2003 NISSAN ALMERA N16 clutch

AT-3
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AT Line Pressure Test ............................................... 265
Road Test ............................................................. 266
TROUBLE DIAGNOSIS — GENERAL DESCRIP-
TION ........................................................................ 283
Symptom Chart .................................................... 283
TCM Terminals and Reference Value ................... 302
CAN COMMUNICATION ........................................ 305
System Description .............................................. 305
CAN Communication Unit .................................... 305
TROUBLE DIAGNOSES FOR SYMPTOMS .......... 307
Wiring Diagram — AT — NONDTC ...................... 307
1. O/D OFF Indicator Lamp Does Not Come On . 309
2. Engine Cannot Be Started In “P” and “N” Position . 309
3. In “P” Position, Vehicle Moves Forward Or Back-
ward When Pushed .............................................. 310
4. In “N” Position, Vehicle Moves .......................... 311
5. Large Shock. “N” → “R” Position ...................... 312
6. Vehicle Does Not Creep Backward In “R” Position . 313
7. Vehicle Does Not Creep Forward In “D”, “2” Or
“1” Position ........................................................... 316
8. Vehicle Cannot Be Started From D
1 ................. 317
9. A/T Does Not Shift: D
1→ D2 Or Does Not Kick
down: D
4→ D2 ..................................................... 320
10. A/T Does Not Shift: D
2→ D3 ......................... 322
11. A/T Does Not Shift: D
3→ D4 .......................... 324
12. A/T Does Not Perform Lock-up ...................... 326
13. A/T Does Not Hold Lock-up Condition ........... 326
14. Lock-up Is Not Released ................................ 328
15. Engine Speed Does Not Return To Idle (Light
Braking D
4→ D3 ) ................................................ 328
16. Vehicle Does Not Start From D
1 ..................... 330
17. A/T Does Not Shift: D
4→ D3 , When Overdrive
Control Switch “ON” → “OFF” .............................. 330
18. A/T Does Not Shift: D
3→ 22 , When Selector
Lever “D” → “2” Position ...................................... 331
19. A/T Does Not Shift: 2
2→ 11 , When Selector
Lever “2” → “1” Position ....................................... 332
20. Vehicle Does Not Decelerate By Engine Brake . 333
21. TCM Self-diagnosis Does Not Activate (PNP &
Overdrive Control Switches, and Throttle Position
Sensor Circuit Checks) ........................................ 333
ALL
MAIN POWER SUPPLY AND GROUND CIRCUIT . 340
Wiring Diagram — AT — MAIN ............................ 340
Diagnostic Procedure ........................................... 341
VEHICLE SPEED SENSOR - A/T (REVOLUTION
SENSOR) ................................................................ 343
Description ........................................................... 343
Wiring Diagram — AT — VSSAT ......................... 345
Diagnostic Procedure ........................................... 346
DTC VEHICLE SPEED SENSOR MTR .................. 348
Description ........................................................... 348
Wiring Diagram — AT — VSSMTR ...................... 350
Diagnostic Procedure ........................................... 351
ACCELE RATOR PEDAL POSITION (APP) SEN-
SOR ........................................................................ 352
Description ........................................................... 352Wiring Diagram — AT — TPS ..............................354
Diagnostic Procedure ...........................................355
SHIFT SOLENOID VALVE A ..................................357
Description ............................................................357
Wiring Diagram — AT — SSV/A ...........................359
Diagnostic Procedure ...........................................360
Component Inspection ..........................................360
SHIFT SOLENOID VALVE B ..................................362
Description ............................................................362
Wiring Diagram — AT — SSV/B ...........................364
Diagnostic Procedure ...........................................365
Component Inspection ..........................................365
OVERRUN CLUTCH SOLENOID VALVE ...............367
Description ............................................................367
Wiring Diagram — AT — OVRCSV ......................369
Diagnostic Procedure ...........................................370
Component Inspection ..........................................371
TORQUE CONVERTER CLUTCH SOLENOID
VALVE .....................................................................372
Description ............................................................372
Wiring Diagram — AT — TCV ..............................374
Diagnostic Procedure ...........................................375
Component Inspection ..........................................375
BATT/FLUID TEMP SEN (A/T FLUID TEMP SEN-
SOR CIRCUIT AND TCM POWER SOURCE) .......377
Description ............................................................377
Wiring Diagram — AT — BA/FTS .........................379
Diagnostic Procedure ...........................................380
Component Inspection ..........................................382
ENGINE SPEED SIGNAL .......................................383
Description ............................................................383
Wiring Diagram — AT — ENGSS .........................385
Diagnostic Procedure ...........................................386
LINE PRESSURE SOLENOID VALVE ...................388
Description ............................................................388
Wiring Diagram — AT — LPSV ............................390
Diagnostic Procedure ...........................................391
Component Inspection ..........................................393
CAN COMMUNICATION LINE ...............................395
Description ............................................................395
On Board Diagnosis Logic ....................................395
Self-Diagnosis Code Confirmation Procedure ......395
Wiring Diagram — AT — CAN ..............................396
Diagnostic Procedure ...........................................397
A/T SHIFT LOCK SYSTEM ....................................398
Description ............................................................398
Shift Lock System Electrical Parts Location .........398
Wiring Diagram — SHIFT — ................................399
Diagnostic Procedure ...........................................400
KEY INTERLOCK CABLE ......................................404
Components .........................................................404
Removal ...............................................................404
Installation ............................................................405
ON-VEHICLE SERVICE ..........................................406
Control Valve Assembly and Accumulators ..........406
Control Cable Adjustment .....................................408
Park/Neutral Position (PNP) Switch Adjustment ..408
Differential Side Oil Seal Replacement ................409
Revolution Sensor Replacement ..........................409

