1995 NISSAN ALMERA N15 Service Manual

COLLISIONDIAGNOSIS -Single AirBag System

To repair theSRS "AIR BAG", perform thefollowing steps:

When SRSisactivated inacollision:

CD
Remove theairbag module.

@
Remove thesteering wheelassembly.

@)
Check thespiral cableusingthetable shown below:
• Ifthe spiral cableshows anyvisible damage suchasdents, cracks, ordeformation, replaceit
with anew one.

@
Install newsteering wheelassembly.

CID
Install newairbag module.

@
Conduct self-diagnosis using"AIRBAG" warning lamptoensure thatentire SRSoperates properly.
Refer toRS-43 fordetails.

When SRSisnot activated inacollision:

CD
Check theSRS components usingthetable shown below:
• Ifthe SRS components showanyvisible damage suchasdents, cracks, ordeformation, replace
them withnewones.

@
Conduct self-diagnosis using"AIRBAG" warning lamptoensure thatentire SRSoperates properly.
Refer toRS-43 fordetails.

SRS inspection

Part SRSisactivated SRSisNOT activated
Air bag module REPLACE 1.Remove airbag module. Checkharness coverandconnectors fordamage,
Install withnew terminalsfordeformities, andharness forbinding.
bolts. 2.Install airbag module intothesteering wheeltocheck fitand alignment
with thewheel.
3. No damage found,reinstall withnewbolts.
4. Ifdamaged-REPLACE. Airbag must bedeployed beforediscarding.
Steering wheel REPLACE 1.Visually checksteering wheelfordeformities.
assembly (includ- 2.Check harness andconnectors fordamage, andterminals fordeformities.
ing diagnosis sen- 3.Check diagnosis sensorunitfordents, cracks ordeformities.
sor unit).
Donot remove diagnosis sensorunitfrom steering wheel.

4. Install airbag module tocheck fitor alignment withsteering wheel.
5. Ifno damage isfound, reinstall thesteering wheelassembly.
6.
If
damaged-REPLACE.
Spiral cable 1.Check spiralcablefordents, cracks ordeformities.
2. Check connectors andprotective tapefordamage.
3. Check
steering wheelfornoise, binding orheavy operation.
4.
If
no damage isfound, reinstall withnewbolts.
5. If
damaged-REPLACE.
Harness andCon- 1.
Check connectors forpoor connection, damage,andterminals fordeformities.
nectors 2.
Check harness forbinding, chafing,cuts,ordeformities.
3. Ifno damage isfound, reinstall theharness andconnectors.
4. Damaged-REPLACE damagedsectionofharness. Donot attempt torepair, spliceormodify any
SRS harness.

RS-45
•

COLLISIONDIAGNOSIS -Seat BeltPre-tensioner

Before replacing "SRS"seatbeltpre-tensioner, checkifseat beltpre-tensioner isactivated ornot as
follows.

Seat beltcanbepulled -Seat beltpre-tensioner isnot activated.

CD
Visually checkseatbeltassemblies includingseatbeltretractors attachedhardware (Le.,guide rail
set) fordamage.

@
Ifno damage isfound, reinstall.

@)
Ifdamaged, installanew seat beltpre-tensioner assembly.

Seat beltcannot bepulled -Seat beltpre-tensioner isactivated.
• Replace withanew seat beltpre-tensioner assembly.
RS-46

STEERINGSYSTEM

SECTIONST

CONTENTS
PRECAUTIONS ANDPREPARATION 2

Precautions 2
Special Service Tools 3
Commercial ServiceTools 4

ON-VEHICLE SERVICE
5

Checking SteeringWheelPlay 5
Checking NeutralPosition onSteering Wheel 5
Front Wheel Turning Angle 5
Checking GearHousing Movement 5
Checking andAdjusting DriveBelts(For
power steering) 6
Checking FluidLevel 6
Checking FluidLeakage 6
Bleeding Hydraulic System 7
Checking SteeringWheelTurning Force(For
power steering) 7
Checking Hydraulic System 8

