Condition NISSAN TERRANO 2002 Service Repair Manual

Precautions for Refrigerant Connection
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
IDo not leave compressor on its side or upside down for more than 10 minutes, as compressor oil
will enter low pressure chamber.
IWhen connecting tubes, always use a torque wrench and a back-up wrench.
IAfter disconnecting tubes, plug all openings immediately to prevent entrance of dirt and moisture.
IWhen installing an air conditioner in the vehicle, the pipes must be connected at the final stage of
the operation. The seal caps of the pipes and other components must not be removed until their
removal is required for connection.
ITo prevent the condensation of moisture inside A/C components, components stored in cool areas
should be allowed to warm to the working area temperature before removing the seal caps.
IThoroughly remove moisture from the refrigeration system before charging the refrigerant.
IAlways replace used O-rings.
IWhen connecting tube, apply lubrication oil to portions shown in illustration. Be careful not to
apply oil to threaded portion.
Lubrication oil name: NISSAN A/C System Oil Type R
Part number: KLH00-PAGR0
IO-ring must be closely attached to inflated portion of tube.
IAfter inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
IAfter 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.
SHA525D
PRECAUTIONS
HA-4

Precautions for Servicing Compressor
IAttach a blind plug to the suction port (low pressure) and discharge port (high pressure) of the
compressor to prevent oil from leaking out and dust from getting inside.
IWhen the compressor is removed, store it under the same condition as it is when mounted on the
car.
IWhen replacing or repairing compressor, be sure to remove oil from the compressor and check
the oil quantity extracted.
IWhen replacing with a new compressor, be sure to remove oil from the new compressor so that
the quantity of oil remaining in the new compressor is equal to the quantity collected from the
removed compressor. See the section ªLUBRICATION OILº.
IPay attention so as not to allow dirt and oil to attach on the friction surfaces between clutch and
pulley. If the surface is contaminated, with oil, wipe it off by using a clean waste cloth moistened
with thinner.
IAfter completing the compressor service operation, be sure to rotate the compressor shaft more
than five turns in both directions by hand to equalize oil distribution inside the compressor, then
run the compressor for about one hour by idling the engine.
IWhen the compressor magnet clutch has been replaced, be sure to check the magnet clutch for
normal operation by applying voltage to the clutch.
PRECAUTIONS
HA-5

Control Operation
FAN CONTROL DIAL
This DIAL turns the fan ON and OFF, and controls fan speed.
AIR CONTROL DIAL
This DIAL allows outlet air to flow.
TEMPERATURE CONTROL DIAL
This DIAL allows the temperature of the outlet air to be adjusted.
AIR RECIRCULATION SWITCH
OFF position:
Outside air is drawn into the passenger compartment.
ON position (Indicator light ON):
Interior air is recirculated inside the vehicle.
AIR CONDITIONER SWITCH
Start the engine, turn the fan control dial to the desired (1 to 4) position and press the air conditioner switch
to turn ON the air conditioner. The indicator light will come on when the air conditioner is ON. To stop the air
conditioner, push the switch again to return it to the original position.
The air conditioner cooling function operates only when the engine is running.
NHA331
DESCRIPTION Ð Overall System
HA-6

Precautions for Service Equipment
RECOVERY/RECYCLING/RECHARGING EQUIPMENT
Be certain to follow the manufacturers instructions for machine
operation and machine maintenance. Never introduce any refriger-
ant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufactures instructions for tester opera-
tion and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
Since the vent side of the vacuum pump is exposed to atmospheric
pressure, it is possible for the vacuum pump lubricant to migrate
out of the pump into the service hose if the pump is switched off
after evacuation (vacuuming) and the service hose is not isolated
from the vacuum pump.
To prevent the migration of vacuum pump lubricant into service
hoses, it is necessary to use a valve (which can be manually
opened or closed) near the connection of the service hose to the
pump.
IOn a vacuum pump which is equipped with an isolator valve
(usually part of the vacuum pump), closing this valve will iso-
late the service hose from the pump.
IFor pumps without an isolator valve, be certain that the service
hose is equipped with a manual shut off valve near the pump
end of the hose.
IHoses which contain an automatic shut off valve at the end of
the service hose must be disconnected from the vacuum pump
to prevent the migration of lubricant: as long as the hose is
connected, the valve is open and lubricant may migrate.
One-way valves which open when vacuum is applied and close
under a no vacuum condition are not recommended, because this
valve may restrict the pump's ability to pull a deep vacuum.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates R-134a or 134a. Be cer-
tain that the manifold gauge set has the 1/2²-16 ACME threaded
connections for service hoses, and that no refrigerants other than
HFC-134a (R-134a) (along with only specified lubricants) have
been used with the manifold gauge set.
RHA270D
SHA814D
PREPARATION
HA-13

Set the recovery/recycling/recharging
equipment.
Recovered lubrication oil
Refer toLUBRICATION
OIL Ð Checking and
Adjusting.Discharge refrigerant into recovery/
recycling/recharging equipment.
Repair or replace parts.
Evacuate the unwanted air in charging
hoses.
Evacuating (over 25 minutes).
Check air tightness.ERepair.
G
ECharging [approx. 200 g (7.05 oz)].
*-1
Preliminary refrigerant leak check.
Complete charging
[specified amount Ð 200 g (7.05 oz)].
*-1
Check for refrigerant leaks.
*-2
Check for A/C operation and
A/C cooling performance
Remove service couplers from A/C service
valves.
Recover refrigerant in charging hoses.
Note: *-1 Before charging refrigerant, ensure engine is off.
*-2 Before checking for leaks, start engine to activate air conditioning system then turn it off.
Service valve caps must be attached to valves (to prevent leak).
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SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure (Cont'd)
HA-16

