repairing thefuel, oil,water, vacuum orexhaust
systems, checkallaffected linesforleaks.
• Dispose ofdrained oilorthe solvent usedforcleaning parts
in an appropriate manner.

Precautions forMultiport FuelInjection System
or ECCS Engine

• Before connecting ordisconnecting anyharness connector
for the multiport fuelinjection systemorEGM (EGGS control
module):
Turn ignition switchto"OFF" position.
Disconnect negativebatteryterminal.
Otherwise, theremaybedamage toEGM.
• Before disconnecting pressurizedfuellinefrom fuelpump to
injectors, besure torelease fuelpressure.
• Becareful nottojar components suchasEGM andmass air
flow sensor.

Precautions forThree WayCatalyst

If a large amount ofunburned fuelflows intothecatalyst, the
catalyst temperature willbeexcessively high.Toprevent this,
follow theinstructions below:
• Use unleaded gasolineonly.Leaded gasoline willseriously
damage thethree waycatalyst.
• When checking forignition sparkormeasuring engine
compression, maketestsquickly andonly when necessary.
• Donot run engine whenthefuel tank level islow, otherwise
the engine maymisfire causing damage tothe catalyst.
Do not place thevehicle onflammable material.Keepflamma-
ble material offthe exhaust pipeandthethree waycatalyst.

Engine Oils

Prolonged andrepeated contactwithused engine oilmay
cause skincancer. Trytoavoid direct skincontact withused oil.
If skin contact is.made, washthoroughly withsoap orhand
cleaner assoon aspossible.

HEALTH PROTECTION PRECAUTIONS

• Avoid prolonged andrepeated contactwithoils, particularly
used engine oils.
• Wear protective clothing,including impervious gloves
where practicable.
• Donot putoily rags inpockets.
• Avoid contaminating clothes,particularly underpants, with

oil.

• Heavily soiledclothing andoil-impregnated footwearshould
not beworn. Overalls mustbecleaned regularly.
• First Aidtreatment shouldbeobtained immediately foropen
cuts andwounds.
• Use barrier creams, applying thembefore eachwork
period, tohelp theremoval ofoil from theskin.

GI-5
•

PRECAUTIONS
Engine Oils(ConI' d)

• Wash withsoap andwater toensure alloil isremoved (skin
cleansers andnailbrushes willhelp). Preparations contain-
ing lanolin replace thenatural skinoilswhich havebeen
removed.
• Donot use gasoline, kerosine, dieselfuel,gasoil,thinners
or solvents forcleaning skin.

• If
skin disorders develop,obtainmedical advicewithout
delay.
• Where practicable, degreasecomponents priortohandling.
• Where thereisarisk ofeye contact, eyeprotection should
be worn, forexample, chemicalgogglesorface shields; in
addition aneye wash facility should beprovided.

ENVIRONMENTAL PROTECTIONPRECAUTIONS

Burning usedengine oilinsmall space heaters orboilers can
be recommended onlyforunits ofapproved design.Theheat-
ing system mustmeettherequirements ofHM Inspectorate of
Pollution forsmall burners ofless than 0.4MW. Ifin doubt check
with theappropriate localauthority and/ormanufacturer ofthe
approved appliance.
Dispose ofused oiland used oilfilters through authorized
waste disposal contractors tolicensed wastedisposal sites,or
to the waste oilreclamation trade.Ifin doubt, contact thelocal
authority foradvice ondisposal facilities.
It is illegal topour used oilontothe ground, downsewers or
drains, orinto water courses.
The regulations concerningthepollution ofthe environment
will vary between regions.

Precautions forFuel
GASOLINE ENGINE:

For Europe

Unleaded gasolineofat least 95octane (RON)
CAUTION: Do not use leaded gasoline. Usingleaded gasoline willdamage
the catalytic converter.

Except Europe

Unleaded gasolineofat least 91octane (RON)

DIESEL ENGINE*:

Diesel fuelofat least 50cetane
If two types ofdiesel fuelareavailable, usesummer or
winter fuelproperly according tothe following temperature
conditions.
• Above -rc(20°F) Summer typediesel fuel.
• Below
-rc
(20°F) Wintertypediesel fuel.
CAUTION:
• Donot use home heating oil,gasoline, orother alternate
fuels inyour diesel engine. Theuseofthose cancause
engine damage.
• Donot use summer fuelattemperature below_7°C(20°F).
The cold temperatures willcause waxtoform inthe fuel. As
a result, itmay prevent theengine fromrunning smoothly.
• Donot add gasoline orother alternate fuelstodiesel fuel.

GI-6