NISSAN ALMERA N16 2003 Electronic Repair Manual

PRECAUTIONS
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS007N3
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
●Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connec-
tors.
Precautions for On Board Diagnostic (EURO-OBD) System of A/T and Engine —
Euro-OBD —
ECS007N4
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.
●Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
●Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MI to light up due to a short circuit.
●Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc.
●Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
Precautions for Trouble DiagnosisECS007N5
CAN SYSTEM
●Do not apply voltage of 7.0V or higher to the measurement terminals.
●Use the tester with its open terminal voltage being 7.0V or less.
Precautions for Harness RepairECS007N6
CAN SYSTEM
●Solder the repaired parts, and wrap with tape. [Frays of twisted
line must be within 110 mm (4.33 in)]
PKIA0306E

AT-6
PRECAUTIONS
●Do not perform bypass wire connections for the repair
parts.(The spliced wire will become separated and the charac-
teristics of twisted line will be lost.)
PrecautionsECS007N7
●Before connecting or disconnecting the TCM harness con-
nector, turn ignition switch OFF and disconnect negative
battery terminal. Failure to do so may damage the TCM.
Because battery voltage is applied to TCM even if ignition
switch is turned off.
●When connecting or disconnecting pin connectors into or
from TCM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on TCM
pin terminal, when connecting pin connectors.
●Before replacing TCM, perform TCM input/output signal
inspection and make sure whether TCM functions properly
or not. (See page AT- 1 0 6 , "
TCM Terminals and Reference
Va l u e".)
PKIA0307E
SEF289H
AAT470A
MEF040DA

PRECAUTIONS
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●After performing each TROUBLE DIAGNOSIS, perform
“DTC (Diagnostic Trouble Code) CONFIRMATION PROCE-
DURE”.
The DTC should not be displayed in the “DTC CONFIRMA-
TION PROCEDURE” if the repair is completed.
●Before proceeding with disassembly, thoroughly clean the out-
side of the transaxle. It is important to prevent the internal parts
from becoming contaminated by dirt or other foreign matter.
●Disassembly should be done in a clean work area.
●Use lint-free cloth or towels for wiping parts clean. Common
shop rags can leave fibers that could interfere with the operation
of the transaxle.
●Place disassembled parts in order for easier and proper assembly.
●All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
●Gaskets, seals and O-rings should be replaced any time the transaxle is disassembled.
●It is very important to perform functional tests whenever they are indicated.
●The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
●Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
●Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
●Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
●After overhaul, refill the transaxle with new ATF.
●When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under AT-13, "
Changing A/T Fluid" when changing A/T fluid.
Service Notice or PrecautionsECS007N8
FA I L - S A F E
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The cus-
tomer may complain of sluggish or poor acceleration.
When the ignition key is turned “ON” following Fail-Safe operation, O/D OFF indicator lamp blinks for about 8
seconds. Refer to AT- 2 5 0 , "
Diagnostic Procedure Without CONSULT-II" (EXCEPT FOR EURO-OBD) or AT-
51, "TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)" (EURO-OBD).
The blinking of the O/D OFF indicator lamp for about 8 seconds will appear only once and be cleared. The
customer may resume normal driving conditions.
Always follow the “Work Flow”, refer to AT- 2 5 9
(EXCEPT FOR EURO-OBD) or AT- 6 0 (EURO-OBD).
The SELF-DIAGNOSIS results will be as follows:
●The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
●During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.
TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:
●External leaks in the hub weld area.
●Converter hub is scored or damaged.
●Converter pilot is broken, damaged or fits poorly into crankshaft.
●Steel particles are found after flushing the cooler and cooler lines.
●Pump is damaged or steel particles are found in the converter.
●Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
●Converter is contaminated with engine coolant containing antifreeze.
SAT652J

AT-8
PRECAUTIONS
●Internal failure of stator roller clutch.
●Heavy clutch debris due to overheating (blue converter).
●Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
●The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
●The threads in one or more of the converter bolt holes are damaged.
●Transaxle failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
●Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
EURO-OBD SELF-DIAGNOSIS — EURO-OBD —
●A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the O/D OFF indicator lamp or the malfunction indicator (MI). Refer to the table on
AT- 4 2 , "
SELF-DIAGNOSTIC RESULT TEST MODE" for the indicator used to display each self-diagnostic
result.
●The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memo-
ries.
Always perform the procedure AT- 3 9 , "
HOW TO ERASE DTC" to complete the repair and avoid
unnecessary blinking of the MI.
●The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the O/D OFF indicator lamp does not indicate any malfunctions.
–PNP switch
–A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of EURO-OBD, refer to AT-37, "
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION" .
●Certain systems and components, especially those related to EURO-OBD, may use a new style
slide-locking type harness connector.
For description and how to disconnect, refer to EL-7, "HARNESS CONNECTOR".
Wiring Diagrams and Trouble DiagnosisECS007N9
When you read wiring diagrams, refer to the following:
●GI-12, "How to Read Wiring Diagrams".
●EL-11, "POWER SUPPLY ROUTING".
When you perform trouble diagnosis, refer to the following:
●GI-22, "How to Perform Efficient Diagnosis for an Electrical Incident".
●GI-32, "How to Follow Trouble Diagnosis".