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

PRECAUTIONS
AT-7
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●After performing each TROUBLE DIAGNOSIS, perform
“DTC (Diagnostic Trouble Code) CONFIRMATION PROCE-
DURE”.
The DTC should not be displayed in the “DTC CONFIRMA-
TION PROCEDURE” if the repair is completed.
●Before proceeding with disassembly, thoroughly clean the out-
side of the transaxle. It is important to prevent the internal parts
from becoming contaminated by dirt or other foreign matter.
●Disassembly should be done in a clean work area.
●Use lint-free cloth or towels for wiping parts clean. Common
shop rags can leave fibers that could interfere with the operation
of the transaxle.
●Place disassembled parts in order for easier and proper assembly.
●All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
●Gaskets, seals and O-rings should be replaced any time the transaxle is disassembled.
●It is very important to perform functional tests whenever they are indicated.
●The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
●Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
●Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
●Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
●After overhaul, refill the transaxle with new ATF.
●When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under AT-13, "
Changing A/T Fluid" when changing A/T fluid.
Service Notice or PrecautionsECS007N8
FA I L - S A F E
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The cus-
tomer may complain of sluggish or poor acceleration.
When the ignition key is turned “ON” following Fail-Safe operation, O/D OFF indicator lamp blinks for about 8
seconds. Refer to AT- 2 5 0 , "
Diagnostic Procedure Without CONSULT-II" (EXCEPT FOR EURO-OBD) or AT-
51, "TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)" (EURO-OBD).
The blinking of the O/D OFF indicator lamp for about 8 seconds will appear only once and be cleared. The
customer may resume normal driving conditions.
Always follow the “Work Flow”, refer to AT- 2 5 9
(EXCEPT FOR EURO-OBD) or AT- 6 0 (EURO-OBD).
The SELF-DIAGNOSIS results will be as follows:
●The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
●During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.
TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:
●External leaks in the hub weld area.
●Converter hub is scored or damaged.
●Converter pilot is broken, damaged or fits poorly into crankshaft.
●Steel particles are found after flushing the cooler and cooler lines.
●Pump is damaged or steel particles are found in the converter.
●Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
●Converter is contaminated with engine coolant containing antifreeze.
SAT652J

AT-8
PRECAUTIONS
●Internal failure of stator roller clutch.
●Heavy clutch debris due to overheating (blue converter).
●Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
●The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
●The threads in one or more of the converter bolt holes are damaged.
●Transaxle failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
●Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
EURO-OBD SELF-DIAGNOSIS — EURO-OBD —
●A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the O/D OFF indicator lamp or the malfunction indicator (MI). Refer to the table on
AT- 4 2 , "
SELF-DIAGNOSTIC RESULT TEST MODE" for the indicator used to display each self-diagnostic
result.
●The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memo-
ries.
Always perform the procedure AT- 3 9 , "
HOW TO ERASE DTC" to complete the repair and avoid
unnecessary blinking of the MI.
●The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the O/D OFF indicator lamp does not indicate any malfunctions.
–PNP switch
–A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of EURO-OBD, refer to AT-37, "
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION" .
●Certain systems and components, especially those related to EURO-OBD, may use a new style
slide-locking type harness connector.
For description and how to disconnect, refer to EL-7, "HARNESS CONNECTOR".
Wiring Diagrams and Trouble DiagnosisECS007N9
When you read wiring diagrams, refer to the following:
●GI-12, "How to Read Wiring Diagrams".
●EL-11, "POWER SUPPLY ROUTING".
When you perform trouble diagnosis, refer to the following:
●GI-22, "How to Perform Efficient Diagnosis for an Electrical Incident".
●GI-32, "How to Follow Trouble Diagnosis".

