Almera Tino V10 (2003 year). Manual — part 238
MEL145L
Removal and Installation
NLSC0013
REMOVAL (QG ENGINE)
NLSC0013S01
1.
Loosen drive belt idler pulley.
2.
Remove drive belt idler pulley (include tightening screw).
3.
Remove alternator harness.
4.
Remove alternator upper bolt and lower bolt.
5.
Remove alternator.
NEL645
REMOVAL (YD ENGINE)
NLSC0013S03
1.
Remove alternator harness.
2.
Loosen alternator upper nut and lower bolt.
3.
Loosen drive belt.
4.
Remove alternator bracket bolts (two).
5.
Remove alternator upper nut and lower bolt.
6.
Remove alternator.
INSTALLATION
NLSC0013S02
To install, reverse the removal procedure.
SEL032Z
Disassembly
NLSC0021
REAR COVER
NLSC0021S01
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
REAR BEARING
NLSC0021S02
CAUTION:
I
Do not reuse rear bearing after removal. Replace with a
new one.
I
Do not lubricate rear bearing outer race.
CHARGING SYSTEM
Removal and Installation
SC-28
SEL033Z
Inspection
NLSC0022
ROTOR CHECK
NLSC0022S01
1.
Resistance test
Resistance: Refer to SDS (SC-31).
I
Not within the specified values ... Replace rotor.
2.
Insulator test
I
Continuity exists ... Replace rotor.
3.
Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SDS (SC-31).
I
Not within the specified values ... Replace rotor.
SEL034Z
BRUSH CHECK
NLSC0022S02
1.
Check smooth movement of brush.
I
Not smooth ... Check brush holder and clean.
2.
Check brush for wear.
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Replace brush if it is worn down to the limit line.
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CHARGING SYSTEM
Inspection
SC-29
SEL037Z
STATOR CHECK
NLSC0022S03
1.
Continuity test
I
No continuity ... Replace stator.
2.
Ground test
I
Continuity exists ... Replace stator.
SEL044Z
Assembly
NLSC0023
RING FITTING IN REAR BEARING
NLSC0023S01
I
Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
SEL048Z
SEL049Z
REAR COVER INSTALLATION
NLSC0023S02
1.
Fit brush assembly, diode assembly, regulator assembly and
stator.
2.
Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
CHARGING SYSTEM
Inspection (Cont’d)
SC-30
Battery
NLSC0014
Applied model
QG engine
YD22 engine
Type
YUASA type code
YUASA type code
025
027
065
075
079
067
096
Capacity V-AH
12-52
12-55
12-50
12-42
12-60
12-64
Starter
NLSC0015
Type
D7E31
S114-800B
M8T75371
M008T71471
VALEO make
HITACHI make
MITSUBISHI make
Non-reduction
Reduction
Reduction
Applied model
QG engine
YD22 engine
System voltage V
12
No-load
Terminal voltage V
11.0
11.0
11.0
11.0
Current A
45
Less than 90
Less than 145
Less than 145
Revolution rpm
12,000
More than 2,700
More than 3,400
More than 3,300
Minimum diameter of commutator mm (in)
28.2 (1.110)
28.0 (1.102)
31.4 (1.236)
Minimum length of brush mm (in)
6.15 (0.242)
10.5 (0.413)
11.0 (0.433)
Brush spring tension N (kg, lb)
16.2 - 19.8
(1.65 - 2.02,
3.64 - 4.45)
12.7 - 17.7
(1.3 - 1.8,
2.9 - 4.0)
26.5 - 36.1
(2.7 - 3.7,
6.0 - 8.2)
Clearance between bearing metal and arma-
ture shaft mm (in)
0.05 (0.002)
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)
—
—
Movement “
” in height of pinion assembly
mm (in)
Max. 12.2 (0.480)
—
0.5 - 2.0
(0.020 - 0.079)
Max. 13 (0.512)
Alternator
NLSC0016
Type
LR180-762
LR1100-724
HITACHI make
Applied model
QG engine
YD engine
Nominal rating V-A
12-80
12-100
Ground polarity
Negative
Minimum revolutions under no-load (When 13.5V is applied) rpm
Less than 1,000
Hot output current (When 13.5V is applied) A/rpm
More than 23/1,300
More than 65/2,500
More than 87/5,000
More than 34/1,300
More than 83/2,500
More than 91/5,000
Regulated output voltage V
14.1 - 14.7
Minimum length of brush mm (in)
6.0 (0.236)
Brush spring pressure N (g, oz)
1.0 - 3.43 (102 - 350, 3.60 - 12.34)
Slip ring minimum diameter mm (in)
6.0 (1.024)
Rotor coil resistance at 20°C (68°F)
Ω
2.67
2.31
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SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
SC-31
NOTES
STEERING SYSTEM
CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . ...2
Supplemental Restraint System (SRS)
. . . ...2
Precautions for Steering System. . . . . . . . .2
