brakes NISSAN ALMERA N16 2003 Electronic Repair Manual

Symptom Check items
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp
Service Data and Specifications (SDS)
THERMOSTATNJLC0029
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F)More than 8/95 (0.31/203)
RADIATORNJLC0030Unit: kPa (bar, kg/cm2, psi)
Cap reliefpressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure157 (1.57, 1.6, 23)
COOLANT CAPACITYNJLC0038Unit:(Imp qt)
M/T*6.7 (5-7/8)
A/T*Sedan 6.6 (5-7/8)
Hatchback 6.7 (5-7/8)
Reservoir tank0.7 (5/8)
*: With reservoir tank
ENGINE COOLING SYSTEMQG
Overheating Cause Analysis (Cont’d)
LC-24

Symptom Check items
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under
no load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp
Service Data and Specifications (SDS)
THERMOSTATNJLC0071
Valve opening temperature Above 80.5 - 83.5°C (177 - 182°F)
Valve liftMore than 9.0 mm/95°C (0.354 in/203°F)
RADIATORNJLC0073Unit: kPa (bar, kg/cm2, psi)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure157 (1.57, 1.6, 23)
ENGINE COOLANT CAPACITYNJLC0080Unit:(Imp qt)
With reservoir tank8.7 (7-5/8)
Reservoir tank0.7 (5/8)
GI
MA
EM
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ENGINE COOLING SYSTEMYD
Overheating Cause Analysis (Cont’d)
LC-47

AT-4
REMOVAL AND INSTALLATION ...........................410
Removal ...............................................................410
Installation .............................................................411
OVERHAUL .............................................................413
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................413
Oil Channel ...........................................................416
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................417
DISASSEMBLY .......................................................418
Disassembly .........................................................418
REPAIR FOR COMPONENT PARTS ......................432
Manual Shaft ........................................................432
Oil Pump ...............................................................435
Control Valve Assembly ........................................439
Control Valve Upper Body ....................................449
Control Valve Lower Body ....................................453
Reverse Clutch .....................................................455
High Clutch ...........................................................459
Forward and Overrun Clutches ............................464
Low & Reverse Brake ...........................................470
Rear Internal Gear, Forward Clutch Hub and Over-
run Clutch Hub ......................................................474
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................478
Band Servo Piston Assembly ...............................483
Final Drive ............................................................488
ASSEMBLY .............................................................493
Assembly (1) .........................................................493Adjustment (1) .......................................................494
Assembly (2) .........................................................500
Adjustment (2) .......................................................504
Assembly (3) .........................................................508
SERVICE DATA AND SPECIFICATIONS (SDS) ....515
General Specifications ......................................... .515
Shift Schedule .......................................................515
Stall Revolution .....................................................515
Line Pressure ........................................................515
Control Valves .......................................................516
Clutch and Brakes .................................................516
Clutch and Brake Return Springs .........................518
Oil Pump ......................................................
.........518
Input Shaft .............................................................518
Planetary carrier ....................................................518
Final Drive .............................................................519
Reduction Pinion Gear ..........................................520
Output Shaft ..........................................................522
Bearing Retainer ...................................................523
Total End Play .......................................................523
Reverse Clutch End Play ......................................523
Accumulator ..........................................................523
Band Servo ...........................................................524
Removal and Installation .......................................524
Shift Solenoid Valves ............................................524
Solenoid Valves ....................................................524
A/T Fluid Temperature Sensor ..............................524
Revolution Sensor .................................................524
Dropping Resistor .................................................524

