2003 NISSAN ALMERA N16 FLUID

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

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

Checking and Adjusting Drive BeltsNJST0011Refer to EM-11 (QG) or EM-11 (YD), “Checking Drive Belts”.
SMA851B
Checking Steering Gear and LinkageNJST0037STEERING GEARNJST0037S01Check gear housing and boots for looseness, damage or
grease leakage.
Check connection with steering column for looseness.
STEERING LINKAGENJST0037S02Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.
YST003
Checking Fluid LevelNJST0012Check fluid level, referring to the scale on reservoir tank.
Use “HOT” range for fluid temperatures of 50 to 80°C (122 to
176°F).
Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION:
Do not overfill.
Recommended fluid is DEXRONTMIII or equivalent. Refer
to MA-19, “Fluids and Lubricants”.
YST006
YST007
Checking Fluid LeakageNJST0013Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
1. Run engine between idle speed and 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each “lock” position for five seconds
and carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
5. If fluid leakage from power steering pump is noticed, check
power steering pump. Refer to ST-25.
6. Check rack boots for accumulation of power steering fluid.
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ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts
ST-7

Bleeding Hydraulic SystemNJST00141. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Then quickly turn steer-
ing wheel fully to right and left and lightly touch steering stop-
pers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2. above.
Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a) Air bubbles in reservoir tank
b) Clicking noise in oil pump
c) Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning the steering wheel
slowly. This does not affect the performance or durability of the
system.
SST491B
SST090B
Checking Steering Wheel Turning ForceNJST00151. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-
ture. [Make sure temperature of fluid is approximately 60 to
80°C (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360° from the neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
5. If steering wheel turning force is out of specification, check
rack sliding force.
a. Disconnect steering column lower joint and knuckle arms from
the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. Pull tie-rod slowly to move it from neutral position to±11 . 5 m m
(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack
sliding force is within specification.
Average rack sliding force:
132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)
Maximum force deviation:
176 N (17.9 kg, 39 lb)
6. If rack sliding force is not within specification, overhaul steer-
ing gear assembly.
7. If rack sliding force is OK, inspect steering column. Refer to
ST-13.
ON-VEHICLE SERVICE
Bleeding Hydraulic System
ST-8

SST834-I
Checking Hydraulic SystemNJST0016Before starting, check belt tension, driving pulley and tire pressure.
1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleed-
ing Hydraulic System”, ST-8.
2. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid in tank rises to 60 to 80°C (140
to 176°F).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, fluid pressure in oil pump
increases to maximum. This will raise oil temperature abnor-
mally.
3. Check pressure with steering wheel fully turned to left and right
positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
QG15, 18 engine
8,600 - 9,200 kPa (86.0 - 92.0 bar, 88.7 - 93.8
kg/cm
2, 1,247 - 1,334 psi)
YD22 engine
8,800 - 9,400 kPa (88.0 - 94.0 bar, 88.7 - 95.8
kg/cm
2, 1,261 - 1,362 psi)
If pressure reaches maximum operating pressure, system is
OK.
If pressure increases above maximum operating pressure,
check power steering pump flow control valve. Refer to ST-25.
4. If power steering pressure is below the maximum operating
pressure, slowly close shut-off valve and check pressure
again.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
If pressure increases to maximum operating pressure, gear is
damaged. Refer to “Removal and Installation”, ST-16.
If pressure remains below maximum operating pressure, pump
is damaged. Refer to “Disassembly”, ST-26.
5. After checking hydraulic system, remove Tool and add fluid as
necessary. Then completely bleed air out of system. Refer to
ST-8.
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ON-VEHICLE SERVICE
Checking Hydraulic System
ST-9

SST879C
Install pipe connector.
Observe specified tightening torque when tightening high-pres-
sure and low-pressure pipe connectors. Excessive tightening
will damage threads of connector or O-ring.
Connector tightening torque:
1 Low-pressure side
27 - 39 N·m (2.8 - 4.0 kg-m, 20 - 29 ft-lb)
2 High-pressure side
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)
The O-ring in low-pressure pipe connector is larger than that
in high-pressure connector. Take care to install the proper
O-ring.
SST824A
Initially, tighten nut on tie-rod outer socket and knuckle arm to
29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further
to align nut groove with first pin hole so that cotter pin can be
installed.
CAUTION:
Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).
NOTE:
Only the dust boot, tie-rod inner socket and tie-rod outer socket can
be disassembled on models for Europe.
SST819A
Before removing lower joint from gear, set gear in neutral
(wheels in straight-ahead position). After removing lower joint,
put matching mark on pinion shaft and pinion housing to record
neutral position.
To install, set left and right dust boots to equal deflection.
Attach lower joint by aligning matching marks of pinion shaft
and pinion housing.
Tighten gear housing mounting bracket bolts.
SST862CB
DisassemblyNJST00231. Prior to disassembling, measure pinion rotating torque. Record
the pinion rotating torque as a reference.
Before measuring, disconnect gear housing tube and
drain fluid.
Use soft jaws when holding steering gear housing. Handle
gear housing carefully, as it is made of aluminum. Do not
grip cylinder in a vise.
2. Remove gear sub-assembly, O-ring and shim.
Gear sub-assembly cannot be disassembled. If it is faulty,
replace with a new one.
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POWER STEERING GEAR AND LINKAGE
Removal and Installation (Cont’d)
ST-17

SST051C
3. Remove tie-rod outer sockets and boots.
4. Loosen tie-rod inner socket by prying up staked portion, and
remove socket and spacer.
5. Remove retainer.
6. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to com-
pletely remove staked portion of gear housing end.
SST052C
7. Remove end cover assembly with a suitable tool.
8. Draw out rack assembly.
9. Remove rack seal ring.
Using a heat gun, heat rack seal to approximately 40°C
(104°F).
Remove rack seal ring.
Be careful not to damage rack.
SST472A
10. Remove center bushing and rack oil seal using tape wrapped
socket and extension bar.
Do not scratch inner surfaces of pinion housing.
InspectionNJST0024Thoroughly clean all parts in cleaning solvent or DEXRONTMIII or
equivalent. Blow dry with compressed air, if available.
BOOTNJST0024S01Check condition of boot. If cracked excessively, replace it.
Check boots for accumulation of power steering fluid.
RACKNJST0024S02Thoroughly examine rack gear. If damaged, cracked or worn,
replace it.
GEAR SUB-ASSEMBLYNJST0024S03Check pinion gear. If it is worn or damaged, replace as a gear
sub-assembly.
Manually spin bearing. If torque variations or free play are
noted, replace as a gear sub-assembly.
GEAR HOUSING CYLINDERNJST0024S04Check gear housing cylinder bore for scratches or other damage.
Replace if necessary.
POWER STEERING GEAR AND LINKAGE
Disassembly (Cont’d)
ST-18