Color NISSAN ALMERA N15 1995 Service Manual

Fluidleakage TROUBLE
DIAGNOSES
Preliminary Check(PriortoRoad Testing)
AIT FLUID CHECK
Fluid leakage check

1. Clean areasuspected ofleaking, -for example, mating
surface ofconverter housingandtransmission case.
2. Start engine, applyfootbrake, placeselector leverin"0"
position andwait afew minutes.
3. Stop engine.
4. Check forfresh leakage.

SAT288G
Fluidcondition check
Fluid levelcheck -Refer toMA section (CHASSIS AND
BODY MAINTENANCE).
Fluid
color
Oark orblack withburned odor
Milky pink
Varnished fluid,lighttodark brown
and tacky Suspected
problem
Wear offrictional material
Water contamination
- Road water entering through
filler tubeorbreather
Oxidation
- Over orunder filling
- Overheating

•

Road Testing

Perform roadtests using "Symptom" chart.Refertopage

AT-20.

"P"
POSITION

1. Place selector leverin"P" position andstart engine. Stop
engine andrepeat theprocedure inall positions, including
neutral position.
2. Stop vehicle onaslight upgrade andplace selector leverin
"P" position. Releaseparkingbraketomake surevehicle
remains locked.

"R"
POSITION

1. Manually moveselector leverfrom"P"to"R", andnote
shift quality.
2. Drive vehicle inreverse longenough todetect slippage or
other abnormalities.

"N"
POSITION

1. Manually moveselector leverfrom"R"and"0"to"N" and
note shift quality.
2. Release parkingbrakewithselector leverin"N" position.
Lightly depress accelerator pedaltomake surevehicle
does notmove. (When vehicle isnew orsoon afterclutches
have been replaced, vehiclemaymove slightly. Thisisnot
a problem.)

AT-17

MAJOROVERHAUL
Locations ofAdjusting Shims,Needle Bearings,
Thrust Washers andSnap Rings -Except
Model 34X81

Outer diameter andcolor ofthrust washers
Outerandinner diameter ofneedle bearings
Outer
&
inner diameter ofbearing races,adjusting shimsand
adjusting spacer

Item
number
@

@
Outer
diameter mm(inl

72.012.8351
78.5 13.091)
Color

black
Item
number Outer
diameter

Innerdiameter

mm(in)
mm(in)

47.0 (1.8501
32.0(1.2601
35011.3781 20.110.7911
60.012.3621 42.00.6541
60.0 (2.362)
45.011.7721
47.011.850) 30011.1811
42.6 0.677)
26.10.0281
48.0 (1890)
33.511.319)
54.0 121261
40.111.5791

Outer diameter Inner
diameter
Item number
mmlinl mm
(in)

@
48.00.8901 33.0
(1.299)

@
29.011.1421 25.0(0.9841

@
34.5
(358)
26.111.0281

@
79.5
13.1301 72.012.835)

~
55.012.165)
42.0(1.654)

*:
Select proper thickness. Outer
diameter ofsnap rings

Item number
Outerdiameter
mmlin)

Q.
142.0
(5.591

CV
113.0
(4.451

@
162.4
(6391

@
135.4
15.331

CID
126.0
(4.961

@
161.516.361

AT-48 SAT510H

Outerdiameter andcolor ofthrust washers
MAJOR
OVERHAUL
Locations ofAdjusting Shims,Needle Bearings,
Thrust Washers andSnap Rings -Model 34X81

Outer
&
inner diameter ofneedle bearings
Item number Outer
diameter mm(in)

CD
142.0
(5.59)

ClJ
113.0
(4.45)

0
162.4
(6.39)

0
135.4
(5.33)
~ 161.5
(6.36)

@
126.0
(4.96)

(j)
40.5
(1.594)

Outer
diameter ofsnap rings
Item
number Outer
diameter
Color
mm (in)

@
72.0(2.835)