PREPARATION . . . . . . . . . . . . . . . ...3
Special Service Tools . . . . . . . . . . . . ..3
Commercial Service Tool. . . . . . . . . . . .4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . . .5
NVH Troubleshooting Chart. . . . . . . . . . .5
ON-VEHICLE SERVICE . . . . . . . . . . . . ..6
Checking Steering Wheel Play. . . . . . . . . 6
Checking Neutral Position on Steering Wheel . . . 6
. . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . ...6
Front Wheel Turning Angle. . . . . . . . . . ..6
Checking Gear Housing Movement . . . . . . . 6
Checking and Adjusting Drive Belts . . . . . . . 7
Checking Steering Gear and Linkage . . . . . . .7
. . . . . . . . . . . . . ..7
. . . . . . . . . . . . .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. . . . . . . . . . . . . . . ...10
Removal and Installation . . . . . . . . . . ...10
. . . . . . . . . . . . .10
. . . . . . . . . . . ... 11
Disassembly and Assembly. . . . . . . . . ...13
Inspection. . . . . . . . . . . . . . . . ...14
. . . . . . . . . . . . ...14
POWER STEERING GEAR AND LINKAGE . . . . 15
Components. . . . . . . . . . . . . . . ...15
Removal and Installation . . . . . . . . . . ...16
Inspection. . . . . . . . . . . . . . . . ...17
. . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . .18
TIE-ROD OUTER AND INNER SOCKETS
. . . . ..18
Assembly . . . . . . . . . . . . . . . . ...18
Adjustment . . . . . . . . . . . . . . . . .20
POWER STEERING OIL PUMP (QG ENGINE) . . ...21
Components. . . . . . . . . . . . . . . ...21
Inspection. . . . . . . . . . . . . . . . ...21
POWER STEERING OIL PUMP (YD ENGINE) . . . 22
Components. . . . . . . . . . . . . . . ...22
Pre-disassembly Inspection. . . . . . . . . ...22
Removal and Installation . . . . . . . . . . ...23
Disassembly. . . . . . . . . . . . . . . ...23
Inspection. . . . . . . . . . . . . . . . ...24
Assembly . . . . . . . . . . . . . . . . ...25
SERVICE DATA AND SPECIFICATIONS (SDS) . . .26
General Specifications. . . . . . . . . . . ...26
Steering Wheel . . . . . . . . . . . . . . ..26
Steering Column . . . . . . . . . . . . . . 26
Steering Gear and Linkage . . . . . . . . . ...27
Power Steering . . . . . . . . . . . . . . ..27
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Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
NLST0001
The 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 V10 is as follows (The compo-
sition varies according to the destination and optional equipment.):
I
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.
I
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 the RS section of this Service Manual.
WARNING:
I
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.
I
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
I
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Steering System
NLST0003
I
Before disassembly, thoroughly clean the outside of the unit.
I
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.
I
Place disassembled parts in order, on a parts rack, for easier and proper assembly.
I
Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
I
Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
I
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.
I
Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRON
TM
III or equivalent. Refer to MA-20, “Fluids and Lubricants”.
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
ST-2
Special Service Tools
NLST0004
Tool number
Tool name
Description
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
ST3127S000
1 GG91030000
Torque wrench
2 HT62940000
Socket adapter
3 HT62900000
Socket adapter
NT541
Measuring turning torque
KV48105210
Sprocket holder
NT809
Removing and Installing power steering oil pump
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PREPARATION
Special Service Tools
ST-3
Commercial Service Tool
NLST0005
Tool name
Description
Oil pump attachment
NT774
Disassembling and assembling oil pump
Unit: mm (in)
PREPARATION
Commercial Service Tool
ST-4
NLST0006
NVH
T
roubleshooting
Chart
NLST0006S01
Use
the
chart
below
to
help
you
find
the
cause
of
the
symptom.
