engine NISSAN ALMERA N15 1995 Service Manual

SERVICEDATAANDSPECIFICATIONS (50S)

Used beltdeflection
Deflection Deflection
of
Limit afteradjust- new
belt
ment
Alternator 14(055) 11
-13 9-11
(0.43 -0.51)
(0.35-0.43)
Air conditioner
14(0.55) 11
-13
9-11
compressor (0.43
-0.51)
(0.35-0.43)
Power steer-
8(0.31) 5
-7
4-6
ing oilpump (0.20-0.28)
(0.16-0.24)
Water pump
without power

-
8
(0.31) 6(0.24)
steering
Applied push-
98N(10 kg, 22Ib)
ing force

Coolant capacity (Refillcapacity)
INSPECTION
ANDADJUSTMENT
Drive beltdeflection

Unit:kPa(bar, kg/cm', psi)
12,749 (127.5, 130,1,849)
Without
oilfilter
With oilfilter
Injection pressure

Injection
nozzle
Idle speed

Unit:rpm
Standard
M/T
700

'go

800'
': Air conditioner "ON"

TIGHTENING TORQUE

Unit N'mkg-m
ft-Ib in-Ib
Manifold nuts
&

18-22
1.8-2.2
bolts 13
-16
Rocker cover
2-4
0.2-0.4 1.4-2.9 17-35
screw
Alternator, power
steering mounting 62-75
6.3-76 46
-55
bolt
Alternator, power
steering adjuster 16
-21
1.6-2.1
12-15
lock bolt
Cylinder block
54-74
5.5-7.5 40
-54
drain plug
Engine oilpan
29-39 3.0-4.0 22-29
drain plug
Injector (Tohead)
59-69 6.0-7.0 43-51
Spill tube 39-49
4.0-5.0 29-36
Delivery tube 22-25 2.2-2.5
16-18

Engine
Maintenance
Engine oilcapacity (Refillcapacity)

Unit:[(Imp qt)•
46 (4)

51 (4--1/2)

Unit:
mm(in)
Unit:
f
(Imp qt)
5.2 (4-5/8)
49 (4-3/8)
0.7 (5/8)
Unit: kPa(bar, kg/cm', psi)
78 -98
(0.78 -0.98, 08-1.0, 11-14)
59 -98
(0.59 -0.98, 06-10, 9-14)
157 (1.57, 1.6,23)
Standard
Limit
With
heater
Without heater
Reservoir tank
Radiator caprelief pressure
Radiator testingpressure

Cooling
systemcheck
MA-55

REMOVALANDINSTALLATION
Removal
1. Remove batterynegative terminal.
2. Remove airduct.
3. Disconnect clutchcontrol cable.(Except forCD20 engine
models)
Remove clutchoperating cylinderandclutch operating cyl-
inder bracket fromtransaxle. (CD20engine models)
4. Disconnect back-uplampswitch, neutralposition switch,
speedometer sensorandground harness connectors.
5. Remove startermotorfromtransaxle.
6. Remove shiftcontrol rodand support rodfrom transaxle.
7. Drain gearoilfrom transaxle.
8. Remove driveshafts. RefertoFA section ("Removal",
"FRONT AXLE-Drive Shaft").
9. Jack uptransaxle togetherwithengine slightly andinsert
wooden blockbetween centermember andengine oilpan.

CAUTION:
Do not place jackunder oilpan drain plug.

10. Remove rearandLHmounts supporting transaxlewithjack.
11. Remove boltssecuring transaxle.
12. Lower transaxle.

MT-7
•

@
M/T
toengine
CD
REMOVAL
ANDINSTAllATION

Installation

Tighten boltssecuring transaxle andinstall anypart removed.

• GA engine models

Bolt No. Tightening
torque
"C"mm (in)
N'm (kg-m, ft-Ib)

G) 30-40 (3.1 -4.1,22 -30) 70
(2.76)
@ 30-40 (3.1 -4.1,22 -30) 85(3.35)

@
30-40 (3.1 -4.1, 22-30) 30(1.18)
@ 16-21 (1.6 -2.1,12 -15) 25(0.98)

Front gusset to

30-40 (3.1 -4.1,22 -30) 20(0.79)

engine
Rear gusset to

16-21 (1.6 -2.1,12 -15) 16
(0.63)

engine

@
M/T
toengine ~

Q9
Engine toM/T
leV

~o". Q~.\

17
SMT747C

CD
SMT740A •
SRengine models

Bolt No. Tightening
torque
"C"mm (in)
N'm (kg-m, ft-Ib)

--

G)
70-79 (7.1 -8.1,51 -59) 55
(2.17)