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:
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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

Operation Check
The purpose of the operational check is to confirm that the system
is as it should be. The systems which will be checked are the
blower, mode (discharge air), intake air, temperature decrease,
temperature increase and A/C switch system.
CONDITIONS:
Engine running and at normal operating temperature.
PROCEDURE:
1. Check blower
1) Turn FAN CONTROL DIAL to 1.
Blower should operate at speed 1.
2) Then turn the DIAL to speed 2.
3) Continue checking blower speed until all speeds are checked.
4) Leave blower on speed 4.
2. Check discharge air
1) Turn AIR CONTROL DIAL toposition.
2) Confirm that all discharge air comes out of face vents.
3) Turn AIR CONTROL DIAL to
position.
4) Confirm that discharge air comes out of face vents and foot
vents.
5) Turn AIR CONTROL DIAL to
position.
6) Confirm that discharge air comes out of foot vents, with some
air from face vents.
7) Turn AIR CONTROL DIAL to
position.
8) Confirm that discharge air comes out of foot vents with some
air from defroster vents.
9) Turn AIR CONTROL DIAL to
position.
10) Confirm that all discharge air comes out of defroster vents, with
some air from face vents.
3. Check recirculation
1) Switch AIR RECIRCULATION SWITCH to ON position (Indica-
tor light ON).
2) Listen for intake door position change (you should hear sound
change slightly).
NHA333
NHA334
RHA035E
NHA335
DIAGNOSES Ð Overall System
HA-28

4. Check temperature decrease
1) Turn TEMPERATURE CONTROL DIAL to full cold (counter-
clockwise).
2) Check for cold air at discharge air outlets.
5. Check temperature increase
1) Turn TEMPERATURE CONTROL DIAL to full hot (clockwise).
2) Check for hot air at discharge air outlets.
6. Check A/C switch
Turn FAN CONTROL DIAL to the desired position (1 to 4) and
switch AIR CONDITIONER SWITCH to turn ON air conditioner.
Indicator light will come on when air conditioner is ON.
NHA336
NHA337
NHA338
DIAGNOSES Ð Overall System
Operation Check (Cont'd)
HA-29

Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-ventilated place)
Doors: Closed
Door window: Open (Front driver side only)
Hood: Open
TEMP. control lever position: Max. COLD
AIR control lever position:
(Ventilation)
INTAKE lever position:
(Recirculation)
FAN lever: 4
Engine speed: 1,500 rpm
Time required before starting testing
after air conditioner starts operating:More than 10 minutes
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air)
at blower assembly inlet
Discharge air temperature at center ventilator
ÉC (ÉF)
Relative humidity
%Air temperature
ÉC (ÉF)
40-6025 (77) 9.8 - 11.5 (50 - 53)
30 (86) 13.8 - 15.9 (57 - 61)
35 (95) 17.9 - 20.3 (64 - 69)
60-8025 (77) 11.5 - 13.3 (53 - 56)
30 (86) 15.9 - 18.0 (61 - 64)
35 (95) 20.3 - 22.7 (69 - 73)
Ambient air temperature-to-compressor pressure table
Ambient air
High-pressure (Discharge side)
kPa (bar, kg/cm
2, psi)Low-pressure (Suction side)
kPa (bar, kg/cm2, psi) Relative humidity
%Air temperature
ÉC (ÉF)
40-8025 (77)1,451 - 1,608 (14.51 - 16.08,
14.8 - 16.4, 210 - 233)157 - 186 (1.57 - 1.86, 1.6 - 1.9,
23 - 27)
30 (86)1,569 - 1,804 (15.69 - 18.04,
16.0 - 18.4, 228 - 262)176 - 235 (1.76 - 2.35, 1.8 - 2.4,
26 - 34)
35 (95)1,834 - 2,138 (18.34 - 21.38,
18.7 - 21.8, 266 - 310)226 - 304 (2.26 - 3.04, 2.3 - 3.1,
33 - 44)
DIAGNOSES Ð Overall System
HA-30

Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure
sides are too low.
AC353A
There is a big temperature dif-
ference between expansion
valve inlet and outlet while the
valve itself is frosted.Expansion valve closes a little
compared with the specifica-
tion.
"
q
1Improper expansion valve
adjustment
q
2Malfunctioning thermal valve
q
3Outlet and inlet may be
clogged.IRemove foreign particles by
using compressed air.
ICheck compressor oil for
contamination.
Areas near low-pressure pipe
connection and service valve
are extremely cold as com-
pared with areas near expan-
sion valve outlet and evapora-
tor.Low-pressure pipe is clogged
or crushed.ICheck and repair malfunc-
tioning parts.
ICheck compressor oil for
contamination.
Air flow volume is not enough
or is too low.Evaporator is frozen.
"
Compressor discharge capac-
ity does not change. (Com-
pressor stroke is set at maxi-
mum length.)Replace compressor.
Low-pressure side sometimes
becomes negative.
AC354A
IAir conditioning system does
not function and does not
cyclically cool the compart-
ment air.
IThe system constantly func-
tions for a certain period of
time after compressor is
stopped and restarted.Refrigerant does not discharge
cyclically.
"
Moisture is frozen at expan-
sion valve outlet and inlet.
"
Water is mixed with refrigerant.IDrain water from refrigerant
or replace refrigerant.
IReplace liquid tank.
DIAGNOSES Ð Overall System
Performance Test Diagnoses (Cont'd)
HA-34