500 NISSAN ALMERA N15 1995 Service Manual

Toolnumber
Tool name
PREPARATION
ANDPRECAUTIONS
Special Service Tools

Description
8T25058001
Oil pressure gaugeset

G)
8T25051001
Oil pressure gauge
@ 8T25052000
Hose

@
8T25053000
Joint pipe

@
8T25054000
Adapter

@
8T25055000
Adapter Measuring
linepressure andgovernor
pressure

NT097

KV31103000
Drift
8T35325000 Drift
KV31103200
Clutch spring compressor
8T23540000 Pin punch
KV32101000
Pin punch
NT105
NT417
NT425
NT442
NT410
AT-3
Installing
differential sideoilseal
(Use with8T35325000)

a: 59 mm (2.32 in)dia.
b: 49 mm (1.93 in)dia.

Installing differential sideoilseal
(Use withKV31103000)

a: 215 mm (8.46 in)
b: 25 mm (0.98 in)dia.
c: M12 x1.5P

Removing andinstalling clutchreturn
spring

a: 179 mm (7.05 in)
b: 76 mm (2.99 in)dia.
c: 174 mm (6.85 in)

Removing andinstalling parkingrodplate
and manual plate

a: 2.3 mm (0.091 in)dia.
b: 4mm (0.16 in)dia.

Installing throttleleverandmanual shaft
retaining pins
Removing andinstalling differential pinion
mate shaft lockpin.

a: 4mm (0.16 in)dia.
•

REPAIRFORCOMPONENT PARTS
Control ValveLower Body(Cont'd)
DISASSEMBL Y

1. Remove valvesatretainer plate.
For removal procedures, referto"DISASSEMBLY" in"Con-
trol Valve Upper Body", AT-B?

SAT1130 Throttle valve

o
f2- •
Remove throttlevalveatE-ring.

•

INSPECTION
Valve springs

• Check eachvalve spring fordamage ordeformation. Also
measure freelength andouter diameter.

Inspection standard:
Refer to50S, AT-167.

• Replace valvesprings ifdeformed orfatigued.

Control valves

• Check sliding surfaces ofcontrol valves, sleeves andplugs
for damage.

ASSEMBLY
Throttle valve

• Insert throttle valvetocontrol valvebodyandthen install
E-ring tothrottle valve.

SAT147D
SAT13BO

Q

(Length)
SAT1490Pressure regulator valve

• Install pressure regulator valveafterassembling sleeve
plug, plugAand plug B.

SAT1500 AT-91

ASSEMBLY
KV31103000 and

ST35325000
Assembly
1

1. Install differential side.

converter
housing
011
seals ontransmiss,'on
cations. 'so that "A" and "8" caseand
are within specifi-

Converter housings'd

Ie
(RHS)
KV31103000 -J..
Transmission caseside(LHS)

KV'"03000~ ..

Unit:mm(in)

B

0.5 (0.020)
or
less

A

5.5 -6.5 (0.217 -0.256)

Install parking actuator su

Pay attention todirection
Pfortt?transmission case.

o parkmg actuator support.
SAT260EA
Converter housing
side
Transmission
case side

B

Oil
seal Oil
seal

A
SAT6390 2.

..
•
~ Inside

...

~ Outside
SAT328D 3.
Install parking
parking shaft.pawlontransmission caseand
fixitwith

SAT3290 AT-138

0.05(0.0020)

Reduction
piniongearbearing
preload mm(in)
Unit:
mm(in)

SERVICE
DATAANDSPECIFICATIONS (SOS)
Specifications andAdjustments (Cont'd)
Table forselecting differential sidebearing Bearingpreload(Model34X81)
adjusting shim(s)

Dial indicator deflection
Suitableshim(s)

