2003 NISSAN ALMERA N16 charging

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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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

PRECAUTIONS
ATC-7
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●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 S
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 con-
nections of seal seat to the specified torque.
Precautions for Servicing CompressorEJS001YU
●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 “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to ATC-20, "
Maintenance of Lubricant Quantity in Compressor" .
●Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, 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 usual
operation.
Precautions for Service EquipmentEJS001YV
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
RHA861F

PRECAUTIONS
ATC-9
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SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press Shift/Reset and Enter at the same time.
2. Press 8787 . “A1 ” will be displayed.
3. Remove all weight from the scale.
4. Press 0 , then press Enter . “0.00 ” will be displayed and change to “A2 ”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press Enter — the display returns to the vacuum mode.
8. Press Shift/Reset and Enter at the same time.
9. Press 6 — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00 ” will be displayed.
11 . P r e s s Shift/Reset to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder′s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.
Precautions for Leak Detection DyeEJS001YW
●The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
●Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
●The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo-
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J-
41995) pin-point refrigerant leaks.
●For your safety and your Customer′s satisfaction, read and follow all manufacture′s operating instructions
and precautions prior to performing the work.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D
RHA274D

ATC-12
PREPARATION
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color: Light blue
Container marking: HFC-134a (R-
134a)
Fitting size: Thread size
●Large container 1/2″ -16 ACME
KLH00-PAGS0
Nissan A/C System Oil Type SType: Poly alkylene glycol oil (PAG),
type S
Application: HFC-134a (R-134a)
swash plate compressors (Nissan
only)
Lubricity: 40 m [Liter] (1.4 Imp fl oz)
Recovery/Recycling/
Recharging equipment (ACR4)Function: Refrigerant Recovery and
Recycling and Recharging
Electrical leak detectorPower supply:
DC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses
(J-41459) Refrigerant dye injector
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
S-NT196
S-NT197
RJIA0195E
SHA705EB
ZHA200H

PREPARATION
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(J-42220)
Fluorescent dye leak detectorPower supply: DC 12V (Battery
terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system.
Includes: UV lamp and UV safety
glasses
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PAG oil
Container: 1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
(J-43872)
Dye cleanerFor cleaning dye spills.
Manifold gauge set (with hoses
and couplers)
Identification:
●The gauge face indicates R-134a.
Fitting size: Thread size
●1/2″ -16 ACME
Service hoses
●High side hose
●Low side hose
●Utility hose
Hose color:
●Low hose: Blue with black stripe
●High hose: Red with black stripe
●Utility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
●1/2″ -16 ACME Tool number
Tool nameDescription
SHA438F
SHA439F
SHA440F
SHA441F
RJIA0196E
S-NT201

LUBRICANT
ATC-21
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4.CHECK ANY PART
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large
amount of lubricant leakage.)
Ye s o r N o
Ye s > > G o t o AT C - 2 1 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR" .
No >> Carry out the A/C performance test.
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-
PRESSOR
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
*1:If refrigerant leak is small, no addition of lubricant is needed.
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
4. Drain the lubricant from the new compressor into a separate, clean container.
5. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this
lubricant to new compressor through the suction port opening.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 m [Liter] (0.2 Imp fl oz.) of lubricant at
this time.
Do not add this 5 m (0.2 Imp fl oz.) of lubricant if only replacing the compressor.
Part replacedLubricant to be added to system
Remarks
Amount of lubricant
m [Liter] (Imp fl oz.)
Evaporator 75 (2.6) -
Condenser 35 (1.2) -
Liquid tank 10 (0.4) -
In case of refrigerant leak30 (1.1) Large leak
- Small leak *1

ATC-132
REFRIGERANT LINES
REFRIGERANT LINES
PFP:92600
HFC-134a (R-134a) Service ProcedureEJS0020I
SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant
WARNING:
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 refrigerant and lubricant manufacturers.
Evacuating System and Charging Refrigerant
SHA539DE
SHA540DC

ATC-146
REFRIGERANT LINES
Dye Injection
EJS0020W
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52kg/cm
2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture′s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak DetectorEJS0020X
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
SHA705EB
SHA707EA
SHA706E