2003 NISSAN ALMERA N16 air suspension

Edition: August 2003
Release: October 2003 (01)
Publication No.: SM3E00-1N16E1E
Reference No.: 7711347018
GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICAL – QGEM-QG
ENGINE MECHANICAL – YDEM-YD
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEM – QGEC - QG
ENGINE CONTROL SYSTEM – YDEC - YD
ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEMSFE
CLUTCHCL
MANUAL TRANSAXLEMT
AUTOMATIC TRANSAXLEAT
FRONT & REAR AXLEAX
FRONT & REAR SUSPENSIONSU
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & MANUAL AIR CONDITIONERHA
AUTOMATIC AIR CONDITIONERATC
STARTING & CHARGING SYSTEMSSC
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
ALMERA
MODEL N16 SERIES
NISSAN EUROPE S.A.S.
© 2003 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.
QUICK REFERENCE INDEX

NJMA0036
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard tothe conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION
Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
Inspect for interior and exterior metal and paint damage
Check for spare tire, jack, tools (wheel chock), and literature
Wash, clean interior and exterior
: Not applicable to this model
PRE-DELIVERY INSPECTION ITEMS
MA-2

Maintenance Under Severe Driving Conditions=NJMA0005S06The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving condition Maintenance itemMaintenance
operationMaintenance intervalReference
page
A........Aircleaner filter Replace More frequently EM-14
ABCD.....Engine oil & oil filter (Gaso-
line engine)ReplaceEvery 5,000 km (3,000
miles) or 3 monthsLC-8, LC-9
.....F...Brakefluid ReplaceEvery 20,000 km (12,000
miles) or 12 monthsBR-7
..C....H.Automatictransaxlefluid ReplaceEvery 40,000 km (24,000
miles) or 24 monthsAT-13
......GH.Steering gear & linkage, axle
& suspension parts & drive
shaftsCheckEvery 10,000 km (6,000
miles) or 6 monthsST-7, SU-6,
SU-18
A.C...GHIBrake pads, rotors & other
brake componentsCheckEvery 5,000 km (3,000
miles) or 3 monthsBR-27,
BR-31
A.C...GHIBrake linings, drums & other
brake componentsCheckEvery 10,000 km (6,000
miles) or 6 monthsBR-7
......G..Lock,hinges & hood latch LubricateEvery 5,000 km (3,000
miles) or 3 monthsBT-16, BT-7
A........Ventilation air filter Replace More frequentlyHA-95 or
ATC-128
PERIODIC MAINTENANCE (EXCEPT FOR EUROPE)
Maintenance Under Severe Driving Conditions
MA-6

CHASSIS AND BODY MAINTENANCE=NJMA0043S0502Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Refer-
ence
pages Perform on a kilometer basis
only.kmx1,000
(miles x
1,000)10
(6)20
(12)30
(18)40
(24)50
(30)60
(36)70
(42)80
(48)90
(54)100
(60)11 0
(66)120
(72)
Underhood and under vehicle
Headlamp aiming I I I EL-44
Wheel alignment (if necessary,
balance & rotate wheels)IIISU-6
SU-18
Brake pads, rotors & other
brake components★IIIIIIBR-27
BR-28
Foot brake, parking brake &
clutch (for free play, stroke &
operation)IIIIIIBR-12
BR-44
CL-9
Brake booster vacuum hoses,
connections, check valveI I BR-21
Brake & clutch, systems and
fluid (for level and leaks)IIIIIIBR-7
Brake fluid★R R BR-7
Power steering fluid and lines
(for level and leaks)IIIIIIST-7
Supplemental air bag systemsSee NOTE
(1)RS-25
Ventilation air filter★RRRRRRHA-95
or ATC-
128
Manual transaxle gear oil
(check for leakage. Use genu-
ine NISSAN XZ gear oil or
exact equivalent)IIIMT-14
MT-15
Steering gear & linkage, axle &
suspension parts, drive shafts,
exhaust system★IIST-7
SU-6
SU-18
FE-26
NISSAN Mobility SystemSee NOTE
(2)IIIIIII —
Body corrosionSee NOTE
(3)BT-6
NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Check expiration date of the tyre sealant bottle. Replace if necessary.
(3) Inspect once per year.
★Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Con-
ditions”.
PERIODIC MAINTENANCE (FOR EUROPE)
Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) (Cont’d)
MA-16

