2003 NISSAN ALMERA N16 Electronic Repair Manual

heater wheel wheel alignment radio manual transmission cruise control

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NISSAN ALMERA N16 2003 Electronic Repair Manual SERVICE DATA AND SPECIFICATIONS (SDS)
AT-521
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REDUCTION PINION GEAR BEARING ADJUSTING SHIMS
*: Always check with the Parts Department for the latest parts information. T

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NISSAN ALMERA N16 2003 Electronic Repair Manual AT-522
[ALL]
SERVICE DATA AND SPECIFICATIONS (SDS)
TABLE FOR SELECTING REDUCTION PINION GEAR BEARING ADJUSTING SHIM
Unit: mm (in)
Output ShaftECS007U4
SEAL RING CLEARANCE
Unit: mm (in)
END PLAY
SEAL R

AT-522
[ALL]
SERVICE DATA AND SPECIFICATIONS (SDS)
TABLE FOR SELECTING REDUCTION PINION GEAR BEARING ADJUSTING SHIM
Unit: mm (in)
Output ShaftECS007U4
SEAL RING CLEARANCE
Unit: mm (in)
END PLAY
SEAL RING
*: Always check with the Parts Department for the latest parts information.
OUTPUT SHAFT END PLAY ADJUSTING SHIMS
*: Always check with the Parts Department for the latest parts information. Dimension “T” Suitable shim(s)
1.77 - 1.81 (0.0697 - 0.0713)
1.81 - 1.85 (0.0713 - 0.0728)
1.85 - 1.89 (0.0728 - 0.0744)
1.89 - 1.93 (0.0744 - 0.0760)
1.93 - 1.96 (0.0760 - 0.0772)
1.96 - 1.98 (0.0772 - 0.0780)
1.98 - 2.00 (0.0780 - 0.0787)
2.00 - 2.02 (0.0787 - 0.0795)
2.02 - 2.04 (0.0795 - 0.0803)
2.04 - 2.06 (0.0803 - 0.0811)
2.06 - 2.08 (0.0811 - 0.0819)
2.08 - 2.10 (0.0819 - 0.0827)
2.10 - 2.12 (0.0827 - 0.0835)
2.12 - 2.14 (0.0835 - 0.0843)
2.14 - 2.16 (0.0843 - 0.0850)
2.16 - 2.18 (0.0850 - 0.0858)
2.18 - 2.20 (0.0858 - 0.0866)
2.20 - 2.22 (0.0866 - 0.0874)
2.22 - 2.24 (0.0874 - 0.0888)
2.24 - 2.26 (0.0882 - 0.0890)
2.26 - 2.28 (0.0890 - 0.0898)
2.28 - 2.30 (0.0898 - 0.0906)
2.30 - 2.32 (0.0906 - 0.0913)
2.32 - 2.34 (0.0913 - 0.0921)
2.34 - 2.37 (0.0921 - 0.0933)
2.37 - 2.41 (0.0933 - 0.0949)
2.41 - 2.45 (0.0949 - 0.0965)
2.45 - 2.49 (0.0965 - 0.0980)
2.49 - 2.53 (0.0980 - 0.0996)
2.53 - 2.57 (0.0996 - 0.1012)
2.57 - 2.61 (0.1012 - 0.1028)
2.61 - 2.65 (0.1028 - 0.1043)
2.65 - 2.69 (0.1043 - 0.1059)
2.69 - 2.73 (0.1059 - 0.1075)1.74 (0.0685)
1.78 (0.0701)
1.82 (0.0717)
1.86 (0.0732)
1.90 (0.0748)
1.92 (0.0756)
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0780)
2.00 (0.0787)
2.02 (0.0795)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0843)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
2.34 (0.0921)
2.38 (0.0937)
2.42 (0.0953)
2.46 (0.0969)
2.50 (0.0984)
2.54 (0.1000)
2.58 (0.1016)
2.62 (0.1031)
2.66 (0.1047)
Output shaft seal ring clearanceStandard 0.10 - 0.25 (0.0039 - 0.0098)
Allowable limit 0.25 (0.0098)
Output shaft end play 0 - 0.5 mm (0 - 0.020 in)
Outer diameter mm (in) Inner diameter mm (in) Width mm (in) Part number*
33.71 (1.327) 30.25 (1.191) 1.95 (0.077) 31525 80X09
Thickness mm (in) Part number*
0.56 (0.0220)
0.96 (0.0378)
1.36 (0.0535)31438-31X46
31438-31X47
31438-31X48

