tow NISSAN ALMERA N15 1995 Service Manual

PREPARATIONANDPRECAUTIONS
Service Notice
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag 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.

Ii
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.

•
Before proceeding withdisassembly, thor-
oughly cleantheoutside ofthe transaxle. Itis
important toprevent theinternal partsfrom
becoming contaminated bydirt orother for-
eign matter.
• Disassembly shouldbedone inaclean work
area.
• Use lint-free clothortowels forwiping parts
clean. Common shopragscanleave fibers
that could interfere withtheoperation ofthe
transaxle.
• Place disassembled partsinorder, onaparts
rack, foreasier andproper assembly.
• Allparts should becarefully cleaned-witha
general purpose, non-flammable solvent
before inspection orreassembly.
• Gaskets, sealsandO-rings shouldbe
replaced anytime thetransaxle isdisassem-
bled.
• Itis very important toperform functional tests
whenever theyareindicated. •
The valve bodycontains precision partsand
requires extremecarewhen partsare
removed andserviced. Placedisassembled
valve bodyparts inorder, onaparts rack,for
easier andproper assembly. Carewillalso
prevent springs andsmall partsfrombecom-
ing scattered orlost.
• Properly installedvales,sleeves, plugs,etc.
will slide along theirbores inthe valve body
under theirownweight.
• Before assembly, applyacoat ofrecom-
mended ATFtoall parts. Apply petroleum
jelly toprotect O-ringandseals, orhold bear-
ings andwashers inplace during assembly.
Do not use grease.
• Extremely careshould betaken toavoid dam-
age toO-rings, sealsandgaskets when
assembling.
• After overhaul, refillthetransaxle withnew
ATF.

•

Supplemental RestraintSystem(SRS)"AIR
BAG" (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.
AT-7

TROUBLEDIAGNOSES
Stall Tasting
STALL TESTPROCEDURE

1. Check
AIT
and engine fluidlevels. Ifnecessary, addfluid.
2. Drive vehicle forabout 10minutes untilengine oiland ATF
reach operating temperature.

ATF operating temperature:
50 -80
0
e (122-176°F)
SAT6478
3.Set parking brakeandblock wheels.
4. Install atachometer whereitcan beseen bydriver during
test.

SAT513G 5.
~ ~ID
•

~c;>
SAT7678
Start
engine, applyfootbrake, andplace selector leverin

"0"
position.
6. Accelerate towide-open throttlegradually whileapplying
foot brake.
7. Quickly notetheengine stallrevolution andimmediately
release throttle.

• During test,never holdthrottle wide-open formore than5
seconds. Stall revolution .standard:
Refer toSDS, AT-166.
SAT514G
8.Move selector leverto"N" position.
9. Cool offATF.

• Run engine atidle foratleast oneminute.

10. Repeat steps5through 9with selector leverin"2", "1"and
"R
n
positions.

SAT7718 AT-24

______ 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-

______ 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-

EXTERIOR
@
Front airspoiler

SEC. 960
8BT074
@
Front struttower barassembly

SEC. 401

[OJ:
N.m (kg-m, ft-lb)

8BT099
•

CAUTION:
Do not remove frontstruttower barassembly whilevehicle isjacked upwith wheels on.

8T-33

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

Coordinates:

@.0
X :522.2
Y :18.1
Z :571.7
@,@ X :465
Y :2,456.4
Z :522

Front
andrear strut tower centers

I

~-t~
BODY
ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS
Rear

{t
Front
Rear
coordinates: coordinates:
@.@
@.@
@
X :250
X:393.5
X:475
Y :-632
Y:1,460
Y:3,082
Z :224.8
Z:126.9
Z:336.8
@.@
@,
@

@
X :492 X
:572
X:-542
Y :-450 Y
:1,940
Y:3,082
Z :355 Z
:200
Z:336.8
@.@
Q).

CD

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

X :352.7 X
:150
Y :69 Y
:2,442.9
Z :240 Z
:241
(g),@ @
X :432
X:300
Y :338
Y:2,480
Z :128 Z:381.8

CEJ,
CD

@
X :395
X:-300
Y :515
Y:2,480
Z :129.2
Z:405.8
12
dia.@.

