brake 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

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

AGI070
HARNESS INDICATIONNJGI0003S0202Letter designations next to test meter probe indicate harness
(connector) wire color.
Connector numbers in a single circle M33 indicate harness
connectors.
COMPONENT INDICATIONNJGI0003S0203Connector numbers in a double circle F211 indicate compo-
nent connectors.
SGI860
SWITCH POSITIONSNJGI0003S0204Switches are shown in wiring diagrams as if the vehicle is in the
“normal” condition.
A vehicle is in the “normal” condition when:
ignition switch is “OFF”,
doors, hood and trunk lid/back door are closed,
pedals are not depressed, and
parking brake is released.
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HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
GI-17

Key to Symbols Signifying Measurements or
Procedures
NJGI0006S02
Symbol Symbol explanation Symbol Symbol explanation
Check after disconnecting the con-
nector to be measured.Procedure with Generic Scan Tool
(GST, OBD-II scan tool)
Check after connecting the connec-
tor to be measured.Procedure without CONSULT-II or
GST
Insert key into ignition switch.A/C switch is “OFF”.
Remove key from ignition switch.A/C switch is “ON”.
Turn ignition switch to “OFF” posi-
tion.REC switch is “ON”.
Turn ignition switch to “ON” position.REC switch is “OFF”.
Turn ignition switch to “START” posi-
tion.Fan switch is “ON”. (At any position
except for “OFF” position)
Turn ignition switch from “OFF” to
“ACC” position.Fan switch is “OFF”.
Turn ignition switch from “ACC” to
“OFF” position.Apply positive voltage from battery
with fuse directly to components.
Turn ignition switch from “OFF” to
“ON” position.Drive vehicle.
Turn ignition switch from “ON” to
“OFF” position.Disconnect battery negative cable.
Do not start engine, or check with
engine stopped.Depress brake pedal.
Start engine, or check with engine
running.Release brake pedal.
Apply parking brake.Depress accelerator pedal.
Release parking brake.Release accelerator pedal.
HOW TO FOLLOW TROUBLE DIAGNOSES
Key to Symbols Signifying Measurements or Procedures
GI-34

2-pole Lift=NJGI0009S04WARNING:
When lifting the vehicle, open the lift arms as wide as possible
and ensure that the front and rear of the vehicle are well bal-
anced.
When setting the lift arm, do not allow the arm to contact the
brake tubes, brake cable, fuel lines and sill spoiler.
S G I 111 A
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LIFTING POINTS AND TOW TRUCK TOWING
2-pole Lift
GI-47

NJMA0036
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard tothe conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION
Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
Inspect for interior and exterior metal and paint damage
Check for spare tire, jack, tools (wheel chock), and literature
Wash, clean interior and exterior
: Not applicable to this model
PRE-DELIVERY INSPECTION ITEMS
MA-2

NJMA0004
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers dothem for a nominal charge.
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified.
Item Reference page
TiresCheck the pressure with a gauge periodically when at a service station,
including the spare, and adjust to the specified pressure if necessary. Check
carefully for damage, cuts or excessive wear.—
Windshield wiper
bladesCheck for cracks or wear if not functioning correctly. —
Doors and engine
hoodCheck that all doors, the engine hood, the trunk lid and back door operate
properly. Also ensure that all latches lock securely. Lubricate if necessary.
Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.BT-7
BT-16
Tire rotationTires should be rotated every 10,000 km (6,000 miles). SU-7
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the
vehicle, etc.
Item Reference page
LampsMake sure that the headlamps, stop lamps, tail lamps, turn signal lamps,
and other lamps are all operating properly and installed securely. Also check
headlamp aim.—
Warning lamps and
chimesMake sure that all warning lamps and buzzers/chimes are operating prop-
erly.—
Steering wheelCheck that it has the specified play.
Check for changes in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)—
Seat beltsCheck that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely.
Check the belt webbing for cuts, fraying, wear or damage.RS-4
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel.
Item Reference page
Windshield washer
fluidCheck that there is adequate fluid in the tank. —
Engine coolant levelCheck the coolant level when the engine is cold. LC-18, LC-43
Engine oil levelCheck the level after parking the vehicle (on level ground) and turning off
the engine.LC-8, LC-30
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the “MAX” and
“MIN” lines on the reservoir.BR-7
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN”
lines.—
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GENERAL MAINTENANCE
MA-3

