2003 NISSAN ALMERA N16 steering wheel

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

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

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

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