NISSAN ALMERA N16 2003 Electronic Repair Manual

REFRIGERANT LINES
ATC-141
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Break-In Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
Low-pressure Flexible HoseEJS0020M
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Remove the clip from the low-pressure flexible hose.
3. Remove the mounting bolts from the low-pressure flexible hose.
4. Remove the low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●When pouring refrigerant, check for leaks.
High-pressure Flexible HoseEJS0022Z
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Remove the clip from high-pressure flexible hose.
3. Remove the mounting bolt and nut from the high-pressure flexi-
ble hose, then remove it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
RJIA1731E
RJIA0185E
Low-pressure flexible hose and bolts mounting the high-pressure pipe (evapo-
rator side)
Tightening torque :2.9 - 5.9 N·m (0.29 - 0.6 kg·m, 26 - 52 in-lb)
Nut (Bolt) mounting the low-pressure flexible hose (compressor side)
Tightening torque :7.8 - 19.6 N·m (0.8 - 2.0 kg·m, 70 - 173 in-lb)
RJIA1735E

ATC-142
REFRIGERANT LINES
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●When pouring refrigerant, check for leaks.
High-pressure PipeEJS00230
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Remove the low-pressure flexible hose. Refer to ATC-141,
"Low-pressure Flexible Hose" .
3. Remove the high-pressure pipe from the clip.
4. Remove the mounting bolt from the high-pressure pipe.
5. Remove the high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure pipe and low-pressure flexible hose with a new one, then
apply compressor oil to it when installing it.
●When pouring refrigerant, check for leaks.
Refrigerant Pressure SensorEJS00231
REMOVAL AND INSTALLATION
1. Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Remove the liquid tank.
3. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION:
● When working, be careful not to damage the compressor
fan.
●Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.Bolt and nut mounting the high-pressure flexible hose
Tightening torque :7.8 - 19.6 N·m (0.8 - 2.0 kg·m, 70 - 173 in-lb)
RJIA1720E
RJIA0030E
Bolts mounting the high-pressure pipe (condenser side, evaporator side)
Tightening torque :2.9 - 5.9 N·m (0.29 - 0.6 kg·m, 26 - 52 in-lb)
Tightening torque :9.8 - 11.7 N·m (1.0 - 1.2kg·m, 87 -
104 in-lb)
RJIA0698E

REFRIGERANT LINES
ATC-143
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Dual-pressure SwitchEJS0020Q
REMOVAL AND INSTALLATION
1. Use refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Remove the liquid tank.
3. Using a vise, secure liquid tank, and remove dual-pressure
switch.
CAUTION:
● When working, be careful not to damage the compressor
fan.
●Apply compressor oil to the O-ring of the refrigerant
pressure sensor when installing it.
Condenser AssemblyEJS0020R
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
3. Remove the battery and battery tray.
4. Remove the front grille and radiator mounting bracket.
5. Remove the mounting nuts from the condenser upper bracket.
6. Remove the radiator from the lower mount, move it to the engine
side, then remove the condenser between the radiator and the radiator core support.
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
INSTALLATION
CAUTION:
●Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
●When pouring refrigerant, check for leaks.Tightening torque :9.8 - 11.7 N·m (1.0 - 1.2kg·m, 87 -
104 in-lb)
RJIA0699E
RJIA0080E
High-pressure flexible hose mounting bolts
Tightening torque :7.8 - 19.6 N·m (0.8 - 2.0 kg·m, 70 - 173 in-lb)
High-pressure pipe mounting bolts
Tightening torque :2.9 - 5.9 N·m (0.29 - 0.6 kg·m, 26- 52 in-lb)
Condenser mounting bolts
Tightening torque :3.82 - 4.51 N·m (0.39 - 0.46 kg·m, 34 - 39 in-lb)

ATC-144
REFRIGERANT LINES
Evaporator
EJS0020S
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Disconnect the low-pressure flexible hose and the high-pressure
pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.
3. Hold expansion valve and move it slightly upward. Push evapo-
rator toward rear of vehicle.
4. Remove the drain hose and lower cover mounting screw.
5. Swivel rear of lower case toward passenger seat to remove
lower case.
6. Remove the intake sensor from evaporator.
7. Slide the evaporator to backward, then remove it from the heater
& cooling unit.
INSTALLATION
CAUTION:
●Replace the O-rings of the low-pressure flexible hose and the high-pressure pipe with new ones,
then apply compressor oil to them when installing them.
●Mark the mounting position of the intake sensor bracket.
Expansion ValveEJS0020T
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.
3. Remove the evaporator. Refer to ATC-144, "
REMOVAL" .
4. Remove the expansion valve from evaporator.
INSTALLATION
1. Set the expansion valve to cooler grommet.
RJIA1720E
RJIA0189E
RJIA1720E
RJIA0840E

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2. Install the evaporator to heater & cooling unit.
3. Install the lower cover, then slide evaporator to forward.
4. Install the expansion valve from engine compartment
Checking for Refrigerant LeaksEJS0020U
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS0020V
1. Check A/C system for leaks using the UV lamp and safety glasses (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
RJIA0841E
Expansion valve mounting bolts
Tightening torque :2.9 - 5.0 N·m (0.30 - 0.50 kg·m, 26
- 44 in-lb)
RJIA0842E

ATC-146
REFRIGERANT LINES
Dye Injection
EJS0020W
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52kg/cm
2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture′s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak DetectorEJS0020X
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
SHA705EB
SHA707EA
SHA706E

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3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.54
kg/cm
2 , 50 psi).
4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet f) to the low side
(evaporator drain hose g to shaft seal i). Refer to AT C - 1 3 4 , "
Components" . Perform a leak check for the
following areas carefully. Clean the component to be checked and move the leak detected probe com-
pletely around the connection/component. ATC-134, "
Components" .
Compressor
Check the fitting of high and low pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer′s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Face mode
c. Intake position: Recirculation
d. Max cold temperature
e. Fan speed: High
SHA708E

ATC-148
REFRIGERANT LINES
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine OFF and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure on the high-pressure side will gradually drop after refrigerant
circulation stops and pressure on the low-pressure side will gradually
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high.
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity.
12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Conduct A/C performance test to ensure system works properly.
SHA839E

SERVICE DATA AND SPECIFICATIONS (SDS)
ATC-149
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
CompressorEJS0020Y
LubricantEJS0020Z
RefrigerantEJS00210
Engine Idling SpeedEJS00211
Refer to EC-30, "IDLE SPEED" for QG engine (WITH EURO-OBD), EC-424, "IDLE SPEED" for QG engine
(WITHOUT EURO-OBD), EC-48, “Basic Inspection” for YD engine.
Belt TensionEJS00212
Refer to EM-12, "Tension Adjustment" for QG engine, EM-11, “DRIVE BELTS” for YD engine.
Model Calsonic Kansei make CSV613
TypeV-6 variable displacement
Displacement
cm
3 (cu. in)/revMax. 125 (7.628)
Min. 6.0 (0.366)
Cylinder bore × stroke
mm (in)32 (1.26) × [1.2 - 25.9 (0.047 - 1.020)]
Direction of rotation Clockwise (viewed from drive end)
Drive beltWith gasoline engine: Poly V
With diesel engine: Type A
Model All models
NameNissan A/C System Oil Type S
Part numberKLH00-PAGS0
Capacity
m (lmp fl oz)Total in system 180 (6.3)
Compressor (Service part) charging
amount180 (6.3)
Ty p eHFC-134a (R-134a)
Capacity
kg (lb)0.45 - 0.55 (0.99 - 1.21)

ATC-150
SERVICE DATA AND SPECIFICATIONS (SDS)