NISSAN TERRANO 2002 Service Repair Manual

TD ENGINE RHD MODELS
YHA449
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
HA-18

ZD ENGINE LHD MODELS
YHA457
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
HA-19

ZD ENGINE RHD MODELS
YHA458
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
HA-20

Compressor Mounting
Belt Tension
IRefer to MA section.
RHA980D
SERVICE PROCEDURES
HA-21

Lubrication Oil
Name: Nissan A/C System Oil Type R
Part number: KLH00-PAGR0
Maintenance of Oil Quantity in Compressor
The oil used to lubricate the compressor circulates through the
system with the refrigerant. Whenever any component of the sys-
tem is replaced or a large amount of gas leakage occurs, add oil
to the compressor to maintain the specified amount.
If oil quantity is not maintained properly, the following malfunctions
may result:
ILack of oil: May lead to a seized compressor
IExcessive oil: Inadequate cooling (thermal exchange impeded)
Checking and Adjusting
Adjust the oil quantity according to the flowchart shown below.
START
Can oil return operation be performed?
IA/C system works properly.
IThere is no evidence of a large amount
of oil leakage.
No
EYe s
Perform oil return operation, proceeding as follows:
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1. Start engine, and set the following conditions:
ITest 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 oil return operating for about 10 minutes.
3. Stop engine.
CAUTION:
If excessive oil leakage is noted, do not perform the oil return operation.
Should the compressor be replaced?
No Yes
qA(Go to next page.)
Is there any part to be replaced?
(Evaporator, condenser, liquid tank or in
case there is evidence of a large amount
of oil leakage.)
No
EYe s
After replacing any of the following major components of the system, be sure
to add the correct amount of oil to the system.
Amount of oil to be added
*1: If compressor is replaced, addition of oil is included in the flow chart.
*2: If refrigerant leak is small, no addition of oil is needed. ªRatioº in this table
indicates the ratio of added oil to the overall amount of oil needed in the
system.
Carry out the A/C performance test.F
Part replacedOil to be added to system
Remarks
Amount of oil 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
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LUBRICATION OIL Ð Checking and Adjusting
HA-22

qA
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure oil discharged into the recovery/recycling
equipment.
2. Drain the oil from the ªoldº (removed) compressor into a graduated container, and record the amount of oil drained.
3. Drain the oil from the ªnewº compressor into a separate, clean container.
4. Measure an amount of the new oil equivalent to that drained from the ªoldº compressor, and add this oil to the ªnewº com-
pressor through the drain plug or suction port opening.
5. Measure an amount of the ªnewº oil equivalent to that recovered during discharging, and add this oil to the ªnewº compressor
through the drain plug or suction port opening.
6. If the liquid tank also needs to be replaced, add an additional 5 m(0.2 Imp fl oz) of oil at this time.
Do not add this 5 m(0.2 Imp fl oz) of oil if only replacing the compressor.
SHA563D
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LUBRICATION OIL Ð Checking and Adjusting
Checking and Adjusting (Cont'd)
HA-23

Compressor Clutch
REMOVAL
IWhen removing center bolt, hold clutch disc with clutch disc
wrench.
IRemove the drive plate using the drive plate puller.
Insert the holder's three pins into the holes in the drive plate,
and rotate the holder clockwise to hook it onto the plate. Then,
tighten the center bolt to remove the drive plate.
When tightening the center bolt, insert a round bar (screwdriver,
etc.) between two of the pins (as shown in the left-hand figure)
to prevent drive plate rotation. After removing the drive plate,
remove the shims from either the drive shaft or the drive plate.
YHA403
RHA070C
RHA071C
COMPRESSOR Ð Model DKV-14C (ZEXEL make)
HA-24

IRemove the snap ring using external snap ring pliers.
IPulley removal
Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail-
able pulley puller.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked into (not under) the pulley groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
IRemove the field coil harness clip using a screwdriver.
IRemove the three field coil fixing screws and remove the field
coil.
INSPECTION
Clutch disc:If the contact surface shows signs of damage due to
excessive heat, the clutch disc and pulley should be replaced.
Pulley:Check the appearance of the pulley assembly. If the con-
tact surface of the pulley shows signs of excessive grooving due
to slippage, both the pulley and clutch disc should be replaced. The
contact surfaces of the pulley assembly should be cleaned with a
suitable solvent before reinstallation.
Coil:Check coil for loose connection or cracked insulation.
INSTALLATION
IInstall the field coil.
Be sure to align the coil's pin with the hole in the compres-
sor's front head.
IInstall the field coil harness clip using a screwdriver.
RHA072C
RHA073C
RHA074C
RHA075C
RHA076C
COMPRESSOR Ð Model DKV-14C (ZEXEL make)
Compressor Clutch (Cont'd)
HA-25

IInstall the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
IInstall the drive plate on the drive shaft, together with the origi-
nal shim(s). Press the drive plate down by hand.
IUsing the holder to prevent drive plate rotation, tighten the bolt
to 12 to 15 N×m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.
After tightening the bolt, check that the pulley rotates
smoothly.
ICheck clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget break-in
operation, accomplished by engaging and disengaging the clutch
about thirty times. Break-in operation raises the level of transmit-
ted torque.
RHA077C
RHA078C
RHA079C
RHA080C
COMPRESSOR Ð Model DKV-14C (ZEXEL make)
Compressor Clutch (Cont'd)
HA-26

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW
CHECK INFReference item
LISTEN TO CUSTOMER COMPLAINT AND CON-
FIRM BY PERFORMING OPERATIONAL CHECK.
Can be
confirmedCannot be
confirmed
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM.
LISTEN TO CUSTOMER COMPLAINTS AND
CONFIRM.FSymptom Chart
(See page HA-36.)
INVESTIGATE ITEMS YOU SHOULD CARRY
OUT RELATED TO EACH SYMPTOM.FSymptom Chart
(See page HA-36.)
EELIMINATE GOOD SYSTEM(S)/PART(S).FPreliminary Check
(See pages HA-37.)
CHECK MAIN POWER SUPPLY AND GROUND
CIRCUITS.FMain Power Supply and Ground Circuit
Check
(See page HA-51.)
Diagnostic
Procedure(s)
(See pages HA-52 -
54.)EELIMINATE GOOD PART(S)/HARNESS(ES)/
CONNECTOR(S) ELECTRICALLY.FHarness Layout for A/C System
(See page HA-39.)
Malfunctioning
harness(es)/
connector(s)Malfunctioning
part(s)
INSPECT EACH
COMPONENT.
FElectrical Components Inspection
(See page HA-60.)
REPAIR.
H
REPAIR/REPLACE.
NG
FINAL CHECK
OK
CHECK OUT
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DIAGNOSES Ð Overall System
HA-27