@
30-40 (3.1 -4.1,22 -30) 35
(1.38)

@
30-40 (3.1 -4.1,22 -30) 45
(1.77)
@ 70-79 (7.1 -8.1,51 -59) 65
(2.56)
• CD20 engine models

Boll No. Tightening
torque
"C"mm (in)
N'm (kg-m, ft-Ib)

G)
30
-40 (3.1 -4.1, 22-30) 120
(4.72)

@
30-40 (3.1 -4.1,22 -30) 85
(3.35)

@
44
-54 (4.5 -5.5, 33-40) 75
(2.95)

@
16-21 (1.6 -2.1,12 -15) 30
(1.18)

@
16-21 (1.6 -2.1,12 -15) 25
(0.98)

Front gusset to

30-40 (3.1 -4.1, 22-30) 35
(1.38)

engine
Rear gusset to

30-40 (3.1 -4.1, 22-30) 40
(1.57)

engine

MT-8

TRANSAXlEGEAR
CONTROL

•

~ .Nom (k

g-m, in-Ib)

~ :Nom (kg-m, ft-Ib)

12

~
4.4.5.9 (0.45
•060
.
,39.1. 52.1)
m

.
..--~~

~~O 't~~~

t"J t"J
12•15
(jj)~~~~l '
3

35 •47 (1.2•15
._le'

(3 6 .,9 •11)
~~

-
.
..--~
/" rIiJ
10.13 ~
I\~~ ~ ;~;
'~.5, 9•11)

, {y"'''
(1.0•
1.3, "",/'
>
"@

'\ _Y 87•113)
I

16

iI5J

t
t"J
22•29 (2.2 .

L,
3.0.16•22)

-~ 18.24(1.8 •2

.4, 13•17)

f?:!-
:g.~
~
14. 18(1

W
.4.18 1

.,
O.13)

SEC.
341

Control leverknb
Boot
0

Control leversocke
Control lever t
Bearing seats.
Seat pring
Bushing
O-ring Hand
Iever socket
Plate bolt
Transaxle hI
S
0
e cover
upport rod
Plate
Collar
Bushing
Support rodbracket
@
@

@)
@

@
@

@
Collar
Bushing
Control rod
Return spring
Return s.
pring rubb
Hold er
er bracket
Mass dame
only) pr(CD20 engine

MT-9

SEC.320 MAJOR
OVERHAUL
Case Components
I

RS5F30A
&
RS5F31 A
I

.. -- RS5F31A---

~16 -21
(1.6 -2.1, 12. 15)

@ ~Mating
surface to
transmiSSion
case ----
@
~20 -29 (2.0 -3.0, 14-22)-

~ Thread ofbolt

(1)
Clutch housing
@)
O-ring

@
Input shaftoilseal
@

Case cover

@
Oilpocket
@

Back-up lampswitch

@
Bearing retainer
@

Differential oilseal

@
Bearing retainer
@

Drain plug

@
Torx screw

@l
Transmission case

(J)
Filler plug
@
Oilgutter

@
Airbreather
@

Reverse idlershaft

@
Welch plug
@

Oilchannel

MT-10
@
~
15-20 (1.5 -2.0, 11-14)

~ Thread ofbolt

Ij] :
Nom (kg-m, in-Ib)

tr'J :
Nom (kg-m, ft-Ib)
~ :Apply recommended sealant
(Nissan genuine part:KP610-00250) orequivalent.

*: :
Pay attention toits direction.
SMT755C

@
Striking rodoilseal

@J
Boot

@
Neutral position switch(GA
engine) orswitch plug(CD
engine)

@
Differential oilseal

@
O-ring

@
Speedometer pinionassembly

TRANSAXLE SERVICE
DATAANDSPECIFICATIONS (SDS)
General Specifications
Except for
Exceptfor
Europe Europeand Europe
EuropeAustralia
Europe
Australia
Applied model
GA14DEGA15DE GA16DE
Without SR20DE
CD20
With catalyzer
catalyzer
Transaxle model
RS5F30ARS5F31ARS5F32ARS5F31A
Number ofspeeds
5
Synchromesh type
Warner
Shift pattern
1
3
5

~tJ
II

2
4
A

Gear ratio 1st 3.333
3.333 3.0633.0633.333
2nd 1.9551.955 1.826 1.8261.955
3rd 12861.286 1.2861.2861.286
4th 0.9020.926 0.975
0.975
0.902
5th 0.7330.756 0.810
0.7560,756
Reverse 3.4173.417 3.417 3.1533.417
Number of Input
1st 15 15
16
1615
teeth gear
2nd 22 22 23 2322
3rd 28 28 28 28
28
4th 41 41 40 40
41
5th 45 45 42 4545
Rev. 12
12 12 1312
Main 1st 50 50 49 4950
gear 2nd 43
43 42
4243
3rd 36
36 36 3636
4th 37 38 39

39/
37
5th 33 34
34 3434
Rev. 41 41
41 41
41
Reverse idler
30 3130
gear
Oil capacity
C
(Imp pt) 2.8-3.0 (4-7/8 -5-1/4) 2.9-3.2 (5-1/8 -5-5/8) 3.7
-3.9 2.9
-3.2
(6-1/2 -6-7/8) (5-1/8-5-5/8)

.

