Nissan Almera 2001 User Manual

STEERING SYSTEM

CONTENTS

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

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″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 CHECKING

Front Wheel Turning Angle..........................................6

Checking Gear Housing Movement ............................6

Checking and Adjusting Drive Belts ............................7

Checking Steering Gear and Linkage.........................7

STEERING GEAR STEERING LINKAGE

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 .........11

Components...............................................................11

Removal and Installation...........................................11

STEERING WHEEL STEERING COLUMN

Disassembly and Assembly.......................................14

Inspection...................................................................15

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

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

......................................................7

.................................................7

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

...............................................12

SECTION

TILT MECHANISM

POWER STEERING GEAR AND LINKAGE ................16

Components...............................................................16

Removal and Installation...........................................17

Disassembly...............................................................18

Inspection...................................................................19

.....................................................................19

BOOT

.....................................................................19

RACK GEAR SUB-ASSEMBLY GEAR HOUSING CYLINDER TIE-ROD OUTER AND INNER SOCKETS

Assembly ...................................................................20

Adjustment.................................................................23

POWER STEERING OIL PUMP (QG ENGINE) ...........25

Components...............................................................25

Pre-disassembly Inspection.......................................25

Disassembly...............................................................26

Inspection...................................................................27

Assembly ...................................................................27

POWER STEERING OIL PUMP (YD ENGINE)............29

Components...............................................................29

Pre-disassembly Inspection.......................................29

Removal and Installation...........................................30

Disassembly...............................................................30

Inspection...................................................................31

Assembly ...................................................................32

SERVICE DATA AND SPECIFICATIONS (SDS).........33

General Specifications...............................................33

Steering Wheel..........................................................33

Steering Column........................................................33

Steering Gear and Linkage .......................................34

Power Steering..........................................................35

...................................................15

...........................................19

....................................19

..................20

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELTPRE-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 composition 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 steering 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 performed 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. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified by yellow harness connector.

NJST0044

Precautions for Steering System

NJST0003

+ 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-16, “Fluids and Lubricants”.

ST-2

PREPARATION

Special Service Tools

Tool number Tool name

KV48100700 Torque adapter

KV48102500 Pressure gauge adapter

ST27180001 Steering wheel puller

Description

NT169

NT542

Special Service Tools

Measuring pinion rotating torque

Measuring oil pressure

Removing steering wheel

NJST0004

HT72520000 Ball joint remover

KV48103500 Pressure gauge

KV48104400 Rack seal ring reformer

ST3127S000 1 GG91030000 Torque wrench 2 HT62940000 Socket adapter 3 HT62900000 Socket adapter

NT544

Removing ball joint

a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: R11.5 mm (0.453 in)

NT546

Measuring oil pressure

NT547

Reforming teflon ring

a: 50 mm (1.97 in) dia. b: 36 mm (1.42 in) dia. c: 100 mm (3.94 in)

NT550

Measuring turning torque

NT541

ST-3

Commercial Service Tool

PREPARATION

Tool number Description Oil pump attachment

NT774

KV48105210 Sprocket holder

NT809

Commercial Service Tool

Disassembling and assembling oil pump Unit: mm (in)

Removing and Installing power steering oil pump

NJST0005

ST-4

×: Applicable

Judder × × ЧЧЧЧЧ

Symptom STEERING

Vibration ЧЧЧЧЧ ××××

Shimmy ××× × ЧЧЧЧЧ

Noise ЧЧЧЧЧЧЧЧЧ ЧЧЧЧЧЧ

Shake ××× ЧЧЧЧЧЧ

Possible cause and

SUSPECTED PARTS

Reference page

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

ST-5

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

ST-7

ST-8 ST-20 ST-20 ST-20

ST-7

ST-6

ST-8

Refer to EM-16.