STEERING WHEElANDSTEERING COLUMN 9

Removal andInstallation 9
Disassembly andAssembly 12
Inspection 13

MANUAL STEERING GEARANDLINKAGE
(Model R24N) 14
Removal
andInstallation 14
Disassembly 15
Inspection 15
Assembly andAdjustment... 16

POWER STEERING GEARANDLINKAGE (Model
PR24AC) 19

Removal andInstallation 19
Disassembly 22
Inspection 22
Assembly ,.. 23
Adjustment 27

POWER STEERING OILPUMP 29

Pre-disassembly Inspection 30
Disassembly 30
Inspection 31
Assembly 31

POWER STEERING OILCOOLER
33

Oil Cooler (Heavy dutykitfor CD20 engine
model) 33
Removal andInstallation 33

SERVICE DATAANDSPECIFICATIONS
(505)34
General Specifications 34
Inspection andAdjustment 34
•

PRECAUTIONSANDPREPARATION
Precautions
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(Dual AirBag System)

The Supplemental RestraintSystem"AirBag" usedalong withaseat belt,helps toreduce therisk or
severity ofinjury tothe driver andfront passenger inafrontal collision. TheSupplemental Restraint
System consists ofair bag modules (locatedinthe center ofthe steering wheelandonthe instrument
panel onthe passenger side),adiagnosis sensorunit,warning lamp,wiring harness andspiral cable.
Information necessarytoservice thesystem safelyisincluded inthe
RSsection
ofthis Service Manual.

WARNING: • Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual. SRSwiring harnesses arecovered withyellow insulation eitherjustbefore the
harness connectors orfor the complete harness,foreasy identification.
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(Single AirBag System)

The Supplemental RestraintSystem"AirBag" andused along withaseat belt,helps toreduce therisk
or severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists of
an air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoservice thesystem safelyisincluded inthe

RS section
ofthis Service Manual.

WARNING: • Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual.
STEERINGSYSTEM
• Before disassembly, thoroughlycleantheoutside ofthe unit.
• Disassembly shouldbedone inaclean workarea. Itis important toprevent theinternal partsfrom
becoming contaminated bydirt orother foreign matter.
• Place disassembled partsinorder, onaparts rack,fore"asier andproper assembly.
• Use nylon cloths orpaper towels toclean theparts; common shopragscanleave lintthat might
interfere withtheir operation.
• Before inspection orreassembly, carefullycleanallparts withageneral purpose, non-flammable
solvent.
• Before assembly, applyacoat ofrecommended ATF*tohydraulic parts.Vaseline maybeapplied to
O-rings andseals. Donot use any grease.
• Replace allgaskets, sealsandO-rings. Avoiddamaging O-rings,sealsandgaskets duringinstalla-
tion. Perform functional testswhenever designated.

*:
Automatic transmission fluid
ST-2

Toolnumber
Tool name PRECAUTIONS
ANDPREPARATION
Special Service Tools
Description
KV481 00700
Torque adapter
KV481 02500
Pressure gaugeadapter NT169
NT542 PF3/B"~

@

@

PF3/B"~ ~x1.5 pitch
M16 x1.5 pitch Measuring
pinionrotating torque
Measuring oilpressure
ST27180001
Steering wheelpuller
NT544(1.14
in)
@Q'O
,'25 0;'0'

@ @
MB
x1.25 pitch Removing
andinstalling steeringwheel
HT72520000
Ball joint remover
ST27091000 Pressure gauge
KV481 04400
Rack sealringreformer
ST3127S000
G)
GG91030000
Torque wrench
@ HT62940000
Socket adapter

@
HT62900000
Socket adapter NT546
NT547
NT550
NT541 To
control valve
Shut-off valve
~ 1/4"~rque wrench
~ withrange of
1/4"
to
3/B" 2.9
N.m

~ ""(30kg-em,

'V
'td"
3/B
to
1/2
26
in-Ib)

