engine NISSAN ALMERA 2001 Service Manual

Incident Simulation TestsNJGI0005S02INTRODUCTIONNJGI0005S0201Sometimes the symptom is not present when the vehicle is brought
in for service. If possible, re-create the conditions present at the
time of the incident. Doing so may help avoid a No Trouble Found
Diagnoses. The following section illustrates ways to simulate the
conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:
+Vehicle vibration
+Heat sensitive
+Freezing
+Water intrusion
+Electrical load
+Cold or hot start up
Get a thorough description of the incident from the customer. It is
important for simulating the conditions of the problem.
VEHICLE VIBRATIONNJGI0005S0202The problem may occur or become worse while driving on a rough
road or when engine is vibrating (idle with A/C on). In such a case,
you will want to check for a vibration related condition. Refer to the
illustration below.
Connectors & Harness
Determine which connectors and wiring harness would affect the
electrical system you are inspecting.Gentlyshake each connec-
tor and harness while monitoring the system for the incident you
are trying to duplicate. This test may indicate a loose or poor elec-
trical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin
film of corrosion on the connector terminals. A visual inspection
may not reveal this without disconnecting the connector. If the
problem occurs intermittently, perhaps the problem is caused by
corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensors & Relays
Gentlyapply a slight vibration to sensors and relays in the system
you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests
GI-22

Engine Compartment
There are several reasons a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for are:
+Connectors not fully seated.
+Wiring harness not long enough and is being stressed due to
engine vibrations or rocking.
+Wires laying across brackets or moving components.
+Loose, dirty or corroded ground wires.
+Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integ-
rity of ground connections. (Refer to GROUND INSPECTION
described later.) First check that the system is properly grounded.
Then check for loose connection bygently shakingthe wiring or
components as previously explained. Using the wiring diagrams
inspect the wiring for continuity.
Behind The Instrument Panel
An improperly routed or improperly clamped harness can become
pinched during accessory installation. Vehicle vibration can aggra-
vate a harness which is routed along a bracket or near a screw.
Under Seating Areas
An unclamped or loose harness can cause wiring to be pinched by
seat components (such as slide guides) during vehicle vibration. If
the wiring runs under seating areas, inspect wire routing for pos-
sible damage or pinching.
SGI842
HEAT SENSITIVENJGI0005S0203The owner's problem may occur during hot weather or after car has
sat for a short time. In such cases you will want to check for a heat
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
Do not heat components above 60ÉC (140ÉF).If incident occurs
while heating the unit, either replace or properly insulate the com-
ponent.
SGI843
FREEZINGNJGI0005S0204The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez-
ing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnoses
of those electrical components which could be affected.
HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
GI-23

Key to Symbols Signifying Measurements or
Procedures
NJGI0006S02
Symbol Symbol explanation Symbol Symbol explanation
Check after disconnecting the con-
nector to be measured.Procedure with Generic Scan Tool
(GST, OBD-II scan tool)
Check after connecting the connec-
tor to be measured.Procedure without CONSULT-II or
GST
Insert key into ignition switch.A/C switch is ªOFFº.
Remove key from ignition switch.A/C switch is ªONº.
Turn ignition switch to ªOFFº posi-
tion.REC switch is ªONº.
Turn ignition switch to ªONº position.REC switch is ªOFFº.
Turn ignition switch to ªSTARTº posi-
tion.Fan switch is ªONº. (At any position
except for ªOFFº position)
Turn ignition switch from ªOFFº to
ªACCº position.Fan switch is ªOFFº.
Turn ignition switch from ªACCº to
ªOFFº position.Apply positive voltage from battery
with fuse directly to components.
Turn ignition switch from ªOFFº to
ªONº position.Drive vehicle.
Turn ignition switch from ªONº to
ªOFFº position.Disconnect battery negative cable.
Do not start engine, or check with
engine stopped.Depress brake pedal.
Start engine, or check with engine
running.Release brake pedal.
Apply parking brake.Depress accelerator pedal.
Release parking brake.Release accelerator pedal.
HOW TO FOLLOW TROUBLE DIAGNOSES
Key to Symbols Signifying Measurements or Procedures
GI-33

Symbol Symbol explanation Symbol Symbol explanation
Check after engine is warmed up
sufficiently.Pin terminal check for SMJ type
ECM and TCM connectors.
For details regarding the terminal
arrangement, refer to the ªELEC-
TRICAL UNITSº electrical refer-
ence page at the end of the
manual.
Voltage should be measured with a
voltmeter.
Circuit resistance should be mea-
sured with an ohmmeter.
Current should be measured with an
ammeter.
Procedure with CONSULT-II
Procedure without CONSULT-II
HOW TO FOLLOW TROUBLE DIAGNOSES
Key to Symbols Signifying Measurements or Procedures (Cont'd)
GI-34

