Manual trans NISSAN ALMERA N15 1995 Owner's Manual

IDENTIFICATIONINFORMATION
Identification Number(Cont'd)
IDENTIFICATION PLATE
Europe
NISSAN MOTORCO.,LTD.JAPAN

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Except
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NISSAN MOTORCO.,LTD. JAPAN

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NO DECHASIS

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CC
1
Type approval number
2 Vehicle identification
number (Chassis number)
3 Gross vehicle weight
4 Gross combination weight
Gross vehicle weight

+
Gross trailing capacity
(Weight)
5 Gross axleweight (Front)
6 Gross axleweight (Rear)
7 Type
8 Body colorcode
9 Trim color code
10 Model
11 Engine model
12 Engine displacement
13 Transaxle model
14 Axle model

SGI704
ENGINE SERIALNUMBER
GA 14DE, GA15DE and
GA16DE engine

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(J~~~6

Front
c:::?
SR20DE
engine CD20engine
SGI912
MANUAL TRANSAXLE NUMBER
RS5F30A, RS5F31AandRS5F32A AUTOMATIC
TRANSAXLE NUMBER
SGI913 GI-38 SGI656

LIFTINGPOINTSANDTOW TRUCK TOWING
~ SGI80S

Automatic transaxlemodel

SG1806-A Tow
Truck Towing •
CAUTION: • All applicable locallawsregarding thetowing operation
must beobeyed.
• Itis necessary touse proper towing equipment toavoid
possible damagetothe vehicle duringtowing operation.
Towing isinaccordance withTowing Procedure Manualat
dealer.
• When towing withtherear wheels onthe ground, release
the parking brakeandmove thegearshift levertoneutral
position.

NISSAN recommends thatvehicle betowed withthedriving
(front) wheels offthe ground asillustrated.

TOWING ANAUTOMATIC TRANSAXLEMODELWITH
FOUR WHEELS ONGROUND

Observe thefollowing restricted towingspeeds anddistances.

Speed: Below 50km/h (30MPH)
Distance: Less than65km (40 miles)
CAUTION: Never towanautomatic transaxlemodelfromtherear
(i.e.,

backward) withfourwheels onthe ground asthis may cause
serious andexpensive damagetothe transaxle.
TOWING ANAUTOMATIC TRANSAXLEMODELWITH
REAR WHEELS RAISED(Withfrontwheels onground)

Never towanautomatic transaxlemodelwithrearwheels
raised (withfrontwheels onground) asthis may cause serious
and expensive damagetothe transaxle. Ifitis necessary totow
it with rearwheels raised,always useatowing dollyunder the
front wheels.

TOWING POINT
Always pullthecable straight outfrom thevehicle. Neverpull
on the hook atasideways angle.
CAUTION: Remove thefront spoiler whentowing thevehicle forward.
Otherwise, thetowing devicemaydamage thefront spoiler.
Front Rear

Sedan models

GI-43
Hatchback
models

Towinghook

SGI911

PRE-DELIVERYINSPECTIONITEMS
Shown belowarePre-delivery InspectionItemsrequired forthe new vehicle. Itis recommended that
necessary itemsotherthanthose listedherebeadded, payingdueregard tothe conditions ineach
country.

Perform applicable itemsoneach model. Consult textofthis section forspecifications .

UNDER HOOD-engine off

o
Radiator coolantlevelandcoolant hosecon-
nections forleaks

o
Battery fluidlevel, specific gravityandcondi-
tions ofbattery terminals

o
Drive beltstension

D
Fuel filter forwater ordusts, andfuel lines
and connections forleaks
[] Engine oillevel andoilleaks

D
Clutch andbrake reservoir fluidlevel and
fluid lines forleaks

o
Windshield andrear window washerand
headlamp cleanerreservoir fluidlevel

D
Power steering reservoir fluidlevel andhose
connections forleaks

ON INSIDE ANDOUTSIDE

D
Remove frontspring/strut spacer(Ifapplica-
ble)