Oillevel* mm(in) 58-66 (2.28 -2.60) 57-66 (2.24 -2.60) 39
-44 54
-61
(1.54 -1.73) (2.13-2.40)
*: Refer toMA. section.
FINAL GEAR
Engine GA14DEGA15DE GA16DESR20DE
CD20
Final gearratio 4.1673.789 4.167 4.176
3.650
Final gear/Pinion 75/1872/19
75/1871/17
73/20
Number of
teeth Side
gear/Pinion
14/1014/10 16/1014/10
16/10
mate gear
MT.60

Thicknessmm(in)
Partnumber
0.10 (0.0039) 32137-M8000
0.15 (0.0059) 32137-M8001
0.20 (0.0079) 32137-M8002
0.25 (0.0098) 32137-M8003
0.30 (0.0118) 32137-M8004
035 (0.0138) 32137-M8005
0.40 (0.0157) 32137-M8006
0.45 (00177) 32137-M8007
0.50 (0.0197) 32137-M8008
0.55 (0.0217) 32137-M8009
0.60 (0.0236) 32137-M8010
0.65 (0.0256) 32137-M8011
0.70 (0.0276) 32137
-M8012
0.75 (0.0295) 32137-M8013
080 (0.0315) 32137-M8014
0.85 (0.0335) 32137-M8015
0.90 (0.0354) 32137
-M8016
095 (0.0374) 32137-M8017
1.00 (0.0394) 32137-M8018
Table forselecting mainshaft bearing
adjusting shim
38424-02111
38424-02112
38424-02113
38424-02114
38424-02115
Part
number
Part number
38424-01 M10
38424-01 M11
38424-01 M12
38424-01M13 0.1
-0.2 mm
(0.004 -0.008 in)
0.1 -0.2 mm
(0.004 -0.008 in)
Thickness
mm(in)
0.75 -0.80 (0.0295 -0.0315)
0.80 -0.85 (0.0315 -0.0335)
0.85 -0.90 (0.0335 -0.0354)
0.90 -0.95 (0.0354 -0.0374)
0.95 -1.00 (0.0374 -0.0394)
Thickness mm(in)
076 -0.81 (0.0299 -0.0319)
0.81 -0.86 (0.0319 -0.0339)
0.86 -0.91 (0.0339 -0.0358)
0.91 -0.96 (0.0358 -0.0378)
Allowable
clearance between
side gear anddifferential case
with washer
Allowable
clearance between
side gear anddifferential case
with washer
• Except forGA16DE andCD20 engine models
SERVICE
DATAANDSPECIFICATIONS (SDS)
Inspection andAdjustment -RS5F30A
&

RS5F31 A(Cont'd)
AVAILABLE WASHERS Mainshaftbearingadjusting shims
Differential sidegear thrust washer
• GA16DE andCD20 engine models
AVAILABLE SHIMS
MAINSHAFT ANDDIFFERENTIAL SIDE
BEARING PRELOAD ANDADJUSTING
SHIM
Bearing preload(Reused bearing)
Unit:mm(in)
Mainshafl bearing Oifferential
side
bearing
RS5F30A 0.18
-0.23 0.24-0.32
(0.0071 -0.0091) (0.0094
-0.0126)
RS5F31A 0.18
-0.27 0.20
-0.25
(0.0071 -0.0106) (0.0079
-0.0098)
Turning torque(Newbearing)
Unit:N'm(kg-em, in-Ib)
Total
Final drive only (Final
drive+
Mainshafl)
RS5F30A 2.0
-7.8 3.9-12.3
(20 -80, 17-69) (40
-125, 35-109)
2.0 -7.8 3.9
-13.7
RS5F31A (20-80, 17-69) (40-140, 35-122) Measured
distance
2.35 -2.40 (0.0925 -0.0945)
2.40 -2.45 (0.0945 -0.0965)
2.45 -2.50 (0.0965 -0.0984)
2.50 -2.55 (0.0984 -0.1004)
2.55 -2.60 (0.1004 -0.1024)
2.60 -2.65 (0.1024 -0.1043)
2.65 -2.70 (0.1043 -0.1063)
2.70 -2.75 (0.1063 -0.1083)
2.75 -2.80 (0.1083 -0.1102)
2.80 -2.85 (0.1102 -0.1122)
2.85 -2.90 (0.1122 -0.1142)
2.90 -2.95 (0.1142 -0.1161)
2.95 -3.00 (0.1161 -0.1181)
3.00 -3.05 (0.1181 -0.1201)
3.05 -3.10 (0.1201 -0.1220)
3.10 -315 (0.1220 -0.1240)
3.15 -3.20 (0.1240 -0.1260)
3.20 -3.25 (0.1260 -0.1280)
3.25 -3.30 (0.1280 -0.1299) Unit:
mm(in)
Suitable shimthickness
0.10 (0.0039)
0.15 (0.0059)
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118)
0.35 (0.0138)
0.40 (0.0157)
0.45 (0.0177)
0.50 (0.0197)
0.55 (0.0217)
0.60 (0.0236)
0.65 (0.0256)
0.70 (0.0276)
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
1.00 (0.0394)
MT-62