Black

@ 78.5
(3.091)

* :
Select proper thickness.
Outer
&
inner diameter ofbearing raceandadjusting shims
Item number Outer
diameter
Innerdiameter
mm (in)
mm(in)

@
48.0(1.890)
33.0(1.299)

@
72.0(2.835) 61.0(2.402)

@
34.5(1358) 26.1
(1.028)
@ 68.0
(2.677)
60.0(2.362)
Item
number Outer
diameter

mm (in)

47.0 (1.850)
35.0 (1.378)
60.0 (2.362)
60.0 (2.362)
47.0 (1.850)
42.6 (1.677)
48.0 (1.890)
55.0 (2.165)
60.0 (2.362)
Inner
diameter
mm (in)

32.0 (1.260)
20.0 (0.787)
42.0 (1.654)
45.0 (1.772)
30.0 (1.181)
26.1 (1.028)
33.5 (1.319)
40.5 (1.594)
40.1 (1.579)

•

SAT106EC
AT-49

REPLACEMENTOPERATIONS
Rear Floor Rear ________
GENERALINFORMATION _
Identification Number(Cont'd)
(Work afterrearpanel havebeen removed.)

ExceptforEurope

IN 1 .B CAN 15A
0
XXXXXX

T
T
--c:::
serialnumber

0:
Stopgap (nomeaning)
Destination
A: Australia andNew Zealand
Z: Except forEurope, Australia, andNew Zealand
Model
A: 2-wheel drive
Engine type
B: GA 15DE engine
C: GA 16DE engine
E: SR20DE engine-For AustraliaandNew Zealand only
Body type
B: 4-door Sedan
F: 5-door Hatchback
Manufacturer
IN 1:Nissan, Passenger vehicle

VEHICLE IDENTIFICATION PLATE

1Type 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 approval number
8 Body colorcode
9 Trim color code
10 Model Specification No.
11 Engine model
12 Engine displacement
13 Transaxle model
14 Axle model

cc

o

PLANT
PlANTA

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NISSAN
MOTORCO.,LTD. APAN

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Europe

~
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1-
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kg

2-
&
kg

COlOR. TRIM

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FARBE. POlST

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NISSAN
MOTORCO.,LTD. JAPAN

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TYPE
TTP

Europe

FR

_2
3D
HI
B:3door hatchback
5D
HI
B:5door hatchback

Service
Joint

111

~

2-spot welds 3-spotwelds M.

I.
G plug weld .MIG seam weld/
(For 3panels plugweld method )P:
F
weld

• rr=- •
A
===-=
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GTJ --- ~

-43-
-2-

REPLACEMENTOPERATIONS
Rear Floor Rear ________
GENERALINFORMATION _
Identification Number(Cont'd)
(Work afterrearpanel havebeen removed.)

ExceptforEurope

IN 1 .B CAN 15A
0
XXXXXX

T
T
--c:::
serialnumber

0:
Stopgap (nomeaning)
Destination
A: Australia andNew Zealand
Z: Except forEurope, Australia, andNew Zealand
Model
A: 2-wheel drive
Engine type
B: GA 15DE engine
C: GA 16DE engine
E: SR20DE engine-For AustraliaandNew Zealand only
Body type
B: 4-door Sedan
F: 5-door Hatchback
Manufacturer
IN 1:Nissan, Passenger vehicle

VEHICLE IDENTIFICATION PLATE

1Type 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 approval number
8 Body colorcode
9 Trim color code
10 Model Specification No.
11 Engine model
12 Engine displacement
13 Transaxle model
14 Axle model

cc

o

PLANT
PlANTA

El
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13IJJ
if[
**
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*1
MADEINJAPAN