D
Operation ofall instruments, gauges,lights
and accessories

o
Operation ofhorn(s), wiperandwasher
[] Steering lockforoperation
[] Check airconditioner forgas leaks

o
Front andrear seats, andseat belts foroper-
ation

n
All moldings, trimsandfittings forfitand
alignment

[J
Allwindows foroperation andalignment

n
Hood, trunklid,door panels forfitand align-
ment

[1
Latches, keysandlocks foroperation

rl
Weatherstrips foradhesion andfit

[l
Headlamp aiming
I~ Tighten wheelnuts(Inc. inner nutsifapplica-
ble)
IJ Tire pressure (Inc.spare tire)

Il
Check frontwheels fortoe-in
IJ Install clock/voltmeter/room lampfuse(If
applicable)
~ Install deodorizing filtertoair purifier (If
applicable)
~ Remove wiperbladeprotectors (Ifapplicable)
UNDER
BODY

o
Manual transmission/transaxle, transferand
differential gearoillevel

D
Brake andfuel lines andoil/fluid reservoirs
for leaks

D
Tighten boltsandnuts ofsteering linkageand
gear box,suspension, propellershaftsand
drive shafts
~ Tighten rearbody boltsandnuts (Models with
wooden bedonly)

ROAD TEST

D
Clutch operation

D
Parking brakeoperation

[J
Service brakeoperation

D
Automatic transmission/transaxle shifttiming
and kickdown
[] Steering controlandreturnability

o
Engine performance

D
Squeaks andrattles

ENGINE OPERATING ANDHOT

D
Adjust idlemixture andspeed (andignition
timing*1)

n
Automatic transmission/transaxle fluidlevel
~ Engine idlingandstop knob operation (Diesel
only)

FINAL INSPECTION

n
Install necessary parts(outside mirror,wheel
covers, seatbelts, mat,carpet ormud flaps)

[1
Inspect forinterior andexterior metaland
paint damage
[] Check forspare tire,jack, tools (wheel
chock), andliterature

n
Wash, cleaninterior andexterior

"1: Not required onmodels withadirect ignition system
~ :Not appiicable tothis model.
•

MA-5

PERIODICMAINTENANCE (ExceptforEurope)
Chassis andBody Service

Abbreviations: I
=
Inspect andcorrect orreplace asnecessary, RReplace, L
=
Lubricate.

MAINTENANCE OPERATION MAINTENANCE
INTERVAL
km x1,000 10
20 30 40
5060 70
80Refer-
Perform eitheratnumber ofkilometers (miles)or
ence

months, whichever comesfirst. (Miles
x1,000) (0.6)(6)(12) (18) (24)(30)(36) (42)(48)
page
Months 612 1824
3036 42
48

Underhood andunder vehicle

Brake, clutch
&
automatic transaxlefluidoroil (For
level
&
leaks)* MA-47,
45, 46
Brake fluid* R
RMA-47
Brake booster
vacuum
hoses,connections
&
check
valve
MA-48
Power steering fluid
&
lines (For
level
&
leaks)

""
I'

"
MA-50
Brake, clutch
&
exhaust systems MA-47,
45
Manual transaxle oil(For level
&
leaks)*

"
I'
I' I'

MA-45
MA-50
Steering gear
&
linkage, axle
&
suspension parts
&
drive
shafts* I'
FA-5
RA-4

Outside andInside

Wheel alignment,
If
necessary, rotate
&
balance wheels MA-49
FA-6
Brake pads,disc
&
other brake components* MA-48
Brake linings, drums
&
other brake components MA-49
Locks, hinges
&
hood latch* L'
LL' LL'
LL'
LMA-51
Seat belts, buckles, retractors, anchors
&
adjuster MA-51
BR-11,
Foot brake, parking brake
&
clutch (Forfreeplay, stroke
&
operation)
I'
I'
I'
I'
37
CL-5
Air bag system See
NOTE (1) RS-11

NOTE: (1)Inspect atthe first 10years, andthen every 2years.