Reductionpiniongearbearing adjusting
shims
0.31
-0.35 (0.0122 -0.0138)
035 -0.39 (0.0138 -0.0154)
0.39 -043 (0.0154 -0.0169)
043 -047 (0.0169 -0.0185)
047 -0.51 (0.0185 -0.0201)
0.51 -0.55 (0.0201 -0.0217)
055 -059 (0.0217 -0.0232)
0.59 -0.63 (0.0232 -0.0248)
0.63 -0.67 (0.0248 -00264)
0.67 -0.71 (0.0264 -0.0280)
071 -075 (0.0280 -0.0295)
075 -079 (0.0295 -0.0311)
0.79 -083 (0.0311 -0.0327)
0.83 -0.87 (0.0327 -0.0343)
087 -0.91 (0.0343 -0.0358)
0.91 -095 (0.0358 -0.0374)
095 -099 (0.0374 -0.0390)
0.99 -1.03 (0.0390 -0.0406)
103 -1.07 (0.0406 -0.0421)
1.07 -1.11 (0.0421 -0.0437)
1.11 -1.15 (0.0437 -00453)
1.15 -1.19 (0.0453 -0.0469)
119 -1.23 (0.0469 -0.0484)
1.23 -1.27 (0.0484 -0.0500)
1.27 -1.31 (0.0500 -0.0516)
1.31 -1.35 (0.0516 -0.0531)
135 -139 (00531 -0.0547)
139 -143 (0.0547 -0.0563)
143 -147 (0.0563 -0.0579)
147 -151 (0.0579 -0.0594)
151 -155 (00594 -0.0610)
1.55 -159 (0.0610 -00626)
1.59 -163 (0.0626 -0.0642)
163 -1.67 (0.0642 -0.0657)
1.67 -1.71 (0.0657 -0.0673)
1.71 -1.75 (0.0673 -0.0689)
1.75 -1.79 (0.0689 -0.0705)
1.79 -183 (0.0705 -0.0720)
1.83 -187 (0.0720 -00736)
1.87 -191 (0.0736 -0.0752)
1.91 -195 (0.0752 -0.0768) 040
(0.0157)
0.44 (0.0173)
048 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
060 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
076 (0.0299)
0.80 (0.0315)
084 (0.0331)
0.88 (0.0346)
0.92 (00362)
048 (0.0189) +048 (0.0189)
048 (0.0189)
+
052 (0.0205)
0.52 (0.0205) +052 (0.0205)
052 (0.0205) +056 (0.0220)
056 (00220) +0.56 (0.0220)
056 (0.0220) +060 (0.0236)
0.60 (0.0236) +0.60 (0.0236)
060 (00236)
+
064 (0.0252)
064 (0.0252)
+
0.64 (0.0252)
0.64 (0.0252) +0.68 (0.0268)
068 (0.0268)
+
0.68 (0.0268)
0.68 (0.0268)
+
0.72 (0.0283)
144 (0.0567)
0.72 (0.0283)
+
0.76 (0.0299)
076 (0.0299)
+
0.76 (0.0299)
0.76 (0.0299)
+
0.80 (0.0315)
0.80 (0.0315) +080 (0.0315)
0.80 (0.0315)
+
0.84 (0.0331)
084 (0.0331)
j-
084 (0.0331)
0.84 (0.0331)
+
088 (0.0346)
088 (0.0346) +0.88 (0.0346)
088 (0.0346)
i
092 (0.0362)
092 (00362)
+
0.92 (0.0362)
044 (0.0173) +144 (0.0567)
048 (0.0189)
+
144 (0.0567)
052 (0.0205) +144 (0.0567)
0.56 (0.0220)
+
144 (0.0567)
Thickness
mm(in)

1.74 (0.0685)
1.78 (00701)
1.82 (0.0717)
1.86 (0.0732)
1.90 (0.0748)
1.92 (0.0756)
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0780)
2.00 (0.0787)
202 (0.0795)
2.04 (0.0803)
206 (0.0811)
2.08 (0.0819)
2.10 (00827)
2.12 (0.0835)
2.14 (0.0843)
2.16 (00850)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.24 (0.0882)
226 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
234 (0.0921)
238 (0.0937)
242 (0.0953)
246 (0.0969)
250 (0.0984)
2.54 (0.1000)
2.58 (01016)
262 (0.1031)
266 (0.1047)
Part
number

31438-31X16
31438-31X17
31438-31X18
31438-31X19 31438-31 X20
31439-31 X60
31438-31X21
31439-31X61
31438-31 X22
31439-31 X62
31438-31 X23
31439-31X63
31438-31X24
31439-31X64
31438-31X60
31439-31X65
31438-31X61
31439-31 X66
31438-31X62
31439-31 X67
31438-31X63
31439-31 X68
31438-31X64
31439-31 X69
31438-31 X65
31438-31X66
31438-31 X67
31438-31 X68
31438-31X69
31438-31 X70
31438-31X71
31438-31 X72
31438-31 X73
31438-31 X74
•