AT-58
[EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
Diagnostic Worksheet
1.❏ Read the Fail-safe and listen to customer complaints.AT-57, "Infor-
mation from
Customer"
2.❏ CHECK A/T FLUIDAT-63, "A/T
Fluid Check"❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.❏ Perform STALL TEST and LINE PRESSURE TEST.AT-64, "
Stall
Te s t",AT- 6 7 ,
"Line Pres-
sure Test"
❏ Stall test — Mark possible damaged components/others.
❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK
❏ Line Pressure test — Suspected parts:
4.❏ Perform all ROAD TEST and mark required procedures.AT-68, "
Road
Te s t"
4-
1.Check before engine is started.AT-70, "1.
CHECK
BEFORE
ENGINE IS
STARTED"
❏ SELF-DIAGNOSTIC PROCEDURE/DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCE-
DURE. — Mark detected items.
❏ PNP switch, AT- 111
.
❏ A/T fluid temperature sensor, AT- 11 7
.
❏ Vehicle speed sensor·A/T (Revolution sensor), AT-123
.
❏ Engine speed signal, AT-129
.
❏ Torque converter clutch solenoid valve, AT- 1 5 9
.
❏ Line pressure solenoid valve, AT-164
.
❏ Shift solenoid valve A, AT-171
.
❏ Shift solenoid valve B, AT-176
.
❏ Accelerator pedal position (APP) sensor, AT-181
.
❏ Overrun clutch solenoid valve, AT-187
.
❏ PNP & overdrive control switches, and throttle position sensor, AT- 2 3 7
.
❏ Batt/fluid temp sen (A/T fluid temperature sensor and TCM power source), AT-195
.
❏ Vehicle speed sensor·MTR, AT- 2 0 1
.
❏ CAN communication line, AT-192
.
❏ Control unit (RAM), control unit (ROM), AT- 2 0 5
.
❏ Control unit (EEP ROM), AT- 2 0 7
.
❏ Battery
❏ Others
4-
2.Check at idleAT-71, "
2.
CHECK AT
IDLE"❏ 1. O/D OFF Indicator Lamp Does Not Come On, AT- 2 11 .
❏ 2. Engine Cannot Be Started In “P” And “N” Position, AT- 2 1 2
.
❏ 3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed, AT- 2 1 3
.
❏ 4. In “N” Position, Vehicle Moves, AT- 2 1 4
.
❏ 5. Large Shock. “N” → “R” Position, AT-215
.
❏ 6. Vehicle Does Not Creep Backward In “R” Position, AT- 2 1 6
.
❏ 7. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT-219
.

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
AT-89
[EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
Clutches or brakes slip somewhat in
starting.ON vehicle1. Fluid levelAT-63, "
FLUID LEVEL
CHECK"
2. Control cable adjustmentAT-408, "Control Cable
Adjustment"
3. Throttle position sensor [Accelerator
pedal position (APP) sensor]AT-181, "
DTC P1705
ACCELERATOR PEDAL
POSITION (APP) SEN-
SOR"
4. Line pressure testAT-67, "Line Pressure Test"
5. Line pressure solenoid valveAT-164, "
DTC P0745 LINE
PRESSURE SOLENOID
VA LV E"
6. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
7. Accumulator N-DAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle8. Forward clutchAT-464, "
Forward and
Overrun Clutches"
9. Reverse clutchAT-455, "Reverse Clutch"
10. Low & reverse brakeAT-470, "Low & Reverse
Brake"
11. Oil pumpAT-435, "Oil Pump"
12. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Excessive creep. ON vehicle 1. Engine idling rpmEC-30, "Idle Speed and
Ignition Timing Check"
No creep at all.
AT-216, "
6. Vehicle Does Not Creep
Backward In “R” Position" and AT-
219, "7. Vehicle Does Not Creep
Forward In “D”,“2” Or “1” Position"
ON vehicle1. Fluid levelAT-63, "
FLUID LEVEL
CHECK"
2. Line pressure testAT-67, "LINE PRESSURE
TEST PROCEDURE"
3. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle4. Forward clutchAT-464, "
Forward and
Overrun Clutches"
5. Oil pumpAT-435, "Oil Pump"
6. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Symptom Condition Diagnostic ItemReference Page
EURO-OBD

TROUBLE DIAGNOSIS — INTRODUCTION
AT-257
[EXC.F/EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
Diagnostic Worksheet
1.❏ Read the Fail-safe and listen to customer complaints.AT- 2 5 6 ,
"Information
from Cus-
tomer"
2.❏ CHECK A/T FLUIDAT- 2 6 1 , "A/T
Fluid Check"❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.❏ Perform STALL TEST and LINE PRESSURE TEST.AT- 2 6 2 , "
Sta l l
Te s t",
AT- 2 6 5 , "
Line
Pressure
Te s t"
❏ Stall test — Mark possible damaged components/others.
❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK
❏ Line Pressure test — Suspected parts:
4.❏ Perform all ROAD TEST and mark required procedures.AT- 2 6 6 ,
"Road Test"
4-
1.Check before engine is started.AT- 2 6 8 , "1.
CHECK
BEFORE
ENGINE IS
STARTED"
❏ SELF-DIAGNOSTIC CONFIRMATION PROCEDURE — Mark detected items.
❏ Vehicle speed sensor·A/T (Revolution sensor), AT- 3 4 3
.
❏ Vehicle speed sensor·MTR, AT-348
.
❏ Accelerator pedal position (APP) sensor, AT-352
.
❏ Shift solenoid valve A, AT- 3 5 7
.
❏ Shift solenoid valve B, AT- 3 6 2
.
❏ Overrun clutch solenoid valve, AT- 3 6 7
.
❏ Torque converter clutch solenoid valve, AT-372
.
❏ A/T fluid temperature sensor and TCM power source, AT-377
.
❏ Engine speed signal, AT- 3 8 3
.
❏ Line pressure solenoid valve, AT-388
.
❏ CAN communication line, AT- 3 9 5
.
❏ Control unit (RAM), control unit (ROM), AT-205
.
❏ Control unit (EEP ROM), AT-207
.
❏ PNP & overdrive control switches, and throttle position sensor, AT- 3 3 3
.
❏ Battery
❏ Others
4-
2.Check at idleAT- 2 6 9 , "
2.
CHECK AT
IDLE"❏ 1. O/D OFF Indicator Lamp Does Not Come On, AT- 3 0 9 .
❏ 2. Engine Cannot Be Started In “P” And “N” Position, AT-309
.
❏ 3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed, AT-310
.
❏ 4. In “N” Position, Vehicle Moves, AT- 3 11
.
❏ 5. Large Shock. “N” → “R” Position, AT- 3 1 2
.
❏ 6. Vehicle Does Not Creep Backward In “R” Position, AT-313
.
❏ 7. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT- 3 1 6
.

