maintenance NISSAN ALMERA 2001 Owner's Manual

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJHA0190The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº 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 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 theRS sectionof 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 Working with HFC-134a
(R-134a)
NJHA0113WARNING:
+CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor fail-
ure is likely to occur.
+Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
+The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
a) When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
b) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as pos-
sible to minimize the entry of moisture into system.
c) Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
d) Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. Remove R-134a from the A/C system, using certified service equipment meeting
requirements of R-134a recycling equipment, or R-134a recovery equipment. If accidental system
discharge occurs, ventilate work area before resuming service. Additional health and safety
information may be obtained from refrigerant and lubricant manufacturers.
e) Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
General Refrigerant PrecautionsNJHA0114WARNING:
+Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
+Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
HA-2

+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

Precautions for Service EquipmentNJHA0117RECOVERY/RECYCLING EQUIPMENTNJHA0117S01Follow the manufacturer's instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.
ELECTRONIC LEAK DETECTORNJHA0117S02Follow the manufacture's instructions for tester operation and
tester maintenance.
RHA270D
VACUUM PUMPNJHA0117S03The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric
pressure. So the vacuum pump lubricant may migrate out of the
pump into the service hose. This is possible when the pump is
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
+Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose from
the pump.
+For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
+If the hose has an automatic shut off valve, disconnect the
hose from the pump: as long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
SHA533D
MANIFOLD GAUGE SETNJHA0117S04Be certain that the gauge face indicates R-134a or 134a. Make
sure the gauge set has 1/2²-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant.
RHA272D
SERVICE HOSESNJHA0117S05Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive
shut off devices (either manual or automatic) near the end of the
hoses opposite the manifold gauge.
PRECAUTIONS
Precautions for Service Equipment
HA-6

Maintenance of Lubricant Quantity in
Compressor
NJHA0160The lubricant in the compressor circulates through the system with
the refrigerant. Add lubricant to compressor when replacing any
component or after a large gas leakage occurred. It is important to
maintain the specified amount.
If lubricant quantity is not maintained properly, the following mal-
functions may result:
+Lack of lubricant: May lead to a seized compressor
+Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANTNJHA0160S01Name: Nissan A/C System Oil Type R for DKV-11G compres-
sor
Part number: KLH00-PAGR0
Name: Nissan A/C System Oil Type S for CSV613 compressor
Part number: KLH00-PAGS0
CHECKING AND ADJUSTINGNJHA0160S02Adjust the lubricant quantity according to the test group shown
below.
1 LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
+A/C system works properly.
+There is no evidence of a large amount of lubricant leakage.
YesorNo
Ye s©GO TO 2.
No©GO TO 3.
2 PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS
1. Start engine, and set the following conditions:
+Test condition
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
Blower speed: Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30ÉC (77 to 86ÉF).]
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
©GO TO 3.
3 CHECK COMPRESSOR
Should the compressor be replaced?
YesorNo
Ye s©GO TO HA-82.
No©GO TO 4.
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor
HA-80

4 CHECK ANY PART
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of
lubricant leakage.)
YesorNo
Ye s©GO TO HA-82.
No©Carry out the A/C performance test.
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont'd)
HA-81

Lubricant Adjusting Procedure for Components
Replacement Except Compressor
=NJHA0160S0201After replacing any of the following major components, add the
correct amount of lubricant to the system.
Amount of lubricant to be added
Part replacedLubricant to be added to
system
Remarks
Amount of lubricant
m!(Imp fl oz)
Evaporator 75 (2.6) Ð
Condenser 75 (2.6) Ð
Liquid tank 5 (0.2)Add if compressor is not
replaced. *1
In case of refrigerant
leak30 (1.1) Large leak
Ð Small leak *2
*1: If compressor is replaced, addition of lubricant is included in the table.
*2: If refrigerant leak is small, no addition of lubricant is needed.
Lubricant Adjustment Procedure for Compressor
Replacement
NJHA0160S02021. Discharge refrigerant into the refrigerant recovery/recycling
equipment. Measure lubricant discharged into the recovery/
recycling equipment.
2. Drain the lubricant from the ªoldº (removed) compressor into a
graduated container and recover the amount of lubricant
drained.
3. Drain the lubricant from the ªnewº compressor into a separate,
clean container.
4. Measure an amount of new lubricant installed equal to amount
drained from ªoldº compressor. Add this lubricant to ªnewº com-
pressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount
recovered during discharging. Add this lubricant to ªnewº com-
pressor through the suction port opening.
6. If the liquid tank also needs to be replaced, add an additional
5m!(0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m!(0.2 Imp fl oz) of lubricant if only
replacing the compressor.
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont'd)
HA-82

