Engine Control NISSAN ALMERA N16 2003 Electronic Repair Manual

AT-412
[ALL]
REMOVAL AND INSTALLATION
4. Tighten bolts fixing transaxle.
5. Reinstall any part removed.
6. Adjust control cable. Refer to AT- 4 0 8 , "
Control Cable Adjust-
ment" .
7. Check continuity of PNP switch. Refer to AT- 111 , "
DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH" .
8. Refill transaxle with ATF and check fluid level.
9. Move selector lever through all positions to be sure that tran-
saxle operates correctly. With parking brake applied, idle
engine. Move selector lever through “N” to “D”, to “2”, to “1” and
“R” positions. A slight shock should be felt through the hand
gripping the selector each time the transaxle is shifted.
10. Perform road test. Refer to AT- 2 6 6 , "
Road Test" .
Bolt No.Tightening torque
N-m (kg-m, ft-lb)Bolt length “ L ”
mm (in)
1 70 - 79 (7.1 - 8.1, 51 - 59) 55 (2.17)
2 70 - 79 (7.1 - 8.1, 51 - 59) 50 (1.97)
3 70 - 79 (7.1 - 8.1, 51 - 59) 65 (2.56)
4 16 - 21 (1.6 - 2.1, 12 - 15) 35 (1.38)
5 16 - 21 (1.6 - 2.1, 12 - 15) 47 (1.85)
MCIB9009E
SAT638A

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION
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AT C
AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a) ..... 4
General Refrigerant Precautions .............................. 4
Lubricant Precautions .............................................. 5
Precautions for Refrigerant Connection ................... 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 5
O-RING AND REFRIGERANT CONNECTION ..... 6
Precautions for Servicing Compressor ..................... 7
Precautions for Service Equipment .......................... 7
RECOVERY/RECYCLING EQUIPMENT .............. 7
ELECTRONIC LEAK DETECTOR ........................ 8
VACUUM PUMP ................................................... 8
MANIFOLD GAUGE SET ...................................... 8
SERVICE HOSES ................................................. 8
SERVICE COUPLERS .......................................... 9
REFRIGERANT WEIGHT SCALE ........................ 9
CALIBRATING ACR4 WEIGHT SCALE ................ 9
CHARGING CYLINDER ........................................ 9
Precautions for Leak Detection Dye ......................... 9
IDENTIFICATION ................................................ 10
IDENTIFICATION LABEL FOR VEHICLE ........... 10
Wiring Diagrams and Trouble Diagnosis ................ 10
PREPARATION ..........................................................11
Special Service Tools .............................................. 11
HFC-134a (R-134a) Service Tools and Equipment .... 11
REFRIGERATION SYSTEM ..................................... 15
Refrigerant Cycle ................................................... 15
REFRIGERANT FLOW ....................................... 15
FREEZE PROTECTION ..................................... 15
Refrigerant System Protection ............................... 15
REFRIGERANT PRESSURE SENSOR (WITH
GASOLINE ENGINE) .......................................... 15
DUAL-PRESSURE SWITCH (WITH DIESEL
ENGINE) ............................................................. 15
PRESSURE RELIEF VALVE ............................... 15
CSV613 Variable Displacement Compressor ......... 16GENERAL INFORMATION ................................. 16
DESCRIPTION .................................................... 16
Component Layout ................................................. 19
LUBRICANT .............................................................. 20
Maintenance of Lubricant Quantity in Compressor ... 20
LUBRICANT ........................................................ 20
LUBRICANT RETURN OPERATION .................. 20
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 21
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 21
AIR CONDITIONER CONTROL ............................... 22
Overview Air Conditioner LAN Control System ...... 22
System Construction .............................................. 22
OPERATION ........................................................ 22
TRANSMISSION DATA AND TRANSMISSION
ORDER ............................................................... 23
AIR MIX DOOR CONTROL (AUTOMATIC TEM-
PERATURE CONTROL) ..................................... 23
FAN SPEED CONTROL ...................................... 24
INTAKE DOOR CONTROL ................................. 24
OUTLET DOOR CONTROL ................................ 24
MAGNET CLUTCH CONTROL ........................... 24
SELF-DIAGNOSTIC SYSTEM ............................ 24
Overview of Control system .................................... 24
Control Operation ................................................... 25
DISPLAY SCREEN .............................................. 25
AUTO SWITCH ................................................... 25
TEMPERATURE DIAL (POTENTIO TEMPERA-
TURE CONTROL) ............................................... 25
A/C SWITCH ....................................................... 25
DEFROSTER (DEF) SWITCH ............................. 25
MODE SWITCH .................................................. 25
FAN SWITCH ...................................................... 25
OFF SWITCH ...................................................... 25
FRESH (FRE) SWITCH ...................................... 25
RECIRCULATION (REC) SWITCH ..................... 26
REAR WINDOW DEFOGGER SWITCH ............. 26
Fail-safe Function ................................................... 26