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NISSAN ALMERA N16 2003 Electronic Repair Manual SERVICE DATA AND SPECIFICATIONS (SDS)
AT-523
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Bearing RetainerECS007U5
SEAL RING CLEARANCE
Unit: mm (in)
Total End PlayECS007U6
BEARING RACE FOR ADJUSTING TOTAL END PLAY

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NISSAN ALMERA N16 2003 Electronic Repair Manual AT-524
[ALL]
SERVICE DATA AND SPECIFICATIONS (SDS)
Band Servo
ECS007U9
RETURN SPRING
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Removal and InstallationE

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NISSAN ALMERA N16 2003 Electronic Repair Manual ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION
A
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AT C
AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Pre

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION
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AT C
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

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NISSAN ALMERA N16 2003 Electronic Repair Manual ATC-2
Discharge Air Flow ................................................. 27
System Description ................................................. 28
SWITCHES AND THEIR CONTROL FUNCTION ... 28
TROUBL

ATC-2
Discharge Air Flow ................................................. 27
System Description ................................................. 28
SWITCHES AND THEIR CONTROL FUNCTION ... 28
TROUBLE DIAGNOSIS ............................................ 29
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 29
WORK FLOW ...................................................... 29
SYMPTOM TABLE .............................................. 29
Component Parts and Harness Connector Location ... 30
ENGINE COMPARTMENT .................................. 30
PASSENGER COMPARTMENT .......................... 31
Circuit Diagram ....................................................... 32
Wiring Diagram ....................................................... 33
Auto Amp. Terminals and Reference Value ............ 40
PIN CONNECTOR TERMINAL LAYOUT ............ 40
AUTO AMP. INSPECTION TABLE ...................... 40
Self-diagnosis Function .......................................... 42
DESCRIPTION .................................................... 42
FUNCTION CONFIRMATION PROCEDURE ...... 43
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 49
Operational Check .................................................. 51
CHECKING MEMORY FUNCTION ..................... 51
CHECKING BLOWER ......................................... 51
CHECKING DISCHARGE AIR ............................ 52
CHECKING RECIRCULATION ............................ 53
CHECKING FRESH SWITCH ............................. 53
CHECKING TEMPERATURE DECREASE ......... 53
CHECKING TEMPERATURE INCREASE .......... 53
CHECKING AUTO MODE ................................... 54
Power Supply and Ground Circuit for Auto Amp. ... 55
INSPECTION FLOW ........................................... 55
COMPONENT DESCRIPTION ............................ 55
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ... 56
LAN System Circuit ............................................. ... 57
DIAGNOSTIC PROCEDURE FOR LAN SYS-
TEM CIRCUIT ..................................................... 57
Mode Door Motor Circuit ........................................ 59
INSPECTION FLOW ........................................... 60
SYSTEM DESCRIPTION .................................... 61
COMPONENT DESCRIPTION ............................ 62
DIAGNOSTIC PROCEDURE FOR MODE
DOOR .................................................................. 62
Air Mix Door Motor Circuit ...................................... 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 65
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR ................................................... 65
Intake Door Motor Circuit ........................................ 66
INSPECTION FLOW ........................................... 66
SYSTEM DESCRIPTION .................................
... 67
COMPONENT DESCRIPTION ............................ 67
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 68
Blower Motor Circuit ............................................... 69
INSPECTION FLOW ........................................... 69
SYSTEM DESCRIPTION .................................... 70
COMPONENT DESCRIPTION ............................ 71DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ................................................................ 71
COMPONENT INSPECTION ............................... 74
Magnet Clutch Circuit .............................................. 75
INSPECTION FLOW ............................................ 75
SYSTEM DESCRIPTION ..................................... 76
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH (WITH CAN SYSTEM) ......................... 76
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH (YD ENGINE WITHOUT COMMON
RAIL) .................................................................... 81
COMPONENT INSPECTION ............................... 85
Insufficient Cooling .................................................. 86
INSPECTION FLOW ............................................ 86
PERFORMANCE TEST DIAGNOSES ................ 88
PERFORMANCE CHART .................................... 90
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ................................................................... 92
Insufficient Heating ................................................. 95
INSPECTION FLOW ............................................ 95
Noise ....................................................................... 97
INSPECTION FLOW ............................................ 97
Self-diagnosis ......................................................... 98
INSPECTION FLOW ............................................ 98
Memory Function .................................................... 99
INSPECTION FLOW ............................................ 99
Ambient Sensor Circuit .........................................100
COMPONENT DESCRIPTION ..........................100
AMBIENT TEMPERATURE INPUT PROCESS .100
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ............................................................100
COMPONENT INSPECTION .............................102
In-vehicle Sensor Circuit .......................................102
COMPONENT DESCRIPTION ..........................102
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR ............................................................103
COMPONENT INSPECTION .............................104
Sunload Sensor Circuit .........................................105
COMPONENT DESCRIPTION ..........................105
SUNLOAD INPUT PROCESS ...........................105
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR ............................................................105
COMPONENT INSPECTION .............................107
Intake Sensor Circuit .............................................108
COMPONENT DESCRIPTION ..........................108
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ...................................................................108
Multiplex Communication Circuit ...........................109
DIAGNOSTIC PROCEDURE FOR MULTIPLEX
COMMUNICATION CIRCUIT ............................109
CONTROLLER ........................................................113
Removal and Installation .......................................113
AUTO AMP ..............................................................114
REMOVAL AND INSTALLATION ..........................114
AMBIENT SENSOR ................................................115
Removal and Installation .......................................115
IN-VEHICLE SENSOR ............................................116
Removal and Installation .......................................116

