NISSAN PICK-UP 1998 Repair Manual

HEATER &
AIR CONDITIONER
SECTIONHA
CONTENTS
PRECAUTIONS AND PREPARATION..................... 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
Precautions for Working with HFC-134a
(R-134a) ................................................................. 2
General Refrigerant Precautions ........................... 2
Precautions for Refrigerant Connection ................ 2
Precautions for Servicing Compressor .................. 6
Special Service Tools ............................................ 6
HFC-134a (R-134a) Service Tools and
Equipment .............................................................. 8
Precautions for Service Equipment ..................... 10
DESCRIPTION......................................................... 12
Refrigeration Cycle .............................................. 12
Component Layout............................................... 13
Discharge Air Flow............................................... 14
Control Operation................................................. 16
TROUBLE DIAGNOSES......................................... 17
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ............................................ 17
Operational Check ............................................... 18
Symptom Chart .................................................... 20
Preliminary Check ................................................ 21
Performance Test Diagnoses .............................. 24
Performance Chart............................................... 26Trouble Diagnoses for Abnormal Pressure ......... 27
Component Location ............................................ 30
Wiring Diagram - HEATER -................................ 31
Circuit Diagram - Air Conditioner......................... 32
Wiring Diagram - A/C - ........................................ 33
Main Power Supply and Ground Circuit Check... 36
Diagnostic Procedure 1 ....................................... 37
Diagnostic Procedure 2 ....................................... 39
Electrical Components Inspection ....................... 43
Control Linkage Adjustment................................. 45
SERVICE PROCEDURES....................................... 48
HFC-134a (R-134a) Service Procedure .............. 48
Maintenance of Lubricant Quantity in
Compressor.......................................................... 50
Refrigerant Lines.................................................. 52
Checking Refrigerant Leaks ................................ 56
Compressor Mounting.......................................... 58
Compressor - DKV-14C (ZEXEL make) .............. 60
Compressor Clutch - DKV-14C
(ZEXEL make) ..................................................... 60
Thermal Protector - DKV-14C (ZEXEL make) .... 63
Compressor - DKS-17CH (ZEXEL make) ........... 64
Compressor Clutch - DKS-17CH
(ZEXEL make) ..................................................... 64
SERVICE DATA AND SPECIFICATIONS (SDS)... 67
General Specifications ......................................... 67
Inspection and Adjustment .................................. 67
When you read wiring diagrams:
lRead GI section, ``HOW TO READ WIRING DIAGRAMS''.
lSee EL section, ``POWER SUPPLY ROUTING'' for power distribution circuit.
When you perform trouble diagnoses, read GI section, ``HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES'' and ``HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT''.
HA

Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo 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 must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), diagnosis sensor unit, warning lamp and spiral cable.
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
lTo 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 must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS.
PRECAUTIONS AND PREPARATION
HA-1

Precautions for Working with HFC-134a
(R-134a)
WARNING:
lCFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrig-
erants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, com-
pressor failure is likely to occur.
lUse only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) com-
ponents. If lubricant other than that specified is used, compressor failure is likely to occur.
lThe specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The
following handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the compo-
nent 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 possible to minimize the entry of moisture into system.
c: Only use the specified lubricant from a sealed container. Immediately reseal containers of
lubricant. 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. Use only approved recovery/recycling equipment to discharge HFC-134a
(R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refriger-
ant 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 Precautions
WARNING:
lDo not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
lAlways wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
lDo not store or heat refrigerant containers above 52ÉC (125ÉF).
lDo not heat a refrigerant container with an open flame; if container warming is required, place
the bottom of the container in a warm pail of water.
lDo not intentionally drop, puncture, or incinerate refrigerant containers.
lKeep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
lRefrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
lDo not introduce compressed air to any refrigerant container or refrigerant component.
Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
lExpansion valve to cooling unit
lCondenser to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
lThe O-ring has been relocated. It has also been provided with a groove for proper installation. This
eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direc-
tion of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve
sealing characteristics.
lThe reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.
PRECAUTIONS AND PREPARATION
HA-2

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse
O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-ring part numbers and specifications
Connection
typeO-ring
sizePart number D mm (in) W mm (in)
New
892471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
New
1292472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
1692473 N8210 13.6 (0.535) 2.43 (0.0957)
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
1992474 N8210 16.5 (0.650) 2.43 (0.0957)
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
SHA815E
SHA814E
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont'd)
HA-3

