NISSAN TERRANO 2004 Service Repair Manual

qA
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure oil discharged into the recovery/recyclingequipment.
2. Drain the oil from the ªoldº (removed) compressor into a graduated container, and record the amount of oil drained.
3. Drain the oil from the ªnewº compressor into a separate, clean container.
4. Measure an amount of the new oil equivalent to that drained from the ªoldº compressor, and add this oil to the ªnewº com- pressor through the drain plug or suction port opening.
5. Measure an amount of the ªnewº oil equivalent to that recovered during discharging, and add this oil to the ªnewº compressor through the drain plug or suction port opening.
6. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 Imp fl oz) of oil at this time.
Do not add this 5 m (0.2 Imp fl oz) of oil if only replacing the compressor.
SHA563D
H
LUBRICATION OIL Ð Checking and Adjusting
Checking and Adjusting (Cont'd)
HA-24
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Compressor Clutch
REMOVAL
IWhen removing center bolt, hold clutch disc with clutch disc
wrench.
I Remove the drive plate using Tool.
Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Then, tighten the center bolt
to remove the drive plate.
After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
I Remove the snap ring using external snap ring pliers.
SHA049F
SHA792E
SHA793E
SHA794E
COMPRESSOR Ð Model DKS-17CH (ZEXEL make)
HA-25
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IPulley removal
Use any commercially available pulley puller and tool. Position
the center of it on the end of the tool, and remove the pulley
assembly.
For pressed pulleys
To prevent deformation of the pulley groove, the puller
claws should be hooked under the pulley (not into the
groove). For machine latched pulleys
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
I Remove the three field coil fixing screws and remove the field
coil.
INSPECTION
Clutch disc: If the contact surface shows signs of damage due to
excessive heat, replace clutch disc and pulley.
Pulley: Check the appearance of the pulley assembly. Check the
contact surface of the pulley for any sign of excessive grooving due
to slippage. If any sign is found, replace both the pulley and clutch
disc. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
Coil: Check coil for loose connection or cracked insulation.
INSTALLATION
IInstall the field coil.
Be sure to align the coil's pin with the hole in the compres-
sor's front head.
I Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
SHA050F
SHA051F
RHA075C
SHA051F
SHA797EA
COMPRESSOR Ð Model DKS-17CH (ZEXEL make)
Compressor Clutch (Cont'd)
HA-26
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IInstall the drive plate on the drive shaft, together with the origi-
nal shim(s). Press the drive plate down by hand.
I Using the holder to prevent drive plate rotation, tighten the bolt
to 12 to 14 N ×m (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.
After tightening the bolt, check that the pulley rotates
smoothly.
I Check clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
shim and readjust.
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
transmitted torque.
SHA798E
SHA799E
SHA052F
COMPRESSOR Ð Model DKS-17CH (ZEXEL make)
Compressor Clutch (Cont'd)
HA-27
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How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW
CHECK INFReference item
LISTEN TO CUSTOMER COMPLAINT AND CON-
FIRM BY PERFORMING OPERATIONAL CHECK.
Can be
confirmedCannot be
confirmed
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM.
LISTEN TO CUSTOMER COMPLAINTS AND
CONFIRM.FSymptom Chart
(See page HA-37.)
INVESTIGATE ITEMS YOU SHOULD CARRY
OUT RELATED TO EACH SYMPTOM.FSymptom Chart
(See page HA-37.)
EELIMINATE GOOD SYSTEM(S)/PART(S).FPreliminary Check
(See pages HA-38.)
CHECK MAIN POWER SUPPLY AND GROUND
CIRCUITS.FMain Power Supply and Ground Circuit
Check
(See page HA-52.)
Diagnostic
Procedure(s)
(See pages HA-53 -
55.)EELIMINATE GOOD PART(S)/HARNESS(ES)/
CONNECTOR(S) ELECTRICALLY.FHarness Layout for A/C System
(See page HA-40.)
Malfunctioning
harness(es)/
connector(s) Malfunctioning
part(s)
INSPECT EACH
COMPONENT.
FElectrical Components Inspection
(See page HA-61.)
REPAIR.
H
REPAIR/REPLACE.
NG FINAL CHECK
OK
CHECK OUT
H
H
H
H
H
H
H
H
HH
H
H
DIAGNOSES Ð Overall System
HA-28
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Operation Check
The purpose of the operational check is to confirm that the system
is as it should be. The systems which will be checked are the
blower, mode (discharge air), intake air, temperature decrease,
temperature increase and A/C switch system.
CONDITIONS:
Engine running and at normal operating temperature.
PROCEDURE:
1. Check blower
1) Turn FAN CONTROL DIAL to 1.Blower should operate at speed 1.
2) Then turn the DIAL to speed 2.
3) Continue checking blower speed until all speeds are checked.
4) Leave blower on speed 4.
2. Check discharge air
1) Turn AIR CONTROL DIAL toposition.
2) Confirm that all discharge air comes out of face vents.
3) Turn AIR CONTROL DIAL to
position.
4) Confirm that discharge air comes out of face vents and foot vents.
5) Turn AIR CONTROL DIAL to
position.
6) Confirm that discharge air comes out of foot vents, with some air from face vents.
7) Turn AIR CONTROL DIAL to
position.
