Start NISSAN ALMERA N16 2003 Electronic Repair Manual

Edition: August 2003
Release: October 2003 (01)
Publication No.: SM3E00-1N16E1E
Reference No.: 7711347018
GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICAL – QGEM-QG
ENGINE MECHANICAL – YDEM-YD
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEM – QGEC - QG
ENGINE CONTROL SYSTEM – YDEC - YD
ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEMSFE
CLUTCHCL
MANUAL TRANSAXLEMT
AUTOMATIC TRANSAXLEAT
FRONT & REAR AXLEAX
FRONT & REAR SUSPENSIONSU
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & MANUAL AIR CONDITIONERHA
AUTOMATIC AIR CONDITIONERATC
STARTING & CHARGING SYSTEMSSC
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
ALMERA
MODEL N16 SERIES
NISSAN EUROPE S.A.S.
© 2003 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.
QUICK REFERENCE INDEX

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
ALMERA, model N16 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
fications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first completely satisfy himself that neither his safety nor the vehicle’s
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............3
PRECAUTIONS FOR SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)″AIR BAG″AND
″SEAT BELT PRE-TENSIONER″
.................................3
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...3
GENERAL PRECAUTIONS.........................................4
PRECAUTIONS FOR MULTIPORT FUEL
INJECTION SYSTEM OR ENGINE CONTROL
SYSTEM
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....6
PRECAUTIONS FOR THREE WAY CATALYST...........6
PRECAUTIONS FOR HOSES.....................................6
PRECAUTIONS FOR ENGINE OILS...........................7
PRECAUTIONS FOR FUEL........................................8
PRECAUTIONS FOR AIR CONDITIONING..................9
HOW TO USE THIS MANUAL......................................10
HOW TO READ WIRING DIAGRAMS..........................12
Sample/Wiring Diagram - EXAMPL - ........................12
OPTIONAL SPLICE..................................................13
Description <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[.............14
CONNECTOR SYMBOLS.........................................16
HARNESS INDICATION...........................................17
COMPONENT INDICATION......................................17
SWITCH POSITIONS...............................................17
DETECTABLE LINES AND NON-DETECTABLE
LINES
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......18
MULTIPLE SWITCH.................................................19
REFERENCE AREA.................................................20
HOW TO PERFORM EFFICIENT DIAGNOSES
FOR AN ELECTRICAL INCIDENT...............................22
Work Flow <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[...........22
Incident Simulation Tests ...........................................23
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>3
VEHICLE VIBRATION..............................................23
HEAT SENSITIVE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011>4
FREEZING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>24
WATER INTRUSION................................................25
ELECTRICAL LOAD.................................................25
COLD OR HOT START UP.......................................25
Circuit Inspection .......................................................25
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>5
TESTING FOR″OPENS″IN THE CIRCUIT................26
TESTING FOR″SHORTS″IN THE CIRCUIT..............27
GROUND INSPECTION...........................................28
VOLTAGE DROP TESTS..........................................28
CONTROL UNIT CIRCUIT TEST...............................30
HOW TO FOLLOW TROUBLE DIAGNOSES...............32
How to Follow Test Groups in Trouble Diagnoses ....33
Key to Symbols Signifying Measurements or
Procedures<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............34
CONSULT-II CHECKING SYSTEM...............................36
Function and System Application ..............................36
Nickel Metal Hydride Battery Replacement...............37
Checking Equipment..................................................37
CONSULT-II Data Link Connector (DLC) Circuit ......38
INSPECTION PROCEDURE.....................................38
IDENTIFICATION INFORMATION................................39
Model Variation ..........................................................39
FOR EUROPE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>9
FOR AUSTRALIA, NEW ZEALAND AND SOUTH
AFRICA
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....39
PREFIX AND SUFFIX DESIGNATIONS.....................40
Identification Number .................................................40
VEHICLE IDENTIFICATION NUMBER
ARRANGEMENT
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>1
IDENTIFICATION PLATE..........................................41
ENGINE SERIAL NUMBER.......................................42
AUTOMATIC TRANSAXLE NUMBER........................42
MANUAL TRANSAXLE NUMBER..............................43
Dimensions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[...........44
Wheels and Tires .......................................................44
LIFTING POINTS AND TOW TRUCK TOWING...........45
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............45
SPECIAL SERVICE TOOLS......................................45
Board-on Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...........45
Garage Jack and Safety Stand .................................46
2-pole Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............47
Tow Truck Towing ......................................................48
TOWING AN AUTOMATIC TRANSAXLE MODEL
WITH FOUR WHEELS ON GROUND
........................48
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PrecautionsNJGI0001Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
SGI646
PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) “AIR BAG” AND “SEAT BELT
PRE-TENSIONER”
NJGI0001S01The 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 passen-
ger for certain types of collision. The SRS system composition
which is available to NISSAN MODEL N16 is as follows (The com-
position varies according to the destination and optional equip-
ment.):
For a frontal collision
The Supplemental Restraint System consists of driver air bag
module (located in the center of the steering wheel), front pas-
senger air bag module (located on the instrument panel on
passenger side), front seat belt pre-tensioners, a diagnoses
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, diagnoses 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 performed by an authorized
NISSAN dealer.
Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system. For removal of
Spiral Cable and Air 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 connector.
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
NJGI0001S02NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
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PRECAUTIONS
Precautions
GI-3