••@ @.
@)

X :393
LH side RH
side Y:2,560

Q

If
Q

Z
:365

II
@
Bottom X:470
view of Y
:2,911
vehicle Z:339.6
@ X :-539
Y :2,911
Z :339.6
Unit: mm
Front SBT097
BT-50

Pistonbootretainer (AD22VF only)
Piston boot
Piston seal
FRONT
DISCBRAKE
Inspection -Caliper (Cont'd)
PISTON

Check pistonforscore, rust,wear, damage orpresence offor-
eign objects. Replace ifany ofthe above conditions are
observed.

CAUTION:
Piston sliding surface isplated. Donot polish withemery paper
even ifrust orforeign objects arestuck tosliding surface.
SLIDE PIN,PINBOLT ANDPINBOOT

Check forwear, cracks, rustorother damage. Replaceifany of
the above conditions areobserved.

Inspection -Rotor
RUNOUT
1: Secure rotortowheel hubwith atleast twonuts (M12 x
1.25).
2. Check runout usingadial indicator.

Make surethatwheel bearing axialendplay iswithin thespec-
ifications beforemeasuring. RefertoFA section ("FrontWheel
Bearing", "ON-VEHICLE SERVICE").
Maximum runout:
SBR936A 0.07mm(0.0028 in)

3.
If
the runout isout ofspecification, findminimum runout
position asfollows:
a. Remove nutsandrotor fromwheel hub.
b. Shift therotor onehole andsecure rotortowheel hub
with nuts.
c. Measure runout.
d. Repeat stepsa.to c.so that minimum runoutposition can
be found.
4. Ifthe runout isstill outofspecification, turnrotor withon-car
brake lathe("MAD, DL-8700", "AMMCO700and 705" or•••
equivalent).

THICKNESS Thickness variation(Atleast 8positions):
Maximum 0.02mm(0.0008 in)

If thickness variationexceedsthespecification, turnrotor with
on-car brakelathe.

Rotor repair limit:
CL22VD andCL22VE 16.0mm(0.630 in)
CL22VF 24.0mm(0.945 in)
SBR944A Assembly
1. With piston bootfitted topiston, insertpiston bootinto
groove oncylinder bodyandinstall piston.
2. Properly securepistonboot.
3. Secure pistonbootwithretainer.
(AD22VF modelonly)

Piston

SBR777B BR-23

SBR847
SBR247B REAR
DISCBRAKE
Inspection -Rotor
RUBBING SURFACE

Check rotorforroughness, cracksorchips.

RUNOUT
1. Secure rotortowheel hubwith atleast twonuts (M12 x1.25).
2. Check runout usingadial indicator.

Make surethatwheel bearing axialendplay iswithin thespec-
ifications beforemeasuring. Referto"Rear Wheel Bearing" of
"ON-VEHICLE SERVICE"inRA section.

3. Change relativepositions ofrotor andwheel hubsothat
runout isminimized.

Maximum runout:
0.07 mm(0.0028 in)
THICKNESS Rotor repair limit:
Minimum thickness
CL7HB 6.0mm (0.236 in)
CL9HC 8.0mm (0.315 in)
Thickness variation(Atleast 8portions)
Maximum 0.02mm(0.0008 in)

Replace rotorifany ofthe above donot meet thespecifications .

Assembly
1. Insert camwithdepression facingtowards openendofcyl-
inder.
2. Generously applyrubber grease tostrut andpush rodto
make insertion easy.

BR-33
•

TROUBLEDIAGNOSES

~i5

E(
C/UNITCONNECTOR
P

,14.9.11 .12, ,15.10.38.13,

SBR247DDiagnostic
Procedure4
WHEEL SENSOR ORROTOR
(Malfunction codeNo.21,22,25,26,31, 32,35, 36or18)

1. Disconnect connectors fromcontrol
~Inspection end

I

unit and wheel sensor ofmalfunction
code No.Check terminals fordam-
age orloose connections. Then
reconnect connectors.
2. Carry outself-diagnosis again.

Does warning lampactivate again?

