tow NISSAN ALMERA N15 1995 Manual PDF

CHASSISANDBODY MAINTENANCE
Checking BodyCorrosion

Visually checkthebody sheet metalpanelforcorrosion, paintdamage (scratches, chipping,rubbing,
etc.) ordamage tothe anti-corrosion materials.Inparticular, checkthefollowing locations.

Hemmed portion

Hood frontend,door lower end,trunk lidrear end, etc.

Panel joint

Side sillofrear fender andcenter pillar,rearwheel housing ofrear fender, aroundstruttower inengine
compartment, etc.

Panel edge

Trunk lidopening, sunroofopening, fenderwheelarch flange,fuelfiller lidflange, around holesinpanel,
etc.

Parts contact

Waist molding, windshield molding,bump.er,etc.

Protectors

Damage orcondition ofmudguard, fenderprotector, chippingprotector, etc.

Anti-corrosion materials

Damage orseparation ofanti-corrosion materialsunderthebody.

Drain holes

Condition ofdrain holes atdoor andside sill.
When repairing corrodedareas,refertothe Corrosion RepairManual.

MA-52

Toward
oil pocket
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Case Components (Cont'd)
Mainshaft frontbearing outerraceandoilchannel

1. Remove mainshaft frontbearing outerrace.
2. Remove oilchannel.

SMT636-A
3.Install oilchannel.

• Ensure theoilgroove facestheoilpocket.
SMT595
•

4. Install mainshaft frontbearing outerrace.

Mainshaft rearbearing outerrace
• Refer to"Differential SideBearing Preload", MT-29.
Differential sidebearing outerrace
• Refer to"Mainshaft BearingPreload", MT-28.
MT-27

Toward
oil pocket
REPAIR
FORCOMPONENT PARTS
Case Components (Cont'd)

4. Install oilchannel.

• Ensure theoilgroove facestheoilpocket.
SMT595
I

RSSF32A
I

5. Install mainshaft frontbearing.
6. Install mainshaft frontbearing retainer.

• Apply locking sealant tothread ofscrew before installation .
MT-53
•

SUPPLEMENTALRESTRAINTSYSTEM(SRS)
Precautions forSRS "AirBag" and"Seat Belt
Pre-tensioner" Service

• Donot use acircuit testertocheck SRScircuits.
• Before servicing theSRS. turnignition switch"OFF", disconnect bothbattery cablesandwait forat
least 10minutes.
For approximately 10minutes afterthecables areremoved, itis still possible forthe airbag to
deploy. Therefore, donot work onany SRS connectors orwires untilatleast 10minutes havepassed.
• For single airbag system, donot separate diagnosis sensorunitfrom steering wheel.
• For dual airbag system. diagnosis sensorunitmust always beinstalled withtheir arrow marks
"Q"

pointing towards thefront ofthe vehicle forproper operation. Alsocheck diagnosis sensorunitfor
cracks. deformities orrust before installation andreplace asrequired.
• The spiral cablemustbealigned withtheneutral position sinceitsrotations arelimited. Donot
attempt toturn steering wheelorcolumn afterremoval ofsteering gear.
• Handle airbag module carefully. Alwaysplaceitwith thepad side facing upward.
• Donot use oldbolts afterremoving anySRS parts; replace withnewones. Conduct self-diagnosis
to check entire SRSforproper function.
• For dual airbag system, instrument panelassembly shouldbereplaced afterairbag inflates.

X

X

Use
forspecial bolts
[TAMPER RESISTANT
TORX (SizeT50))

a:
3.5 (0.138)
dia.

b: 8.5 -8.6
(0.335 •0.339) dia.

c: approx.
10

(0.39) sq.

c

NT354
a

HT61961000
and
HT62152000 com-
bined *1 Special torxbit
Special
Service Tools

Application
Tool number
Description Seat
belt DualAir Single
Tool name
pre-ten-BagAirBag
sioner*2 Sstem Sstem
KV991072So Disposingofair bag
Air bag deployment kit module
KV991 06400
X
X

Deployment tool
KV991065So
Deployment tool
adapters
X

For passenger
air bag module
NT353

KV991 05300 Anchorthepassenger
Passenger airbag
airbag module
bracket
X

NT361
Unit:
mm(in)

*1: Special toolorcommercial equivalent
*2: Tools arenotapplicable becauseofits mechanical type.

RS-8

SUPPLEMENTALRESTRAINTSYSTEM(SRS)
Disposal ofAir Bag Module andSeat Belt
Pre-tensioner

• Before disposing ofair bag module andseat beltpre-tensioner, orvehicles equipped withsuch
systems, deploythesystems. Ifsuch systems havealready beendeployed duetoan accident, dis-
pose ofas indicated in"DISPOSING OFAIR BAG MODULE ANDSEAT BELTPRE-TENSIONER" (RS-

24).

• When deploying theairbag module, alwaysusetheSpecial Service Tool;Deployment tool
KV99106400.
• When deploying theairbag module andseat beltpre-tensioner, standatleast 5m (16 ft)away from
the deployment component.
• Due toheat, leave airbag module unattended formore than30minutes afterdeployment. Alsoleave
seat beltpre-tensioner unattendedformore than10minutes afterdeployment.
• Besure towear gloves whenhandling adeployed airbag module andseat beltpre-tensioner.
• Never applywater toadeployed airbag module.
• Wash yourhands cleanafterfinishing- work.
• Donot dispose ofthe airbag module andseat beltpre-tensioner un-deployed.