AT-286
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Clutches or brakes slip somewhat in
starting.ON vehicle1. Fluid levelAT-261, "
FLUID LEVEL
CHECK"
2. Control cable adjustmentAT-408, "Control Cable
Adjustment"
3. Throttle position sensor (Accelerator
pedal position (APP) sensor)AT-352, "ACCELE
RATOR PEDAL POSI-
TION (APP) SENSOR"
4. Line pressure testAT-265, "Line Pressure
Te s t"
5. Line pressure solenoid valveAT-388, "
LINE PRES-
SURE SOLENOID
VA LV E"
6. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
7. Accumulator N-DAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle8. Forward clutchAT-464, "
Forward and
Overrun Clutches"
9. Reverse clutchAT-455, "Reverse Clutch"
10. Low & reverse brakeAT-470, "Low & Reverse
Brake"
11. Oil pumpAT-435, "Oil Pump"
12. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Excessive creep. ON vehicle 1. Engine idling rpmEC-722, "Idle Speed and
Ignition Timing"
No creep at all.
AT- 3 1 3 , "
6. Vehicle Does Not Creep
Backward In “R” Position" and AT-
316, "7. Vehicle Does Not Creep For-
ward In “D”,“2” Or “1” Position"
ON vehicle1. Fluid levelAT-261, "
FLUID LEVEL
CHECK"
2. Line pressure testAT-265, "Line Pressure
Te s t"
3. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle4. Forward clutchAT-464, "
Forward and
Overrun Clutches"
5. Oil pumpAT-435, "Oil Pump"
6. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Symptom Condition Diagnostic Item Reference Page

AT-516
[ALL]
SERVICE DATA AND SPECIFICATIONS (SDS)
Control Valves
ECS007TW
CONTROL VALVE AND PLUG RETURN SPRINGS
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Clutch and BrakesECS007TX
REVERSE CLUTCH
*: Always check with the Parts Department for the latest parts information.
HIGH CLUTCH
No. Parts Part No.* Free length Outer diameter
Upper body
Refer to “Control
Valve Upper
Body”, AT- 4 4 9
.35 3-2 timing valve spring 31736-01X00 23.0 (0.906) 6.65 (0.2618)
19 Cooler check valve spring 31742-3AX05 28.04 (1.1039) 7.15 (0.2815)
23 Pilot valve spring 31742-3AX03 38.98 (1.5346) 8.9 (0.350)
15 1-2 accumulator valve spring 31742-3AX00 20.5 (0.807) 6.95 (0.2736)
28 1-2 accumulator piston spring 31742-3AX09 55.66 (2.1913) 19.5 (0.7677)
33 1st reducing valve spring 31742-80X05 27.0 (1.063) 7.0 (0.276)
2 Overrun clutch reducing valve spring 31742-80X06 37.5 (1.476) 7.0 (0.276)
7 Torque converter relief valve spring 31742-3AX04 33.3 (1.3110) 9.0 (0.354)
10Torque converter clutch control valve
spring31742-3AX02 53.01 (2.0870) 6.5 (0.256)
Lower body
Refer to “Control
Valve Lower
Body”, AT- 4 5 3
.34 Shuttle valve spring 31762-41X04 51.0 (2.0079) 5.65 (0.2224)
18 Pressure regulator valve spring 31742-80X13 45.0 (1.772) 15.0 (0.591)
23 Overrun clutch control valve spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
27 Accumulator control valve spring 31742-80X02 22.0 (0.866) 6.5 (0.256)
29 Shift valve A spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
2 Shift valve B spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
11
Pressure modifier valve spring31742-41X15 30.5 (1.201) 9.8 (0.386)
7 31742-80X16 32.0 (1.260) 6.9 (0.272)
— Fluid cooler relief valve spring 31872-31X00 17.02 (0.670) 8.0 (0.315)
— T/C pressure spring 31742-3AX07 9.0 (0.354) 7.3 (0.287)
Number of drive plates2
Number of driven plates2
Drive plate thickness mm (in)Standard 2.0 (0.079)
Allowable limit 1.8 (0.071)
Clearance mm (in)Standard 0.5 - 0.8 (0.020 - 0.031)
Allowable limit 1.2 (0.047)
Thickness of retaining platesThickness mm (in) Part number*
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)31537-31X00
31537-31X01
31537-31X02
31537-31X03
31537-31X04
Number of drive plates3
Number of driven plates5
Drive plate
thickness mm (in)Standard 1.6 (0.063)
Allowable limit 1.5 (0.059)
Clearance mm (in)Standard 1.4 - 1.8 (0.055 - 0.071)
Allowable limit 2.4 (0.094)

