ABS NISSAN ALMERA N15 1995 Service Manual

Description REPLACEMENT
OPERATIONS
Outer Sill

Sedan

5-door hatchback

FR

_4A

.cm

(OIerlap cutting)

_4

117

Unit:mm
119

112A 111A
114 111

114

M. I.G plug weld MIG seam weld/
(For 3panels plugweld method )P.an.
0int
;=::

· r .
A
=6=___
.8=:=
V

11
12

_4

111
112A

113

2-spot welds 3-spotwelds

Service
Joint

One-side precoated

Steel
sheet
~ Outside

Two-side precoated

Zn-Ni
alloy
Cationic electrodeposition primer

PHOSPHATE
COATINGTREATMENT AND
CATIONIC ELECTRODEPOSITION PRIMER
ANTI-CORROSIVE
PRECOATEDSTEEL
(DURASTEEL)

To
provide improved corrosion prevention, thefollowing anti-corrosive measureshavebeen implemented in
our production plants.Whenrepairing orreplacing bodypanels, itis necessary touse these sameanti-corrosive
measures.

Nissan Genuine ServicePartsalsoaretreated inthe same manner. Therefore, itis recommended tbat
GENUINE NISSANPARTSbeused forpanel replacement tomaintain anti-corrosive performancebuilt
into thevehicle atthe factory.

A
phosphate coatingtreatment andacationic electrodeposition primer,whichprovide anexcellent anti-
corrosion effect,areemployed onallbody components.

Caution:
Confine paintremoval inthe welding operation tothe absolute minimum.

Durasteel
isclassified aseither one-side precoated
steel ortwo-side precoated steel.Thetwo side
precoated steelprovides excellent corrosion resis-
tance. To
improve repairability andcorrosion resistance, a
new type ofanti-corrosive precoatedsteelsheets have
been adopted takingtheplace ofconventional zinc-
coated steelsheets.
This durasteel iselectroplated, zinc-nickelalloyunder
organic film,which provides excellent corrosion resis-
tance.

Nissan Genuine ServicePartsarefabricated fromdurasteel sheets.Therefore, itis recommended that
GENUINE NISSANPARTSbeused forpanel replacement tomaintain theanti-corrosive performance
built intothevehicle atthe factory.

-7-
-38-

______ HANDLINGPRECAUTIONS FORPLASTICS __
BODYALIGNMENT _
Location OfPlastic Parts
Underbody

Kicking plate(PP)
Front

@,
076
dia.
Rear
@,@
62 dia.

Front
Rear
coordinates: coordinates:
@,@ @,@@
X :250
X:393.5
X:475
V :-632
V:1,460
V:3,082
Z :224.8
Z:126.9
Z:336.8
@,@
(8),
@
@
X :492 X
:572
X:-542
V :-450 V
:1,940
V:3,082
Z :355 Z
:200
Z:336.8
@,@
CD,
CD

X :406
X:600
V :64
V:2,035
Z :172
Z:235.2
@,@
Q)

X :352.7 X
:150
V :69 V
:2,442.9
Z :240 Z
:241

@,
@
@
X :432
X:300
V :338
V:2,480
Z :128
Z:381.8
(f),
CD
@
X :395
X:-300
V :515
V:2,480
Z :129.2
Z:405.8

@,
@)

X :393
Y :2,560
Z :365
@
X :470
Y :2,911
Z :339.6
@
X :-539
Y :2,911
Z :339.6
Unit: mm
Coordinates:
@,0
X :522.2
V :18.1
Z :571.7
@,@ X :465
V :2,456.4
Z :522

Front
andrear strut tower centers

I

~t-~

Rear
(f
••@
LH side
RHside

Q
Q

Bottom
view of

,1

vehicle

__
MEASURMENT POINTS__

Glove box(PPC)
Side
wind molding(PVC)
Cluster lidC(PPC)
Instrument
panel(PPC)
Console box(PPC)

5-door
Hatchback

Cluster lidA(PPC)

