2003 NISSAN ALMERA N16 brakes

Symptom Check items
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp
Service Data and Specifications (SDS)
THERMOSTATNJLC0029
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F)More than 8/95 (0.31/203)
RADIATORNJLC0030Unit: kPa (bar, kg/cm2, psi)
Cap reliefpressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure157 (1.57, 1.6, 23)
COOLANT CAPACITYNJLC0038Unit:(Imp qt)
M/T*6.7 (5-7/8)
A/T*Sedan 6.6 (5-7/8)
Hatchback 6.7 (5-7/8)
Reservoir tank0.7 (5/8)
*: With reservoir tank
ENGINE COOLING SYSTEMQG
Overheating Cause Analysis (Cont’d)
LC-24

Symptom Check items
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under
no load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp
Service Data and Specifications (SDS)
THERMOSTATNJLC0071
Valve opening temperature Above 80.5 - 83.5°C (177 - 182°F)
Valve liftMore than 9.0 mm/95°C (0.354 in/203°F)
RADIATORNJLC0073Unit: kPa (bar, kg/cm2, psi)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure157 (1.57, 1.6, 23)
ENGINE COOLANT CAPACITYNJLC0080Unit:(Imp qt)
With reservoir tank8.7 (7-5/8)
Reservoir tank0.7 (5/8)
GI
MA
EM
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ENGINE COOLING SYSTEMYD
Overheating Cause Analysis (Cont’d)
LC-47

AT-4
REMOVAL AND INSTALLATION ...........................410
Removal ...............................................................410
Installation .............................................................411
OVERHAUL .............................................................413
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................413
Oil Channel ...........................................................416
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................417
DISASSEMBLY .......................................................418
Disassembly .........................................................418
REPAIR FOR COMPONENT PARTS ......................432
Manual Shaft ........................................................432
Oil Pump ...............................................................435
Control Valve Assembly ........................................439
Control Valve Upper Body ....................................449
Control Valve Lower Body ....................................453
Reverse Clutch .....................................................455
High Clutch ...........................................................459
Forward and Overrun Clutches ............................464
Low & Reverse Brake ...........................................470
Rear Internal Gear, Forward Clutch Hub and Over-
run Clutch Hub ......................................................474
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................478
Band Servo Piston Assembly ...............................483
Final Drive ............................................................488
ASSEMBLY .............................................................493
Assembly (1) .........................................................493Adjustment (1) .......................................................494
Assembly (2) .........................................................500
Adjustment (2) .......................................................504
Assembly (3) .........................................................508
SERVICE DATA AND SPECIFICATIONS (SDS) ....515
General Specifications ......................................... .515
Shift Schedule .......................................................515
Stall Revolution .....................................................515
Line Pressure ........................................................515
Control Valves .......................................................516
Clutch and Brakes .................................................516
Clutch and Brake Return Springs .........................518
Oil Pump ......................................................
.........518
Input Shaft .............................................................518
Planetary carrier ....................................................518
Final Drive .............................................................519
Reduction Pinion Gear ..........................................520
Output Shaft ..........................................................522
Bearing Retainer ...................................................523
Total End Play .......................................................523
Reverse Clutch End Play ......................................523
Accumulator ..........................................................523
Band Servo ...........................................................524
Removal and Installation .......................................524
Shift Solenoid Valves ............................................524
Solenoid Valves ....................................................524
A/T Fluid Temperature Sensor ..............................524
Revolution Sensor .................................................524
Dropping Resistor .................................................524

AT-58
[EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
Diagnostic Worksheet
1.❏ Read the Fail-safe and listen to customer complaints.AT-57, "Infor-
mation from
Customer"
2.❏ CHECK A/T FLUIDAT-63, "A/T
Fluid Check"❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.❏ Perform STALL TEST and LINE PRESSURE TEST.AT-64, "
Stall
Te s t",AT- 6 7 ,
"Line Pres-
sure Test"
❏ Stall test — Mark possible damaged components/others.
❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK
❏ Line Pressure test — Suspected parts:
4.❏ Perform all ROAD TEST and mark required procedures.AT-68, "
Road
Te s t"
4-
1.Check before engine is started.AT-70, "1.
CHECK
BEFORE
ENGINE IS
STARTED"
❏ SELF-DIAGNOSTIC PROCEDURE/DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCE-
DURE. — Mark detected items.
❏ PNP switch, AT- 111
.
❏ A/T fluid temperature sensor, AT- 11 7
.
❏ Vehicle speed sensor·A/T (Revolution sensor), AT-123
.
❏ Engine speed signal, AT-129
.
❏ Torque converter clutch solenoid valve, AT- 1 5 9
.
❏ Line pressure solenoid valve, AT-164
.
❏ Shift solenoid valve A, AT-171
.
❏ Shift solenoid valve B, AT-176
.
❏ Accelerator pedal position (APP) sensor, AT-181
.
❏ Overrun clutch solenoid valve, AT-187
.
❏ PNP & overdrive control switches, and throttle position sensor, AT- 2 3 7
.
❏ Batt/fluid temp sen (A/T fluid temperature sensor and TCM power source), AT-195
.
❏ Vehicle speed sensor·MTR, AT- 2 0 1
.
❏ CAN communication line, AT-192
.
❏ Control unit (RAM), control unit (ROM), AT- 2 0 5
.
❏ Control unit (EEP ROM), AT- 2 0 7
.
❏ Battery
❏ Others
4-
2.Check at idleAT-71, "
2.
CHECK AT
IDLE"❏ 1. O/D OFF Indicator Lamp Does Not Come On, AT- 2 11 .
❏ 2. Engine Cannot Be Started In “P” And “N” Position, AT- 2 1 2
.
❏ 3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed, AT- 2 1 3
.
❏ 4. In “N” Position, Vehicle Moves, AT- 2 1 4
.
❏ 5. Large Shock. “N” → “R” Position, AT-215
.
❏ 6. Vehicle Does Not Creep Backward In “R” Position, AT- 2 1 6
.
❏ 7. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT-219
.

