clutch NISSAN ALMERA 2001 Service Manual

Code Section Wiring Diagram Name
MULTI EL Multi-remote Control System
NATS EL Nissan Anti-Theft System
NAVI EL Navigation System
NONDTC AT Non-detectable Items
O2H1B1 EC Front Heated Oxygen Sensor Heater
(E-OBD)
O2H2B1 EC Rear Heated Oxygen Sensor Heater
(E-OBD)
O2S1B1 EC Front Heated Oxygen Sensor
(E-OBD)
O2S2B1 EC Rear Heated Oxygen Sensor
(E-OBD)
OVRCSV AT Overrun Clutch Solenoid Valve
P/ANT EL Power Antenna
PGC/V EC EVAP Canister Purge Volume Con-
trol Solenoid Valve
PHASE EC Camshaft Position Sensor (PHASE)
PNP/SW EC Park/Neutral Position Switch
PNP/SW AT Park/Neutral Position Switch
POS EC Crankshaft Position Sensor (POS)
POWER EL Power Supply Routing
PST/SW EC Power Steering Oil Pressure Switch
R/FOG EL Rear Fog Lamp
ROOM/L EL Interior Room Lamp
RRO2 EC Rear Heated Oxygen Sensor (Non
E-OBD)
RRO2/H EC Rear Heated Oxygen Sensor Heater
(Non E-OBD)
S/SIG EC Start Signal
SHIFT AT A/T Shift Lock System
S/LOCK EL Power Door Lock Ð Super Lock Ð
SROOF EL Sunroof
SRS RS Supplemental Restraint System
SSV/A AT Shift Solenoid Valve A
SSV/B AT Shift Solenoid Valve B
START SC Starting System
STOP/L EL Stop Lamp
SWL/C EC Swirl Control Valve Control Solenoid
Valve (Non E-OBD)
SWL/V EC Swirl Control Valve Control Solenoid
Valve (E-OBD)
TAIL/L EL Parking, License and Tail LampsCode Section Wiring Diagram Name
TCV AT Torque Converter Clutch Solenoid
Valve
THEFT EL Theft Warning System
TLID EL Trunk Lid Opener
TP/SW EC Throttle Position Switch
TPS AT Throttle Position Sensor
TPS EC Throttle Position Sensor
TURN EL Turn Signal and Hazard Warning
Lamps
VSS EC Vehicle Speed Sensor
VSSA/T AT Vehicle Speed Sensor A/T (Revolu-
tion Sensor)
VSSMTR AT Vehicle Speed Sensor MTR
WARN EL Warning Lamps
WINDOW EL Power Window
WIP/R EL Rear Wiper and Washer
WIPER EL Front Wiper and Washer
WIRING DIAGRAM CODES (CELL CODES)
EL-576

NJGI0011
ISO 15031-2 Terminology ListNJGI0011S01All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure sensor BARO sensor ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List
GI-50

NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Simultaneous multiport fuel injection sys-
tem*** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter
systemTWC + OC system ***
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid
Lock-up solenoid
Transmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
temWU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter
systemWU-TWC system ***
Wide open throttle position switch WOTP switch Full switch
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List (Cont'd)
GI-53

HEATER &
AIR CONDITIONER
SECTION
HA
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
Precautions for Working with HFC-134a (R-134a) .....2
General Refrigerant Precautions .................................2
Precautions for Refrigerant Connection ......................3
Precautions for Servicing Compressor ........................5
Precautions for Service Equipment .............................6
Wiring Diagrams and Trouble Diagnosis .....................8
PREPARATION...............................................................9
Special Service Tools ..................................................9
HFC-134a (R-134a) Service Tools and
Equipment .................................................................. 11
DESCRIPTION...............................................................13
Refrigeration System .................................................13
CSV613 Variable Displacement Compressor............14
Component Layout ....................................................18
Control Operation ......................................................19
Discharge Air Flow.....................................................20
System Description ....................................................21
TROUBLE DIAGNOSES................................................22
Component Location..................................................22
Wiring Diagram - Heater............................................24
Circuit Diagram - Air Conditioner...............................26
Wiring Diagram - A/C, M - .........................................27
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................33
Operational Check .....................................................34
Intake Door ................................................................36
Mode Door .................................................................40Air Mix Door ...............................................................42
Max Hot Door (For Scandinavia and Cold Spec
Models) ......................................................................44
Blower Motor..............................................................48
Magnet Clutch............................................................55
Insufficient Cooling ....................................................68
Insufficient Heating ....................................................76
Noise ..........................................................................77
SERVICE PROCEDURE................................................78
HFC-134a (R-134a) Service Procedure ....................78
Maintenance of Lubricant Quantity in
Compressor ...............................................................80
Compressor ...............................................................83
Compressor Clutch - CSV613 (CALSONIC
make) .........................................................................84
Heater & Cooling Unit (Heater Core) ........................88
A/C Evaporator ..........................................................88
Blower Unit ................................................................89
Refrigerant Lines .......................................................91
Belt .............................................................................95
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve ..................................................96
Ventilation Air Filter ....................................................96
SERVICE DATA AND SPECIFICATIONS (SDS).........97
Compressor ...............................................................97
Lubricant ....................................................................97
Refrigerant .................................................................97
Engine Idling Speed (When A/C is On).....................97
Belt Tension ...............................................................97