~----_/

Front
pillargarnish(PPC)
Side
wind molding(PVC)
Back doorfinisher(ABS)
Roof
spoilar(FRP)

3-doorHatchback

Center pillarlower garnish(PP)
Center pillarupper garnish(PPC)
Rear pillar garnish(PPC)
High
mounted stoplamp
(Lens: PMMA )
Housing: ABS

FrontSBT097

-27-
-18-

__________ BODYALIGNMENT _
_HANDLINGPRECAUTIONS FORPLASTICS _
Passenger Compartment Sedan
5-door Hatchback Location
OfPlastic Parts

Side turnsignal lamplens
(Lens: AS)
Housing: ASS
Wind-shield molding
(Upper: PVC )
Side:Stainless+PVC
Doorout-side molding
(Stainless+PVC)
Wheel cover
(Full cover: PP+PA6 )
Half cover: PA66+PPO
Center cap:PA6
Door
mirror
(Housing: AAS)
Garnish: ASS
Front turnsignal lamp
(Lens: PMMA)
Housing: PP
Fog
lamp
(Lens: Glass)
Housing: PP
Head
lamp
(Lens: Glass)
Housing: pp
Radiator grille

(ABS)

Fog lamp finisher
(PM MA)
Front
bumper fascia

(PP)

Front airspoiler

(PP)

Point
Dimension

@-@
1228

CB- 1374

@-@
1366

(8)-{6)
1159

CD--cD
1387
Q)-{J) 1367

@--@
1156

(b)--{[)
1385

~-4iV
1370

@~
1364

@~
1364

C'e)--@
1598

@--@
989*

@-{E)
918*

@~
1156*

@--{[)
917*

@~@
975*

@~(b)
757*

@~
1004*

@--@
723*

,
... ._MEASURMENT _

Figures marked witha
*
show symmetrically identical
dimensions onboth right andlefthand sides ofthe
vehicle.
Unit:
mm

@ :
Cowl tophole center (5dia.)
CB>
:
Front roofflange endatcenter
Positioning mark ~~
~}Outer frontpillarjoggle
Sideguard molding (PVC)
Rear combination lamp
(Lens: PMMA)
Housing: PP
Door
outside handle
(Handle: POM )
Escutcheon: POM
Mud guard (TPR)
Rear
Windowmolding
(PVC)
-for Sedan
Rear bumper fascia

(PP)

License
lamp
(Lens: PC)
Housing: PP
Trunk
lidfinisher(pp)
-for Sedan
Rear
spoiler(PPO)
-for Sedan
High mounted stoplamp
(In Rear SpoilerType)
(Lens: PMMA)-for Sedan
Housing: ASS
(Fixed Trunk LidTipe)
(Lens: PC)-for Sedan
Housing: PP

(f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

Outer center pillarindention

CDCD :
Outer center pillarstandard hole
center

CBCD:
}

~@:
Outerfrontpillar indention

@@
:
Dash upper flange endcorner

-19- -26-

______ HANDLINGPRECAUTIONS FORPLASTICS __________
BODYALIGNMENT _
Handling Precautions ForPlastics

Heat resisting
Resistancetogasoline and
Abbreviation Materialname
temperature Othercautions

QC rF)
solvents

PE Polyethylene
80
(176)
Gasoline
andmost solvents
Flammable
are harmless.
PET Polyethylene

180(356)
Gasoline
andmost solvents
terephthalate areharmless.
Gasoline andmost solvents
PVC Polyvinylchloride
80
(176)
are
harmless ifapplied fora
Poison gasisemitted
very short time(wide up
whenburned.
quickly).

pp
Polypropylene
90
(194)
Same
asabove.
Flammable
Also avoid battery acid.
ABS Acrylonitrile
butadiene

80(176)

Avoidgasoline andsolvents.
styrene resin
AES Acrylonitrile
ethylene

80(176)

Avoidgasoline andsolvents.
styrene
PMMA Polymethylmethacrylate
85
(185)