O-RING AND REFRIGERANT CONNECTION
LHD models
RHD models
RHA341G
RHA342G
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont'd)
HA-4

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
lWhen the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
lWhen connecting tubes, always use a torque wrench and a back-up wrench.
lAfter disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
lWhen installing an air conditioner in the vehicle, connect the pipes as the final stage of the
operation. Do not remove the seal caps of pipes and other components until just before required
for connection.
lAllow components stored in cool areas to warm to working area temperature before removing
seal caps. This prevents condensation from forming inside A/C components.
lThoroughly remove moisture from the refrigeration system before charging the refrigerant.
lAlways replace used O-rings.
lWhen connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type R (Except for the Middle East)
Nissan A/C System Oil Type S (For the Middle East)
Part number: KLH00-PAGR0 (Except for the Middle East)
KLH00-PAGS0 (For the Middle East)
lO-ring must be closely attached to inflated portion of tube.
lAfter inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
lAfter 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 AND PREPARATION
Precautions for Refrigerant Connection
(Cont'd)
HA-5

Precautions for Servicing Compressor
lPlug all openings to prevent moisture and foreign matter from entering.
lWhen the compressor is removed, store it in the same position as it is when mounted on the car.
lWhen replacing or repairing compressor, follow ``Maintenance of Lubricant Quantity in Compres-
sor'' exactly. Refer to HA-50.
lKeep 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.
lAfter 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 compres-
sor is installed, let the engine idle and operate the compressor for one hour.
lAfter replacing the compressor magnet clutch, apply voltage to the new one and check for nor-
mal operation.
Special Service Tools
FOR DKV-14C COMPRESSOR
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
Center pulley puller
NT208
Removing pulley
PRECAUTIONS AND PREPARATION
HA-6

FOR DKS-17CH COMPRESSOR
Tool number
Tool nameDescription
KV99231260
Clutch disc wrench
NT204
Removing shaft nut and clutch disc
KV992T0001
Clutch disc puller
NT206
Removing clutch disc
KV992T0002
Pulley installer
NT207
Installing pulley
PRECAUTIONS AND PREPARATION
Special Service Tools (Cont'd)
HA-7

HFC-134a (R-134a) Service Tools and
Equipment
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-
cation oil.
Separate and non-interchangeable service equipment must be used for each type of refrigerant/lubricant.
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 failure will result.
Tool name Description Note
HFC-134a (R-134a) refrig-
erant
NT196
Container color: Light blue
Container marking: HFC-134a (R-134a)
Fitting size: Thread size
llarge container 1/2²-16 ACME
Nissan A/C System Oil
Type R
NT197
Type: Poly alkylene glycol oil (PAG), type R
Application: HFC-134a (R-134a) vane rotary
compressors (Nissan only)
Lubricity: 40 m!(1.4 Imp fl oz)
Nissan A/C System Oil
Type SType: Poly alkylene glycol oil (PAG), type S
Application: HFC-134a (R-134a) swash plate
(piston) compressors (Nissan only)
Lubricity: 40 m!(1.4 Imp fl oz)
Recovery/Recycling/
Recharging equipment
NT195
Function: Refrigerant Recovery and Recycling
and Recharging
Electrical leak detector
NT198
Power supply:
lDC 12 V (Cigarette lighter)
Manifold gauge set (with
hoses and couplers)
NT199
Identification:
lThe gauge face indicates R-134a.
Fitting size: Thread size
l1/2²-16 ACME
PRECAUTIONS AND PREPARATION
HA-8

Tool name Description Note
Service hoses
lHigh side hose
lLow side hose
lUtility hose
NT201
Hose color:
lLow hose: Blue with black stripe
lHigh hose: Red with black stripe
lUtility hose: Yellow with black stripe or green
with black stripe
Hose fitting to gauge:
l1/2²-16 ACME
Service couplers
lHigh side coupler
lLow side coupler
NT202
Hose fitting to service hose:
lM14 x 1.5 fitting is optional or
permanently attached.
Refrigerant weight scale
NT200
For measuring of refrigerant
Fitting size: Thread size
l1/2²-16 ACME
Vacuum pump
(Including the isolator
valve)
NT203
Capacity:
lAir displacement: 4 CFM
lMicron rating: 20 microns
lOil capacity: 482 g (17 oz)
Fitting size: Thread size
l1/2²-16 ACME
PRECAUTIONS AND PREPARATION
HFC-134a (R-134a) Service Tools and
Equipment (Cont'd)
HA-9