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
AT-89
[EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
Clutches or brakes slip somewhat in
starting.ON vehicle1. Fluid levelAT-63, "
FLUID LEVEL
CHECK"
2. Control cable adjustmentAT-408, "Control Cable
Adjustment"
3. Throttle position sensor [Accelerator
pedal position (APP) sensor]AT-181, "
DTC P1705
ACCELERATOR PEDAL
POSITION (APP) SEN-
SOR"
4. Line pressure testAT-67, "Line Pressure Test"
5. Line pressure solenoid valveAT-164, "
DTC P0745 LINE
PRESSURE SOLENOID
VA LV E"
6. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
7. Accumulator N-DAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle8. Forward clutchAT-464, "
Forward and
Overrun Clutches"
9. Reverse clutchAT-455, "Reverse Clutch"
10. Low & reverse brakeAT-470, "Low & Reverse
Brake"
11. Oil pumpAT-435, "Oil Pump"
12. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Excessive creep. ON vehicle 1. Engine idling rpmEC-30, "Idle Speed and
Ignition Timing Check"
No creep at all.
AT-216, "
6. Vehicle Does Not Creep
Backward In “R” Position" and AT-
219, "7. Vehicle Does Not Creep
Forward In “D”,“2” Or “1” Position"
ON vehicle1. Fluid levelAT-63, "
FLUID LEVEL
CHECK"
2. Line pressure testAT-67, "LINE PRESSURE
TEST PROCEDURE"
3. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle4. Forward clutchAT-464, "
Forward and
Overrun Clutches"
5. Oil pumpAT-435, "Oil Pump"
6. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Symptom Condition Diagnostic ItemReference Page
EURO-OBD

TROUBLE DIAGNOSIS — INTRODUCTION
AT-257
[EXC.F/EURO-OBD]
D
E
F
G
H
I
J
K
L
MA
B
AT
Diagnostic Worksheet
1.❏ Read the Fail-safe and listen to customer complaints.AT- 2 5 6 ,
"Information
from Cus-
tomer"
2.❏ CHECK A/T FLUIDAT- 2 6 1 , "A/T
Fluid Check"❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.❏ Perform STALL TEST and LINE PRESSURE TEST.AT- 2 6 2 , "
Sta l l
Te s t",
AT- 2 6 5 , "
Line
Pressure
Te s t"
❏ Stall test — Mark possible damaged components/others.
❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK
❏ Line Pressure test — Suspected parts:
4.❏ Perform all ROAD TEST and mark required procedures.AT- 2 6 6 ,
"Road Test"
4-
1.Check before engine is started.AT- 2 6 8 , "1.
CHECK
BEFORE
ENGINE IS
STARTED"
❏ SELF-DIAGNOSTIC CONFIRMATION PROCEDURE — Mark detected items.
❏ Vehicle speed sensor·A/T (Revolution sensor), AT- 3 4 3
.
❏ Vehicle speed sensor·MTR, AT-348
.
❏ Accelerator pedal position (APP) sensor, AT-352
.
❏ Shift solenoid valve A, AT- 3 5 7
.
❏ Shift solenoid valve B, AT- 3 6 2
.
❏ Overrun clutch solenoid valve, AT- 3 6 7
.
❏ Torque converter clutch solenoid valve, AT-372
.
❏ A/T fluid temperature sensor and TCM power source, AT-377
.
❏ Engine speed signal, AT- 3 8 3
.
❏ Line pressure solenoid valve, AT-388
.
❏ CAN communication line, AT- 3 9 5
.
❏ Control unit (RAM), control unit (ROM), AT-205
.
❏ Control unit (EEP ROM), AT-207
.
❏ PNP & overdrive control switches, and throttle position sensor, AT- 3 3 3
.
❏ Battery
❏ Others
4-
2.Check at idleAT- 2 6 9 , "
2.
CHECK AT
IDLE"❏ 1. O/D OFF Indicator Lamp Does Not Come On, AT- 3 0 9 .
❏ 2. Engine Cannot Be Started In “P” And “N” Position, AT-309
.
❏ 3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed, AT-310
.
❏ 4. In “N” Position, Vehicle Moves, AT- 3 11
.
❏ 5. Large Shock. “N” → “R” Position, AT- 3 1 2
.
❏ 6. Vehicle Does Not Creep Backward In “R” Position, AT-313
.
❏ 7. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT- 3 1 6
.