Avoidgasoline andsolvents.
PUR Polyurethane
90
(194)
Gasoline
andmost solvents
Avoidbattery acid.
are harmless.
AAS Acrylonitrile
acrylic

85(185)

Avoidgasoline andsolvents.
ru bber styrene
AS Styrene-a crylo nitri Ie
85
(185)

Avoidgasoline andsolvents.
PPO Polyphenylene oxide
110
(230)

Avoidgasoline .andsolvents.
POM Polyacetal
120
(248)
Gasoline
andsolvents
Avoidbattery acid.
are harmless.
PC Polycarbonate
120
(248)

Avoidgasoline andsolvents.
PA Polyamide(Nylon)
140
(284)
Gasoline
andmost solvents
Avoidimmersing inwater.
are harmless.
FRP Fiberreinforced plastics
170
(338)
Gasoline
andmost solvents
Avoidbattery acid.
are harmless.
PPC Polypropylene composite
115
(239)
Gasoline
andmost solvents
Flammable
are harmless.
PBT Polybutylene terephthalate
140
(284)
Gasoline
andmost solvents
are harmless.
TPR Thermoplastic rubber
80
(176)

Avoidgasoline andsolvents.
TPE Thermoplastic elastomer
80
(176)

Avoidgasoline andsolvents.
TPUR Thermoplastic

80(176)

Avoidgasoline andsolvents.
polyurethane

1 . When repairing andpainting aportion ofthe body adjacent toplastic parts,consider theircharacteristics
(influence ofheat andsolvent) andremove themifnecessary ortake suitable measures toprotect them._
2. Plastic partsshould berepaired andpainted usingmethods suitingthematerials.

-25-
Passenger
Compartment

____ MEASURMENT _
Unit:mm

~@ :
Rear fender standard holecenter
@:
2nd crossmember standardhole
(7dia) centeratcenter positioning mark

(Q)@ :
Rear fender indention (8dia.)

(B@ :
Door switch installing holecen-
@([):
Rearfloor harness installing hole
ter center(8dia.)
(20 dia.) ~
(D<)

~~ ~~'---- ~ k@(fdiaol",

(7 diajj \\1 ~;..·
C')\U--

~ ~O"~Wiaol ~
-Z

J
D~

-20-
Sedan
5-door Hatchback

______ HANDLINGPRECAUTIONS FORPLASTICS __________
BODYALIGNMENT _
Handling Precautions ForPlastics

Heat resisting
Resistancetogasoline and
Abbreviation Materialname
temperature Othercautions

QC rF)
solvents

PE Polyethylene
80
(176)
Gasoline
andmost solvents
Flammable
are harmless.
PET Polyethylene

180(356)
Gasoline
andmost solvents
terephthalate areharmless.
Gasoline andmost solvents
PVC Polyvinylchloride
80
(176)
are
harmless ifapplied fora
Poison gasisemitted
very short time(wide up
whenburned.
quickly).

pp
Polypropylene
90
(194)
Same
asabove.
Flammable
Also avoid battery acid.
ABS Acrylonitrile
butadiene

80(176)

Avoidgasoline andsolvents.
styrene resin
AES Acrylonitrile
ethylene

80(176)

Avoidgasoline andsolvents.
styrene
PMMA Polymethylmethacrylate
85
(185)

Avoidgasoline andsolvents.
PUR Polyurethane
90
(194)
Gasoline
andmost solvents
Avoidbattery acid.
are harmless.
AAS Acrylonitrile
acrylic

85(185)

Avoidgasoline andsolvents.
ru bber styrene
AS Styrene-a crylo nitri Ie
85
(185)

Avoidgasoline andsolvents.
PPO Polyphenylene oxide
110
(230)

Avoidgasoline .andsolvents.
POM Polyacetal
120
(248)
Gasoline
andsolvents
Avoidbattery acid.
are harmless.
PC Polycarbonate
120
(248)