PREPARATION
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PREPARATIONPFP:00100
Special Service ToolsECS007NA
Tool number
Tool nameDescription
(J34301-C)
Oil pressure gauge set
1 (J34301-1)
Oil pressure gauge
2 (J34301-2)
Hoses
3 (J34298)
Adapter
4 (J34282-2)
Adapter
5 (790-301-1230-A)
60°Adapter
6 (J34301-15)
Square socketMeasuring line pressure and governor pressure
KV311030000
(J38982)
Drift Installing differential oil seal
(Use with ST35325000.)
a: 59mm (2.32 in) dia.
b: 49mm (1.93 in) dia.
ST35325000
( - )
Drift Installing differential oil seal
(Use with KV311030000.)
a: 215 mm (8.46 in)
b: 25 mm (0.98 in)
c: M12 x 1.5P
KV38107700
(J39027)
Preload adapter
●Measuring turning torque of final drive assembly
●Measuring clearance between side gear and
differential case with washer
●Selecting differential side bearing adjusting shim
KV31103200
(J34285-A and J34285-87)
Clutch spring compressor Removing and installing clutch return spring
a: 320mm (12.0 in)
b: 174 mm (6.85in)
ST23540000
(J25689-A)
Pin punch Removing and installing parking rod plate, manual
plate and differential pinion mate shaft retaining pins
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
AAT896
NT105
NT417
NT087
NT423
NT442

AT-10
PREPARATION
KV32101000
(J25689-A)
Pin punch Installing throttle lever and manual shaft retaining
pins
a: 4 mm (0.16 in) dia.
ST25710000
( - )
Pin punch Aligning groove of manual shaft and hole of
transmission case
a: 2 mm (0.08 in) dia.
ST3306S001
(J22888-D)
Differential side bearing
puller set
1 ST33051001
(J22888-D)
Puller
ST33061000
2 (J8107-2)
AdapterRemoving differential side bearing inner race
a: 39 mm (1.54 in) dia.
b: 29.5 mm (1.161 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 120 mm (4.72 in)
KV381054S0
(J34286)
Puller
●Removing idler gear bearing outer race
●Removing differential side oil seals
●Removing differential side bearing outer race
●Removing needle bearing from bearing retainer
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST27180001
(J25726-A)
Puller
●Removing idler gear
a: 100 mm (3.94 in)
b: 110 mm (4.33 in)
c: M8 x 1.25P
ST30031000
(J22912-1)
Puller Removing reduction gear bearing inner race
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST3527200
(J26092)
Drift
●Installing reduction gear bearing inner race
●Installing idler gear bearing inner race
a: 72 mm (2.83 in) dia.
b: 35.5 mm (1.398 in) dia. Tool number
Tool nameDescription
NT410
NT410
NT745
NT414
NT424
NT411
NT426

PREPARATION
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ST37830000
( - )
Drift●Installing idler gear bearing outer race
a: 62 mm (2.44 in) dia.
b: 39 mm (1.54 in) dia.
ST35321000
( - )
Drift Installing output shaft bearing
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ST30633000
( - )
Drift Installing differential side bearing outer race
a: 67mm (2.64 in) dia.
b: 49 mm (1.93 in) dia.
ST35271000
(J26091)
Drift
●Installing idler gear
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
ST33400001
(J26082)
Drift
●Installing oil pump housing oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia. Tool number
Tool nameDescription
NT427
NT073
NT073
NT115
NT115

AT-12
PREPARATION
Commercial Service Tools
ECS007NB
Tool name Description
Puller
●Removing idler gear bearing inner race
●Removing and installing band servo piston
snap ring
DriftRemoving idler gear bearing inner race
a: 34 mm (1.34 in) dia.
DriftInstalling differential left side bearing
a: 86 mm (3.39 in) dia.
b: 80 mm (3.15 in) dia.
DriftInstalling differential right side bearing
a: 46 mm (1.81 in) dia.
b: 40 mm (1.57 in) dia.
NT077
NT109
NT115
NT115

A/T FLUID
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A/T FLUIDPFP:KLE40
Checking A/T FluidECS007NC
1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures
of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove dipstick and note reading. If level is at low side of either
range, and fluid to the charging pipe.
e. Re-insert dipstick into charging pipe as far as it will go.
f. Remove dipstick and note reading. If reading is at low side of range, add fluid to the charging pipe.
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on dipstick.
6. Check fluid condition.
●If fluid is very dark or smells burned, refer to AT section for
checking operation of A/T. Flush cooling system after repair of
A/T.
●If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to LC-16, "Radi-
ator".
Changing A/T FluidECS007ND
1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid from drain plug and refill with new A/T fluid.
Always refill same volume with drained fluid.
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to AT- 1 3 , "
Checking A/T Fluid" . If fluid is still dirty, repeat steps 2
through 5.
SMA827CA
SMA853B
Fluid grade:
Genuine Nissan ATF or equivalent. Refer to MA-
19, "RECOMMENDED FLUID AND LUBRI-
CANTS".
Fluid capacity (With torque converter):
Approx. 7.7 (6-3/4 lmp qt)
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SMA027D

AT-14
OVERALL SYSTEM
OVERALL SYSTEM
PFP:00000
A/T Electrical Parts LocationECS007NE
MCIB0002E