Chassis and Body MaintenanceNJMA0005S05Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference page Perform either at number of kilome-
ters (miles) or months, whichever
comes first.kmx1,000
(Miles x
1,000)
Months1
(0.6)
—10
(6)
620
(12)
1230
(18)
1840
(24)
2450
(30)
3060
(36)
3670
(42)
4280
(48)
48
Underhood and under vehicle
Brake, clutch & automatic transaxle
fluid (For level & leaks)★IIIIIIII BR-7,AT-13
Brake fluid★R R BR-18
Brake booster vacuum hoses, con-
nections & check valveI I BR-22
Power steering fluid & lines (For
level & leaks)I*1 I I*1 I I*1 I I*1 I ST-7
Brake, clutch & exhaust systemsIIIIIIIIBR-7, FE-10,
FE-26
Manual transaxle gear oil (For level
& leaks)I*1 I I*1 I I*1 I I*1 I MT-15, MT-14
Steering gear & linkage, axle & sus-
pension parts & drive shafts★I*2IIIIST-7,SU-6,SU-7
Outside and inside
Wheel alignment (If necessary,
rotate & balance wheels)IIIISU-7,SU-14
Brake pads, rotors & other brake
components★IIIIIIII BR-27,BR-31
Brake linings, drums & other brake
components★IIIIBR-7
Lock, hinges & hood latch★L*1 L L*1 L L*1 L L*1 L BT-7, BT-16
Seat belts, buckles, retractors,
anchors & adjusterIIIIRS-4
Foot brake, parking brake & clutch
(For free play, stroke & operation)I*1 I I*1 I I*1 I I*1 I BR-12, BR-43, CL-5
Ventilation air filter★Replace every 12,000 km (7,500 miles) or 12 months HA-95 or ATC-128
Supplemental air bag systemsSee NOTE
(1)RS-25
NOTE:
(1) Inspect at the first 10 years, and then every 2 years.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
*1: Models except for Australia
*2: Models without three way catalystGI
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PERIODIC MAINTENANCE (EXCEPT FOR EUROPE)
Chassis and Body Maintenance
MA-5

Maintenance Under Severe Driving Conditions=NJMA0005S06The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving condition Maintenance itemMaintenance
operationMaintenance intervalReference
page
A........Aircleaner filter Replace More frequently EM-14
ABCD.....Engine oil & oil filter (Gaso-
line engine)ReplaceEvery 5,000 km (3,000
miles) or 3 monthsLC-8, LC-9
.....F...Brakefluid ReplaceEvery 20,000 km (12,000
miles) or 12 monthsBR-7
..C....H.Automatictransaxlefluid ReplaceEvery 40,000 km (24,000
miles) or 24 monthsAT-13
......GH.Steering gear & linkage, axle
& suspension parts & drive
shaftsCheckEvery 10,000 km (6,000
miles) or 6 monthsST-7, SU-6,
SU-18
A.C...GHIBrake pads, rotors & other
brake componentsCheckEvery 5,000 km (3,000
miles) or 3 monthsBR-27,
BR-31
A.C...GHIBrake linings, drums & other
brake componentsCheckEvery 10,000 km (6,000
miles) or 6 monthsBR-7
......G..Lock,hinges & hood latch LubricateEvery 5,000 km (3,000
miles) or 3 monthsBT-16, BT-7
A........Ventilation air filter Replace More frequentlyHA-95 or
ATC-128
PERIODIC MAINTENANCE (EXCEPT FOR EUROPE)
Maintenance Under Severe Driving Conditions
MA-6

CHASSIS AND BODY MAINTENANCE=NJMA0043S0102Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis, but on
an annual basis when driving less than
15,000 km (9,000 miles) in a year.kmx1,000
(miles x 1,000)
Months15
(9)
1230
(18)
2445
(27)
3660
(36)
4875
(45)
6090
(54)
72105
(63)
84120
(72)
96
Underhood and under vehicle
Headlamp aimingIIIIIIIIEL-44
Wheel alignment (if necessary, balance
& rotate wheels)IIIIIIIISU-6/
SU-18
Brake pads, rotors & other brake com-
ponents★IIIIIIIIBR-27/
BR-28
Foot brake, parking brake & clutch (for
free play, stroke & operation)IIIIIIIIBR-12/
BR-44/
CL-9
Brake booster vacuum hoses,
connections, check valveIIIIBR-21
Brake & clutch, systems and fluid (for
level and leaks)IIIIIIIIBR-7
Brake fluid★RRRRBR-7
Power steering fluid and lines (for level
and leaks)IIIIIIIIST-7
Supplemental air bag systems See NOTE (1) RS-25
Ventilation air filter★RRRRHA-95 or
AT C - 1 2 8
Manual transaxle gear oil (check for
leakage. Use genuine NISSAN XZ
gear oil or exact equivalent)IIIIIIIIMT-14
MT-15
Automatic transaxle fluid (for level and
leaks)★IIIIIIIIAT-13
Steering gear & linkage, axle & sus-
pension parts, drive shafts, exhaust
system★IIIIST-7/
SU-6/
SU-18/
FE-10
NISSAN Mobility System See NOTE (2)IIIIIII —
Body corrosion See NOTE (3) BT-6
NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Check expiration date of the tyre sealant bottle. Replace if necessary.
(3) Inspect once per year.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) (Cont’d)
MA-8