Avoidgasoline andsolvents.
PA Polyamide(Nylon)
140
(284)
Gasoline
andmost solvents
Avoidimmersing inwater.
are harmless.
FRP Fiberreinforced plastics
170
(338)
Gasoline
andmost solvents
Avoidbattery acid.
are harmless.
PPC Polypropylene composite
115
(239)
Gasoline
andmost solvents
Flammable
are harmless.
PBT Polybutylene terephthalate
140
(284)
Gasoline
andmost solvents
are harmless.
TPR Thermoplastic rubber
80
(176)

Avoidgasoline andsolvents.
TPE Thermoplastic elastomer
80
(176)

Avoidgasoline andsolvents.
TPUR Thermoplastic

80(176)

Avoidgasoline andsolvents.
polyurethane

1 . When repairing andpainting aportion ofthe body adjacent toplastic parts,consider theircharacteristics
(influence ofheat andsolvent) andremove themifnecessary ortake suitable measures toprotect them._
2. Plastic partsshould berepaired andpainted usingmethods suitingthematerials.

-25-
Passenger
Compartment

____ MEASURMENT _
Unit:mm

~@ :
Rear fender standard holecenter
@:
2nd crossmember standardhole
(7dia) centeratcenter positioning mark

(Q)@ :
Rear fender indention (8dia.)

(B@ :
Door switch installing holecen-
@([):
Rearfloor harness installing hole
ter center(8dia.)
(20 dia.) ~
(D<)

~~ ~~'---- ~ k@(fdiaol",

(7 diajj \\1 ~;..·
C')\U--

~ ~O"~Wiaol ~
-Z

J
D~

-20-
Sedan
5-door Hatchback

__________ BODYALIGNMENT _
_HANDLINGPRECAUTIONS FORPLASTICS _
Passenger Compartment Sedan
5-door Hatchback Location
OfPlastic Parts

Side turnsignal lamplens
(Lens: AS)
Housing: ASS
Wind-shield molding
(Upper: PVC )
Side:Stainless+PVC
Doorout-side molding
(Stainless+PVC)
Wheel cover
(Full cover: PP+PA6 )
Half cover: PA66+PPO
Center cap:PA6
Door
mirror
(Housing: AAS)
Garnish: ASS
Front turnsignal lamp
(Lens: PMMA)
Housing: PP
Fog
lamp
(Lens: Glass)
Housing: PP
Head
lamp
(Lens: Glass)
Housing: pp
Radiator grille

(ABS)

Fog lamp finisher
(PM MA)
Front
bumper fascia

(PP)

Front airspoiler

(PP)

Point
Dimension

@-@
1228

CB- 1374

@-@
1366

(8)-{6)
1159

CD--cD
1387
Q)-{J) 1367

@--@
1156

(b)--{[)
1385

~-4iV
1370

@~
1364

@~
1364

C'e)--@
1598

@--@
989*

@-{E)
918*

@~
1156*

@--{[)
917*

@~@
975*

@~(b)
757*

@~
1004*

@--@
723*

,
... ._MEASURMENT _

Figures marked witha
*
show symmetrically identical
dimensions onboth right andlefthand sides ofthe
vehicle.
Unit:
mm

@ :
Cowl tophole center (5dia.)
CB>
:
Front roofflange endatcenter
Positioning mark ~~
~}Outer frontpillarjoggle
Sideguard molding (PVC)
Rear combination lamp
(Lens: PMMA)
Housing: PP
Door
outside handle
(Handle: POM )
Escutcheon: POM
Mud guard (TPR)
Rear
Windowmolding
(PVC)
-for Sedan
Rear bumper fascia

(PP)

License
lamp
(Lens: PC)
Housing: PP
Trunk
lidfinisher(pp)
-for Sedan
Rear
spoiler(PPO)
-for Sedan
High mounted stoplamp
(In Rear SpoilerType)
(Lens: PMMA)-for Sedan
Housing: ASS
(Fixed Trunk LidTipe)
(Lens: PC)-for Sedan
Housing: PP

(f3),Cfi),Q),CD,@,@,CD,CD,~,@ :

Outer center pillarindention

CDCD :
Outer center pillarstandard hole
center

CBCD:
}

~@:
Outerfrontpillar indention

@@
:
Dash upper flange endcorner

-19- -26-

______ HANDLINGPRECAUTIONS FORPLASTICS __
BODYALIGNMENT _
Location OfPlastic Parts
Underbody

Kicking plate(PP)
Front

@,
076
dia.
Rear
@,@
62 dia.