REDUCTION GEAR
Bearing preload(Model34X68,34X69,
34X70, 34X80)

Reduction piniongearbearing

011-069 (11-70, 095 -6.08)

preload Nm(kg-em, in-Ib)

AT-171

BODYALIGNMENT
Underbody

MEASUREMENT

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500

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88T096

BT-49

Approx.125mm (4.92 In) BRAKE
BOOSTER

Inspection

OUTPUT RODLENGTH CHECK

1. Supply brakebooster withvacuum of-66.7 kPa(-667 mbar,
-500 mmHg, -19.69inHg)usingahand vacuum pump.
2. Check output rodlength.
Specified length:
M195, S205orC205
10.275 -10.525 mm(0.4045 -0.4144 in)
Installation
CAUTION: • Becareful nottodeform orbend brake pipesduring instal-
lation ofbooster.
• Replace clevispinifdamaged.
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donol mix different typesofbrake fluids(DOT3,DOT 4).
• Due tothe angle ofinstallation, threadcanbedamaged by
the dash panel.
1. Before fittingbooster, temporarily adjustclevistodimen-
sion shown. (Doesnotapply tovehicles fittedwithABS.)
2. Fitbooster, thensecure mounting nuts(brake pedalbracket
to booster) lightly.
3. Connect brakepedalandbooster inputrodwith clevis pin.
4. Secure mounting nuts.
Specification:
~: 13-16 N'm (1.3-1.6 kg-m, 9-12 ft-Ib)
5. Install master cylinder. RefertoBR-12.
6. Bleed air.Refer to"Bleeding Procedure", BR-6.

BR-16

•
SEL019Z
Vernier caliper
SEL021Z

Round 0.5-0.8 ,;,;;

~""I
Correct
~File
~ Commutator
SEL022Z STARTING
SYSTEM
Armature Check

1. Continuity test(b
• Nocontinuit etweentwosegm .
2. Insulation tY ... Replace. entssIde byside)
• C .. est (between .
ontlnulty exists Reachcommutato b
....
eplace. rar and shaft).
3. Check comm t
• Rough Sua~or surface.
... and lightly withN
0.500 -600 emery paper.
4. Check diameter of

Commutator ml"
"commutator.

R f
mmumdia
e er toSOS (EL meter:

Less thanspe'f'
-50).

CI
led value R
... eplace.
5. Check depthof.
• Less than02 Insulating moldfrom
(0.020 to003' 1~m) (0.008 in)...Und commutator surface
. In ercutto0.5 to0.8 m'm

EL-48

STARTINGSYSTEM
Service DataandSpecifications (SDS)
STARTER
S114-766A M1T72087A
M1T77281S114-769A S114-630M3T37783 M2T62071A S13-305S13-331M2T61871A
Type HITACHIMITSUBISHI HITACHI
MITSUBISHI HITACHIMITSUB-
ISHI
Reduction Non-reduction
Reduction
Europe
Applied model
GAengines
CD20
A/T MIT
System voltage
V

12
No-load Terminal voltage
V
11.0 11511.0
Less than
50-75 Less
than
Lessthan60 Less
than
Lessthan140 Less
than
Current A
85 85105110
More than Morethan More
Morethan More
than Morethan
Revolution rpm
2,950 3,000
-4,000
2,950than
6,500 4,030More
than3,900
4,100
7,000
Minimum diameterof 28.0
28.8(1.134) 28.0
39.0
31.4(1.236) 35.5(1.398) 31.4
commutator mm(in) (1,102) (1,102)(1.535) (1236)
Minimum length
10.5 10.511.0
11.5(0.453) 11.0
(0.433) 11.5
of brush mm(in) (0.413) 12.0
(0.472)
(0.413)(0.433) (0.453)
16.2 14.7
-17.7 17.7
-
13.7-25.5
Brush spring tension
(1.65, 13.7
-25.5
(1.5-1.8, 21.6
13.7-25.5 28.4
-34.3 (2.90 -
(1.4 -2.6,
N (kg, Ib)
3.64) (1.4
-2.6, 3.1-5.7)
3.3-4.0) (1.8
-2.2, (1.4-2.6, 3.1-5.7) 3.50,
6.38-7.71)
3.1-5.7)
4.0 -4.9)
Clearance between
Lessthan Less
Less
bearing metaland
-
than0.2
-
than
0.2
-

armature shaftmm(in) 0.2
(0.008)
(0.008) (0.008)
Clearance
'T'