If
necessary
,
repair
or
replace
these
parts.
Reference
page
Refer to EM-13, EM-117.
—
Possible
cause
and
SUSPECTED
P
A
R
T
S
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
STEERING
Noise
×××××××××
××××××
Shake
×××
××××××
V
ibration
×××××
××××
Shimmy
×××
×
×××××
Judder
×
×
×××××
×
:
Applicable
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NOISE,
V
IBRATION
AND
HARSHNESS
(NVH)
T
ROUBLESHOOTING
NVH
T
roubleshooting
Chart
ST-5
SST489B
Checking Steering Wheel Play
NLST0007
I
With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
I
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 Wheel
NLST0008
PRE-CHECKING
NLST0008S01
I
Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SU-15, SDS.
I
Verify that the steering gear is centered before removing the
steering wheel.
CHECKING
NLST0008S02
1.
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 Angle
NLST0009
1.
Rotate steering wheel all the way right and left; measure turn-
ing angle.
Turning angle of full turns:
Refer to SU-15, SDS.
2.
If it is not within specification, check rack stroke.
Rack stroke “S”:
Refer to SDS, ST-27.
SST663B
Checking Gear Housing Movement
NLST0010
1.
Check the movement of steering gear housing during station-
ary steering on a dry paved surface.
I
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:
±
2 mm (
±
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 Belts
NLST0011
Refer to EM-13, EM-117, “Checking Drive Belts”.
SMA851B
Checking Steering Gear and Linkage
NLST0037
STEERING GEAR
NLST0037S01
I
Check gear housing and boots for looseness, damage or
grease leakage.
I
Check connection with steering column for looseness.
STEERING LINKAGE
NLST0037S02
I
Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.
YST003
Checking Fluid Level
NLST0012
Check 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:
I
Do not overfill.
I
Recommended fluid is DEXRON
TM
III or equivalent. Refer
to MA-20, “Fluids and Lubricants”.
YST028
YST005
Checking Fluid Leakage
NLST0013
Check 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-21.
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 System
NLST0014
1.
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.
I
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 Force
NLST0015
1.
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:
26 - 32 N (2.7 - 3.3 kg, 5.8 - 7.2 lb)
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 mm
(
±
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:
197 - 255 N (20.1 - 26.0 kg, 44.3 - 57.3 lb)
6.
If rack sliding force is not within specification, replace steering
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 System
NLST0016
Before 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:
QG engine
8,100 - 8,700 kPa (81 - 87 bar, 82.6 - 88.7 kg/cm
2
,
1,175 - 1,262 psi)
YD engine
8,520 - 9,320 kPa (85.2 - 93.2 bar, 86.9 - 95.1
kg/cm
2
, 1,235 - 1,351 psi)
I
If pressure reaches maximum operating pressure, system is
OK.
I
If pressure increases above maximum operating pressure,
check power steering pump flow control valve. Refer to ST-21.
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.
I
If pressure increases to maximum operating pressure, gear is
damaged. Refer to “Removal and Installation”, ST-16.
I
If pressure remains below maximum operating pressure, pump
is damaged. Refer to “Disassembly”, ST-23.
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
Components
NLST0017
YST029
1.
Air bag module
2.
Steering wheel
3.
Spiral cable
4.
Column cover
5.
Combination switch
6.
Steering column assembly
7.
Clip
8.
Hole cover
9.
Lower joint
CAUTION:
I
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.
I
Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.
Removal and Installation
NLST0018
STEERING WHEEL
NLST0018S01
I
Remove remote audio control (if applied)
I
Remove air bag module and spiral cable.
Refer to RS-24, “Removal — Air Bag Module and Spiral Cable”.
STEERING WHEEL AND STEERING COLUMN
Components
ST-10
YST030
I
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 2.5 revolutions
from the right end position. Align the two marks (
).
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 2.5 turns from
the neutral position to both the right and left.)
SST777C
I
Remove steering wheel with Tool.
YST031
STEERING COLUMN
NLST0018S02
I
Remove key interlock cable (A/T models).
SST800A
I
When installing steering column, fingertighten all lower bracket
and clamp retaining bolts; then tighten them securely. Do not
apply undue stress to steering column.
I
When attaching coupling joint, be sure tightening bolt faces
cutout portion.
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STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
ST-11
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