Front
Rear
coordinates: coordinates:
@,@ @,@@
X :250
X:393.5
X:475
V :-632
V:1,460
V:3,082
Z :224.8
Z:126.9
Z:336.8
@,@
(8),
@
@
X :492 X
:572
X:-542
V :-450 V
:1,940
V:3,082
Z :355 Z
:200
Z:336.8
@,@
CD,
CD

X :406
X:600
V :64
V:2,035
Z :172
Z:235.2
@,@
Q)

X :352.7 X
:150
V :69 V
:2,442.9
Z :240 Z
:241

@,
@
@
X :432
X:300
V :338
V:2,480
Z :128
Z:381.8
(f),
CD
@
X :395
X:-300
V :515
V:2,480
Z :129.2
Z:405.8

@,
@)

X :393
Y :2,560
Z :365
@
X :470
Y :2,911
Z :339.6
@
X :-539
Y :2,911
Z :339.6
Unit: mm
Coordinates:
@,0
X :522.2
V :18.1
Z :571.7
@,@ X :465
V :2,456.4
Z :522

Front
andrear strut tower centers

I

~t-~

Rear
(f
••@
LH side
RHside

Q
Q

Bottom
view of

,1

vehicle

__
MEASURMENT POINTS__

Glove box(PPC)
Side
wind molding(PVC)
Cluster lidC(PPC)
Instrument
panel(PPC)
Console box(PPC)

5-door
Hatchback

Cluster lidA(PPC)

~----_/

Front
pillargarnish(PPC)
Side
wind molding(PVC)
Back doorfinisher(ABS)
Roof
spoilar(FRP)

3-doorHatchback

Center pillarlower garnish(PP)
Center pillarupper garnish(PPC)
Rear pillar garnish(PPC)
High
mounted stoplamp
(Lens: PMMA )
Housing: ABS

FrontSBT097

-27-
-18-

Description REPLACEMENT
OPERATIONS
Outer Sill

Sedan

5-door hatchback

FR

_4A

.cm

(OIerlap cutting)

_4

117

Unit:mm
119

112A 111A
114 111

114

M. I.G plug weld MIG seam weld/
(For 3panels plugweld method )P.an.
0int
;=::

· r .
A
=6=___
.8=:=
V

11
12

_4

111
112A

113

2-spot welds 3-spotwelds

Service
Joint

One-side precoated

Steel
sheet
~ Outside

Two-side precoated

Zn-Ni
alloy
Cationic electrodeposition primer

PHOSPHATE
COATINGTREATMENT AND
CATIONIC ELECTRODEPOSITION PRIMER
ANTI-CORROSIVE
PRECOATEDSTEEL
(DURASTEEL)

To
provide improved corrosion prevention, thefollowing anti-corrosive measureshavebeen implemented in
our production plants.Whenrepairing orreplacing bodypanels, itis necessary touse these sameanti-corrosive
measures.

Nissan Genuine ServicePartsalsoaretreated inthe same manner. Therefore, itis recommended tbat
GENUINE NISSANPARTSbeused forpanel replacement tomaintain anti-corrosive performancebuilt
into thevehicle atthe factory.

A
phosphate coatingtreatment andacationic electrodeposition primer,whichprovide anexcellent anti-
corrosion effect,areemployed onallbody components.

Caution:
Confine paintremoval inthe welding operation tothe absolute minimum.

Durasteel
isclassified aseither one-side precoated
steel ortwo-side precoated steel.Thetwo side
precoated steelprovides excellent corrosion resis-
tance. To
improve repairability andcorrosion resistance, a
new type ofanti-corrosive precoatedsteelsheets have
been adopted takingtheplace ofconventional zinc-
coated steelsheets.
This durasteel iselectroplated, zinc-nickelalloyunder
organic film,which provides excellent corrosion resis-
tance.