CHECKING DEPLOYMENT TOOL
Connecting tobattery

• Place thevehicle outdoors withanopen space ofat least 6
m (20
ft)
on allsides.
• Use avoltmeter tomake surethevehicle batteryisfully
charged.

CAUTION:
The battery mustshow voltage of9.6V ormore.

Remove thebattery fromthevehicle andplace iton dry wood

Deployment
tool blocksapproximately 5m (16 ft)away fromthevehicle.

(KV99106400j SRS005-B•
Wait 10to12 minutes afterthevehicle batteryisdiscon-
nected beforeproceeding.
• Connect redclip ofdeployment tooltobattery positive ter-
minal andblack cliptonegative terminal.

Make surethepolarity iscorrect. Theright sidelamp inthe tool,
marked "deployment toolpower", shouldglowwithagreen
light. Ifthe right sidelamp glows red,reverse theconnections
to the battery.

•

SBF266H Deployment
toolcheck

Press thedeployment toolswitch tothe "ON" position. Theleft
side lamp inthe tool, marked "airbagconnector voltage"
should illuminate.
If
it
does notilluminate, replacethetool.

Air bag deployment toollamp illumination chart(Battery
connected)

Leftside lamp, green' RighI
sidelamp,
Switch operation "AIR
BAGCONNEC- green'
"DEPLOYMENT TOOL
TOR VOLTAGE"
POWER"
OFF OFF ON
ON ON
ON
,. Ifthis lamp glows red,the1001 isconnecled tothe battery incorrectly.
Reverse theconnections andmake surethelamp glows green.

RS-19

SBF276H
SUPPLEMENTAL
RESTRAINTSYSTEM(SRS)

Disposal ofAir Bag Module andSeat Belt
Pre-tensioner (Cont'd)

DISPOSING OFAIR BAG MODULE ANDSEAT BELT
PRE- TENSIONER

Deployed airbag module andseat beltpre-tensioner arevery
hot. Before disposing ofair bag module andseat beltpre-
tensioner, waitatleast 30minutes. Sealthem inaplastic bag
before disposal.

CAUTION:

• Never applywater toadeployed airbag module andseat
belt pre-tensioner.
• Besure towear gloves whenhandling adeployed airbag
module andseat beltpre-tensioner.
• Nopoisonous gasisproduced uponairbag module deploy-
ment. However, becareful nottoinhale gassince itirritates
throat andcancause choking.
• Donot attempt todisassemble airbag module andseat belt
pre-tensioner.
• Air bag module andseat beltpre-tensioner cannotbe
re-used.
• Wash yourhands cleanafterfinishing work.

RS-24

TROUBLEDIAGNOSES -Supplemental RestraintSystem(SRS)-
Dual AirBag System
Self-diagnosis (Cont'd)
No.
ON
OFF
IGN
ON

t
"AIR
BAG" warning lampoperation -Diagnosis mode-

@
through
@
are repeated.

MRS100A
SRS
condition
No malfunc-
tion is
detected. No further
action isnec-
essary.

2 ON
OFF
IGN
ON

I

7 sec.
@)

@
(c)
3sec.
2 sec. 2sec. Varies withmalfunctioning part

MRS099A
@

through
@
are repeated.

NOTE: @ -
Interval I

@ -
Start signal (Startsignal
identifies displaymodes)

@ -
Interval II

@ -
Indicates malfunctioning
part (0.5sec. ONand 0.5
sec. OFF iscounted as
one flash.) The
system
has problem
and needs to
be repaired.

5. Malfunctioning partisindicated bythe number offlashes
(part
@).
Compare thenumber offlashes toWARNING
LAMP FLASH CODECHART, pageRS-37, andlocate mal-
functioning part.
6. Turn ignition switch"OFF", anddisconnect bothbattery
cables.
7. Repair thesystem asoutlined bythe "Repair order"in
WARNING LAMPFLASH CODECHART thatcorresponds to
the flash code. Forreplacement procedureofcomponent
parts, refertoRS-12.
8. After repairing thesystem, conduct DIAGNOSTIC PROCE-
DURE 3again.
If repair iscompleted, turnignition switch"OFF"andthen
turn "ON". Pressdriver's doorswitch atleast 5times within
7 seconds afterturning ignition switch"ON".
9. The system isreset fromDiagnostic modetoUser mode.
Next, gotoDIAGNOSTIC PROCEDURE 1,page RS-32. •
RS-35

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

POWERSTEERING OILPUMP
Pre-disassembly Inspection

Disassemble thepower steering oilpump onlyifthe following
items arefound.
• Oilleak from anypoint shown inthe figure
• Deformed ordamaged pulley
• Poor performance

SST984A Disassembly
CAUTION: • Parts which canbedisassembled arestrictly limited. Never
disassemble partsother thanthose specified.
• Disassemble inas clean aplace aspossible.
• Clean yourhands before disassembly.
• Donot use rags; usenylon cloths orpaper towels.
• Follow theprocedures andcautions inthe Service Manual.
• When disassembling andreassembling, donot letforeign
matter enterorcontact theparts.
Front housing Extension
bar
•
Remove snapring,thendraw drive shaftout.

Be careful nottodrop drive shaft.
SST010B
•Remove oilseal.

Be careful nottodamage fronthousing.

• Remove connector andflow control valvewithspring.

Be careful nottodrop flowcontrol valve.
SST036A 5T-30