ATC-2
Discharge Air Flow ................................................. 27
System Description ................................................. 28
SWITCHES AND THEIR CONTROL FUNCTION ... 28
TROUBLE DIAGNOSIS ............................................ 29
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 29
WORK FLOW ...................................................... 29
SYMPTOM TABLE .............................................. 29
Component Parts and Harness Connector Location ... 30
ENGINE COMPARTMENT .................................. 30
PASSENGER COMPARTMENT .......................... 31
Circuit Diagram ....................................................... 32
Wiring Diagram ....................................................... 33
Auto Amp. Terminals and Reference Value ............ 40
PIN CONNECTOR TERMINAL LAYOUT ............ 40
AUTO AMP. INSPECTION TABLE ...................... 40
Self-diagnosis Function .......................................... 42
DESCRIPTION .................................................... 42
FUNCTION CONFIRMATION PROCEDURE ...... 43
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 49
Operational Check .................................................. 51
CHECKING MEMORY FUNCTION ..................... 51
CHECKING BLOWER ......................................... 51
CHECKING DISCHARGE AIR ............................ 52
CHECKING RECIRCULATION ............................ 53
CHECKING FRESH SWITCH ............................. 53
CHECKING TEMPERATURE DECREASE ......... 53
CHECKING TEMPERATURE INCREASE .......... 53
CHECKING AUTO MODE ................................... 54
Power Supply and Ground Circuit for Auto Amp. ... 55
INSPECTION FLOW ........................................... 55
COMPONENT DESCRIPTION ............................ 55
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ... 56
LAN System Circuit ............................................. ... 57
DIAGNOSTIC PROCEDURE FOR LAN SYS-
TEM CIRCUIT ..................................................... 57
Mode Door Motor Circuit ........................................ 59
INSPECTION FLOW ........................................... 60
SYSTEM DESCRIPTION .................................... 61
COMPONENT DESCRIPTION ............................ 62
DIAGNOSTIC PROCEDURE FOR MODE
DOOR .................................................................. 62
Air Mix Door Motor Circuit ...................................... 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 65
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR ................................................... 65
Intake Door Motor Circuit ........................................ 66
INSPECTION FLOW ........................................... 66
SYSTEM DESCRIPTION .................................
... 67
COMPONENT DESCRIPTION ............................ 67
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 68
Blower Motor Circuit ............................................... 69
INSPECTION FLOW ........................................... 69
SYSTEM DESCRIPTION .................................... 70
COMPONENT DESCRIPTION ............................ 71DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ................................................................ 71
COMPONENT INSPECTION ............................... 74
Magnet Clutch Circuit .............................................. 75
INSPECTION FLOW ............................................ 75
SYSTEM DESCRIPTION ..................................... 76
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH (WITH CAN SYSTEM) ......................... 76
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH (YD ENGINE WITHOUT COMMON
RAIL) .................................................................... 81
COMPONENT INSPECTION ............................... 85
Insufficient Cooling .................................................. 86
INSPECTION FLOW ............................................ 86
PERFORMANCE TEST DIAGNOSES ................ 88
PERFORMANCE CHART .................................... 90
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ................................................................... 92
Insufficient Heating ................................................. 95
INSPECTION FLOW ............................................ 95
Noise ....................................................................... 97
INSPECTION FLOW ............................................ 97
Self-diagnosis ......................................................... 98
INSPECTION FLOW ............................................ 98
Memory Function .................................................... 99
INSPECTION FLOW ............................................ 99
Ambient Sensor Circuit .........................................100
COMPONENT DESCRIPTION ..........................100
AMBIENT TEMPERATURE INPUT PROCESS .100
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ............................................................100
COMPONENT INSPECTION .............................102
In-vehicle Sensor Circuit .......................................102
COMPONENT DESCRIPTION ..........................102
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR ............................................................103
COMPONENT INSPECTION .............................104
Sunload Sensor Circuit .........................................105
COMPONENT DESCRIPTION ..........................105
SUNLOAD INPUT PROCESS ...........................105
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR ............................................................105
COMPONENT INSPECTION .............................107
Intake Sensor Circuit .............................................108
COMPONENT DESCRIPTION ..........................108
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ...................................................................108
Multiplex Communication Circuit ...........................109
DIAGNOSTIC PROCEDURE FOR MULTIPLEX
COMMUNICATION CIRCUIT ............................109
CONTROLLER ........................................................113
Removal and Installation .......................................113
AUTO AMP ..............................................................114
REMOVAL AND INSTALLATION ..........................114
AMBIENT SENSOR ................................................115
Removal and Installation .......................................115
IN-VEHICLE SENSOR ............................................116
Removal and Installation .......................................116

