Almera Tino V10 (2003 year). Manual

MEL145L

Removal and Installation

NLSC0013

REMOVAL (QG ENGINE)

NLSC0013S01

Loosen drive belt idler pulley.

Remove drive belt idler pulley (include tightening screw).

Remove alternator harness.

Remove alternator upper bolt and lower bolt.

Remove alternator.

NEL645

REMOVAL (YD ENGINE)

NLSC0013S03

Remove alternator harness.

Loosen alternator upper nut and lower bolt.

Loosen drive belt.

Remove alternator bracket bolts (two).

Remove alternator upper nut and lower bolt.

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:

Do not reuse rear bearing after removal. Replace with a
new one.

Do not lubricate rear bearing outer race.

CHARGING SYSTEM

Removal and Installation

SC-28

SEL033Z

Inspection

NLSC0022

ROTOR CHECK

NLSC0022S01

Resistance test

Resistance: Refer to SDS (SC-31).

Not within the specified values ... Replace rotor.

Insulator test

Continuity exists ... Replace rotor.

Check slip ring for wear.

Slip ring minimum outer diameter:

Refer to SDS (SC-31).

Not within the specified values ... Replace rotor.

SEL034Z

BRUSH CHECK

NLSC0022S02

Check smooth movement of brush.

Not smooth ... Check brush holder and clean.

Check brush for wear.

Replace brush if it is worn down to the limit line.

IDX

CHARGING SYSTEM

Inspection

SC-29

SEL037Z

STATOR CHECK

NLSC0022S03

Continuity test

No continuity ... Replace stator.

Ground test

Continuity exists ... Replace stator.

SEL044Z

Assembly

NLSC0023

RING FITTING IN REAR BEARING

NLSC0023S01

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

Fit brush assembly, diode assembly, regulator assembly and
stator.

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

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

Applied model

QG engine

YD22 engine

System voltage V

No-load

Terminal voltage V

11.0

Current A

Less than 90

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

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

Battery

SC-31

STEERING SYSTEM

SECTION

CONTENTS

PRECAUTIONS ...............................................................2

Supplemental Restraint System (SRS)

SEAT BELT PRE-TENSIONER

″

...............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

PRE-CHECKING

........................................................6

CHECKING

...............................................................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

......................................................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...............................................................10
Removal and Installation ...........................................10

STEERING WHEEL

.................................................10

STEERING COLUMN

............................................... 11

Disassembly and Assembly.......................................13
Inspection...................................................................14

TILT MECHANISM

...................................................14

POWER STEERING GEAR AND LINKAGE ................15

Components...............................................................15
Removal and Installation ...........................................16
Inspection...................................................................17

STEERING GEAR

....................................................18

BOOT

.....................................................................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

IDX

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.):

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 the RS section of 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 removal of Spiral Cable and Air
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. 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

Before 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 general purpose, 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 and gaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRON

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

IDX

PREPARATION

Special Service Tools

ST-3

NLST0006

NVH

roubleshooting

Chart

NLST0006S01

Use

the

chart

below

to
help

you

find

the

cause

of
the

symptom.

necessary

repair

or
replace

these

parts.

Reference

page

Refer to EM-13, EM-117.

—

Possible

cause

and

SUSPECTED

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

×××

××××××

ibration

×××××

××××

Shimmy

×××

×××××

Judder

×××××

Applicable

IDX

NOISE,

IBRATION

AND

HARSHNESS

(NVH)

ROUBLESHOOTING

NVH

roubleshooting

Chart

ST-5

SST489B

Checking Steering Wheel Play

NLST0007

With 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 Wheel

NLST0008

PRE-CHECKING

NLST0008S01

Make sure that wheel alignment is correct.

Wheel alignment:

Refer to SU-15, SDS.

Verify that the steering gear is centered before removing the
steering wheel.

CHECKING

NLST0008S02

Check that the steering wheel is in the neutral position when
driving straight ahead.

If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.

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

Rotate steering wheel all the way right and left; measure turn-
ing angle.

Turning angle of full turns:

Refer to SU-15, SDS.

If it is not within specification, check rack stroke.

Rack stroke “S”:

Refer to SDS, ST-27.

SST663B

Checking Gear Housing Movement

NLST0010

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:

2 mm (

0.08 in) or less

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

Check gear housing and boots for looseness, damage or
grease leakage.

Check connection with steering column for looseness.

STEERING LINKAGE

NLST0037S02

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:

Do not overfill.

Recommended fluid is DEXRON

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.

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.

Check rack boots for accumulation of power steering fluid.

IDX

ON-VEHICLE SERVICE

Checking and Adjusting Drive Belts

ST-7

Bleeding Hydraulic System

NLST0014

Raise front end of vehicle until wheels are clear of the ground.

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.

Start engine.
Repeat step 2. above.

Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.

Air bubbles in reservoir tank

Clicking noise in oil pump

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

Park vehicle on a level, dry surface and set parking brake.

Start engine.

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)

If steering wheel turning force is out of specification, check
rack sliding force.

Disconnect steering column lower joint and knuckle arms from
the gear.

Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.

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)

If rack sliding force is not within specification, replace steering
gear assembly.

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.

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

1,175 - 1,262 psi)

YD engine

8,520 - 9,320 kPa (85.2 - 93.2 bar, 86.9 - 95.1
kg/cm

, 1,235 - 1,351 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-21.

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-23.

After checking hydraulic system, remove Tool and add fluid as
necessary. Then completely bleed air out of system. Refer to
ST-8.

IDX

ON-VEHICLE SERVICE

Checking Hydraulic System

ST-9

Components

NLST0017

YST029

Air bag module

Steering wheel

Spiral cable

Column cover

Combination switch

Steering column assembly

Clip

Hole cover

Lower joint

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.

Removal and Installation

NLST0018

STEERING WHEEL

NLST0018S01

Remove remote audio control (if applied)

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

Align spiral cable correctly when installing steering wheel.

Set the front wheels in the straight-ahead position.

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

Remove steering wheel with Tool.

YST031

STEERING COLUMN

NLST0018S02

Remove key interlock cable (A/T models).

SST800A

When installing steering column, fingertighten all lower bracket
and clamp retaining bolts; then tighten them securely. Do not
apply undue stress to steering column.

When attaching coupling joint, be sure tightening bolt faces
cutout portion.

IDX

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

ST-11

Almera Tino V10 (2003 year). Manual - part 238