The security indicator is located on the combi meter. The indicator
blinks when the ignition switch is in “OFF” or “ACC” position.
Therefore, NATS warns outsiders that the vehicle is equipped with
the anti-theft system.
When NATS detects trouble, the security indicator lamp lights
up while ignition switch is in “ON” position.
This lighting up indicates that the anti-theft is not functioning,
so prompt service is required.
When servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs),
CONSULT-II hardware and CONSULT-II NATS software is
necessary.
Regarding the procedures of NATS initialization and NATS
ignition key ID registration, refer to CONSULT-II operation
manual, NATS.
Therefore, CONSULT-II NATS software (program card and
operation manual) must be kept strictly confidential to main-
tain the integrity of the anti-theft function.
When servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs), it
may be necessary to re-register original key identification.
Therefore, be sure to receive all keys from vehicle owner. A
maximum of five key IDs can be registered into NATS.
When failing to start the engine first time using the key of
NATS, start as follows.
a) Leave the ignition key in “ON” position for approximately 5
seconds.
b) Turn ignition key to “OFF” or “LOCK” position and wait approxi-
mately 5 seconds.
c) Repeat step 1 and 2 again.
d) Restart the engine while keeping the key separate from any
others on key-chain.
SGI285
GENERAL PRECAUTIONSNJGI0001S03Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refrig-
erant gas, etc. When working in a pit or other enclosed area,
be sure to properly ventilate the area before working with haz-
ardous materials.
Do not smoke while working on the vehicle.
SGI231
Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before work-
ing on the vehicle.
These operations should be done on a level surface.
When removing a heavy component such as the engine or
transaxle, be careful not to lose your balance and drop them.
Also, do not allow them to strike adjacent parts, especially the
brake tubes and master cylinder.
PRECAUTIONS
Precautions (Cont’d)
GI-4

SEF289H
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
SGI233
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
SGI234
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
Arrange the disassembled parts in accordance with their
assembled locations and sequence.
Do not touch the terminals of electrical components which use
microcomputers (such as ECMs).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents
when required.
Use tools and recommended special tools where specified for
safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
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PRECAUTIONS
Precautions (Cont’d)
GI-5

Incident Simulation TestsNJGI0005S02INTRODUCTIONNJGI0005S0201Sometimes the symptom is not present when the vehicle is brought
in for service. If possible, re-create the conditions present at the
time of the incident. Doing so may help avoid a No Trouble Found
Diagnoses. The following section illustrates ways to simulate the
conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:
Vehicle vibration
Heat sensitive
Freezing
Water intrusion
Electrical load
Cold or hot start up
Get a thorough description of the incident from the customer. It is
important for simulating the conditions of the problem.
VEHICLE VIBRATIONNJGI0005S0202The problem may occur or become worse while driving on a rough
road or when engine is vibrating (idle with A/C on). In such a case,
you will want to check for a vibration related condition. Refer to the
illustration below.
Connectors & Harness
Determine which connectors and wiring harness would affect the
electrical system you are inspecting.Gentlyshake each connec-
tor and harness while monitoring the system for the incident you
are trying to duplicate. This test may indicate a loose or poor elec-
trical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin
film of corrosion on the connector terminals. A visual inspection
may not reveal this without disconnecting the connector. If the
problem occurs intermittently, perhaps the problem is caused by
corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensors & Relays
Gentlyapply a slight vibration to sensors and relays in the system
you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
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HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests
GI-23