ATC-3
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AT C SUNLOAD SENSOR ...............................................117
Removal and Installation ....................................... 117
INTAKE SENSOR CIRCUIT ....................................118
Removal and Installation ....................................... 118
BLOWER UNIT ........................................................119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION .................................................. 119
Disassembly and Assembly .................................. 119
BLOWER MOTOR .................................................. 120
Removal and Installation ...................................... 120
INTAKE DOOR MOTOR ......................................... 121
Removal and Installation ...................................... 121
HEATER & COOLING UNIT ASSEMBLY .............. 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSTALLATION ................................................. 123
Disassembly and Assembly ................................. 123
MODE DOOR MOTOR ........................................... 125
Removal and Installation ...................................... 125
AIR MIX DOOR MOTOR ......................................... 126
Removal and Installation ...................................... 126
FAN CONTROL AMPLIFIER .................................. 127
Removal and Installation ...................................... 127
VENTILATION AIR FILTER .................................... 128
Removal and Installation ...................................... 128
FUNCTION ........................................................ 128
REPLACEMENT TIMING .................................. 128
REPLACEMENT AND PROCEDURES ............ 128
HEATER CORE ...................................................... 129
Removal and Installation ...................................... 129
DUCTS AND GRILLES .......................................... 130
Removal and Installation ...................................... 130
VENTILATOR DUCT, DEFROSTER NOZZLE
AND DEFROSTER DUCTS .............................. 130
CENTER VENTILATOR GRILLE ...................... 130
SIDE VENTILATOR GRILLE ............................. 130
FOOT DUCT ..................................................... 130
FLOOR DUCT ................................................... 131
REFRIGERANT LINES ........................................... 132
HFC-134a (R-134a) Service Procedure ............... 132
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................ 132Components .........................................................134
Compressor ..........................................................136
REMOVAL .........................................................136
INSTALLATION .................................................137
Compressor Clutch .............................................. .138
REMOVAL .........................................................138
INSTALLATION .................................................139
Low-pressure Flexible Hose .................................141
REMOVAL .........................................................141
INSTALLATION .................................................141
High-pressure Flexible Hose ................................141
REMOVAL .........................................................141
INSTALLATION .................................................142
High-pressure Pipe ...............................................142
REMOVAL .........................................................142
INSTALLATION .................................................142
Refrigerant Pressure Sensor ................................142
REMOVAL AND INSTALLATION ......................142
Dual-pressure Switch ...........................................143
REMOVAL AND INSTALLATION ......................143
Condenser Assembly ...........................................143
REMOVAL .........................................................143
INSTALLATION .................................................143
Evaporator ............................................................144
REMOVAL .........................................................144
INSTALLATION .................................................144
Expansion Valve ...................................................144
REMOVAL .........................................................144
INSTALLATION .................................................144
Checking for Refrigerant Leaks ............................145
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................145
Dye Injection .........................................................146
Electronic Refrigerant Leak Detector ....................146
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................146
CHECKING PROCEDURE ...............................147
SERVICE DATA AND SPECIFICATIONS (SDS) ....149
Compressor ..........................................................149
Lubricant ...............................................................149
Refrigerant ............................................................149
Engine Idling Speed .............................................149
Belt Tension ..........................................................149

