NISSAN ALMERA N16 2003 Electronic Repair Manual

4 CHECK DIAGNOSIS SENSOR UNIT
Connect CONSULT-II and touch “START”.
Is “AIR BAG” displayed on CONSULT-II?
SRS771
YesorNo
Ye s G O T O 5 .
No Visually check the wiring harness connection of diagnosis sensor unit.If the harness
connection check result is OK, replace diagnosis sensor unit.
5 CHECK HARNESS CONNECTION
Is harness connection between warning lamp and diagnosis sensor unit OK?
OK or NG
OK Replace diagnosis sensor unit.
NG Connect “AIR BAG” warning lamp and diagnosis sensor unit connector properly. If “AIR
BAG” warning lamp still does not go off, replace harness.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off (Cont’d)
RS-69

Trouble Diagnoses: “AIR BAG” Warning Lamp
Does Not Turn On
=NJRS0051DIAGNOSTIC PROCEDURE 10NJRS0051S01
1 CHECK “METER” FUSE
Is meter fuse OK?
SRS836
OK or NG
OK GO TO 3.
NG GO TO 2.
2 CHECK “METER” FUSE AGAIN
Replace meter fuse and turn ignition switch ON.
Is meter fuse blown again?
Yes Repair main harness.
NoINSPECTION END
3 CHECK “AIR BAG” WARNING LAMP LED
Is “AIR BAG” warning lamp LED OK?
OK or NG
OK GO TO 4.
NG Replace “AIR BAG” warning lamp LED.
4 CHECK HARNESS CONNECTION BETWEEN DIAGNOSIS SENSOR UNIT AND “AIR BAG” WARNING
LAMP
Disconnect diagnosis sensor unit connector and turn ignition switch “ON”.
Does “AIR BAG” warning lamp turn on?
YesorNo
Yes Replace diagnosis sensor unit.
No Check the ground circuit of “AIR BAG” warning lamp.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On
RS-70

Collision Diagnosis=NJRS0033FOR FRONTAL COLLISIONNJRS0033S07To repair the SRS, perform the following steps.
When SRS (except the side air bag) is activated in a collision:
1) Replace the diagnosis sensor unit.
2) Remove the air bag modules (except the side air bag module) and front seatbelt pre-tensioner assem-
blies.
3) Check the SRS components using the table shown below:
Replace any SRS components showing visible signs of damage (dents, cracksand deformation).
4) Install new air bag modules (except the side air bag module) and front seat belt pre-tensioner assemblies.
5) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
When SRS is not activated in a collision:
1) Check the SRS components using the table shown below:
Replace any SRS components showing visible signs of damage (dents, cracksand deformation).
2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
SRS Inspection (For frontal collision)NJRS0033S0701
Part SRS is activated SRS is NOT activated
Air bag module (driver
and front passenger
side)REPLACE
Install with new bolts.1. Remove air bag module. Check harness cover and connectors for damage,
terminals for deformities, and harness for binding.
2.
a. Install driver’s air bag module into the steering wheel to check fit and align-
ment with the wheel.
b. Install front passenger air bag module into the instrument panel to checkfit
with the instrument panel.
3. No damage found, reinstall with new bolts.
4. If damaged—REPLACE. Install air bag modules with new bolts. Air bag must
be deployed before disposing.
Front seat belt pre-
tensioner assemblyREPLACE
Install seat belt pre-
tensioner with new
bolts.1. Remove front seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities,
and harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. If no damage is found, reinstall front seat belt pre-tensioner assembly.
5. If damaged—REPLACE. Install the front seat belt pre-tensioners with new bolts
coated with bonding agent. Front seat belt pre-tensioners must be deployed
before discarding.
Diagnosis sensor unit REPLACE
Install with new bolts
coated with bonding
agent.1. Check case for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall with new special bolts and ground bolt coated
with bonding agent.
4. If damaged—REPLACE. Install diagnosis sensor unit with new special bolts
and ground bolt coated with bonding agent.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install driver air bag module to check fit or alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall with bolts.
6. If damaged—REPLACE.
Spiral cable 1. Visually check spiral cable and combination switch for damage.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
4. If no damage is found, reinstall with bolts.
5. If damaged—REPLACE.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis
RS-71