+When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
+Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
+Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
+Always replace used O-rings.
+When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type R for DKV-11G compressor
Part number: KLH00-PAGR0
Lubricant name: Nissan A/C System Oil Type S for CSV613 compressor
Part number: KLH00-PAGS0
+O-ring must be closely attached to dented portion of tube.
+When replacing the O-ring, be careful not to damage O-ring and tube.
+Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
+After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.
RHA861F
Precautions for Servicing CompressorNJHA0116+Plug all openings to prevent moisture and foreign matter from entering.
+When the compressor is removed, store it in the same position as it is when mounted on the car.
+When replacing or repairing compressor, follow ªMaintenance of Lubricant Quantity in Compres-
sorº exactly. Refer to HA-80.
+Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with
lubricant, wipe it off by using a clean waste cloth moistened with thinner.
+After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
+After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
PRECAUTIONS
Precautions for Refrigerant Connection (Cont'd)
HA-5

Special Service ToolsNJHA0119DKV-11G COMPRESSORNJHA0119S01
Tool number
Tool nameDescription
KV99231260
Clutch disc wrench
NT204
Removing shaft nut and clutch disc
KV99232340
Clutch disc puller
NT206
Removing clutch disc
KV99234330
Pulley installer
NT207
Installing pulley
KV99233130
Pulley puller
NT208
Removing pulley
CSV613 COMPRESSORNJHA0119S02
Tool number
Tool nameDescription
KV99106100
Clutch disc wrench
NT232
NT378
Removing center bolt
PREPARATION
Special Service Tools
HA-9

Tool number
Tool nameDescription
KV99232340
Clutch disc puller
NT376
Removing clutch disc
KV99106200
Pulley installer
NT235
Installing pulley
PREPARATION
Special Service Tools (Cont'd)
HA-10

CSV613 Variable Displacement Compressor
GENERAL INFORMATIONNJHA02061. The CSV613 compressor differs from previous units. The vent temperatures of the CSV613 compressor
do not drop too far below 5ÉC (41ÉF) when:
+evaporator intake air temperature is less than 20ÉC (68ÉF)
+engine is running at speeds less than 1,500 rpm.
This is because the CSV613 compressor provides a means of ªcapacityº control.
2. The CSV613 compressor provides refrigerant control under varying conditions. During cold winters, it may
not produce high refrigerant pressure discharge (compared to previous units) when used with air condi-
tioning systems.
3. A ªclankingº sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt
angle of the swash plate has changed and is not a problem.
4. For air conditioning systems with the CSV613 compressor, the clutch remains engaged unless: the sys-
tem main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are
low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.
5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It
normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm
2, 21 to 26 psi) under varying con-
ditions.
In previous compressors, however, suction pressure was reduced with increases in engine speed.
DESCRIPTION
CSV613 Variable Displacement Compressor
HA-14

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
NJHA0129WORK FLOWNJHA0129S01
SHA900E
*1: HA-34
SYMPTOM TABLENJHA0129S02
Symptom Reference page
+Intake door does not change.+Go to Trouble Diagnosis Procedure for Intake Door. HA-36
+Air outlet does not change.+Go to Trouble Diagnosis Procedure for mode door. HA-40
+Air mix door does not change.+Go to Trouble Diagnosis Procedure for Air mix door. HA-42
+Max hot door does not change.+Go to Trouble Diagnosis Procedure for Max Hot Door. HA-44
+Blower motor does not rotate at all.+Go to Trouble Diagnosis Procedure for Blower Motor. HA-48
+Magnet clutch does not engage when A/C switch and
fan switch are ON.+Go to Trouble Diagnosis Procedure for Magnet Clutch. HA-55
+Insufficient cooling.+Go to Trouble Diagnosis Procedure for Insufficient cool-
ing.HA-68
+Insufficient heating.+Go to Trouble Diagnosis Procedure for Insufficient
heating.HA-76
+Noise+Go to Trouble Diagnosis Procedure for Noise. HA-77
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair
HA-33

NHA377
3. Check RecirculationNJHA0130S02031. Press the Recirculation (REC) switch. Recirculation indicator
should illuminate.
2. Listen for intake door position change.
If NG, go to trouble diagnosis procedure for intake door (HA-36).
If OK, continue with next check.
NHA378
4. Check Temperature DecreaseNJHA0130S02041. Turn the temperature control knob to full cold.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for insufficient cooling
(HA-68).
If OK, continue with next check.
NHA379
5. Check Temperature IncreaseNJHA0130S02051. Turn the temperature control knob to full hot.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for insufficient heating
(HA-76).
NHA380
6. Check Air Conditioner SwitchNJHA0130S0206Turn the fan control switch to the desired (1 to 4 speed) position
and push the A/C switch to turn ON the air conditioner.
The indicator lamp should come on when air conditioner is ON.
If NG, go to trouble diagnosis procedure for magnet clutch (HA-55).
TROUBLE DIAGNOSES
Operational Check (Cont'd)
HA-35