NISSAN
MOTORCO.,LTD. APAN

~ tt
~(:l
&

~~~sg~
CNHOA"SIS ~

~~~~~o
&

o ~
0
:ggtg~
~~~RNICION ~
&.

~~ ~~~~~ &
£

; ;~)~ /~~~~~'. AE~~
A1L11

Expect
Europe

~
&
kgO

1-
&
kg

2-
&
kg

COlOR. TRIM

~
&

FARBE. POlST

&

NISSAN
MOTORCO.,LTD. JAPAN

I ~ I
~

o

TYPE
TTP

Europe

FR

_2
3D
HI
B:3door hatchback
5D
HI
B:5door hatchback

Service
Joint

111

~

2-spot welds 3-spotwelds M.

I.
G plug weld .MIG seam weld/
(For 3panels plugweld method )P:
F
weld

• rr=- •
A
===-=
.'S~
.L.LLL

GTJ --- ~

-43-
-2-

CLUTCHDISCANDCLUTCH COVER

~1st: 10-20(1.0-2.0,7.2-14)
2nd: 22-29 (2.2 -3.0 ,16 -22)

ACL019
SEC.
300

o

Clutchdisc
• Do not clean insolvent.
• When installing, becareful thatgrease from
main drive shaft doesnotadhere toclutch disc. Clutch
cover

m
(iJ:
Apply lithium-based greaseincluding
molybdenum disulphide.
~ :N'm (Kg-m, ft-Ib).

•

SCL221 Clutch
Disc
INSPECTION

Check thefollowing items,andreplace ifnecessary.
• Clutch disc,forburns, discoloration, oilorgrease leakage
• Clutch disc,forwear offacing

Wear limitoffacing surface torivet head:
0.3 mm (0.012 in)

• Clutch disc,forbacklash ofspline andrunout offacing.

Maximum backlashofspline (atouter edgeofdisc):
Model 180 0.7mm (0.028 in)

Model 190
and 200 0.8mm (0.031 in)
Model 215 0.9mm(0.035in)
Runout limit:
1.0 mm (0.039 in)
Distance ofrunout checkpoint(from hubcenter):

Model 180
85mm (3.35 in)

Model 190
90mm (3.54 in)

Model 200
95mm (3.74 in)
Model 215102.5mm (4.04in)
CL-11

CLUTCHDISCANDCLUTCH COVER
Clutch Disc(Cont'd)
INSTALLATION

• Apply recommended greasetocontact surface ofsplines.

• Too much lubricant maydamage clutchdiscfacing.
Dial gauge Clutch
CoverandFlywheel
INSPECTION ANDADJUSTMENT

• Check clutchcover, installed onvehicle, foruneven dia-
phragm springtoeheight.

Uneven limit:
Model 180 1.0mm (0.039 in)

Model 190,
200and 215 0.7mm (0.028 in)

• Ifout oflimit, adjust theheight withTool.

SCL466-A FLYWHEEL INSPECTION
CAUTION:
Do not allow anymagnetic materials tocontact thering gear
teeth.

• Inspect contact surface offlywheel forslight burns ordis-
coloration. Cleanflywheel withemery paper.
• Check flywheel runout.

Maximum allowable runout:
Refer toEM section ("Inspection", "CYLINDER
BLOCK").
AEM100
INSTALLATION

• Insert Toolintoclutch dischubwhen installing clutchcover
and disc.
• Becareful nottoallow grease tocontaminate clutchfacing.
• Tighten boltsinnumerical order,intwo steps.

First step:
~: 10•20 N'm '(1.0 •2.0 kg-m, 7-14 ft-Ib)
Final step:
~: 22•29 N'm (2.2•3.0 kg-m, 16•22 ft-Ib)
SCL616-A
CL-12

51ANDARDIZED RELAY
Description (Cont'd)
Type Outer
view
CircuitConnector
symbol
and connection Case
color

•

GRAY

BLUE

BROWN

=
=

2M 1T
BLACK
1M

1M.1B

The arrangement ofterminal numbers onthe actual relaysmaydiffer fromthose shown above.

SEL661TA
EL-7

HARNESSLAYOUT
How toRead Harness Layout

