2001 NISSAN ALMERA maintenance

Basic InspectionNJEC0632Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+Headlamp switch is OFF,
+On vehicles equipped with daytime light systems, set
lighting switch to the 1st position to light only small
lamps.
+Air conditioner switch is OFF,
+Rear defogger switch is OFF,
+Steering wheel is in the straight-ahead position, etc.
1 INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to MA-6, ªPeri-
odic Maintenanceº.
3. Open engine hood and check the following:
+Harness connectors for improper connections
+Vacuum hoses for splits, kinks, or improper connections
+Wiring for improper connections, pinches, or cuts
SEF142I
4. Start engine and warm it up to the normal operating temperature.
©GO TO 2.
2 PREPARATION FOR CHECKING IDLE SPEED
With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
©GO TO 3.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONYD
Basic Inspection
EC-641

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJEL0001The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To 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 should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
Wiring Diagrams and Trouble DiagnosisNJEL0002When you read wiring diagrams, refer to the following:
+Refer to GI-11, ªHOW TO READ WIRING DIAGRAMSº
+Refer to EL-10, ªPOWER SUPPLY ROUTINGº for power distribution circuit
When you perform trouble diagnosis, refer to the following:
+Refer to GI-32, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSESº
+Refer to GI-21, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº
Check for any Service bulletins before servicing the vehicle.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EL-5

PrecautionsNJGI0001Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
SGI646
PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) ªAIR BAGº AND ªSEAT BELT
PRE-TENSIONERº
NJGI0001S01The Supplemental Restraint System such as ªAIR BAGº and ªSEAT
BELT PRE-TENSIONERº used along with a seat belt, helps to
reduce the risk or severity of injury to the driver and front passen-
ger for certain types of collision. The SRS system composition
which is available to NISSAN MODEL N16 is as follows (The com-
position varies according to the destination and optional equip-
ment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag
module (located in the center of the steering wheel), front pas-
senger air bag module (located on the instrument panel on
passenger side), front seat belt pre-tensioners, a diagnoses
sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air
bag module (located in the outer side of front seat), side air bag
(satellite) sensor, diagnoses sensor unit (one of components of
air bags for a frontal collision), wiring harness, warning lamp
(one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in
theRS sectionof this Service Manual.
WARNING:
+To 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 should be performed by an authorized
NISSAN dealer.
+Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system. For removal of
Spiral Cable and Air Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses can be identified by yellow harness
connector.
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
NJGI0001S02NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
The security indicator is located on the instrument panel or in the
PRECAUTIONS
Precautions
GI-3

HEATER &
AIR CONDITIONER
SECTION
HA
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
Precautions for Working with HFC-134a (R-134a) .....2
General Refrigerant Precautions .................................2
Precautions for Refrigerant Connection ......................3
Precautions for Servicing Compressor ........................5
Precautions for Service Equipment .............................6
Wiring Diagrams and Trouble Diagnosis .....................8
PREPARATION...............................................................9
Special Service Tools ..................................................9
HFC-134a (R-134a) Service Tools and
Equipment .................................................................. 11
DESCRIPTION...............................................................13
Refrigeration System .................................................13
CSV613 Variable Displacement Compressor............14
Component Layout ....................................................18
Control Operation ......................................................19
Discharge Air Flow.....................................................20
System Description ....................................................21
TROUBLE DIAGNOSES................................................22
Component Location..................................................22
Wiring Diagram - Heater............................................24
Circuit Diagram - Air Conditioner...............................26
Wiring Diagram - A/C, M - .........................................27
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................33
Operational Check .....................................................34
Intake Door ................................................................36
Mode Door .................................................................40Air Mix Door ...............................................................42
Max Hot Door (For Scandinavia and Cold Spec
Models) ......................................................................44
Blower Motor..............................................................48
Magnet Clutch............................................................55
Insufficient Cooling ....................................................68
Insufficient Heating ....................................................76
Noise ..........................................................................77
SERVICE PROCEDURE................................................78
HFC-134a (R-134a) Service Procedure ....................78
Maintenance of Lubricant Quantity in
Compressor ...............................................................80
Compressor ...............................................................83
Compressor Clutch - CSV613 (CALSONIC
make) .........................................................................84
Heater & Cooling Unit (Heater Core) ........................88
A/C Evaporator ..........................................................88
Blower Unit ................................................................89
Refrigerant Lines .......................................................91
Belt .............................................................................95
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve ..................................................96
Ventilation Air Filter ....................................................96
SERVICE DATA AND SPECIFICATIONS (SDS).........97
Compressor ...............................................................97
Lubricant ....................................................................97
Refrigerant .................................................................97
Engine Idling Speed (When A/C is On).....................97
Belt Tension ...............................................................97