REFRIGERATION SYSTEM
ATC-15
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AT C
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.

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

ATC-24
AIR CONDITIONER CONTROL
FAN SPEED CONTROL
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and air mix door position.
With FAN switch set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing.
INTAKE DOOR CONTROL
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.
OUTLET DOOR CONTROL
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature and amount of sunload.
MAGNET CLUTCH CONTROL
The ECM controls compressor operation using input signals from the refrigerant pressure sensor (with QG
engine), throttle position sensor and auto amplifier.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems.
Overview of Control systemEJS001Z7
The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs.
The relationship of these components is shown in the diagram below:
RJIA0687E

TROUBLE DIAGNOSIS
ATC-41
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10 L/RMultiplex communication
(Rx) signal
AV → A/C amp.IGN
ON-
11 B/Y Sensor ground IGN
ON-Approx. 0
12 OR Sunload sensorIGN
ON--
17 PU/WWater temperature sen-
sor signalIGN
ONEngine coolant temperature: Approx.
60°C
18 BR/WCompressor feed back
signal (With gasoline
engine)IGN
ONA/C ON-Approx. 0
When refrigerant pres-
sure sensor connector is
disconnected.Approx. 5
20 LMultiplex communication
(CLK) signalIGN
ON-
21 G/YPower supply for mode
door, air mix door and
intake door motorIGN
ON-Approx. 12
22 L/R Compressor ON signalIGN
ONCompressor: ON Approx. 0
Compressor: OFF Approx. 5
24 B GroundIGN
ON-Approx. 0
26 R/B Power supply for BATTIGN
OFF-Approx. 12
27 Y/G Power supply for IGNIGN
ON-Approx. 12
29 LG/B Fan ON signalIGN
ONBlower fan: ON Approx. 0
Blower fan: OFF Approx. 5
33 L/W Power supply for ACCIGN
ON-Approx. 12
34 L/BBlower fan motor feed
back signalIGN
ONFan speed: Manual 1st Approx. 8
35 L/YFan control amp. control
signalIGN
ONFan speed:Manual 1st - 4th speed Approx. 2.5 - 3.5
Manual 5th speed Approx. 9.0 TERMI-
NAL NO.WIRE
COLORITEM CONDITIONVo lta g e
(V)
RJIA0213E
SKIA0056J
HAK0363D

ATC-42
TROUBLE DIAGNOSIS
Self-diagnosis Function
EJS001ZH
DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to appli-
cable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by
starting the engine (turning the ignition switch from OFF to ON) and pressing OFF switch for at least 5 sec-
onds. The “OFF” switch must be pressed within 10 seconds after starting the engine (ignition switch is turned
ON). This system will be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting
from one step to another is accomplished by means of turning temperature dial, as required.
Additionally shifting from STEP 6 to AUXILIARY MECHANISM is accomplished by means of pushing (fan)
UP switch.
RJIA1681E