light NISSAN ALMERA TINO 2001 Service Repair Manual

Precautions for Supplemental Restraint System
(SRS) ªAIR BAGº and ªSEAT BELT
PRE-TENSIONERº
NLAT0002The Supplemental Restraint System ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº, used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The
Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and
on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable.
In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along
with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side col-
lision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats),
satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision),
wiring harness, warning lamp (one of components of supplemental 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 must be performed
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.
+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 with yellow harness connector (and with
yellow harness protector or yellow insulation tape before the harness connectors).
Precautions for On Board Diagnostic (EURO-
OBD) System of CVT and Engine
NLAT0198The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MI) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:
+Be sure to turn the ignition switch ªOFFº and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause the MI to light up.
+Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
+Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MI to light up due to a short circuit.
+Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc.
+Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
SEF289H
PrecautionsNLAT0003+Before connecting or disconnecting the TCM harness
connector, turn ignition switch OFF and disconnect nega-
tive battery terminal. Failure to do so may damage the
TCM. Because battery voltage is applied to TCM even if
ignition switch is turned off.
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
AT-6

HOW TO ERASE DTC (WITH GST)=NLAT0020S041. If the ignition switch stays ªONº after repair work, be sure to turn ignition switch ªOFFº once. Wait at least
5 seconds and then turn it ªONº (engine stopped) again.
2. Perform ªEURO-OBD SELF-DIAGNOSTIC PROCEDURE (No Tools)º. Refer to AT-28. (The engine
warm-up step can be skipped when performing the diagnosis only to erase the DTC.)
3. Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC section ªGeneric Scan Tool (GST)º.
HOW TO ERASE DTC (NO TOOLS)NLAT0020S051. If the ignition switch stays ªONº after repair work, be sure to turn ignition switch ªOFFº once. Wait at least
5 seconds and then turn it ªONº (engine stopped) again.
2. Perform ªTCM SELF-DIAGNOSTIC PROCEDURE (No Tools)º. Refer to AT-28. (The engine warm-up step
can be skipped when performing the diagnosis only to erase the DTC.)
3. Change the diagnostic test mode from Mode II to Mode I by turning the mode selector on the ECM.
Refer to EC section ªHOW TO SWITCH DIAGNOSTIC TEST MODESº.
SAT652J
Malfunction Indicator (MI)NLAT00211. The malfunction indicator will light up when the ignition switch
is turned ON without the engine running. This is for checking
the lamp.
+If the malfunction indicator lamp does not light up, refer to EL
section (ªWarning Lamps/System Descriptionº, ªWARNING
LAMPS AND CHIMEº).
(Or see MI & Data Link Connectors in EC section.)
2. When the engine is started, the malfunction indicator lamp
should go off.
If the lamp remains on, the on board diagnostic system has
detected an emission-related (EURO-OBD) malfunction. For
detail, refer to EC section (ªON BOARD DIAGNOSTIC SYS-
TEM DESCRIPTIONº).
CONSULT-IINLAT0022After performing ªSELF-DIAGNOSTIC PROCEDURE (WITH CON-
SULT-II)º (AT-22), place check marks for results on the ªDIAGNOS-
TIC WORKSHEETº, AT-43. Reference pages are provided follow-
ing the items.
NOTICE:
+Additional CONSULT-II information can be found in the Opera-
tion Manual supplied with the CONSULT-II unit.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONEURO-OBD
EURO-OBD Diagnostic Trouble Code (DTC) (Cont'd)
AT-21

SAT767B
CVT Fluid CheckNLAT0025FLUID LEAKAGE CHECKNLAT0025S011. Clean area suspected of leaking. Ð for example, mating sur-
face of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in ªDº posi-
tion and wait a few minutes.
3. Stop engine.
SAT288G
4. Check for fluid leakage.
SAT638A
FLUID CONDITION CHECKNLAT0025S02
Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material
Milky pink Water contamination Ð Road water
entering through filler tube or breather
Varnished fluid, light to dark brown
and tackyOxidation Ð Over or under filling, Ð
Overheating
FLUID LEVEL CHECKNLAT0025S03Refer to ªChecking CVT Fluidº, AT-10.
SAT647B
Stall TestNLAT0026STALL TEST PROCEDURENLAT0026S011. Check CVT fluid and engine oil levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until engine oil and CVT
fluid reach operating temperature.
CVT fluid operating temperature:
50 - 80ÉC (122 - 176ÉF)
TROUBLE DIAGNOSIS Ð BASIC INSPECTION
CVT Fluid Check
AT-51

SAT266K
InstallationNLAT01161. Tighten bolts fixing transaxle.
Bolt No.Tightening torque
N´m (kg-m, ft-lb)Bolt length ª!º
mm (in)
1 70 - 79 (7.1 - 8.1, 51 - 59) 40 (1.57)
2 31 - 36 (3.1 - 3.7, 23 - 26) 35 (1.38)
3 31 - 36 (3.1 - 3.7, 23 - 26) 47 (1.85)
4 70 - 79 (7.1 - 8.1, 52 - 58) 65 (2.56)
5 75 - 85 (7.6 - 8.7, 55 - 62) 65 (2.56)
6 70 - 79 (7.1 - 8.1, 52 - 58) 45 (1.77)
2. Install torque converter to drive plate.
+With converter installed, rotate crankshaft several turns to
check that transaxle rotates freely without binding.
SAT638A
3. Reinstall any part removed.
4. Adjust control cable. Refer to AT-204.
5. Check continuity of PNP switch. Refer to AT-72.
6. Refill transaxle with CVT fluid and check fluid level.
7. Move selector lever through all positions to be sure that tran-
saxle operates correctly. With parking brake applied, idle
engine. A slight shock should be felt through the hand gripping
the selector each time the transaxle is shifted.
8. Perform road test. Refer to AT-53.
REMOVAL AND INSTALLATION
Installation
AT-207