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJHA0190The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To 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 should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Working with HFC-134a
(R-134a)
NJHA0113WARNING:
+CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor fail-
ure is likely to occur.
+Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
+The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
a) When removing refrigerant components from a vehicle, immediately cap (seal) the component 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 pos-
sible to minimize the entry of moisture into system.
c) Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. 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. Remove R-134a from the A/C system, using certified service equipment meeting
requirements of R-134a recycling equipment, or R-134a recovery equipment. If accidental system
discharge occurs, ventilate work area before resuming service. Additional health and safety
information may be obtained from refrigerant 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 PrecautionsNJHA0114WARNING:
+Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
+Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
HA-2

+When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
+Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
+Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
+Always replace used O-rings.
+When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type R for DKV-11G compressor
Part number: KLH00-PAGR0
Lubricant name: Nissan A/C System Oil Type S for CSV613 compressor
Part number: KLH00-PAGS0
+O-ring must be closely attached to dented portion of tube.
+When replacing the O-ring, be careful not to damage O-ring and tube.
+Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
+After 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 for Servicing CompressorNJHA0116+Plug all openings to prevent moisture and foreign matter from entering.
+When the compressor is removed, store it in the same position as it is when mounted on the car.
+When replacing or repairing compressor, follow ªMaintenance of Lubricant Quantity in Compres-
sorº exactly. Refer to HA-80.
+Keep 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.
+After 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 compressor
is installed, let the engine idle and operate the compressor for one hour.
+After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
PRECAUTIONS
Precautions for Refrigerant Connection (Cont'd)
HA-5

Precautions for Service EquipmentNJHA0117RECOVERY/RECYCLING EQUIPMENTNJHA0117S01Follow the manufacturer's instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.
ELECTRONIC LEAK DETECTORNJHA0117S02Follow the manufacture's instructions for tester operation and
tester maintenance.
RHA270D
VACUUM PUMPNJHA0117S03The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric
pressure. So the vacuum pump lubricant may migrate out of the
pump into the service hose. This is possible when the pump is
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
+Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose from
the pump.
+For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
+If the hose has an automatic shut off valve, disconnect the
hose from the pump: as long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
SHA533D
MANIFOLD GAUGE SETNJHA0117S04Be certain that the gauge face indicates R-134a or 134a. Make
sure the gauge set has 1/2²-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant.
RHA272D
SERVICE HOSESNJHA0117S05Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive
shut off devices (either manual or automatic) near the end of the
hoses opposite the manifold gauge.
PRECAUTIONS
Precautions for Service Equipment
HA-6

Maintenance of Lubricant Quantity in
Compressor
NJHA0160The lubricant in the compressor circulates through the system with
the refrigerant. Add lubricant to compressor when replacing any
component or after a large gas leakage occurred. It is important to
maintain the specified amount.
If lubricant quantity is not maintained properly, the following mal-
functions may result:
+Lack of lubricant: May lead to a seized compressor
+Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANTNJHA0160S01Name: Nissan A/C System Oil Type R for DKV-11G compres-
sor
Part number: KLH00-PAGR0
Name: Nissan A/C System Oil Type S for CSV613 compressor
Part number: KLH00-PAGS0
CHECKING AND ADJUSTINGNJHA0160S02Adjust the lubricant quantity according to the test group shown
below.
1 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.
YesorNo
Ye s©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 30ÉC (77 to 86ÉF).]
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?
YesorNo
Ye s©GO TO HA-82.
No©GO TO 4.
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor
HA-80