8) Confirm that discharge air comes out of foot vents with some air from defroster vents.
9) Turn AIR CONTROL DIAL to
position.
10) Confirm that all discharge air comes out of defroster vents, with some air from face vents.
3. Check recirculation
1) Switch AIR RECIRCULATION SWITCH to ON position (Indica-tor light ON).
2) Listen for intake door position change (you should hear sound change slightly).
NHA333
NHA334
RHA035E
NHA335
DIAGNOSES Ð Overall System
HA-29
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4. Check temperature decrease
1) Turn TEMPERATURE CONTROL DIAL to full cold (counter-clockwise).
2) Check for cold air at discharge air outlets.
5. Check temperature increase
1) Turn TEMPERATURE CONTROL DIAL to full hot (clockwise).
2) Check for hot air at discharge air outlets.
6. Check A/C switch
Turn FAN CONTROL DIAL to the desired position (1 to 4) and
switch AIR CONDITIONER SWITCH to turn ON air conditioner.
Indicator light will come on when air conditioner is ON.
NHA336
NHA337
NHA338
DIAGNOSES Ð Overall System
Operation Check (Cont'd)
HA-30
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Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location:Indoors or in the shade (in a well-ventilated place)
Doors: Closed
Door window: Open (Front driver side only)
Hood: Open
TEMP. control dial position: Max. COLD
AIR control dial position:
(Ventilation)
Air recirculation switch position:
(Recirculation)
Fan control dial position: 4
Engine speed: 1,500 rpm
Time required before starting testing
after air conditioner starts operating: More than 10 minutes
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air)
at blower assembly inlet Discharge air temperature at center ventilator
ÉC (ÉF)
Relative humidity
% Air temperature
ÉC (ÉF)
40-60 25 (77) 9.8 - 11.5 (50 - 53)
30 (86) 13.8 - 15.9 (57 - 61)
35 (95) 17.9 - 20.3 (64 - 69)
60-80 25 (77) 11.5 - 13.3 (53 - 56)
30 (86) 15.9 - 18.0 (61 - 64)
35 (95) 20.3 - 22.7 (69 - 73)
Ambient air temperature-to-compressor pressure table
Ambient air
High-pressure (Discharge side)
kPa (bar, kg/cm
2, psi) Low-pressure (Suction side)
kPa (bar, kg/cm2, psi)
Relative humidity
% Air temperature
ÉC (ÉF)
40-80 25 (77)
1,451 - 1,608 (14.51 - 16.08,
14.8 - 16.4, 210 - 233) 157 - 186 (1.57 - 1.86, 1.6 - 1.9,
23 - 27)
30 (86) 1,569 - 1,804 (15.69 - 18.04,
16.0 - 18.4, 228 - 262) 176 - 235 (1.76 - 2.35, 1.8 - 2.4,
26 - 34)
35 (95) 1,834 - 2,138 (18.34 - 21.38,
18.7 - 21.8, 266 - 310) 226 - 304 (2.26 - 3.04, 2.3 - 3.1,
33 - 44)
DIAGNOSES Ð Overall System
HA-31
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Performance Test Diagnoses
INSUFFICIENT COOLING
MHA176B
DIAGNOSES Ð Overall System
HA-32
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TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE
Whenever abnormal pressure of high and/or low sides of the system is noted, diagnosis must be conducted
by using a manifold gauge. The large-line zone on the gauge scale (see illustrations.) shown in the following
table refers to the standard (normal) pressure range for the corresponding pressure side (high or low). Since
the standard (normal) pressure, however, differs from vehicle to vehicle, refer to the ªAmbient air temperature-
to-compressor pressure tableº.
Gauge indicationRefrigerant cycleProbable causeCorrective action
Both high- and low-pressure
sides are too high.
AC359A
I Pressure is reduced soon
after water is splashed on
condenser. Excessive refrigerant charge in
refrigeration cycle
Reduce refrigerant until speci-
fied pressure is obtained.
Air suction by radiator or con-
denser fan is insufficient. Insufficient condenser cooling
performance
"
q
1Condenser fins are
clogged.
q
2Improper rotation of radiator
fan or condenser fan I
Clean condenser.
I Check and repair radiator or
condenser fan as necessary.
I Low-pressure pipe is not
cold.
I When compressor is stopped
high-pressure value quickly
drops by approximately 196
kPa (2 kg/cm
2, 28 psi). It
then decreases gradually
thereafter. Poor heat exchange in con-
denser
(After compressor operation
stops, high pressure
decreases too slowly.)
"
Air in refrigeration cycle Evacuate repeatedly and
recharge system.
Engine tends to overheat. Engine cooling systems mal- function.Check and repair each engine
cooling system.
I Areas near low-pressure
pipe connection and service
valves are considerably cold
compared with areas near
expansion valve outlet or
evaporator.
I Plates are sometimes cov-
ered with frost. I
Excessive liquid refrigerant
on low-pressure side
I Excessive refrigerant dis-
charge flow
I Expansion valve is open a
little compared with the
specification.
"
q
1Improper expansion valve
installation
q
2Improper expansion valve
adjustment Replace expansion valve.
DIAGNOSES Ð Overall System
Performance Test Diagnoses (Cont'd)
HA-33
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