NISSAN ALMERA N16 2003 Electronic Repair Manual

5 WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Is inspection result OK?
OK Normal
NG Wheel sensor and rotor lines repair
3. Longer Stopping DistanceNJBR0172
1 INSPECTION START
Check that the stopping distance when braking becomes longer only on a snowy or gravel road.
Does the stopping distance when braking become longer only on a snowy or gravel road?
Yes It may be longer than that of vehicle without ABS.
No GO TO 2.
2 PERFORMANCE CHECK
Disconnect the actuator relay box to deactivate the ABS function.
Is the stopping distance still longer?
Yes Brake line air bleeding
Brake line inspection
No GO TO 3.
3 ABS WARNING LAMP INDICATOR INSPECTION
Check that the ABS warning lamp illuminates.
Does the ABS warning lamp illuminate?
Yes Perform the self-diagnosis.
No GO TO 4.
4 WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
OK or NG
OK Normal
NG Wheel sensor and rotor lines repair
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TROUBLE DIAGNOSES FOR SYMPTOMSABS
2. Unexpected Pedal Action (Cont’d)
BR-67

4. ABS Does Not WorkNJBR0173
1 ABS WARNING LAMP INDICATOR INSPECTION
Check that the ABS warning lamp illuminates.
Does the ABS warning lamp illuminate?
Yes Perform the self-diagnosis.
No GO TO 2.
2 WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
OK or NG
OK Normal
NG Wheel sensor and rotor lines repair
5. Pedal Vibration and NoiseNJBR0174
1 SYMPTOM CHECK
Check the brake system for pedal vibration or noise at the engine start.
OK or NG
OK Perform the self-diagnosis.
NG GO TO 2.
2 SYMPTOM CHECK 2
Check the brake system for pedal vibration or noise when the pedal depressed lightly (just put a foot on).
CAUTION:
Under the following driving conditions, the wheel speed will fluctuates,resulting in ABS activation.
When shifting gears
High speed cornering
When a gust of wind
OK or NG
OK GO TO 3.
NG Normal
3 SYMPTOM CHECK 3
Does the symptom appear during normal braking operation?
CAUTION:
ABS may work in following driving conditions even if there is no sudden brake.
When road friction is low.
High speed cornering
When a gust of wind
OK or NG
OK GO TO 4.
NG Normal
TROUBLE DIAGNOSES FOR SYMPTOMSABS
4. ABS Does Not Work
BR-68

4 SYMPTOM CHECK 4
Check that the symptom is reproduce when the engine speed is increased withthe vehicle stopped.
OK or NG
OK GO TO 5.
NG Normal.
CAUTION:
This symptom may appear with vehicle stopped.
5 SYMPTOM CHECK 5
Check that the symptom is reproduce when any switch of electrical equipment is operated.
OK or NG
OK Check that there are no radio, antenna, and antenna lead-in wires (including wiring) near
control unit.
NG GO TO 6.
6 ABS WARNING LAMP INSPECTION
Check that the ABS warning lamp turns on.
OK or NG
OK Perform the self-diagnosis.
NG GO TO 7.
7 WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Wheel sensor path harness and connector inspection
OK or NG
OK Normal
NG Wheel sensor and rotor lines repair
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TROUBLE DIAGNOSES FOR SYMPTOMSABS
5. Pedal Vibration and Noise (Cont’d)
BR-69

NJBR0111
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, first
remove the ABS wheel sensor from the assembly. Failure to
do so may result in damage to the sensor wires making the
sensor inoperative.
Wheel SensorsNJBR0111S01
SBR902D
REMOVAL AND INSTALLATIONABS
BR-70

ABS Actuator and Electric UnitNJBR0111S10
SBR630E
REMOVALNJBR0111S10011. Disconnect battery cable.
2. Drain brake fluid.
3. Remove mounting bracket fixing bolts and nuts.
4. Disconnect connector, brake pipes and remove fixing nuts.
INSTALLATIONNJBR0111S1002CAUTION:
After installation, refill brake fluid. Then bleed air.
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes.
4. Connect connector and battery cable.
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REMOVAL AND INSTALLATIONABS
ABS Actuator and Electric Unit
BR-71

SBR984C
SBR873CA
Sensor RotorNJBR0111S02REMOVALNJBR0111S02011. Remove the drive shaft and rear wheel hub. Refer to “Drive
Shaft” and “Wheel Hub” in AX section.
2. Remove the sensor rotor using suitable puller, drift and bear-
ing replacer.
SBR985C
INSTALLATIONNJBR0111S0202Install the sensor rotor. For front sensor rotor, use hammer and
wooden block. For rear sensor rotor, use suitable drift and press.
Always replace sensor rotor with new one.
SBR986C
Pay attention to the dimension of rear sensor rotor as show in
figure.
h: 24.8 - 25.8 mm (0.976 - 1.016 in)
REMOVAL AND INSTALLATIONABS
Sensor Rotor
BR-72