PREPARATION
AT-9
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PREPARATIONPFP:00100
Special Service ToolsECS007NA
Tool number
Tool nameDescription
(J34301-C)
Oil pressure gauge set
1 (J34301-1)
Oil pressure gauge
2 (J34301-2)
Hoses
3 (J34298)
Adapter
4 (J34282-2)
Adapter
5 (790-301-1230-A)
60°Adapter
6 (J34301-15)
Square socketMeasuring line pressure and governor pressure
KV311030000
(J38982)
Drift Installing differential oil seal
(Use with ST35325000.)
a: 59mm (2.32 in) dia.
b: 49mm (1.93 in) dia.
ST35325000
( - )
Drift Installing differential oil seal
(Use with KV311030000.)
a: 215 mm (8.46 in)
b: 25 mm (0.98 in)
c: M12 x 1.5P
KV38107700
(J39027)
Preload adapter
●Measuring turning torque of final drive assembly
●Measuring clearance between side gear and
differential case with washer
●Selecting differential side bearing adjusting shim
KV31103200
(J34285-A and J34285-87)
Clutch spring compressor Removing and installing clutch return spring
a: 320mm (12.0 in)
b: 174 mm (6.85in)
ST23540000
(J25689-A)
Pin punch Removing and installing parking rod plate, manual
plate and differential pinion mate shaft retaining pins
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
AAT896
NT105
NT417
NT087
NT423
NT442

A/T FLUID
AT-13
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A/T FLUIDPFP:KLE40
Checking A/T FluidECS007NC
1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures
of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove dipstick and note reading. If level is at low side of either
range, and fluid to the charging pipe.
e. Re-insert dipstick into charging pipe as far as it will go.
f. Remove dipstick and note reading. If reading is at low side of range, add fluid to the charging pipe.
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on dipstick.
6. Check fluid condition.
●If fluid is very dark or smells burned, refer to AT section for
checking operation of A/T. Flush cooling system after repair of
A/T.
●If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to LC-16, "Radi-
ator".
Changing A/T FluidECS007ND
1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid from drain plug and refill with new A/T fluid.
Always refill same volume with drained fluid.
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to AT- 1 3 , "
Checking A/T Fluid" . If fluid is still dirty, repeat steps 2
through 5.
SMA827CA
SMA853B
Fluid grade:
Genuine Nissan ATF or equivalent. Refer to MA-
19, "RECOMMENDED FLUID AND LUBRI-
CANTS".
Fluid capacity (With torque converter):
Approx. 7.7 (6-3/4 lmp qt)
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SMA027D

AT-18
OVERALL SYSTEM
Shift Mechanism
ECS007NI
CONSTRUCTION
FUNCTION OF CLUTCH AND BRAKE
CLUTCH AND BAND CHART
1. Torque converter 2. Oil pump 3. Input shaft
4. Brake band 5. Reverse clutch 6. High clutch
7. Front sun gear 8. Front pinion gear 9. Front internal gear
10. Front planetary carrier 11. Rear sun gear 12. Rear pinion gear
13. Rear internal gear 14. Rear planetary carrier 15. Forward clutch
16. Forward one-way clutch 17. Overrun clutch 18. Low one-way clutch
19. Low & reverse brake 20. Parking pawl 21. Parking gear
22. Output shaft 23. Idle gear 24. Output gear
SAT998I
Clutch and brake components Abbr. Function
5 Reverse clutch R/C To transmit input power to front sun gear 7 .
6 High clutch H/C To transmit input power to front planetary carrier 10 .
15 Forward clutch F/C To connect front planetary carrier 10 with forward one-way clutch 16 .
17 Overrun clutch O/C To connect front planetary carrier 10 with rear internal gear 13 .
4 Brake band B/B To lock front sun gear 7 .
16 Forward one-way clutch F/O.C When forward clutch 15 is engaged, to stop rear internal gear 13 from rotatin g in
opposite direction against engine revolution.
18 Low one-way clutch L/O.C To stop front planetary carrier 10 from rotating in opposite direction against
engine revolution.
19 Low & reverse brake L & R/B To lock front planetary carrier 10 .
Shift posi-
tionReverse
clutch
5High
clutch
6For-
ward
clutch
15Over-
run
clutch
17Band servo
Forward
one-way
clutch
16Low
one-
way
clutch
18Low &
revers
e brake
19Lock-
upRemarks
2nd
apply3rd
release4th
apply
PPA R K
POSITION
RREVERSE
POSITION
NNEUTRAL
POSITION

OVERALL SYSTEM
AT-19
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●*1: Operates when overdrive control switch is set in “OFF” position.
●*2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not con-
tract because oil pressure area on the “release” side is greater than that on the “apply” side.
●*3: Oil pressure is applied to 4th “apply” side in condition *2 above, and brake band contracts.
●*4: A/T will not shift to 4th when overdrive control switch is set in “OFF” position.
●*5: Operates when overdrive control switch is “OFF”.
●: Operates.
●A: Operates when throttle opening is less than 3/16, activating engine brake.
●B: Operates during “progressive” acceleration.
●C: Operates but does not affect power transmission.
●D: Operates when throttle opening is less than 3/16, but does not affect engine brake. D*41st *1D B B
Automatic
shift
1⇔ 2 ⇔ 3
⇔ 4 2nd *1A B
3rd *1A *2C C B
*5
4th C *3C C
21st D B BAutomatic
shift
1⇔ 2 2nd A B
11stBLocks (held
stationary) in
1st speed
1⇐ 2 2ndB Shift posi-
tionReverse
clutch
5High
clutch
6For-
ward
clutch
15Over-
run
clutch
17Band servo
Forward
one-way
clutch
16Low
one-
way
clutch
18Low &
revers
e brake
19Lock-
upRemarks
2nd
apply3rd
release4th
apply