Part SRS is activated SRS is NOT activated
Harness and Connec-
tors1. Check connectors for poor connection, damage, and terminals for deformities.
2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.
Instrument panel 1. When passenger air bag inflates, check the following points for bending, deformities or cracks.
Opening portion for front passenger air bag
SRS837
Front passenger air bag module brackets
SRS838
The portions securing the instrument panel
SRS839
2. If no damage is found, reinstall the instrument panel.
3. If damaged—REPLACE the instrument panel with bolts.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis (Cont’d)
RS-72

FOR SIDE COLLISION=NJRS0033S08To repair the SRS for a side collision, perform the following steps.
When the side air bag is activated in a side collision:
1) Replace the following component:
− All parts of front seatback (including front seatback frame) with side air bag module (on the side on which
side air bag is activated)
− Diagnosis sensor unit
− Side air bag (satellite) sensor (on the side on which side air bag is activated)
2) Check the SRS components and the related parts using the table shown below.
Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
3) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
When SRS is not activated in the side collision:
1) Check the SRS components and the related parts using the table shown below.
Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
SRS Inspection (For side collision)NJRS0033S0801
PartSide air bag is acti-
vatedSRS is NOT activated
Front (LH or RH) side
air bag moduleREPLACE all parts of
front seatback with
deployed front side air
bag module.1. Check for visible signs of damage (dents, tears, deformation) of the seatback
on the collision side.
2. If damaged—REPLACE the damaged seat parts with new bolts and remove
the front side air bag module.
3. Check for visible signs of damaged (tesrs etc.) of the side air bag module.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damaged is found, reinstall the front side air bag module with new nuts.
6. If damaged—REPLACE the front side air bag module with new nuts. Air bag
must be deployed before disposing.
(LH or RH) side air
bag (satellite) sensorREPLACE the side air
bag (satellite) sensor
on the collision side
with new nuts coated
with bonding agent.
(Repair the center
pillar inner, etc. before
installing new one if
damaged.)1. Remove the satellite sensor on the collision side. Check harness connectors
for damage, terminals for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the satellite
sensor.
3. Install the side air bag (satellite) sensor to check fit.
4. If no damage is found, reinstall the side air bag (satellite) sensor withnew
nuts.
5. If damaged—REPLACE the side air bag sensor with new nuts coated with
bonding agent.
Diagnosis sensor unit REPLACE the diag-
nosis sensor unit with
the new bolts.1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new special bolts
and ground bolt.
4. If damaged—REPLACE. Install the diagnosis sensor unit with new special
bolts and ground bolt.
Front seat belt pre-
tensioner assembly1. Check if the seat belt can be extended smoothly.
If the seat belt cannot be extended smoothly.
– Check for deformities of the center pillar inner.
– If the center pillar inner has no damage, REPLACE the front seat belt pre-tensioner assembly.
2. Remove the front seat belt pre-tensioner assembly on the collision side. Check harness cover and con-
nectors for damage, terminals for deformities, and harness for binding.
3. Check for visible signs of damage (dents, cracks, deformation) of the front seat belt pre-tensioner
assembly.
4. If no damage is found, reinstall the front seat belt pre-tensioner assembly.
5. If damaged—REPLACE the front seat belt pre-tensioner assembly with newbolts coated with bonding
agent. The front seat belt pre-tensioner assembly must be deployed beforedisposing of it.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis (Cont’d)
RS-73

PartSide air bag is acti-
vatedSRS is NOT activated
Seat with built-in side
air bagREPLACE all parts of
front seatback (includ-
ing front seatback
frame)1. Visually check the seat on the collision side.
2. Remove the seat on the collision side and check the following for damage and
deformities.
Harness, connectors and terminals
Frame and recliner (for front and rear seat), and also adjuster and slides (for
front seat)
3. If no damage is found, reinstall the seat.
4. If damaged—REPLACE the damaged seat parts with new bolts.
Center pillar inner 1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation).
2. If damaged—REPAIR the center pillar inner.
Trim 1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side.
2. If damaged—REPLACE the damaged trim parts.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis (Cont’d)
RS-74