NJGI0007
Function and System ApplicationNJGI0007S05
Diagnostic
test modeFunction ENGINE A/T ABS AIR BAGSMART
EN-
TRANCENATS*1NAVIGA-
TION
Work sup-
portThis mode enables a technician to
adjust some devices faster and
more accurate by following the indi-
cations on CONSULT-II.x ÐÐÐXÐÐ
Self-diag-
nostic
resultsSelf-diagnostic results can be read
and erased quickly.x x x xÐxÐ
Trouble
diagnostic
recordCurrent self-diagnostic results and
all trouble diagnostic records previ-
ously stored can be read.ÐÐÐ x ÐÐÐ
ECU dis-
criminated
No.Classification number of a replace-
ment ECU can be read to prevent
an incorrect ECU from being
installed.ÐÐÐ x ÐÐÐ
Data monitorInput/Output data in the ECU
(ECM) can be read.x x xÐxÐÐ
Data monitor
(Spec.)The specified values will be dis-
played when an OK/NG judgement
is difficult for the DATA MONITOR
items by Barchart and Line Graph.X ÐÐÐÐÐÐ
DTC work
supportThis mode enables a technician to
set operating conditions to confirm
self-diagnoses status/results.x*2x ÐÐÐÐÐ
Active testDiagnostic Test Mode in which
CONSULT-II drives some actuators
apart from the ECMs and also
shifts some parameters in a speci-
fied range.xÐxÐxÐÐ
ECU (ECM)
part numberECU (ECM) part number can be
read.x x x ÐÐÐÐ
Control unit
initializationAll registered ignition key IDs in
NATS components can be initial-
ized and new IDs can be regis-
tered.ÐÐÐÐÐ x Ð
PIN
INITIALIZA-
TIONNavigation system will be locked
when the vehicle's owner enters
the wrong PIN five consecutive
times.
To release the lock, use ªPIN INI-
TIALIZATIONº.ÐÐÐÐÐÐ x
NAVI ID
INITIALIZA-
TIONIn nomal times regulation codes are
being communicated between Navi-
gation Control Unit and Dongle
Control Unit.
Use ªNAVI ID INITIALIZATIONº to
match the codes when either one
has been replaced due to break-
down or etc.ÐÐÐÐÐÐ x
x: Applicable
*1: NATS (Nissan Anti-Theft System)
*2: For models with Euro-OBD system
CONSULT-II CHECKING SYSTEM
Function and System Application
GI-35

NJGI0008
Model VariationNJGI0008S01
Body Engine Transaxle GradeDestination
RHDSouthern/Central
EuropeNorthern Europe
4-door SedanQG15DE RS5F30ALX CDFARCF-EEA CDFALCF-EGA CDFALCF-ESA
GX CDFAREF-EEA CDFALEF-EGA CDFALEF-ESA
QG18DERS5F70A GX CATAREF-EEA CATALEF-EGA CATALEF-ESA
RE4F03B GX CATAREA-EEA CATALEA-EGA CATALEA-ESA
YD22DDT RS5F50ALX CVHARCF-TEA CVHALCF-TGA CVHALCF-TSA
GX CVHAREF-TEA CVHALEF-TGA CVHALEF-TSA
3-door HatchbackQG15DE RS5F30ALX EDFARCF-EEA EDFALCF-EGA EDFALCF-ESA
GX EDFAREF-EEA EDFALEF-EGA EDFALEF-ESA
QG18DERS5F70A GX EATAREF-EEA EATALEF-EGA EATALEF-ESA
RE4F03B GX EATAREA-EEA EATALEA-EGA EATALEA-ESA
YD22DDT RS5F50A GX EVHAREF-TEA EVHALEF-TGA EVHALEF-TSA
5-door HatchbackQG15DE RS5F30ALX FDFARCF-EEA FDFALCF-EGA FDFALCF-ESA
GX FDFAREF-EEA FDFALEF-EGA FDFALEF-ESA
QG18DERS5F70A GX FATAREF-EEA FATALEF-EGA FATALEF-ESA
RE4F03B GX FATAREA-EEA FATALEA-EGA FATALEA-ESA
YD22DDT RS5F50A GX FVHAREF-TEA FVHALEF-TGA FVHALEF-TSA
IDENTIFICATION INFORMATION
Model Variation
GI-38

SGI117A
SGI118A
ENGINE SERIAL NUMBERNJGI0008S0203
SGI113A
AUTOMATIC TRANSAXLE NUMBERNJGI0008S0204
IDENTIFICATION INFORMATION
Identification Number (Cont'd)
GI-41

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
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection system MFI system Fuel injection control
Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnoses
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
Park/neutral position switch PNP switch Park/neutral switch
Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system ***
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control
solenoid valvePAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List (Cont'd)
GI-52

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