2003 NISSAN ALMERA N16 steering

NRS121
INSTALLATIONNJRS00171. Set the front wheels in the straight-ahead position.
2. Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left about 3.5 revo-
lutions from the right end position. Align the two marks (
)or
make sure that the white indicator is visible in the upper part
of the indicator window, with the cable pointed downwards.
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable
may snap by turning the steering wheel beyond the limited
number of turns. The spiral cable can be turned up to
about 3.5 turns from the neutral position to both the right
and left.
3. Connect spiral cable connector and tighten with screws. Install
steering column cover.
4. Install steering wheel, aligning with spiral cable pin guides, and
pull spiral cable through.
5. Connect horn/audio connector and engage spiral cable with
pawls in steering wheel. Move driver air bag module connec-
tor away from steering wheel lower lid opening.
6. Tighten nut.
: 29.4 - 39.2 N·m (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
7. Position driver air bag module and tighten with new special
bolts.
8. Connect driver air bag module connector.
9. Install steering switches and lids.
SHIA0184E
10. Install the air bag module, press the center of the horn pad to
make contact (RH/LH) ON.
11. Conduct self-diagnosis to ensure entire SRS operates prop-
erly. (Use CONSULT-II or warning lamp check.)
Before performing self-diagnosis, connect both battery cables.
12. Turn steering wheel to the left end and then to the right end
fully to make sure that spiral cable is set in the neutral posi-
tion.
If “AIR BAG” warning lamp blinks or stays ON (at the user
mode), it shows the spiral cable may be snapped due to its
improper position. Perform self-diagnosis again (use CON-
SULT-II or warning lamp). If a malfunction is detected, replace
the spiral cable with a new one.
13. Perform self-diagnosis again to check that no malfunction is
detected.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Driver Air Bag Module and Spiral Cable (Cont’d)
RS-31

SRS825
INSTALLATIONNJRS0019CAUTION:
Always work from the side of or under front passenger air
bag module.
1. Install front passenger air bag module on steering member and
secure with new special bolts.
Ensure harness is not caught between rear of front passenger
air bag module and steering member.
2. Install grove box cover.
3. Install glove box assembly. (Glove box is open.)
SRS827
4. Connect front passenger air bag module connector to air bag
harness connector.
5. Close the connector cover.
6. Close the glove box.
7. Connect both battery cable.
8. Conduct self-diagnosis to ensure entire SRS operates prop-
erly. (Use CONSULT-II or warning lamp check.)
YRS098
Front Side Air Bag Module
REMOVALNJRS0059CAUTION:
Before servicing SRS, turn the ignition switch OFF, dis-
connect both battery cables and wait at least 3 minutes.
Always work from the rear of the front side air bag mod-
ule.
1. Disconnect front side air bag module connector.
SRS867
2. Pull up the seatback trim.
3. Remove the nuts coated with bonding agent securing front
side air bag and the inner cloth with seatback frame.
SRS868
4. Remove inner cloth.
5. Remove front side air bag connector. Front side air bag mod-
ule can then be removed.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Front Passenger Air Bag Module (Cont’d)
RS-33

Collision Diagnosis=NJRS0033FOR FRONTAL COLLISIONNJRS0033S07To repair the SRS, perform the following steps.
When SRS (except the side air bag) is activated in a collision:
1) Replace the diagnosis sensor unit.
2) Remove the air bag modules (except the side air bag module) and front seatbelt pre-tensioner assem-
blies.
3) Check the SRS components using the table shown below:
Replace any SRS components showing visible signs of damage (dents, cracksand deformation).
4) Install new air bag modules (except the side air bag module) and front seat belt pre-tensioner assemblies.
5) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
When SRS is not activated in a collision:
1) Check the SRS components using the table shown below:
Replace any SRS components showing visible signs of damage (dents, cracksand deformation).
2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”
for details (RS-49). Ensure entire SRS operation properly.
SRS Inspection (For frontal collision)NJRS0033S0701
Part SRS is activated SRS is NOT activated
Air bag module (driver
and front passenger
side)REPLACE
Install with new bolts.1. Remove air bag module. Check harness cover and connectors for damage,
terminals for deformities, and harness for binding.
2.
a. Install driver’s air bag module into the steering wheel to check fit and align-
ment with the wheel.
b. Install front passenger air bag module into the instrument panel to checkfit
with the instrument panel.
3. No damage found, reinstall with new bolts.
4. If damaged—REPLACE. Install air bag modules with new bolts. Air bag must
be deployed before disposing.
Front seat belt pre-
tensioner assemblyREPLACE
Install seat belt pre-
tensioner with new
bolts.1. Remove front seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities,
and harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. If no damage is found, reinstall front seat belt pre-tensioner assembly.
5. If damaged—REPLACE. Install the front seat belt pre-tensioners with new bolts
coated with bonding agent. Front seat belt pre-tensioners must be deployed
before discarding.
Diagnosis sensor unit REPLACE
Install with new bolts
coated with bonding
agent.1. Check case for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall with new special bolts and ground bolt coated
with bonding agent.
4. If damaged—REPLACE. Install diagnosis sensor unit with new special bolts
and ground bolt coated with bonding agent.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install driver air bag module to check fit or alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall with bolts.
6. If damaged—REPLACE.
Spiral cable 1. Visually check spiral cable and combination switch for damage.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
4. If no damage is found, reinstall with bolts.
5. If damaged—REPLACE.
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SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis
RS-71