Yes

m
WHEEL SENSOR ELECTRICAL CHECK
OK

~@
(Seenextpage.)
1. Disconnect controlunitconnector.
2. Check resistance betweencontrol
unit connector terminals.
Code No.21or22 (Front RHwheel)
Terminals
@
and @
Code No.25or26 (Front LHwheel)
Terminals
@
and
@

Code No.31or32 (Rear RHwheel)
Terminals
@
and
@

Code No.35or36 (Rear LHwheel)
Terminals
@
and
@

Resistance: 0.8•1.2 kD

NG
Note Note

CHECK WHEELSENSOR.

~Replace wheelsensor.

I

Refer toWHEEL SENSOR inElectrical
Components Inspection,SR-85.
OK
Note
Note:
Wheel position should

Repair harness andconnectors
be
distinguished by

between controlunitconn'ector and
code
No.
exceplcode

wheel sensor connector.
No.
18(sensor rotor).
BR-74

WARNINGLAMPSANDBUZZER
Warning Buzzer/System Description

The warning buzzeriscontrolled bythe warning buzzerunit.
Power issupplied atall times
(RHD models exceptforEurope)
• through 7.5Afuse (No.
[fA],
located inthe fuse block)
• tokey switch terminal
CD.

Power issupplied atall times
(LHD models withoutdaytime lightsystem)
• through 75Afusible link(letter
[.9J,
located inthe fusible linkand fuse box).
• tolighting switchterminal
@.

(LHD models withdaytime lightsystem andRHD models)
• through 10Afuse (No.
~J,
located inthe fuse block)
• tolighting switchterminal
@.

Power issupplied atall times
(Except forAustralia)
• through 7.5Afuse (No.~,located inthe fusible linkand fuse box)
• torear foglamp switch terminal
CD.

With theignition switchinthe ONorSTART position, powerissupplied
• through 7.5Afuse (No.
11J,
located inthe fuse block)
• towarning buzzerunitterminal
@
(LHD models exceptforAustralia) or
CD
(For Australia).
When driver's doorisopened, groundissupplied
• through bodygrounds
@
and
@

• todriver's sidedoor switch terminal
@

• through driver'ssidedoor switch terminal
G)

• towarning buzzerunitterminal
@
(Except forAustralia) or
(J)
(For Australia).
With power andground supplied, thewarning buzzerwillsound.

Ignition keywarning buzzer(RHOmodels exceptforEurope)

With thekey inthe ignition switchinthe OFF position, andthedriver's dooropen, thewarning buzzer
will sound. Abattery positive voltageissupplied
• from keyswitch terminal
CID

• towarning buzzerunitterminal
CID
(Except forAustralia) or
@)
(For Australia).
Ground issupplied
• from driver sidedoor switch terminal
G)

• towarning buzzerunitterminal
@
(Except forAustralia) or
(J)
(For Australia).
Driver sidedoor switch terminal
@
isgrounded throughbodygrounds
@
and
@.

Light warning buzzer

With ignition switchOFF,driver's dooropen, andlighting switchin1ST or2ND position, warningbuzzer
will sound. Abattery positive voltageissupplied
(LHD models withoutdaytime lightsystem)
• from lighting switchterminal
@

• through 10Afuse (No.
@ID,
located inthe fusible linkand. fuse box)
• towarning buzzerunitterminal
@>.

(LHD models withdaytime lightsystem)
• from lighting switchterminal
@

• todaytime lightunitterminal
@

• through daytime lightunitterminal
@>

• towarning buzzerunitterminal
@>

(RHD models)
• from lighting switchterminal
@

• towarning buzzerunitterminal
@>
(Except forAustralia) or
@
(For Australia).
Ground issupplied
• from driver sidedoor switch terminal
G)

• towarning buzzerunitterminal
@
(Except forAustralia) or
(J)
(For Australia).
Driver sidedoor switch terminal
@
isgrounded throughbodygrounds
(!ill
and
@.

Rear foglamp switch warning buzzer(ForEurope models)

With ignition switchOFF,driver's dooropen, andrear foglamp switch ON,warning buzzerwillsound.
A battery positive voltageissupplied

EL-152