NISSAN ALMERA N16 2003 Electronic Repair Manual

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEJS001YY
HFC-134a (R-134a) Service Tools and EquipmentEJS001YZ
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor malfunction will result.
Tool number
Tool nameDescription
KV99106100
Clutch disc wrenchRemoving shaft nut and clutch disc
KV99232340
or
KV992T0001
Clutch disc pullerRemoving clutch disc
KV99106200
Pulley installerInstalling pulley
S-NT232
RJIA0194E
S-NT376
S-NT235

ATC-12
PREPARATION
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color: Light blue
Container marking: HFC-134a (R-
134a)
Fitting size: Thread size
●Large container 1/2″ -16 ACME
KLH00-PAGS0
Nissan A/C System Oil Type SType: Poly alkylene glycol oil (PAG),
type S
Application: HFC-134a (R-134a)
swash plate compressors (Nissan
only)
Lubricity: 40 m [Liter] (1.4 Imp fl oz)
Recovery/Recycling/
Recharging equipment (ACR4)Function: Refrigerant Recovery and
Recycling and Recharging
Electrical leak detectorPower supply:
DC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses
(J-41459) Refrigerant dye injector
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
S-NT196
S-NT197
RJIA0195E
SHA705EB
ZHA200H

PREPARATION
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(J-42220)
Fluorescent dye leak detectorPower supply: DC 12V (Battery
terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system.
Includes: UV lamp and UV safety
glasses
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PAG oil
Container: 1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
(J-43872)
Dye cleanerFor cleaning dye spills.
Manifold gauge set (with hoses
and couplers)
Identification:
●The gauge face indicates R-134a.
Fitting size: Thread size
●1/2″ -16 ACME
Service hoses
●High side hose
●Low side hose
●Utility hose
Hose color:
●Low hose: Blue with black stripe
●High hose: Red with black stripe
●Utility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
●1/2″ -16 ACME Tool number
Tool nameDescription
SHA438F
SHA439F
SHA440F
SHA441F
RJIA0196E
S-NT201

ATC-14
PREPARATION
Service couplers
●High side coupler
●Low side coupler
Hose fitting to service hose:
●M14 x 1.5 fitting is optional or
permanently attached.
Refrigerant weight scaleFor measuring of refrigerant
Fitting size: Thread size
●1/2″ -16 ACME
Vacuum pump
(Including the isolator valve)
Capacity:
●Air displacement: 4 CFM
●Micron rating: 20 microns
●Oil capacity: 482 g (17 oz.)
Fitting size: Thread size
●1/2″ -16 ACME Tool number
Tool nameDescription
S-NT202
S-NT200
S-NT203

REFRIGERATION SYSTEM
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REFRIGERATION SYSTEMPFP:KA990
Refrigerant CycleEJS001Z0
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the CSV613 displacement compressor to
prevent freeze up.
Refrigerant System ProtectionEJS001Z1
REFRIGERANT PRESSURE SENSOR (WITH GASOLINE ENGINE)
The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sen-
sor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refriger-
ant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side
detected by refrigerant pressure sensor is over about 2,746 kPa (27.5 bar, 28 kg/cm
2 , 398 psi), or below
about 134 kPa (1.37 bar, 1.4 kg/cm
2 , 20 psi).
DUAL-PRESSURE SWITCH (WITH DIESEL ENGINE)
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pres-
sure switch opens to interrupt the compressor operation.
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (37.3 bar,
38 kg/cm
2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refriger-
ant into the atmosphere.
RHA682H

ATC-16
REFRIGERATION SYSTEM
CSV613 Variable Displacement Compressor
EJS001Z2
GENERAL INFORMATION
1. The CSV613 compressor differs from previous units. The vent temperatures of the CSV613 compressor
do not drop too far below 5°C (41°F) when:
Evaporator intake air temperature is less than 20°C (68°F).
Engine is running at speeds less than 1,500 rpm.
This is because the CSV613 compressor provides a means of “capacity” 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 “clanking” 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
General
The variable compressor is basically a swash plate type that changes piston stroke in response to the required
cooling capacity.

REFRIGERATION SYSTEM
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The tilt of the swash plate allows the piston′s stroke to change so that refrigerant discharge can be continu-
ously changed from 6.0 to 125 cm
3 (0.366 to 7.628 cu in).
Operation
1. Operation Control Valve
Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response
to changes in refrigerant suction pressure.
Operation of the valve controls the internal pressure of the crankcase.
The angle of the swash plate is controlled between the crankcase′s internal pressure and the piston cylin-
der pressure.
2. Maximum Cooling
Refrigerant pressure on the low–pressure side increases with an increase in heat loads.
When this occurs, the control valve′s bellows compress to open the low-pressure side valve and close the
high-pressure side valve.
This causes the following pressure changes:
● The crankcase′s internal pressure to equal the pressure on the low-pressure side;
RHA854HA

ATC-18
REFRIGERATION SYSTEM
● The cylinder′s internal pressure to be greater than the crankcase′s internal pressure.
Under this condition, the swash plate is set to the maximum stroke position.
3. Capacity Control
● Refrigerant pressure on suction side is low during high speed driving or when ambient or interior tem-
perature is low.
● The bellows expands when refrigerant pressure on the suction pressure side drops below approxi-
mately 177 kPa (1.77 bar, 1.8 kg/cm
2 , 26 psi).
Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crank-
case pressure becomes high as high pressure enters the crankcase.
● The force acts around the journal pin near the swash plate, and is generated by the pressure difference
before and behind the piston.
The drive lug and journal pin are located where the piston generates the highest pressure. Piston pres-
sure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If
crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash
plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase
triggers pressure difference between the piston and the crankcase. The pressure difference changes the
angle of the swash plate.
RHA473C
RHA474C

REFRIGERATION SYSTEM
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Component LayoutEJS001Z3
RHA589H

ATC-20
LUBRICANT
LUBRICANT
PFP:KLG00
Maintenance of Lubricant Quantity in CompressorEJS001Z4
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci-
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
●Lack of lubricant: May lead to a seized compressor
●Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.
1. CHECK 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.
Ye s o r N o
Yes >> 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 30°C (77 to 86°F).]
Intake position: Recirculation (REC)
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?
Ye s o r N o
Ye s > > G o t o AT C - 2 1 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
No >> GO TO 4.Name Nissan A/C System Oil Type S
Part number KLH00-PAGS0