STEERING SYSTEM
SECTION
ST
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[2
Supplemental Restraint System (SRS)″AIR
BAG″and″SEAT BELT PRE-TENSIONER″...............2
Precautions for Steering System .................................2
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Special Service Tools ..................................................3
Commercial Service Tool .............................................4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>5
NVH Troubleshooting Chart.........................................5
ON-VEHICLE SERVICE..................................................6
Checking Steering Wheel Play ....................................6
Checking Neutral Position on Steering Wheel ............6
PRE-CHECKING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>6
CHECKING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[6
Front Wheel Turning Angle ..........................................6
Checking Gear Housing Movement ............................6
Checking and Adjusting Drive Belts ............................7
Checking Steering Gear and Linkage .........................7
STEERING GEAR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>7
STEERING LINKAGE.................................................7
Checking Fluid Level ...................................................7
Checking Fluid Leakage ..............................................7
Bleeding Hydraulic System..........................................8
Checking Steering Wheel Turning Force ....................8
Checking Hydraulic System.........................................9
STEERING WHEEL AND STEERING COLUMN.........10
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........10
Removal and Installation ........................................... 11
STEERING WHEEL................................................. 11
STEERING COLUMN...............................................12Disassembly and Assembly .......................................13
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............14
TILT MECHANISM<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>4
POWER STEERING GEAR AND LINKAGE................15
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........15
Removal and Installation ...........................................16
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........17
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............18
BOOT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......18
RACK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......18
GEAR SUB-ASSEMBLY...........................................18
GEAR HOUSING CYLINDER....................................18
TIE-ROD OUTER AND INNER SOCKETS..................19
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............19
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............22
POWER STEERING OIL PUMP (QG ENGINE)...........24
Component Description .............................................24
POWER STEERING OIL PUMP (YD ENGINE)............25
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........25
Pre-disassembly Inspection .......................................25
Removal and Installation ...........................................26
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........26
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............27
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............28
SERVICE DATA AND SPECIFICATIONS (SDS).........29
General Specifications ...............................................29
Steering Wheel ..........................................................29
Steering Column ........................................................29
Steering Gear and Linkage .......................................30
Power Steering ..........................................................30
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Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
NJST0044The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of 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 should be per-
formed 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. For removalofSpiralCableandAir
Bag Module, see the RS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be
identified by yellow harness connector.
Precautions for Steering SystemNJST0003Before disassembly, thoroughly clean the outside of the unit.
Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
Place disassembled parts in order, on a parts rack, for easier and proper assembly.
Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
Before inspection or reassembly, carefully clean all parts with a generalpurpose, non-flammable
solvent.
Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Vaseline
may be applied to O-rings and seals. Do not use any grease.
Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals andgaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRON
TMIII or equivalent. Refer to MA-19, “Fluids and Lubricants”.
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
ST-2

Special Service ToolsNJST0004
Tool number
Tool nameDescription
KV48100700
Torque adapter
NT169
Measuring pinion rotating torque
KV48102500
Pressure gauge adapter
NT542
Measuring oil pressure
ST27180001
Steering wheel puller
NT544
Removing steering wheel
HT72520000
Ball joint remover
NT546
Removing ball joint
a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)
KV48103500
Pressure gauge
NT547
Measuring oil pressure
KV48104400
Rack seal ring reformer
NT550
Reforming teflon ring
a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in)
ST3127S000
1 GG91030000
Torque wrench
2 HT62940000
Socket adapter
3 HT62900000
Socket adapter
NT541
Measuring turning torque
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PREPARATION
Special Service Tools
ST-3

Commercial Service ToolNJST0005
Tool number Description
Oil pump attachment
NT774
Disassembling and assembling oil pump
Unit: mm (in)
KV48105210
Sprocket holder
NT809
Removing and Installing power steering oil pump
PREPARATION
Commercial Service Tool
ST-4

NJST0006
NVH Troubleshooting Chart
NJST0006S01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.Reference page
ST-7
ST-8
ST-19
ST-19
ST-19
ST-7
ST-6
ST-8
Refer to EM-11.
—
ST-10
ST-6
ST-14
ST-13
ST-15
AX-3
AX-3
SU-4
SU-4
SU-4
BR-6
Possible cause and
SUSPECTED PARTS
Fluid level
Air in hydraulic system
Tie-rod ball joint swinging force
Tie-rod ball joint rotating torque
Tie-rod ball joint end play
Steering gear fluid leakage
Steering wheel play
Steering gear rack sliding force
Drive belt looseness
Improper steering wheel
Improper installation or looseness or tilt lock lever
Mounting rubber deterioration
Steering column deformation or damage
Improper installation or looseness of steering column
Steering linkage looseness
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
Symptom STEERINGNoise×××××××××——————××××××
Shake —————————×××———××××××
Vibration —————————×××××—××××——
Shimmy —————————×××——×—×××××
Judder———————————×——×—×××××
×: Applicable
—: Not applicable
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
ST-5