Engine Compartment
There are several reasons a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for are:
Connectors not fully seated.
Wiring harness not long enough and is being stressed due to
engine vibrations or rocking.
Wires laying across brackets or moving components.
Loose, dirty or corroded ground wires.
Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integ-
rity of ground connections. (Refer to GROUND INSPECTION
described later.) First check that the system is properly grounded.
Then check for loose connection bygently shakingthe wiring or
components as previously explained. Using the wiring diagrams
inspect the wiring for continuity.
Behind The Instrument Panel
An improperly routed or improperly clamped harness can become
pinched during accessory installation. Vehicle vibration can aggra-
vate a harness which is routed along a bracket or near a screw.
Under Seating Areas
An unclamped or loose harness can cause wiring to be pinched by
seat components (such as slide guides) during vehicle vibration. If
the wiring runs under seating areas, inspect wire routing for pos-
sible damage or pinching.
SGI842
HEAT SENSITIVENJGI0005S0203The owner’s problem may occur during hot weather or after car has
sat for a short time. In such cases you will want to check for a heat
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
Do not heat components above 60°C (140°F).If incident occurs
while heating the unit, either replace or properly insulate the com-
ponent.
SGI843
FREEZINGNJGI0005S0204The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez-
ing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnoses
of those electrical components which could be affected.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont’d)
GI-24

The second method is to put the suspect component into a freezer
long enough for any water to freeze. Reinstall the part into the car
and check for the reoccurrence of the incident. If it occurs, repair
or replace the component.
SGI844
WATER INTRUSIONNJGI0005S0205The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water
intrusion on an electrical part. This can be simulated by soaking the
car or running it through a car wash.
Do not spray water directly on any electrical components.
SGI845
ELECTRICAL LOADNJGI0005S0206The incident may be electrical load sensitive. Perform diagnoses
with all accessories (including A/C, rear window defogger, radio,
fog lamps) turned on.
COLD OR HOT START UPNJGI0005S0207On some occasions an electrical incident may occur only when the
car is started cold. Or it may occur when the car is restarted hot
shortly after being turned off. In these cases you may have to keep
the car overnight to make a proper diagnoses.
Circuit InspectionNJGI0005S03INTRODUCTIONNJGI0005S0301In general, testing electrical circuits is an easy task if it is
approached in a logical and organized method. Before beginning
it is important to have all available information on the system to be
tested. Also, get a thorough understanding of system operation.
Then you will be able to use the appropriate equipment and follow
the correct test procedure.
You may have to simulate vehicle vibrations while testing electrical
components.Gently shakethe wiring harness or electrical com-
ponent to do this.
OPEN A circuit is open when there is no continuity through a section of
the circuit.
SHORT There are two types of shorts.
SHORT CIRCUIT When a circuit contacts another circuit
and causes the normal resistance to
change.
SHORT TO GROUND When a circuit contacts a ground source
and grounds the circuit.
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HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont’d)
GI-25

TESTING FOR “OPENS” IN THE CIRCUITNJGI0005S0302Before you begin to diagnose and test the system, you should
rough sketch a schematic of the system. This will help you to logi-
cally walk through the diagnoses process. Drawing the sketch will
also reinforce your working knowledge of the system.
SGI846
Continuity Check Method
The continuity check is used to find an open in the circuit. The
Digital Multimeter (DMM) set on the resistance function will indicate
an open circuit as over limit (no beep tone or no ohms symbol).
Make sure to always start with the DMM at the highest resistance
level.
To help in understanding the diagnoses of open circuits please
refer to the schematic above.
1) Disconnect the battery negative cable.
2) Start at one end of the circuit and work your way to the other
end. (At the fuse block in this example)
3) Connect one probe of the DMM to the fuse block terminal on
the load side.
4) Connect the other probe to the fuse block (power) side of SW1.
Little or no resistance will indicate that portion of the circuit has
good continuity. If there were an open in the circuit, the DMM
would indicate an over limit or infinite resistance condition.
(point A)
5) Connect the probes between SW1 and the relay. Little or no
resistance will indicate that portion of the circuit has good con-
tinuity. If there were an open in the circuit, the DMM would
indicate an over limit or infinite resistance condition. (point B)
6) Connect the probes between the relay and the solenoid. Little
or no resistance will indicate that portion of the circuit has good
continuity. If there were an open in the circuit, the DMM would
indicate an over limit or infinite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the above
example.
Voltage Check Method
To help in understanding the diagnoses of open circuits please
refer to the previous schematic.
In any powered circuit, an open can be found by methodically
checking the system for the presence of voltage. This is done by
switching the DMM to the voltage function.
1) Connect one probe of the DMM to a known good ground.
2) Begin probing at one end of the circuit and work your way to
the other end.
3) With SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
4) Close SW1 and probe at relay.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
GI-26