2003 NISSAN ALMERA N16 ECU

BLOWER UNIT
ATC-119
C
D
E
F
G
H
I
K
L
MA
B
AT C
BLOWER UNITPFP:27200
Removal and InstallationEJS00206
REMOVAL
1. Remove the glove box assembly.
2. Remove the glove box cover and instrument lower assist panel.
3. Remove the ECM with ECM bracket.
4. Remove the blower unit fixing bolt and screw.
5. Disconnect the blower motor connector, intake door motor con-
nector and auto amp. connector.
6. Remove the harness fixing clip.
7. Move the blower unit downwards.
CAUTION:
Slide the blower unit toward the passenger side, remove loca-
tion pins (2 pieces), then move it downwards.
8. Remove the blower unit.
INSTALLATION
CAUTION:
●Make sure the location pins (2 pieces) are securely installed.
Disassembly and AssemblyEJS00207
NOTE:
This illustration is for RHD models. The layout for LHD models is symmetrically opposite.
RJIA0167E
1. Auto amplifier 2. Screw 3. Cooling hose
4. Blower fan motor assembly 5. Washer 6. Blower fan
7. Nut 8. Screw 9. Intake bellmouth
10. Intake door lever 2 11. Intake door lever 1 12. Intake door link
13. Intake door motor 14. Screw 15. Upper case
16. Intake door 2 17. Intake door 1 18. Adapter assembly
19. Screw 20. Ventilation air filter 21. Filter cover
22. Screw 23. Bracket 24. Screw
25. Under cover clip 26. Screw
RJIA0168J

ATC-142
REFRIGERANT LINES
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●When pouring refrigerant, check for leaks.
High-pressure PipeEJS00230
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Remove the low-pressure flexible hose. Refer to ATC-141,
"Low-pressure Flexible Hose" .
3. Remove the high-pressure pipe from the clip.
4. Remove the mounting bolt from the high-pressure pipe.
5. Remove the high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure pipe and low-pressure flexible hose with a new one, then
apply compressor oil to it when installing it.
●When pouring refrigerant, check for leaks.
Refrigerant Pressure SensorEJS00231
REMOVAL AND INSTALLATION
1. Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Remove the liquid tank.
3. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION:
● When working, be careful not to damage the compressor
fan.
●Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.Bolt and nut mounting the high-pressure flexible hose
Tightening torque :7.8 - 19.6 N·m (0.8 - 2.0 kg·m, 70 - 173 in-lb)
RJIA1720E
RJIA0030E
Bolts mounting the high-pressure pipe (condenser side, evaporator side)
Tightening torque :2.9 - 5.9 N·m (0.29 - 0.6 kg·m, 26 - 52 in-lb)
Tightening torque :9.8 - 11.7 N·m (1.0 - 1.2kg·m, 87 -
104 in-lb)
RJIA0698E

REFRIGERANT LINES
ATC-143
C
D
E
F
G
H
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AT C
Dual-pressure SwitchEJS0020Q
REMOVAL AND INSTALLATION
1. Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Remove the liquid tank.
3. Using a vise, secure liquid tank, and remove dual-pressure
switch.
CAUTION:
● When working, be careful not to damage the compressor
fan.
●Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.
Condenser AssemblyEJS0020R
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
3. Remove the battery and battery tray.
4. Remove the front grille and radiator mounting bracket.
5. Remove the mounting nuts from the condenser upper bracket.
6. Remove the radiator from the lower mount, move it to the engine
side, then remove the condenser between the radiator and the radiator core support.
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
INSTALLATION
CAUTION:
●Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
●When pouring refrigerant, check for leaks.Tightening torque :9.8 - 11.7 N·m (1.0 - 1.2kg·m, 87 -
104 in-lb)
RJIA0699E
RJIA0080E
High-pressure flexible hose mounting bolts
Tightening torque :7.8 - 19.6 N·m (0.8 - 2.0 kg·m, 70 - 173 in-lb)
High-pressure pipe mounting bolts
Tightening torque :2.9 - 5.9 N·m (0.29 - 0.6 kg·m, 26- 52 in-lb)
Condenser mounting bolts
Tightening torque :3.82 - 4.51 N·m (0.39 - 0.46 kg·m, 34 - 39 in-lb)

REFRIGERANT LINES
ATC-147
C
D
E
F
G
H
I
K
L
MA
B
AT C
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.54
kg/cm
2 , 50 psi).
4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet f) to the low side
(evaporator drain hose g to shaft seal i). Refer to AT C - 1 3 4 , "
Components" . Perform a leak check for the
following areas carefully. Clean the component to be checked and move the leak detected probe com-
pletely around the connection/component. ATC-134, "
Components" .
Compressor
Check the fitting of high and low pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer′s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Face mode
c. Intake position: Recirculation
d. Max cold temperature
e. Fan speed: High
SHA708E