AT-286
[EXC.F/EURO-OBD]
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Clutches or brakes slip somewhat in
starting.ON vehicle1. Fluid levelAT-261, "
FLUID LEVEL
CHECK"
2. Control cable adjustmentAT-408, "Control Cable
Adjustment"
3. Throttle position sensor (Accelerator
pedal position (APP) sensor)AT-352, "ACCELE
RATOR PEDAL POSI-
TION (APP) SENSOR"
4. Line pressure testAT-265, "Line Pressure
Te s t"
5. Line pressure solenoid valveAT-388, "
LINE PRES-
SURE SOLENOID
VA LV E"
6. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
7. Accumulator N-DAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle8. Forward clutchAT-464, "
Forward and
Overrun Clutches"
9. Reverse clutchAT-455, "Reverse Clutch"
10. Low & reverse brakeAT-470, "Low & Reverse
Brake"
11. Oil pumpAT-435, "Oil Pump"
12. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Excessive creep. ON vehicle 1. Engine idling rpmEC-722, "Idle Speed and
Ignition Timing"
No creep at all.
AT- 3 1 3 , "
6. Vehicle Does Not Creep
Backward In “R” Position" and AT-
316, "7. Vehicle Does Not Creep For-
ward In “D”,“2” Or “1” Position"
ON vehicle1. Fluid levelAT-261, "
FLUID LEVEL
CHECK"
2. Line pressure testAT-265, "Line Pressure
Te s t"
3. Control valve assemblyAT-406, "
Control Valve
Assembly and Accumula-
tors"
OFF vehicle4. Forward clutchAT-464, "
Forward and
Overrun Clutches"
5. Oil pumpAT-435, "Oil Pump"
6. Torque converterAT-417, "
Locations of
Adjusting Shims, Needle
Bearings, Thrust Washers
and Snap Rings"
Symptom Condition Diagnostic Item Reference Page

AT-516
[ALL]
SERVICE DATA AND SPECIFICATIONS (SDS)
Control Valves
ECS007TW
CONTROL VALVE AND PLUG RETURN SPRINGS
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Clutch and BrakesECS007TX
REVERSE CLUTCH
*: Always check with the Parts Department for the latest parts information.
HIGH CLUTCH
No. Parts Part No.* Free length Outer diameter
Upper body
Refer to “Control
Valve Upper
Body”, AT- 4 4 9
.35 3-2 timing valve spring 31736-01X00 23.0 (0.906) 6.65 (0.2618)
19 Cooler check valve spring 31742-3AX05 28.04 (1.1039) 7.15 (0.2815)
23 Pilot valve spring 31742-3AX03 38.98 (1.5346) 8.9 (0.350)
15 1-2 accumulator valve spring 31742-3AX00 20.5 (0.807) 6.95 (0.2736)
28 1-2 accumulator piston spring 31742-3AX09 55.66 (2.1913) 19.5 (0.7677)
33 1st reducing valve spring 31742-80X05 27.0 (1.063) 7.0 (0.276)
2 Overrun clutch reducing valve spring 31742-80X06 37.5 (1.476) 7.0 (0.276)
7 Torque converter relief valve spring 31742-3AX04 33.3 (1.3110) 9.0 (0.354)
10Torque converter clutch control valve
spring31742-3AX02 53.01 (2.0870) 6.5 (0.256)
Lower body
Refer to “Control
Valve Lower
Body”, AT- 4 5 3
.34 Shuttle valve spring 31762-41X04 51.0 (2.0079) 5.65 (0.2224)
18 Pressure regulator valve spring 31742-80X13 45.0 (1.772) 15.0 (0.591)
23 Overrun clutch control valve spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
27 Accumulator control valve spring 31742-80X02 22.0 (0.866) 6.5 (0.256)
29 Shift valve A spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
2 Shift valve B spring 31762-80X00 21.7 (0.854) 7.0 (0.276)
11
Pressure modifier valve spring31742-41X15 30.5 (1.201) 9.8 (0.386)
7 31742-80X16 32.0 (1.260) 6.9 (0.272)
— Fluid cooler relief valve spring 31872-31X00 17.02 (0.670) 8.0 (0.315)
— T/C pressure spring 31742-3AX07 9.0 (0.354) 7.3 (0.287)
Number of drive plates2
Number of driven plates2
Drive plate thickness mm (in)Standard 2.0 (0.079)
Allowable limit 1.8 (0.071)
Clearance mm (in)Standard 0.5 - 0.8 (0.020 - 0.031)
Allowable limit 1.2 (0.047)
Thickness of retaining platesThickness mm (in) Part number*
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)31537-31X00
31537-31X01
31537-31X02
31537-31X03
31537-31X04
Number of drive plates3
Number of driven plates5
Drive plate
thickness mm (in)Standard 1.6 (0.063)
Allowable limit 1.5 (0.059)
Clearance mm (in)Standard 1.4 - 1.8 (0.055 - 0.071)
Allowable limit 2.4 (0.094)