RHA065DH
Compressor
REMOVAL AND INSTALLATIONNJHA0161
RHA803H
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont'd)
HA-83

CHECKING REFRIGERANT LEAKS=NJHA0168Preliminary CheckNJHA0168S01Perform a visual inspection of all refrigeration parts, fittings, hoses,
and components for signs of A/C lubricant leakage, damage and
corrosion. Take note of the areas with A/C lubricant leakage to
allow extra time in these areas with electronic leak detector.
SHA705EB
Precautions for Handling Leak DetectorNJHA0168S02When performing a refrigerant leak check, use an A/C leak detec-
tor or equivalent. Ensure that the instrument is calibrated and set
properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak
detector properly, read the operating instructions and perform any
specified maintenance.
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 detec-
tor.
SHA707EA
1. Position probe approximately 5 mm (3/16 in) away from point
to be checked.
SHA706E
2. When testing, circle each fitting completely with probe.
SERVICE PROCEDURE
Refrigerant Lines (Cont'd)
HA-93

Idle Air Control Valve (IACV) Ð Auxiliary Air
Control (AAC) Valve
INSPECTIONNJHA0199+Refer to EC-376 (QG), ªSystem Descriptionº.
RHA680H
Ventilation Air Filter
FUNCTIONNJHA0171Air inside passenger compartment is kept clean at either recircula-
tion or fresh mode by installing ventilation air filter into cooling unit.
SHA868E
REPLACEMENT TIMINGNJHA0172Replace ventilation air filter.
Refer to MA-4, ªPERIODIC MAINTENANCEº.
Caution label is fixed inside the glove box.
RHA681H
REPLACEMENT PROCEDURENJHA0173+Remove glove box.
+Remove filter cover.
+Take out the ventilation air filter from blower unit.
+Replace with new one and reinstall on blower unit.
+Reinstall glove box.
SERVICE PROCEDURE
Idle Air Control Valve (IACV) Ð Auxiliary Air Control (AAC) Valve
HA-96

MAINTENANCE
SECTION
MA
CONTENTS
PRE-DELIVERY INSPECTION ITEMS............................2
GENERAL MAINTENANCE............................................3
PERIODIC MAINTENANCE (FOR EUROPE).................4
Maintenance Schedule for Petrol Engines
(Annual Mileage < 30,000 km/year) ............................4
QG15DE/QG18DE ENGINES......................................4
CHASSIS AND BODY MAINTENANCE........................5
Maintenance Schedule for Diesel Engines
(Annual Mileage < 30,000 km/year) ............................6
YD22DDT ENGINE....................................................6
CHASSIS AND BODY MAINTENANCE........................7
Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year) ..............8
Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year) ..........................10
QG15DE/QG18DE ENGINES....................................10
CHASSIS AND BODY MAINTENANCE...................... 11
Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year) ..........................12
YD22DDT ENGINE..................................................12
CHASSIS AND BODY MAINTENANCE......................13
Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year) ............14
RECOMMENDED FLUIDS AND LUBRICANTS...........16
Fluids and Lubricants ................................................16
SAE Viscosity Number ..............................................17
GASOLINE ENGINE.................................................17
DIESEL ENGINE......................................................17
Engine Coolant Mixture Ratio....................................18