Example:
G2
@
8/6:ASCD ACTUATOR

T
T
~nector color/Cavity
Connector number
Grid reference

The following HarnessLayoutsuseamap style gridtohelp locate connectors onthe drawings:
• Engine RoomHarness (EngineCompartment)
• Main Harness
• Body Harness

To use thegrid reference

1) Find thedesired connector numberonthe connector list.
2) Find thegrid reference.
3) Onthe drawing, findthecrossing ofthe grid reference lettercolumn andnumber row.
4) Find theconnector numberinthe crossing zone.
5) Follow theline (ifused) tothe connector.

CONNECTOR SYMBOL

Main symbols ofconnector (inHarness Layout)areindicated inthe below.

Water prooftype Standardtype
Connector type
MaleFemale MaleFemale

•
Cavity:
Lessthan
4
~ ~
~
@i)

•
Relay
connector

•
Cavity:
From
5
to
8

~ ~~

c90

•
Cavity:
Morethan

9

$
~

-
-

•
Ground
terminal etc.

@?

-

FFC (FLAT FLEXIBLE CIRCUIT)

An FFC (Flat Flexible Circuit)hasbeen adopted fordoor harness of3-door Hatchback modelsforEurope.

CAUTION:
• Donot attempt torepair, spliceormodify theFFC. Ifthe FFC isdamaged, replacewithanew one.
• Donot force theFFC inthe opposite direction towhich itis bent.
EL-269
•

TROUBLEDIAGNOSES -General Description @K]
ECM Terminals andReference Value(Conl'd)
ECM INSPECTION TABLE-GA16DE forAustralia
Specification dataarereference valuesandaremeasured betweeneachterminal and
@
(ECCS ground).

TER- WIRE
MINAL ITEM
CONDITION DATA
NO. COLOR
[Efl9ineisrunning.
I

0.3-0.6V
L Idle speed
1
WIB
Ignitionsignal

I
Engine isrunning.
I

L Engine speedis2,000 rpm. Approximately
0.9V
2
GYIR
Ignition
check IEngine
isrunning.
I

Approximately12V
L Idle speed
3 LIB Tachometer [Engine
isrunning.
I

Approximately0.9V
L Idle speed
IEngine isrunning.
I

Ilgnition switch"OFF'.'
0-1V
4
WIG
ECCS
relay(Self-shut- L
For afew seconds afterturning ignition
off) switch
"OFF"
Ilgnition switch"OFF"
I

BATTERYVOLTAGE
L Afew seconds passedafterturning ignition
(11-14V)
switch "OFF"
Ilgnition switch"ON"
I

L For 5seconds afterturning ignition switch
0.07-0.20V
"ON"

8
BIP Fuel
pump relay I
Engine isrunning.
I

Ilgnition switch"ON"
I

BATTERYVOLTAGE
L More than5seconds afterturning ignition
(11-14V)
switch "ON"
10
BIW

ECCSground IEngine
isrunning.
I

Engineground
L Idle speed
IEngine isrunning.
I

BATTERYVOLTAGE
Cooling fanrelay ~Cooling fanisnot operating.
(11-14V).
13 LG
(Highspeed: For
AIT
Cooling
fanisoperating atlow speed.
models)
I
Engine isrunning.
I

L Cooling fanisoperating athigh speed. Approximately
OV
IEngine isrunning.
I

BATTERYVOLTAGE
Cooling fanrelay L
Cooling fanisnot operating. (11-14V)
14 LGIR
(Lowspeed)

I
Engine isrunning.
I

L_
Cooling fanisoperating. 0.07
-0.30V

I
Engine isrunning.
I

L Both
AIC
switch andblower switchare 0.08
-0.2V
15
Y
Air
conditioner relay "ON".
IEngine isrunning.
I

BATTERYVOLTAGE
LAIC switchis"OFF". (11
-14V)

EC-79
•