1995 NISSAN ALMERA N15 Service Manual

CLUTCHDISCANDCLUTCH COVER

~1st: 10-20(1.0-2.0,7.2-14)
2nd: 22-29 (2.2 -3.0 ,16 -22)

ACL019
SEC.
300

o

Clutchdisc
• Do not clean insolvent.
• When installing, becareful thatgrease from
main drive shaft doesnotadhere toclutch disc. Clutch
cover

m
(iJ:
Apply lithium-based greaseincluding
molybdenum disulphide.
~ :N'm (Kg-m, ft-Ib).

•

SCL221 Clutch
Disc
INSPECTION

Check thefollowing items,andreplace ifnecessary.
• Clutch disc,forburns, discoloration, oilorgrease leakage
• Clutch disc,forwear offacing

Wear limitoffacing surface torivet head:
0.3 mm (0.012 in)

• Clutch disc,forbacklash ofspline andrunout offacing.

Maximum backlashofspline (atouter edgeofdisc):
Model 180 0.7mm (0.028 in)

Model 190
and 200 0.8mm (0.031 in)
Model 215 0.9mm(0.035in)
Runout limit:
1.0 mm (0.039 in)
Distance ofrunout checkpoint(from hubcenter):

Model 180
85mm (3.35 in)

Model 190
90mm (3.54 in)

Model 200
95mm (3.74 in)
Model 215102.5mm (4.04in)
CL-11

CLUTCHDISCANDCLUTCH COVER
Clutch Disc(Cont'd)
INSTALLATION

• Apply recommended greasetocontact surface ofsplines.

• Too much lubricant maydamage clutchdiscfacing.
Dial gauge Clutch
CoverandFlywheel
INSPECTION ANDADJUSTMENT

• Check clutchcover, installed onvehicle, foruneven dia-
phragm springtoeheight.

Uneven limit:
Model 180 1.0mm (0.039 in)

Model 190,
200and 215 0.7mm (0.028 in)

• Ifout oflimit, adjust theheight withTool.

SCL466-A FLYWHEEL INSPECTION
CAUTION:
Do not allow anymagnetic materials tocontact thering gear
teeth.

• Inspect contact surface offlywheel forslight burns ordis-
coloration. Cleanflywheel withemery paper.
• Check flywheel runout.

Maximum allowable runout:
Refer toEM section ("Inspection", "CYLINDER
BLOCK").
AEM100
INSTALLATION

• Insert Toolintoclutch dischubwhen installing clutchcover
and disc.
• Becareful nottoallow grease tocontaminate clutchfacing.
• Tighten boltsinnumerical order,intwo steps.

First step:
~: 10•20 N'm '(1.0 •2.0 kg-m, 7-14 ft-Ib)
Final step:
~: 22•29 N'm (2.2•3.0 kg-m, 16•22 ft-Ib)
SCL616-A
CL-12

SERVICEDATAANDSPECIFICATIONS (SOS)
CLUTCH CONTROL SYSTEM General
Specifications
CLUTCH MASTER CYLINDER

Engine
Type ofclutch con-
trol Except
forCD20
Mechanical CD20
Hydraulic Inner
diameter
mm(in)
15.87(5/8)
CLUTCH OPERATING CYLINDER
CLUTCH DAMPER
Inner
diameter
mm(in)
17.46
(11/16)

Inner diameter
mm(in)
19.05
(3/4)

CLUTCH DISC

Unit:mm(in)

Engine GA14DEGA15DE,
GA16DE CD20
SR20DE
Model 180190
200 215
Facing size
180x125 x3.5 190
x132 x3.5 200
x130 x3.5 215x140 x3.5
(Outer dia.xinner dia.x
(7.09x4.92 x0.138) (7.48x5.20 x0.138) (7.87
x5.12 x0.138) (8.46x5.51 x0.138)
thickness)
Thickness ofdisc assem- 7.6
-8.0 (0.299 -0.315)
bly with load 8.0
-8.4 (0.315 -0331) with3,923 N(400 kg,A2Ib) with3,923 N
(400 kg,882 Ib)

CLUTCH COVER

Engine GA14DE
GA15DE

I
GA16DE
CD20
SR20DE
Model 180 190200
215
Full-load N
(kg, Ib) 3,236(330,728) 3,432(350,772)

I
3,825
(390,860) 3,481(355,783) 4,413
(450,992)

CL-13
•

SERVICEDATAANDSPECIFICATIONS (SOS)
Inspection andAdjustment
CLUTCH PEDAL

Unit:mm(in)
Except forCD20 engine models
CD20engine models
Applied model
RHOLHD
RHO LHD
Pedal height "H"
159-169 (6.26 -6.65)'1 153-163 (6.02 -6.42)*2 156-166 (6.14 -6.54)'1
149-159 (5.87 -6.26)'2
Pedal freetravel "A"
11-15 (0.43 -0.59)
9-16 (0.35 -0.63)
(at pedal pad)
Withdrawal leverplay"8" 2.5-3.5 (0.098 -0.138)

-

'1: Measured fromsurface ofdash reinforcement paneltosurface ofpedal pad.
'2: Measured fromsurface ofdash lower paneltosurface ofpedal pad.