*
Maintenance itemswith
"*"
should beperformed morefrequently accordingto"Maintenance UnderSevere Driv-
ing Conditions".
*:
Except
for
Australia models

MA-8

PERIODICMAINTENANCE (ExceptforEurope)
Maintenance UnderSevere DrivingConditions

The maintenance intervalsshownonthe preceding pagesarefornormal operating conditions. Ifthe
vehicle ismainly operated undersevere drivingconditions asshown below, morefrequent maintenance •
must beperformed onthe following itemsasshown inthe table. •

SEVERE DRIVING CONDITIONS

A -Driving underdustyconditions
B -Driving repeatedly shortdistances
C -Towing atrailer orcaravan
D -Extensive idling
E -Driving inextremely adverseweather con-
ditions orinareas where ambient temper-
atures areeither extremely lowor
extremely high F
-Driving inhigh humidity areasorinmoun-
tainous areas
G -Driving inareas usingsaltorother corro-
sive materials
H -Driving onrough and/or muddy roadsorin
the desert
- Driving withfrequent useofbraking orin
mountainous areas
Driving
condition Maintenance
item Maintenance
operation Maintenance
interval Reference
page
GA
SR

A Aircleaner filter
Dry paper type
Clean MA
23
-

All types ReplaceMorefrequently MA
2333
PCV filter Replace MA26
-

A BC D
Engineoil
&
oil filter ReplaceEvery
5,000km
MA2424
(3,000 miles) or3months
A E Fuel
filter Replace
Every20,000 km MA
2232
F Brakefluid Replace(12,000
miles)or12 months
MA-47
C
H
Automatic

&
manual transaxle Replace Every40,000 km
MA-46,45
oil (24,000
miles)or24 months
G
H
Steering
gear
&
linkage, axle
&
Check
Every10,000 km MA-50
suspension parts
&
drive shafts
(6,000miles) or6months FA-5,
7
RA-4
A C G
H

I
Brake pads,discs
&
other brake Check Every
5,000km
MA-48
components (3,000
miles) or3months
A C
G
H

1
Brake
linings, drums
&
other
Check Every
10,000 km
MA-49
brake components (6,000
miles) or6months
G Lock,
hinges
&
hood latch Lubricate
Every5,000km
MA-51
(3,000 miles) or3months
Maintenance operation:Check
=
Check. Correct orreplace
if
necessary.

MA-9

PERIODICMAINTENANCE (ForEurope)
Chassis andBody Services

Abbreviations: R
=
Replace. Inspect,andcorrect orreplace asnecessary.

MAINTENANCE OPERATION

MAINTENANCEINTERVAL
Steering gear
&
linkage, axle
&
suspension parts
&
exhaust system*

OutsideandInside

Wheel alignment (Ifnecessary, rotate
&
balance wheels)
Brake pads,disc
&
other brake components*
Brake linings, drums
&
other components*
Headlamp aiming
Foot brake, parking brake
&
clutch (Forfreeplay, stroke
&
operation)
Annually120
Reference page

(72)

48
MA-47,45MA-46
R MA-47
MA-48
MA-50
MA-47,45 MA-45
MA-50, 45,FA-5,
RA-4
FA-7
MA-49, FA-6
MA-48
MA-49 EL-75
BR-11, 37,CL-5
MA-52 RS-11

90
(54)
36

R

60

See NOTE (1)

(36)
24
30
(18)

12

km
x1,000
(Miles x1,000)
Months

Underhood andunder vehicle

Perform
eitheratnumber ofkilometers (miles)ormonths,
whichever comesfirst.
Brake booster vacuum hoses,connections
&
check valve
Brake

&
clutch oil(For level
&
leaks)*
Automatic transaxlefluid(Forlevel
&
leaks)*
Brake f1uid*

CHASSIS
ANDBODY

Power steering fluid
&
lines (Forlevel
&
leaks)
Brake
&
clutch systems
Manual transaxle oil(For leaks)*
Drive shafts*
Air bag system
Body
corrosion

NOTE:
*
Maintenance itemswith
"*"
should beperformed morefrequently accordingto"Maintenance undersevere driving
conditions" .
(1) Inspect atthe first 10years andthen every 2years.
MA-12