Support BearingNJAX0018S05Make sure wheel bearing rolls freely and is free from noise, cracks,
pitting or wear.
Support Bearing BracketNJAX0018S06Check support bearing bracket for cracks with a magnetic explora-
tion or dyeing test.
ASSEMBLYNJAX0019After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
Use NISSAN GENUINE GREASE or equivalent after every
overhaul.
SFA800
Wheel SideNJAX0019S011. 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:
AC2300I type 40 - 50 g (1.41 - 1.76 oz)
AC2000I type 118 g (4.16 oz)
ZF80 type 75 - 85 g (2.65 - 3.00 oz)
BF83 type 80 - 100 g (2.82 - 3.53 oz)
BF90 type 100 - 120 g (3.53 - 4.23 oz)
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”.
FRONT AXLE
Drive Shaft (Cont’d)
AX-16

Length “L1”:
AC2300I type 94 - 96 mm (3.70 - 3.78 in)
AC2000I type 90 mm (3.54 in)
ZF80 type 91.4 - 91.6 mm (3.598 - 3.606 in)
BF83 type 95 mm (3.74 in)
BF90 type 85.5 mm (3.366 in)
SFA443B
5. Lock new larger and smaller boot bands securely with a suit-
able tool.
SFA313B
Dynamic Damper (Where Fitted)NJAX0019S021. Use new damper bands when installing.
2. Install dynamic damper from stationary-joint side while holding
it securely.
Length:
Refer to AX-21, SDS.
SFA800
Transaxle Side (TS70C, TS79C, TS83, DS90, DS83,
GI2000I and GI2300I types)
NJAX0019S031. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA514A
2. Install ball cage, inner race and balls or spider assembly as a
unit, making sure the marks which were made during disas-
sembly are properly aligned.
3. Install new snap ring.
GI
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FRONT AXLE
Drive Shaft (Cont’d)
AX-17

SFA149A
4. Pack drive shaft with specified amount of grease.
Specified amount of grease:
GI2300I type 125.5 - 135.5 g (4.42 - 4.77 oz)
GI2000I type 90 g (3.17 oz)
TS79C type 155 - 165 g (5.47 - 5.82 oz)
TS70C type 110 - 120 g (3.88 - 4.23 oz)
TS83 type 125 - 145 g (4.41 - 5.11 oz)
DS83 type 115 - 135 g (4.06 - 4.76 oz)
DS90 type 145 - 165 g (5.11 - 5.82 oz)
5. Install slide joint housing, then install new snap ring.
6. 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
2”.
Length “L2”:
TS70C type
96.4 - 96.6 mm (3.795 - 3.803 in)
TS79C type
101.5 - 103.5 mm (3.996 - 4.075 in)
TS83 type
99 mm (3.90 in)
DS83 type
98 mm (3.86 in)
DS90 type
98 mm (3.86 in)
GI2000I type
90 mm (3.54 in)
GI2300I type
98 - 100 mm (3.86 - 3.94 in)
SFA395
7. Lock new larger and smaller boot bands securely with a suit-
able tool.
SFA618
Support BearingNJAX0019S04Press bearing into retainer.
FRONT AXLE
Drive Shaft (Cont’d)
AX-18

SRA695A
SSU038
REMOVALNJSU0031S01CAUTION:
Before removing the rear suspension assembly, disconnect
the ABS wheel sensor from the assembly. Failure to do so may
result in damage to the sensor wires and the sensor becom-
ing inoperative.
Remove suspension assembly.
1. Disconnect parking brake cable from caliper and remove brake
caliper and rotor.
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.
2. Using a transmission jack, raise torsion beam a little, and
remove nuts and bolts from the trailing arm, shock absorber
assembly (lower side) and lateral link (Body side).
3. Lower transmission jack, and remove suspension.
4. Remove strut securing nuts (upper side). Then pull out strut
assembly.
SRA697A
INSTALLATIONNJSU0031S02Install suspension assembly.
CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Attach torsion beam, at trailing arm and lateral link, to vehicle.
Do not tighten bolts at this time.
SRA698A
2. Using a transmission jack, place lateral link and control rod
horizontally against torsion beam. Tighten lateral link on
vehicle.
3. Attach shock absorber assembly to vehicle. Then tighten the
lower side of shock absorber assembly.
4. Lower torsion beam to fully extended position. Remove trans-
mission jack and tighten torsion beam, at trailing arm, to speci-
fied torque. Refer to SU-20.
5. Install brake caliper and rotor, then connect parking brake
cable to caliper.
6. Install ABS wheel sensor.
Coil Spring and Shock Absorber
REMOVAL AND INSTALLATIONNJSU0032Remove shock absorber upper and lower fixing nuts.
Do not remove piston rod lock nut on vehicle.
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FE
CL
MT
AT
AX
BR
ST
RS
BT
HA
SC
EL
IDX
REAR SUSPENSION
Removal and Installation (Cont’d)
SU-21