ST-3 Removing
balljoint

a:
33
mm
(1.30
in)

b: 50
mm
(1.97
in)
r:
R11.5
mm
(0.453
in)

Measuring oilpressure
Reforming teflonring

a: 50 mm (1.97 in)dia.
b: 36 mm (1.42 in)dia.
c:
100
mm
(3.94
in)

Measuring turningtorque
•

Toolname
PRECAUTIONS
ANDPREPARATION
Commercial ServiceTools

Description
Rear oilseal drift
Pinion oilseal drift
Oil pump attachment
NT063
NT063 Welding
12(0.47)
40 (1.57)

---12 (0.47)

ST-4
Installing
rearoilseal

a:
28mm (1.10 in)dia.

Installing pinionoilseal

a :35
mm
(1.38 in)dia.

Disassembling andassembling oilpump
Unit: mm(in)

ON-VEHICLESERVICE
Checking SteeringWheelPlay

• With wheels inastraight-ahead position,checksteering
wheel play.

Steering wheelplay:
35 mm (1.38 in)orless

• Ifit is not within specification, checkthefollowing forloose
or worn components.

Steering gearassembly
Steering column
Front suspension andaxle
SST489B

OK
NGChecking
NeutralPosition onSteering Wheel
Pre-checking

• Make surethatwheel alignment iscorrect.

Wheel alignment:
Refer toSOS inFA section.

• Verify thatthesteering geariscentered beforeremoving
the steering wheel.

Checking
SST490BA
1.Check thatthesteering wheelisin the neutral position when
driving straight ahead.
2. Ifit is not inthe neutral position, removethesteering wheel
and reinstall itcorrectly.
3. Ifthe neutral position isbetween twoteeth,. loosen tie-rod
lock nuts. Turnthetie-rods bythe same amount inopposite
directions onboth leftand right sides.

Front Wheel Turning Angle •

1. Rotate steering wheelallthe way right andleft;measure
turning angle.

Turning angleoffull turns:
Refer toSOS inFA section.

2. Ifit is not within specification, checkrackstroke.

Rack stroke
"S":

Refer toSOS (ST-35).
SMA127 Checking GearHousing Movement

1. Check themovement ofsteering gearhousing duringsta-
tionary steering onadry paved surface.
• Apply aforce of49 N(5 kg, 11Ib) tosteering wheeltocheck
the gear housing movement.
Turn offignition keywhile checking.

Movement ofgear housing:

:I:
2 mm
(:I:
0.08 in)orless

2. Ifmovement exceedsthelimit, replace mountinsulator after
confirming properinstallation ofgear housing clamps.

ST-5

ON-VEHICLESERVICE
Checking andAdjusting DriveBelts(Forpower
steering)

Refer to"Checking DriveBelts" for"ENGINE MAINTENANCE"
in MA section.

SST476C

S
r

SST681B Checking
Fluidlevel

Check fluidlevel using dipstick onreservoir cap,orreferring to
the scale onreservoir tank.
Use "HOT" rangeforfluid temperatures of50 to80°C (122to

176°F).

Use "COLD" rangeforfluid temperatures of0to 30°C (32to

86°F).
CAUTION:
• Donot overfill.
• Recommended fluidisAutomatic Transmission Fluid
''DEXRON™,, typeorequivalent.
Checking Fluidleakage

Check thelines forimproper attachment andforleaks, cracks,
damage, looseconnections, chafingordeterioration.
1. Run engine between idlespeed and1,000 rpm.

Make suretemperature offluid inoil tank rises to60 to80°C
(140 to176°F).

2. Turn steering wheelright-to-Ieft severaltimes.
3. Hold steering wheelateach "lock" position forfive seconds
and carefully checkforfluid leakage.

CAUTION:
Do not hold thesteering wheelinalocked position formore
than 15seconds.

4. Iffluid leakage atconnectors isnoticed, loosenflarenutand
then retighten.

Do not overtighten connectorasthis candamage O-ring,
washer andconnector.

5. Check rackboots foraccumulation ofpower steering fluid.

ST-6