—

ST-11

ST-6 ST-15 ST-14 ST-16

AX-3

SU-4 SU-4 SU-4 BR-7

NVH Troubleshooting Chart

NJST0006S01

NJST0006

Checking Steering Wheel Play

ON-VEHICLE SERVICE

SST489B

SST490BA

Checking Steering Wheel Play

NJST0007

+ 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

Checking Neutral Position on Steering Wheel

PRE-CHECKING

NJST0008

NJST0008S01

+ Make 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.

CHECKING

NJST0008S02

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

2. If it isnot in the neutral position, remove the steeringwheel 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 directions on both left and right sides.

SMA127

SST663B

Front Wheel Turning Angle

NJST0009

1. Rotate steering wheel all the way right and left; measure turning 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-34.

Checking Gear Housing Movement

NJST0010

1. Check the movement of steering gear housing during stationary 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.

ST-6

ON-VEHICLE SERVICE

Checking and Adjusting Drive Belts

SMA851B

Checking and Adjusting Drive Belts

NJST0011

Refer to EM-16, “Checking Drive Belts”.

Checking Steering Gear and Linkage

STEERING GEAR

NJST0037

NJST0037S01

+ Check gear housing and boots for looseness, damage or

grease leakage.

+ Check connection with steering column for looseness.

STEERING LINKAGE

NJST0037S02

+ Check ball joint, dust cover and other component parts for

looseness, wear, damage or grease leakage.

Checking Fluid Level

NJST0012

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-16, “Fluids and Lubricants”.

YST003

YST006

YST007

Checking Fluid Leakage

NJST0013

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-25.

6. Check rack boots for accumulation of power steering fluid.

ST-7

Bleeding Hydraulic System

ON-VEHICLE SERVICE

SST491B

SST090B

Bleeding Hydraulic System

NJST0014

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 steering wheel fully to right and left and lightly touch steering stoppers. 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.

Checking Steering Wheel Turning Force

NJST0015

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

2. Start engine.

3. Bring power steering fluid up to adequate operating temperature. [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 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:

Sedan

152 - 240 N (15.5 - 24.5 kg, 34 - 54 lb)

Hatchback

132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)

Maximum force deviation:

Sedan

98 N (10 kg, 22 lb)

Hatchback

176 N (17.9 kg, 39 lb)

d. Check sliding force outside the above range at rack speed of

40 mm (1.75 in)/s.

ST-8

ON-VEHICLE SERVICE

Checking Steering Wheel Turning Force (Cont’d)

Rack sliding force (Sedan only):

Not more than 294 N (30 kg, 66 lb)

Maximum force deviation:

147 N (15 kg, 33 lb)

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

7. If rack sliding force is OK, inspect steering column. Refer to ST-14.

SST834-I

Checking Hydraulic System

NJST0016

Before starting, check belt tension, driving pulley and tire pressure.

1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleeding 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 abnormally.

3. Check pressure with steering wheel fully turned to leftand 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 engine (Sedan)

7,600 - 8,200 kPa (76.0 - 82.0 bar, 77.5 - 83.6

kg/cm

, 1,102 - 1,189 psi)

QG 18 engine (Sedan)

8,600 - 9,200 kPa (86.0 - 92.0 bar, 87.7 - 93.8

kg/cm

, 1,247 - 1,334 psi)

QG15, 18 engine (Hatchback)

8,600 - 9,200 kPa (86.0 - 92.0 bar, 88.7 - 93.8

kg/cm

, 1,247 - 1,334 psi)

YD22 engine

8,800 - 9,400 kPa (88.0 - 94.0 bar, 88.7 - 95.8

kg/cm

, 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-17.

+ 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

ST-9

Checking Hydraulic System (Cont’d)

ON-VEHICLE SERVICE

necessary. Then completely bleed air out of system. Refer to ST-8.

ST-10

STEERING WHEEL AND STEERING COLUMN

Components

NJST0017

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

10. Lower cover

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

STEERING WHEEL

+ Remove air bag module and spiral cable.

Refer to RS-29, “Removal — Air Bag Module and Spiral Cable”.

JST875C

NJST0018

NJST0018S01

SBF812E

ST-11

+ 25 hidden pages