Nissan Genuine ServicePartsarefabricated fromdurasteel sheets.Therefore, itis recommended that
GENUINE NISSANPARTSbeused forpanel replacement tomaintain theanti-corrosive performance
built intothevehicle atthe factory.

-7-
-38-

BRAKESYSTEM
SECTION

CONTENTS BR
PRECAUTIONS ANDPREPARATION
3

Precautions 3
Special Service Tools 4
Commercial ServiceTools 4

CHECK ANDADJUSTMENT 5

Checking BrakeFluidLevel 5
Checking BrakeLine 5
Changing BrakeFluid 5

AIR
BLEEDING 6

Bleeding Procedure 6

BRAKE HYDRAULIC LINE 7

Removal 8
Inspection 8
Installation 8

CONTROL VALVE 9

Proportioning Valve 9

BRAKE PEDALANDBRACKET 11

Removal andInstallation 11
Inspection 11
Adjustment 11

MASTER CYLINDER 12

Removal 12
Disassembly 12
Inspection 13
Assembly 13
Installation 14

BRAKE BOOSTER 15

On-vehicle Service 15
Removal 15
Inspection 16
Installation 16

VACUUM HOSE 17

Removal andInstallation 17
Inspection 17

FRONT DISCBRAKE 19

Pad Replacement.. 19
Removal 22
Disassembly 22Inspection
-Caliper 22
Inspection -Rotor 23
Assembly '".23
Installation 24

REAR DRUM BRAKE 25

Removal 25
Inspection -Wheel Cylinder 26
Wheel Cylinder Overhaul 27
Inspection -Drum 27
Inspection -Lining 27
Installation 27

REAR DISCBRAKE 29

Pad Replacement 29

~~s:~::~'~I~':::::::::::'::: ::.::::::::.::::::.::::::::::.::::::.::::::::~~ •••

Inspection -Caliper 32
Inspection -Rotor 33
Assembly 33
Installation 35

PARKING BRAKECONTROL 36

Removal andInstallation 36
Inspection 36
Adjustment ." 37

ANTI-LOCK BRAKESYSTEM 38

Purpose 38
Operation 38
ABS Hydraulic Circuit 38
System Components 39
System Description 39
Removal andInstallation .40
Wiring Diagram -ABS - .45

TROUBLE DIAGNOSES
52

Contents 52
Component PartsandHarness Connector
Location 64

SERVICE DATAANDSPECIFICATIONS (SDS)86

General Specifications 86
Inspection andAdjustment 88

SBR995
SBR419C AIR
BLEEDING
Bleeding Procedure
CAUTION:
• Carefully monitorbrakefluidlevel atmaster cylinder during
bleeding operation.
• Ifmaster cylinder issuspected tohave airinside, bleedair
from master cylinder first.Refer to"Installation", "MASTER
CYLINDER", BR-12.
• Fill reservoir withnewbrake fluid"DOT 3"or"DOT
4".

Make sureitis full atall times whilebleeding airout of
system.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Place acontainer undermaster cylinder toavoid spillage of
brake fluid.
• For models withABS, turnignition switchOFFanddiscon-
nect ABS actuator connector orbattery cable.

• Bleed airinthe following order:

I
RHO models
I

Left rear brake-+Right frontbrake-+Right rearbrake-+Left
front brake

I
LAD models
I

Right rearbrake-+Left frontbrake-+Left rearbrake-+Right
front brake.
1. Connect atransparent vinyltubetoair bleeder valve.
2. Fully depress brakepedalseveral times.
3. With brake pedaldepressed, openairbleeder valveto
release air.
4. Close airbleeder valve.
5. Release brakepedalslowly.
6. Repeat steps2.through 5.until clear brake fluidcomes out
of air bleeder valve.
7. Tighten airbleeder valve.

~: 7-
9 N.m (0.7-0.9 kg-m, 61-78 in-Ib)
BR-6