2003 NISSAN ALMERA N16 Front

SEL026Z
PINION PROTRUSION LENGTH ADJUSTMENTNJSC0020S01Clearance (QG engine models)NJSC0020S0101With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “” between the front edge
of the pinion and the pinion stopper.
Clearance “”:
Refer to SDS (SC-37).
MEL140L
Movement (YD engine models)NJSC0020S0102Compare movement “” in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement “”:
Refer to SDS (SC-37).
SEL633BA
Not in the specified value ... Adjust by adjusting plate.
STARTING SYSTEM
Assembly (Cont’d)
SC-26

BatteryNJSC0014
Applied
modelQG engine YD engine
Type 34B19L 46B24L 55D23L 65D26LYUASA type code YUASA type code
110D26L
025 027 063 065 075 096L 010S 067 096
Capac-
ity V-AH12-27 12-36 12-48 12-52 12-47 12-55 12-50 12-65 12-60 12-64 12-70
StarterNJSC0015
Ty p eD7E31 S114-570B S114-800B M2T48681 M0T83581A M8T71371
VALEO make HITACHI make MITSUBISHI make
Non-reduction Non-reduction Reduction Non-reduction Reduction Reduction
Applied model QG engine YD engine
System voltage V12
No-loadTerminal voltage V 11.0 11.5 11.0 11.5 11.0 11.0
Current A 45 Less than 60 Less than 90 Less than 53 Less than 90 Less than 145
Revolution rpm 12,000More than
6,000More than
2,750More than
6,000More than
2,750More than
3,400
Minimum diameter of commutator mm
(in)28.2 (1.110) 28.0 (1.102) 31.4 (1.236) 28.8 (1.134) 31.4 (1.236)
Minimum length of brush mm (in) 6.15 (0.242) 9.0 (0.354) 10.5 (0.413) 11.5 (0.453) 7.0 (0.276) 11.0 (0.433)
Brush spring tension N (kg, lb)16.2 - 19.8
(1.65 - 2.02,
3.46 - 4.45)9.8 - 13.7
(1.0 - 1.4,
2.2 - 3.1)12.7 - 17.7
(1.3 - 1.8,
2.9 - 4.0)13.7 - 25.5
(1.4 - 2.6,
3.1 - 5.7)15.0 - 20.4
(1.5 - 2.1,
3.4 - 4.6)26.5 - 36.3
(2.7 - 3.7,
6.0 - 8.2)
Clearance between bearing metal and
armature shaft mm (in)0.05 (0.0020) Less than 0.2 (0.008) —
Clearance “” between pinion front
edge and pinion stopper mm (in)Max. 1 (0.039) 0.3 - 2.5 (0.012 - 0.098)0.5 - 2.0
(0.020 - 0.079)—
Movement “” in height of pinion
assembly mm (in)Max. 12.2
(0.480)—0.5 - 2.0
(0.020 - 0.079)
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SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
SC-37

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

SST489B
Checking Steering Wheel PlayNJST0007With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
If it is not within specification, check the following for loose or
worn components.
Steering gear assembly
Steering column
Front suspension and axle
SST490BA
Checking Neutral Position on Steering WheelNJST0008PRE-CHECKINGNJST0008S01Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SU-14, SDS.
Verify that the steering gear is centered before removing the
steering wheel.
CHECKINGNJST0008S021. Check that the steering wheel is in the neutral position when
driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two teeth, loosen tie-rod lock
nuts. Turn the tie-rods by the same amount in opposite direc-
tions on both left and right sides.
SMA127
Front Wheel Turning AngleNJST00091. Rotate steering wheel all the way right and left; measure turn-
ing angle.
Turning angle of full turns:
Refer to SU-14, SDS.
2. If it is not within specification, check rack stroke.
Rack stroke “S”:
Refer to SDS, ST-30.
SST663B
Checking Gear Housing MovementNJST00101. Check the movement of steering gear housing during station-
ary steering on a dry paved surface.
Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
±2mm(±0.08 in) or less
2. If movement exceeds the limit, replace mount insulator after
confirming proper installation of gear housing clamps.
ON-VEHICLE SERVICE
Checking Steering Wheel Play
ST-6

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

ComponentsNJST0017
YST026
1. Air bag module
2. Steering wheel
3. Combination switch with spiral
cable4. Column cover
5. Steering column assembly
6. Hole cover7. Lower joint
8. Lower cover
CAUTION:
The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.
Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.
STEERING WHEEL AND STEERING COLUMN
Components
ST-10

MHIA0017E
Removal and Installation=NJST0018STEERING WHEELNJST0018S01Remove air bag module and spiral cable.
Refer to RS-29, “Removal — Driver Air Bag Module and Spiral
Cable”.
NRS121
Align spiral cable correctly when installing steering wheel.
a) Set the front wheels in the straight-ahead position.
b) 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.)
SST777C
Remove steering wheel with Tool.
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STEERING WHEEL AND STEERING COLUMN
Removal and Installation
ST-11