SFA898A
2. Remove brake caliper assembly and rotor.
Brake hose need not be disconnected from brake caliper. In
this case, suspend caliper assembly with wire so as not to
stretch brake hose. Be careful not to depress brake pedal, or
piston will pop out.
Make sure brake hose is not twisted.
SFA372-A
3. Separate tie-rod from knuckle with Tool.
Install stud nut on stud bolt to prevent damage to stud bolt.
SFA181A
4. Separate drive shaft from knuckle by lightly tapping it. If it is
hard to remove, use a puller.
Cover boots with shop towel so as not to damage them when
removing drive shaft.
SFA153B
5. Remove strut lower mounting bolts.
SFA113AC
6. Loosen lower ball joint tightening nut.
7. Separate knuckle from lower ball joint stud with Tool.
8. Remove knuckle from transverse link.
FRONT AXLE
Wheel Hub and Knuckle (Cont’d)
AX-6

SFA090A
REMOVALNLAX00141. Remove wheel bearing lock nut.
Brake caliper need not be disconnected. Do not twist or
stretch brake hose when moving components.
SFA153B
2. Remove strut lower mount bolts.
3. Remove brake hose clip.
SFA499A
4. Separate drive shaft from knuckle by lightly tapping it. If it is
hard to remove, use a puller.
Cover boots with shop towel so as not to damage them
when removing drive shaft.
Refer to“Wheel Hub and Knuckle”,“FRONT AXLE”, AX-5.
5. Remove right drive shaft from transaxle.
NAX004
6. Remove left drive shaft from transaxle.
+Pry off drive shaft from transaxle as shown at left.
SFA482-D
INSTALLATIONNLAX0015Transaxle SideNLAX0015S011. Drive a new oil seal to transaxle. Refer to MT-15 or AT-204,
“Replacing Oil Seal”or“Differential Side Oil Seal
Replacement”,“ON-VEHICLE SERVICE”.
2. Set Tool along the inner circumference of oil seal.
FRONT AXLE
Drive Shaft (Cont’d)
AX-11

+Use grease according to AX-19, SDS.
SFA800
Wheel Side (B83, B90 & AC2300I)NLAX0019S011. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA942A
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring marks which were
made during disassembly are properly aligned.
SFA592B
3. Pack drive shaft with specified amount of grease.
Specified amount of grease:
Refer to AX-19, SDS
4. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is“L
1”.
Length“L
1”:
Refer to AX-19, SDS
SFA443B
5. Lock new larger and smaller boot bands securely with a suit-
able tool.
FRONT AXLE
Drive Shaft (Cont’d)
AX-15

InstallationNLBR0121CAUTION:
+Refill with new brake fluid“DOT 4”.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
:13-15N·m (1.3 - 1.5 kg-m,9-11ft-lb)
NBR363
NBR364
3. Check hoses for damage. If the hoses show cracks or damage,
replace the hose.
4. Insert the dot (coloured) mark hoses to the primary - and sec-
ondary inlet ports adapter. Then secure it with clamps.
Hose marking
Booster model M215T S255
Primary-inlet port White dot Blue dot
Secondary-inlet port Yellow dot Green dot
NBR362
5. Fill up reservoir tank with new brake fluid.
6. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
7. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
8. Fit brake lines to master cylinder.
9. Tighten flare nuts.
:15-18N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
10. Bleed air procedure from brake and clutch system. Refer to
“Bleeding Brake System”, BR-8 and“Air Bleeding Procedure”,
CL-10.
MASTER CYLINDER
Installation
BR-15

SBR002A
On-vehicle ServiceNLBR0023OPERATING CHECKNLBR0023S011. Stop engine and depress brake pedal several times. Check
that pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
SBR365AA
AIRTIGHT CHECKNLBR0023S021. Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
down at the first time, and then it should gradually rise there-
after.
2. Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change
after holding pedal down for30 seconds.
SBR232CB
RemovalNLBR0024CAUTION:
+Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+Be careful not to deform or bend brake pipes, during
booster removal.
SBR208E
InspectionNLBR0025OUTPUT ROD LENGTH CHECKNLBR0025S011. Apply vacuum of 66.7 kPa (667 mbar, 500 mmHg, 19.69
inHg) to brake booster with a handy vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
BRAKE BOOSTER
On-vehicle Service
BR-16

InstallationNLBR0026CAUTION:
+Be careful not to deform or bend brake pipes, during
booster installation.
+Replace clevis pin if damaged.
+Refill with new brake fluid“DOT 4”.
+Never reuse drained brake fluid.
+Take care not to damage brake booster mounting bolt
thread during installation. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
SBR237EA
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
13-16N·m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to“Installation”in“MASTER
CYLINDER”, BR-15.
6. Bleed air. Refer to“Bleeding Brake System”, BR-8 and“Air
Bleeding Procedure”, CL-10.
BRAKE BOOSTER
Installation
BR-17