SMT940D
SMT951D
21. Pick up EGI harness clamp and install engine slinger. Next, set
chain block.
22. Jack up the air compressor engine bracket.
23. Remove engine front mounting.
24. Remove LH side mounting. Refer to EM-67, “Removal and
Installation”.
SMT952D
25. Jack up until engine oil filter bracket bolts are just about to
touch the side frame.
SMT941D
26. Remove bolts securing transaxle.
27. While the transaxle is suspended, withdraw the transaxle case
from the engine without hitting suspension member.
Open the front of the transaxle when the clutch cover
appears. Then, lower the transaxle pulling it toward the
right front.
The spacer between the engine and transaxle should be
left at the engine side.
28. Remove spacer.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REMOVAL AND INSTALLATIONRS5F50A
Removal (Cont’d)
MT-27

Noise, Vibration and Harshness (NVH)
Troubleshooting
=NJAX0004NVH TROUBLESHOOTING CHARTNJAX0004S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page—
AX-15
—
AX-5, 24
—
AX-3, 23
—
—
SU-4
SU-4
SU-4
BR-6
ST-5
Possible cause and
SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
Wheel bearing damage
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomDRIVE SHAFTNoise, Vibration××———— —× ×××××
Shake×—×——— —× ×××××
AXLENoise — — —××—×—×××××
Shake — — —××—×—×××××
Vibration — — —××—×—××——×
Shimmy — — —××—— —×××××
Judder — — —×—— — —×××××
Poor quality ride or
handling———×××——×××——
×: Applicable
—: Not applicable
SMA525A
On-vehicle Service
FRONT AXLE PARTSNJAX0005Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
Shake each front wheel to check for excessive play.
Make sure that cotter pin is inserted.
Retighten all axle and suspension nuts and bolts to the speci-
fied torque.
Tightening torque:
Refer to SU-5, “FRONT SUSPENSION”.
SFA805B
FRONT WHEEL BEARINGNJAX0006Check that wheel bearings operate smoothly.
Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
If out of specification or wheel bearing does not turn smoothly,
replace wheel bearing assembly.
Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, AX-5.
GI
MA
EM
LC
EC
FE
CL
MT
AT
SU
BR
ST
RS
BT
HA
SC
EL
IDX
FRONT AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-3

Noise, Vibration and Harshness (NVH)
Troubleshooting
=NJSU0004NVH TROUBLESHOOTING CHARTNJSU0004S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
SU-5, 17
SU-10, 21
—
—
—
SU-9, 20
SU-7
SU-11
SU-7
—
—
—
—
—
—
AX-3
AX-3
Refer to SUSPENSION
in this chart.
Refer to TIRES
in this chart.
Refer to ROAD WHEEL
in this chart.
BR-6
ST-5
Possible Cause and
SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation,
damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer bar fatigue
Out-of-round
Imbalance
Incorrect air pressure
Uneven tire wear
Deformation or damage
Non-uniformity
Incorrect tire size
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING Symptom
SUSPENSION
Noise× × ××××—————————××—××××
Shake××××—×—————————××—××××
Vibration× × ×××——————————××—×——×
Shimmy××××——×—————————×—××××
Judder×××—————————————×—××××
Poor quality
ride or han-
dling× × ×××—××————————×—××——
TIRES
Noise×— ——————××××××—×× ×—×××
Shake×— ——————×××××—××× ×—×××
Vibration — — ————————×———××× ×———×
Shimmy×— ——————×××××××—××—×××
Judder×— ——————×××××—×—××—×××
Poor quality
ride or han-
dling×— ——————×××××—×—××—×——
ROAD WHEEL
Noise×— ——————××——×——×× × ×—××
Shake×— ——————××——×——×× × ×—××
Shimmy,
Judder×— ——————××——×———×× ×—××
Poor quality
ride or han-
dling×— ——————××——×———×× ×———
×: Applicable
—: Not applicable
FRONT SUSPENSION
Noise, Vibration and Harshness (NVH) Troubleshooting
SU-4

NJBR0005
NVH Troubleshooting ChartNJBR0005S01Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-27, 31
BR-27, 31
BR-27, 31
—
—
BR-29, 35
—
—
—
BR-29, 35
AX-3
SU-4, AX-3
SU-4
SU-4
ST-5
SUSPECTED PARTS
(Possible cause)
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
DRIVE SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
STEERING
Symptom BRAKENoise X X X———————XXXXX
Shake ——— X ——————XXXXX
Shimmy, Jud-
der———XXXXXXX—XXXX
X: Applicable
—: Not Applicable
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
BR-6