STARTING & CHARGING SYSTEMS
SECTION
SC
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[2
Supplemental Restraint System (SRS)″AIR
BAG″and″SEAT BELT PRE-TENSIONER″...............2
Wiring Diagrams and Trouble Diagnoses....................2
BATTERY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..........3
How to Handle Battery ................................................3
METHODS OF PREVENTING OVER-DISCHARGE......3
CHECKING ELECTROLYTE LEVEL............................3
SPECIFIC GRAVITY CHECK......................................4
Battery Test and Charging Chart .................................6
CHART I<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....6
CHART II<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...7
A: SLOW CHARGE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>8
B: STANDARD CHARGE..........................................10
C: QUICK CHARGE................................................. 11
STARTING SYSTEM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>3
System Description ....................................................13
M/T MODELS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>3
A/T MODELS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>3
Wiring Diagram - START -/M/T Models.....................14
Wiring Diagram - START -/A/T Models .....................16
Trouble Diagnoses.....................................................17
Construction <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[............18
Removal and Installation ...........................................22
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[22
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............23
MAGNETIC SWITCH CHECK...................................23
PINION/CLUTCH CHECK.........................................23
BRUSH CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>3
YOKE CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>4
ARMATURE CHECK................................................24
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............25
PINION PROTRUSION LENGTH ADJUSTMENT........26
CHARGING SYSTEM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>7
System Description ....................................................27
Wiring Diagram - CHARGE -.....................................28
Trouble Diagnoses.....................................................29
WITH IC REGULATOR.............................................29
MALFUNCTION INDICATOR....................................29
Construction <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[............30
Removal and Installation ...........................................33
REMOVAL (QG ENGINE MODELS)..........................33
REMOVAL (YD ENGINE MODELS)...........................33
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>4
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........34
REAR COVER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>4
REAR BEARING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>4
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............34
ROTOR CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>4
BRUSH CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>5
STATOR CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>5
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............35
RING FITTING IN REAR BEARING...........................35
REAR COVER INSTALLATION.................................36
SERVICE DATA AND SPECIFICATIONS (SDS).........37
Battery<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[................37
Starter <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[................37
Alternator <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............38
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Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
NJSC0001The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof 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 should be per-
formed by an authorized NISSAN 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 removalofSpiralCableandAir
Bag Module, see the RS 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-
tor.
Wiring Diagrams and Trouble DiagnosesNJSC0002When you read wiring diagrams, refer to the following:
GI-12, “HOW TO READ WIRING DIAGRAMS”
EL-12, “POWER SUPPLY ROUTING” for power distribution circuit
When you perform trouble diagnoses, refer to the following:
GI-33, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES”
GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
SC-2

How to Handle BatteryNJSC0003CAUTION:
If it becomes necessary to start the engine with a booster
battery and jumper cables,
1) Use a 12-volt booster battery.
2) After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
3) Never add distilled water through the hole used to check
specific gravity.
MEL040F
METHODS OF PREVENTING OVER-DISCHARGENJSC0003S01The following precautions must be taken to prevent over-discharg-
ing a battery.
The battery surface (particularly its top) should always be kept
clean and dry.
The terminal connections should be clean and tight.
At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”.
MEL041F
When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal.
MEL042F
Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVELNJSC0003S02WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.
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BATTERY
How to Handle Battery
SC-3

MEL043F
Remove the cell plug using a suitable tool.
Add distilled water up to the MAX level.
SEL709E
SulphationNJSC0003S0201A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been “sulphated”, note its volt-
age and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test.
MEL042FA
SPECIFIC GRAVITY CHECKNJSC0003S031. Read hydrometer and thermometer indications at eye level.
2. Convert into specific gravity at 20°C (68°F).
Example:
When electrolyte temperature is 35°C (95°F) and specific grav-
ity of electrolyte is 1.230, converted specific gravity at 20°C
(68°F) is 1.240.
When electrolyte temperature is 0°C (32°F) and specific grav-
ity of electrolyte is 1.210, converted specific gravity at 20°C
(68°F) is 1.196.
BATTERY
How to Handle Battery (Cont’d)
SC-4