CLUTCH DISC

Unit:mm(in)
Disc model
180190

I
200
215
Wear limitoffacing surface torivet head
0.3(0.012)
Runout limitoffacing 1.0(0.039)
Distance ofrunout checkpoint(from hub
85(3.35) 90(3.54)

I
95
(3.74) 102.5(4.04)
center)
Maximum backlashofspline (atouter edgeof
0.7(0.028) 0.8(0.031)
0.9(0.035)
disc)

CLUTCH COVER

Cover model
Uneven limitofdiaphragm springtoeheight 180
1.0 (0.039)

CL-14 190

I
200
0.7 (0.028)
I
Unit:
mm(in)
215

ELECTRICALSYSTEM
SECTION
EL

When youread wiring diagrams:
• Read GIsection, "HOWTOREAD WIRING DIAGRAMS".
When youperform troublediagnos.es, readGIsection, "HOWTOFOllOW FLOWCHART
IN TROUBLE DIAGNOSES" and"HOW TOPERFORM EFFICIENT DIAGNOSIS FORAN
ELECTRICAL INCIDENT".
CONTENTS
PRECAUTIONS 4
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 4
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 4
HARNESS CONNECTOR 5
Description 5
STANDARDIZED RELAy 6
Description 6
POWER SUPPLY ROUTING 8
Schematic 8
Wiring Diagram -POWER - 10
Fuse 19
Fusible Link 19
Circuit Breaker 19
GROUND DISTRIBUTION 20
BATTERy 25
How toHandle Battery 25
Battery TestandCharging Chart.. 28
Service DataandSpecifications (SOS) 32
STARTING SySTEM
33

Wiring Diagram -START - 33
Trouble Diagnoses 35
Construction 36
Removal andInstallation .45
Magnetic SwitchCheck .46
Pinion/Clutch Check 46
Brush Check 46
Yoke Check 47
Armature Check 48
Assembly .49
Service DataandSpecifications (SDS) 50
CHARGING SYSTEM 52
Wiring Diagram -CHARGE - 52
Trouble Diagnoses 54Construction
55
Removal andInstallation 57
Disassembly 57
Rotor Check 57
Brush Check 58
Stator Check 58
Diode Check 59
Assembly 60
Service DataandSpecifications (SDS) 61
COMBINATION SWITCH 62
Combination Switch/Check 62
Replacement 64
HEADLAMP -Without Daytime lightSystem -65
Wiring Diagram -H/LAMP - 65
Trouble Diagnoses 67
HEADLAMP -Daytime lightSystem - 68
Operation (Daytimelightsystem) 68
System Description 69
Schematic 70
Wiring Diagram -DTRL - 71
Trouble Diagnoses (DaytimeLight) 74
HEADLAMP 75
Bulb Replacement... 75•
Aiming Adjustment. 75
HEADLAMP -Headlamp Aiming
Control- 77

Wiring Diagram -AIM - 77
Description 81
EXTERIOR LAMP 82
Clearance, LicenseandTail Lamps/Schematic 82
Clearance, LicenseandTail Lamps/Wiring
Diagram -TAILIL - 83
Stop Lamp/Wiring Diagram-STOP/L - 92
Back-up Lamp/Wiring Diagram-BACK/L -94
Front FogLamp/Wiring Diagram-F/FOG -96
Front FogLamp BulbReplacement 101