PERIODICMAINTENANCE (ForEurope)
Maintenance UnderSevere Driving Conditions

The maintenance intervalsshownonthe preceding pagesarefornormal operating conditions. Ifthe
vehicle ismainly operated undersevere drivingconditions asshown below,morefrequent maintenance •
must beperformed onthe following itemsasshown inthe table. •

SEVERE DRIVING CONDITIONS

A -Driving underdustyconditions
B -Driving repeatedly shortdistances
C -Towing atrailer
D -Extensive idling
E -Driving inextremely adverseweather con-
ditions orinareas where ambient temper-
atures areeither extremely lowor
extremely high F
-Driving inhigh humidity areasorinmoun-
tainous areas
G -Driving inareas usingsaltorother corro-
sive materials
H -Driving onrough and/or muddy roadsorin
the desert
- Driving withfrequent useofbraking orin
mountainous areas

Driving
MaintenanceMaintenance
MaintenanceReference
condition itemoperationintervalpage
A B
C D Engine
oil
&
oil filter
Gasoline engine ReplaceEvery
7.500km(4,500 miles) MA-24
or 6months
Diesel engine ReplaceEvery5.000km(3,000 miles) or MA-41
3 months
A Aircleaner IiIter
&
PCV filter Replace MA-23,
41
A E Fuel
filter ReplaceMA-22,41
Every 30,000 km(18,000 miles)
F Brakefluid Replaceor
12months MA-47
G H
Steering gear
&
linkage, axle
&
suspension parts
&
exhaust Check MA-50,45
system FA-5
RA-4
C H
Automatic
&
manual transaxle oil Replace
Every60,000 km(36,000 miles) MA-46,45
or 24 months
A C GH

I
Brake pads,discs
&
other brake components Check MA-48
Every 15,000 km(9,000 miles)
A C GH

I
Brake
lining,drums
&
other brake components Check
or6months MA-49
C H
Driveshaft CheckFA-7

Maintenance operation:Check
=

Check. Correct orreplace
if
necessary.

MA-13

RECOMMENDEDLUBRICANTSANDFLUIDS
Lubricants andFluids
Capacity (Approximate)
Liter Impmeasure Recommended
lubricants
and fluids
Anti-freeze coolant
(Ethylene glycolbase)
or soft water

5-1/4

qt

5-5/8
qt

5-3/8
qt

5-7/8
qt

4-7/8
qt

5-3/8
qt

5-1/8
qt

5-1/2
qt

3.2

2-7/8
qt For
Europe:
3.4 3qt API
SGorSH*1
Except forEurope:
2.8
2-1/2
qt
APISE,SF,SGorSH*1
3.2
2-718
qt
5.1
4-1/2
qt API
CD*1
4.6 4qt
5.9

6.4

6.1

6.6

5.6
6.1
5.8

6.3

GA
SR20DE GA
SR20DE
GA series
(M/T)

GA series
(A/T)

SR series
(M/T)

SR series
(A/T)

GA series
(M/T)

GA series
(A/T)

SR series
(M/T)

SR series (AfT)
Without
heater
Without
oilfilter
Engine
oil(Refill)
Gasoline With oilfilter
Diesel With oilfilter CD20
Without oilfilter CD20
Cooling system
(With reservoir tank)
Gasoline With heater
Diesel With heater
Without heater CD20
CD20 5.2

4.9
4-5/8

qt

4-3/8
qt

Manual transaxle gearoil
RS5F30A
RS5F31A
RS5F32A
Automatic transaxlefluid
RL4F03A
Power steering fluid
Brake
&
clutch fluid
Multi-purpose grease
2.8
-3.0

2.9 -3.2
3,7 -3.9

7.0
4-7/8
-5-1/4
pt

5-1/8 -5-5/8
ptAPIGL-4*1

6-1/2 -6-7/8
pt

Genuine NISSANATForequiv-

6-1/8
qt alent*2
Type DEXRON™
For Europe:

0013
orDOT4 (USFMVSS
NO. 116)*3
Except forEurope:
DOT3 (USFMVSS NO.116)
NLGI NO.2 (Lithium soapbase)
*1: For further details, see"SAE Viscosity Number". _
*2: For morainformation regardingsuitablefluids,contact aNISSAN dealership forcorrect brandofDEXRON
'P:
liE or
DEXRON:
A
III.
*3: Never mixdifferent typesoffluids (DOT3 and
0014).