General SpecificationsNJBR0077Unit: mm (in)
Engine QG15DE Except QG15DE
ABS Without With Without
Front brakeBrake model CL25VG CL25VBG
Cylinder bore diameter 57.2 (2.252)
Pad
Length×width×thick-
ness11 3 . 1×45.5×11 . 0
(4.45×1.791×0.433)108.8×47.7×11.0 (4.28×1.878×0.433)
Rotor outer diameter×
thickness257×22 (10.12×
0.87)280×22 (11.02×0.87)
ABS Without With Without
Rear brakeBrake model CL9HCG CL11HEG (Ball & Ramp type) CL9HCG
Cylinder bore diameter 33.96 (1.3370) 38.2 (1.504) 33.96 (1.3370)
Pad
Length×width×thick-
ness79.8×38.5×9.3 (3.142×1.516×0.37)
Rotor outer diameter×
thickness258×10 (10.16×0.39)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valveValve model Dual proportioning valve [without ABS]
Split point
kPa (bar, kg/cm
2, psi)×
reducing ratio3.43 (34.3×35×497)×0.4
Brake boosterBooster model V255 S255 V255
Diaphram
diameterPrimary 255 (10.04)
Secondary —
Specified brake fluidDOT 4
Disc BrakeNJBR0078Unit: mm (in)
Brake model CL25VG, CL25VBG CL9HCG, CL11HEG
Pad wear limit Minimum thickness 2.0 (0.078) 2.0 (0.079)
Rotor repair limitMaximum runout 0.07 (0.0028) 0.07 (0.0028)
Minimum thickness 20.0 (0.787) 9 (0.35)
Brake PedalNJBR0079Unit: mm (in)
Free height “H”*LHDM/T 156.0 - 166.0 (6.14 - 6.54)
A/T 165.0 - 175.0 (6.54 - 6.89)
RHDM/T 155.0 - 165.0 (6.10 - 6.50)
A/T 164.0 - 174.0 (6.46 - 6.85)
Clearance “C” between pedal stopper and threaded end of stop lamp switch orbrake switch 0.74 - 1.96 (0.0291 - 0.0772)
*: Measured from surface of dash panel to surface of pedal pad
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SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
BR-73

Parking BrakeNJBR0080
Ty p eCenter lever
Number of notches
[under force of 196 N (20 kg, 44 lb)]5-6
Number of notches
when warning lamp switch comes on1
SERVICE DATA AND SPECIFICATIONS (SDS)
Parking Brake
BR-74

BODY & TRIM
SECTION
BT
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Service Notice..............................................................3
Supplemental Restraint System (SRS)″AIR
BAG″and″SEAT BELT PRE-TENSIONER″...............3
CLIP AND FASTENER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>4
Description <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...............4
CHASSIS AND BODY MAINTENANCE.........................6
Checking Body Corrosion ............................................6
BODY FRONT END<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>7
Removal and Installation .............................................7
FRONT BUMPER ASSEMBLY....................................7
BODY REAR END AND OPENER................................10
Removal and Installation (Sedan) .............................10
REAR BUMPER ASSEMBLY....................................10
Removal and Installation (Hatchback).......................13
REAR BUMPER ASSEMBLY....................................13
DOOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..............16
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............16
STRIKER ADJUSTMENT..........................................16
Front Door Glass .......................................................17
FRONT DOOR GLASS AND REGULATOR................17
Rear Door Glass ........................................................18
REAR DOOR GLASS AND REGULATOR..................19
Front Door Lock .........................................................21
BELL CRANK ADJUSTMENT....................................21
OUTSIDE HANDLE ROD ADJUSTMENT...................21
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[22
Rear Door Lock <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[......23
OUTSIDE HANDLE ROD ADJUSTMENT...................23
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[24
INSTRUMENT PANEL ASSEMBLY.............................25
Removal and Installation ...........................................25
SIDE AND FLOOR TRIM...............................................31
Removal and Installation ...........................................31
SEDAN<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....31
3-DOOR HATCHBACK.............................................34
5-DOOR HATCHBACK.............................................36
DOOR TRIM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....39
Removal and Installation ...........................................39
ROOF TRIM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....43Removal and Installation ...........................................43
TRUNK ROOM TRIM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>5
Removal and Installation ...........................................45
SEDAN<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....45
BACK DOOR TRIM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>6
Removal and Installation ...........................................46
3-DOOR AND 5-DOOR HATCHBACK.......................46
EXTERIOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......47
Removal and Installation ...........................................47
FRONT SEAT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.56
Removal and Installation ...........................................56
MANUAL SEAT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>7
Heated Seat <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........58
Active Head Restraint ................................................58
OPERATION OUTLINE............................................58
REAR SEAT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....59
Removal and Installation ...........................................59
SUNROOF<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.......60
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............60
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............60
Trouble Diagnoses.....................................................64
DIAGNOSTIC TABLE................................................64
WIND DEFLECTOR.................................................64
ADJUSTMENT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>5
DRAIN HOSES<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>6
WEATHERSTRIP<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>6
LINK AND WIRE ASSEMBLY....................................67
WINDSHIELD AND WINDOWS....................................68
Removal and Installation ...........................................68
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[68
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>8
WINDSHIELD<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>9
SIDE WINDOW<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>0
BACK DOOR WINDOW............................................71
DOOR MIRROR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>2
Removal and Installation ...........................................72
REAR VIEW MIRROR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>3
Removal and Installation ...........................................73
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[73
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>3
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BODY (ALIGNMENT)<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>4
Alignment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[.............74ENGINE COMPARTMENT........................................75
UNDERBODY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>7
CONTENTS(Cont’d)
BT-2