PRECAUTIONSANDPREPARATION
SBR820B Precautions
• When installing eachrubber part,finaltightening mustbe
carried outunder unladen condition* withtires onground.

*:
Fuel, radiator coolantandengine oilfull. Spare tire,jack,
hand tools andmats indesignated positions.
• Use flare nutwrench whenremoving orinstalling brake
tubes.
• After installing removedsuspension parts,check wheel
alignment.
• Donot jack upatthe trailing armandlateral link.
• Always torquebrakelineswhen installing.
Special Service Tools

Tool number
Tool name Description

GG9431 0000

Flare nuttorque
wrench

HT71780000

Spring compressor

ST35652000
Shock absorber
attachment
NT406
NT144
NT145
Removing
andinstalling brakepiping

a:
10
mm
(0.39
in)

Removing andinstalling coilspring
Fixing strutassembly
Tool name
Description
Commercial
ServiceTools

Equivalent to

GG9431 0000

G)
Flare nutcrows
foot
@
Torque wrench Removing
andinstalling brakepiping

NT360
a:

10
mm
(0.39
in)

RA-2

REARSUSPENSION SYSTEM

SEC. 431

When installing eachrubber part,finaltightening
must becarried outunder unladen condition'
with tires onground.
, Fuel, radiator coolantandengine oilfull.
Spare tire,lack, handtools andmats in
designated positions.
~ :N.m (kg-m, fHb)

SRA709AA
•

G)
Shock absorber cap

@
Shock absorber mountingseal

@
Coilspring
@

Shock absorber

@
Torsion beam

RA-3 @

Lateral link

(J)
Control rod

ON-VEHICLESERVICE
Rear Wheel Alignment
PRELIMINARY INSPECTION

Make following checks.Adjust,repairorreplace ifnecessary.
• Check tiresforwear andforimproper inflation.
• Check rearwheel bearings forexcessive play.
• Check wheelrunout.

Wheel runout: RefertoSOS inFA section.

• Check thatrear shock absorber worksproperly.
• Check rearaxleandrear suspension partsforexcessive

SFA575B
play.
• Check vehicle posture (Unladen*).
*: Fuel, radiator andengine oilfull. Spare tire,jack, hand
tools andmats indesignated positions.

•

CAMBER
Camber ispreset atfactory andcannot beadjusted.
Camber: Refer toSOS (RA-12).

• Ifthe camber isnot within specification, inspectandreplace
any damaged orworn rearsuspension parts.

TOE-IN
Toe-in ispreset atfactory andcannot beadjusted.
Measure toe-inusingfollowing procedure. Ifout of
specification, inspectandreplace anydamaged orworn rear
suspension parts.
WARNING:
• Perform following procedure alwaysonaflat surface.
• Make surethatnoperson isin front ofthe vehicle before
pushing it.

1. Bounce rearofvehicle upand down tostabilize theposture.
2. Push thevehicle straight aheadabout5m (16
ft).

3. Putamark onbase lineofthe tread (rearside) ofboth tires at
the same height ofhub center. Thismark isameasuring point.
4. Measure distance"A"(rear side).
5. Push thevehicle slowlyaheadtorotate thewheels 180
degrees (1/2turn).

If the wheels haverotated morethan180degrees (1/2turn), try
the above procedure againfromthebeginning. Neverpush
vehicle backward.

6. Measure distance"B"(front side).

Total toe-in:
Refer toSOS, RA-12.

Front

SFA948A
SFA614B
SFA234AC

Lines
parallel to
center lineofbOdY~

Q

Front
Hub
center
height

RA-5