MA-14

MANUALTRANSAXLE
SECTION
MT
CONTENTS
PREPARATION 2
Special Service Tools 2
Commercial ServiceTools 4
ON-VEHICLE SERVICE
5

Replacing OilSeal 5
Position SwitchCheck 6
REMOVAL ANDINSTAllATION 7
Removal ,7
Installation '8
TRANSAXlE GEARCONTROL 9
RS5F30A
&
RS5F31 A
MAJOR OVERHAUL 10
Case Components 10
Gear Components ,11
Shift Control Components , 12
DiSASSEMBly ,13
REPAIR FORCOMPONENT PARTS 16
Input Shaft andGears 16
Mainshaft andGears 19
Final Drive ,,23
Shift Control Components 25
Case Components ,25
ADJUSTMENT ,,.. , 28
Differential SideBearing Preload 28
Mainshaft BearingPreload ,29
ASSEMBly ,30 RS5F32A
MAJOR OVERHAUl ,,,
33

Case Components , 33
Gear Components 34
Shift Control Components 35
DiSASSEMBly ",.,., , ,36
REPAIR FORCOMPONENT PARTS 39
Input Shaft andGears 39
Mainshaft andGears 42
Final Drive .47
Shift Control Components 49
Case Components ' 51
ADJUSTMENT ,, ", 54
Differential SideBearing Preload ,54
ASSEMBLY ',
56

'----_-JI RS5F30A
&
RS5F31A
&
RS5F32A
SERVICE DATAANDSPECIFICATIONS (SDS)60
General Specifications 60
Inspection andAdjustment -RS5F30A &
RS5F31 A ' 61
Inspection andAdjustment -RS5F32A 64
•

PRECAUTIONSANDPREPARATION
Precautions
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(Dual AirBag System)

The Supplemental RestraintSystem"AirBag" usedalong withaseat belt,helps toreduce therisk or
severity ofinjury tothe driver andfront passenger inafrontal collision. TheSupplemental Restraint
System consists ofair bag modules (locatedinthe center ofthe steering wheelandonthe instrument
panel onthe passenger side),adiagnosis sensorunit,warning lamp,wiring harness andspiral cable.
Information necessarytoservice thesystem safelyisincluded inthe
RSsection
ofthis Service Manual.

WARNING: • Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual. SRSwiring harnesses arecovered withyellow insulation eitherjustbefore the
harness connectors orfor the complete harness,foreasy identification.
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(Single AirBag System)

The Supplemental RestraintSystem"AirBag" andused along withaseat belt,helps toreduce therisk
or severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists of
an air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoservice thesystem safelyisincluded inthe

RS section
ofthis Service Manual.

WARNING: • Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual.
STEERINGSYSTEM
• Before disassembly, thoroughlycleantheoutside ofthe unit.
• Disassembly shouldbedone inaclean workarea. Itis important toprevent theinternal partsfrom
becoming contaminated bydirt orother foreign matter.
• Place disassembled partsinorder, onaparts rack,fore"asier andproper assembly.
• Use nylon cloths orpaper towels toclean theparts; common shopragscanleave lintthat might
interfere withtheir operation.
• Before inspection orreassembly, carefullycleanallparts withageneral purpose, non-flammable
solvent.
• Before assembly, applyacoat ofrecommended ATF*tohydraulic parts.Vaseline maybeapplied to
O-rings andseals. Donot use any grease.
• Replace allgaskets, sealsandO-rings. Avoiddamaging O-rings,sealsandgaskets duringinstalla-
tion. Perform functional testswhenever designated.

*:
Automatic transmission fluid
ST-2