0.3-2.5 0.5
-2.0 0.3-2.0 0.3
-0.8
between pinionfront
(0.012- 0.5
-2.0 0.3-2.5
(0.020- (0.012
-(0.012 -

- -

edge andpinion
0.098)(0.020
-0.079) (0.012
-0.098)
0.079) 0.079)0.031)
stopper mm
(in)
Movement
'T'
in 0.5
-2.0 0.3
-1.5
height ofpinion

-
(0.020
-
-
-
(0.012
-
assembly mm(in) 0.079)0.059)
EL-50

CHARGINGSYSTEM
Trouble Diagnoses

Before conducting analternator test,make surethatthebattery isfully charged. A3D-volt voltmeter and
suitable testprobes arenecessary forthe test. Thealternator canbechecked easilybyreferring tothe
Inspection Table.

Before starting, inspectthefusible link.
WITH IeREGULATOR

Burned-out
bulb.
Replace and
proceed to

"@".

Light "ON"
Light "OFF"
Connect
connector (S,
L) and
ground F
terminal
Engine
speed: 1,500 rpm
(Measure B
terminal
voltage)
Make sure
connector (S,L)is
connected
correctly.

(HITACHI

make)
'See
4)for grounding Fterminal.
(MITSUBISHI
make)
Check or
replace drive
belt.
Light "ON"
Light "OFF"
Disconnect
connector (S,
L) and
ground L
lead wire.
Engine
speed:
1,500 rpm
Lighting
switch "ON"
With
alternator sideLterminal
grounded. internalshortoccurs
when
+
diode isshort-circuited.
Light "ON
Dim
light
Light flickers
Bright light
Light
"ON"
Light
"OFF"
Ignition
switch "ON"

@

1) Use fully charged battery.
2) light: Charge warning light
ACG :Alternator partsexcept I'Cregulator
IC-RG :IC regulator
OK :IC-alternator isingood condition.
3) When reaching "Damaged ACG",remove
alternator fromvehicle anddisassembly, inspect
and correct orreplace faultyparts.
4) *Method ofgrounding Fterminal (HITACHI make
only)
Gasoline enginemodel
Contact tipofwire withbrush andattach
wire toalternator body.
~~~
;;z..'~~.~

~~~/j
S$.~~'
s<(r~, -
Brush liftwire

;;.. ~ Q<:::z"d,l'T7.

~ .. ~ ~-)o,IJ!"-f/

- -~~ C);
0~~/

'~-/i ~-,~

-~j~n

- <::::; -~ \•

'" 1A/-'

SEL030Z
5) Terminals
"S","l","B"
and
"E"
aremarked onrear cover ofalternator.
EL-54

CHARGINGSYSTEM
Service DataandSpecifications (SOS)

ALTERNATOR

A5T06891LR170-746E LR170-504B A2T82491A
Type MITSUBISHIHITACHIMITSUBISHI
Applied model GA
engines CD20SR20DE
Nominal rating V-A
12-70 12-80
Ground polarity Negative
Minimum revolutions
under no-load Less
than
Lessthan1,000 Less
than
(when 13.5Visapplied) 1,300 1,300
rpm
Hot output current More
than Morethan
(When 13.5Visapplied) More
than 22/1,300 27/1,300
Morethan

.
21/1,300
Morethan More
than 22/1,300
More than 50/2,500 56/2,500More
than
50/2,500 Morethan Morethan 65/2,500
A/rpm 67/5,000
66/5,000
Regulated output
14.1-14.7
voltage V
Minimum lengthof
50(0.197) 6.0
(0.236) 5.0(0.197)
brush mm(in)
Brush spring pressure 4.609
-5.786 1.0-343 0.92
-328 4.609-5.786
(470 -590, (102
-350, (94-334, (470
-590,
N (g, oz)
16.58 -20.81) 3.60
-12.34) 332-11.78) 16.58
-20.81)
Slip ringminimum
221(0.870) 26.0
(1.024) 31.6(1.244) 221(0.870)
diameter mm(in)
Rotor coilresistance at
2.5-2.9 258 4824
-29
20'C (68'F)

n

EL-61
•