CONTENTS(Conl'd.)
Front FogLamp Aiming Adjustment.. 101
Rear FogLamp/Wiring Diagram-R/FOG -102
Turn Signal andHazard Warning Lamps/
Schematic 106
Turn Signal andHazard Warning
Lamps/Wiring Diagram-TURN - 107
Turn Signal andHazard Warning
Lamps/Trouble Diagnoses 113
Combination FlasherUnitCheck 113
Bulb Specifications 114
INTERIOR LAMP 115
Illumination/Schematic 115
Illumination/Wiring Diagram-ILL - 116
Interior, Spot,Trunk Room andLuggage
Room Lamps/Wiring Diagram-INT/L - 122
Bulb Specifications 126
METER ANDGAUGES 127
Combination Meter 127
Speedometer, Tachometer,Temp.andFuel
Gauges/Wiring Diagram-METER - 129
Inspection/Fuel GaugeandWater
Temperature Gauge 133
Inspection/Tachometer 134
Inspection/Speedometer andVehicle Speed
Sensor 135
Fuel Tank Gauge UnitCheck 137
Thermal Transmitter Check 137
Vehicle SpeedSensor SignalCheck 137
WARNING LAMPSANDBUZZER 138
Warning Lamps/Schematic 138
Warning Lamps/Wiring Diagram-WARN -139
Oil Pressure SwitchCheck 151
Fuel Warning LampSensor Check 151
Diode Check 151
Warning BuzzerUnit... 151
Warning Buzzer/System Description 152
Warning Buzzer/Wiring Diagram
- BUZZER - 154
Components Inspection-Warning Buzzer 157
WIPER ANDWASHER 160
Front Wiper andWasher/System Description160
Front Wiper andWasher/Wiring Diagram
- WIPER - 162
Front Wiper Amplifier Check 166
Front Wiper Installation andAdjustment.. 166
Front Wiper Linkage 167
Front Washer NozzleAdjustment... 168
Front Washer TubeLayout 168
Rear Wiper andWasher/System Description169Rear
Wiper andWasher/Wiring Diagram
- WIP/R - 171
Rear Wiper Amplifier Check 175
Rear Wiper Installation andAdjustment.. 175
Rear Washer NozzleAdjustment 175
Rear Washer TubeLayout.. 176
Check Valve(forrear washer) 176
Headlamp WiperandWasher/Wiring Diagram
- HLC - 177
Headlamp WiperMotorCheck 179
Headlamp WiperInstallation 179
Headlamp WasherTubeLayout.. 179
Check Valve(Forheadlamp washer) 179
POWER WINDOW 180
System Description 180
Schematic 183
Wiring Diagram -WINDOW - 185
Trouble Diagnoses 197
POWER DOORLOCK 198
System Description 198
Schematic 200
Wiring Diagram -D/LOCK - 202
Trouble Diagnoses -Type 1(For Europe and
Austral ia) 212
Trouble Diagnoses -Type 2(Except for
Europe andAustralia) 216
POWER DOORMIRROR 220
Wiring Diagram -MIRROR - 220
ELECTRIC SUNROOF 224
Wiring Diagram -SROOF - 224
HORN, CIGARETTE LIGHTERANDCLOCK 226
Wiring Diagram -HORN - 226
REAR WINDOW DEFOGGER ANDDOOR
MIRROR DEFOGGER 230
System Description (Formodels withdaytime
light system) 230
Wirin.g Diagram -DEF - 231
Filament Check 235
Fi lament Repai
r
236
AUDIO ANDANTENNA 237
Audio/System Description 237
Wiring Diagram -AUDIO - 238
Radio FuseCheck 243
Location ofAntenna 243
Antenna RodReplacement.. 243
HEATED SEAT 245
Wiring Diagram -H/SEAT - 245
NATS (Nissan Anti-Theft System) 247
System Description 247
System Composition 247

CONTENTS(Cont'd.)

Component PartsLocation 248
Wiring Diagram -NATS - 249
Trouble Diagnoses 251

LOCATION OFELECTRICAL UNITS
266
Engine Compartment 266
Passenger Compartment 267

HARNESS LAyOUT
269
How toRead Harness Layout... 269
Outline 270
Engine Control Harness 271
Engine RoomHarness 274
Main Harness '" 280
Body Harness :284
Body No.2 Harness 292
Engine Harness 294Air
Bag Harness 297
Room LampHarness 298
Back DoorHarness 299
Front DoorHarness (LHside) 300
Front DoorHarness (RHside) 302
Rear Door Harness 304

SUPER MULTIPLE JUNCTION
(SMJ) Foldout
Terminal Arrangement Foldout

FUSE BLOCK -Junction Box
(JIB)
Foldout
Terminal Arrangement Foldout

ELECTRICAL UNITS
Foldout
Terminal Arrangement Foldout

JOINT CONNECTOR
(J/C)
Foldout
Terminal Arrangement Foldout

WIRING DIAGRAM REFERENCE CHART
COOLING SYSTEM
LC
SECTION
ECCS (Ignition syslem) ECSECTION
AUTOMATIC TRANSAXLECONTROLSYSTEM ATSECTION
ANTI-LOCK BRAKESYSTEM BRSECTION
SRS "AIR BAG" RSSECTION
HEATER ANDAIRCONDITIONER HASECTION

•

PRECAUTIONS
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag 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)"AIR
BAG" (Single AirBag System)

The Supplemental RestraintSystem"AirBag", usedalong withaseat belt,helps toreduce therisk or
severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists ofan
air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lampand
spiral 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.
EL-4