Noise, Vibration and Harshness (NVH)
Troubleshooting
=NJAX0004NVH TROUBLESHOOTING CHARTNJAX0004S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page—
AX-15
—
AX-5, 24
—
AX-3, 23
—
—
SU-4
SU-4
SU-4
BR-6
ST-5
Possible cause and
SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
Wheel bearing damage
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomDRIVE SHAFTNoise, Vibration××———— —× ×××××
Shake×—×——— —× ×××××
AXLENoise — — —××—×—×××××
Shake — — —××—×—×××××
Vibration — — —××—×—××——×
Shimmy — — —××—— —×××××
Judder — — —×—— — —×××××
Poor quality ride or
handling———×××——×××——
×: Applicable
—: Not applicable
SMA525A
On-vehicle Service
FRONT AXLE PARTSNJAX0005Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
Shake each front wheel to check for excessive play.
Make sure that cotter pin is inserted.
Retighten all axle and suspension nuts and bolts to the speci-
fied torque.
Tightening torque:
Refer to SU-5, “FRONT SUSPENSION”.
SFA805B
FRONT WHEEL BEARINGNJAX0006Check that wheel bearings operate smoothly.
Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
If out of specification or wheel bearing does not turn smoothly,
replace wheel bearing assembly.
Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, AX-5.
GI
MA
EM
LC
EC
FE
CL
MT
AT
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FRONT AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-3

Noise, Vibration and Harshness (NVH)
Troubleshooting
=NJSU0004NVH TROUBLESHOOTING CHARTNJSU0004S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
SU-5, 17
SU-10, 21
—
—
—
SU-9, 20
SU-7
SU-11
SU-7
—
—
—
—
—
—
AX-3
AX-3
Refer to SUSPENSION
in this chart.
Refer to TIRES
in this chart.
Refer to ROAD WHEEL
in this chart.
BR-6
ST-5
Possible Cause and
SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation,
damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer bar fatigue
Out-of-round
Imbalance
Incorrect air pressure
Uneven tire wear
Deformation or damage
Non-uniformity
Incorrect tire size
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING Symptom
SUSPENSION
Noise× × ××××—————————××—××××
Shake××××—×—————————××—××××
Vibration× × ×××——————————××—×——×
Shimmy××××——×—————————×—××××
Judder×××—————————————×—××××
Poor quality
ride or han-
dling× × ×××—××————————×—××——
TIRES
Noise×— ——————××××××—×× ×—×××
Shake×— ——————×××××—××× ×—×××
Vibration — — ————————×———××× ×———×
Shimmy×— ——————×××××××—××—×××
Judder×— ——————×××××—×—××—×××
Poor quality
ride or han-
dling×— ——————×××××—×—××—×——
ROAD WHEEL
Noise×— ——————××——×——×× × ×—××
Shake×— ——————××——×——×× × ×—××
Shimmy,
Judder×— ——————××——×———×× ×—××
Poor quality
ride or han-
dling×— ——————××——×———×× ×———
×: Applicable
—: Not applicable
FRONT SUSPENSION
Noise, Vibration and Harshness (NVH) Troubleshooting
SU-4