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NISSAN ALMERA N16 2003 Electronic Repair Manual ATC-3
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AT C SUNLOAD SENSOR ...............................................117
Removal and Installation ....................................... 117
INTAKE SENSOR CIRCUIT ......

ATC-3
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AT C SUNLOAD SENSOR ...............................................117
Removal and Installation ....................................... 117
INTAKE SENSOR CIRCUIT ....................................118
Removal and Installation ....................................... 118
BLOWER UNIT ........................................................119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION .................................................. 119
Disassembly and Assembly .................................. 119
BLOWER MOTOR .................................................. 120
Removal and Installation ...................................... 120
INTAKE DOOR MOTOR ......................................... 121
Removal and Installation ...................................... 121
HEATER & COOLING UNIT ASSEMBLY .............. 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSTALLATION ................................................. 123
Disassembly and Assembly ................................. 123
MODE DOOR MOTOR ........................................... 125
Removal and Installation ...................................... 125
AIR MIX DOOR MOTOR ......................................... 126
Removal and Installation ...................................... 126
FAN CONTROL AMPLIFIER .................................. 127
Removal and Installation ...................................... 127
VENTILATION AIR FILTER .................................... 128
Removal and Installation ...................................... 128
FUNCTION ........................................................ 128
REPLACEMENT TIMING .................................. 128
REPLACEMENT AND PROCEDURES ............ 128
HEATER CORE ...................................................... 129
Removal and Installation ...................................... 129
DUCTS AND GRILLES .......................................... 130
Removal and Installation ...................................... 130
VENTILATOR DUCT, DEFROSTER NOZZLE
AND DEFROSTER DUCTS .............................. 130
CENTER VENTILATOR GRILLE ...................... 130
SIDE VENTILATOR GRILLE ............................. 130
FOOT DUCT ..................................................... 130
FLOOR DUCT ................................................... 131
REFRIGERANT LINES ........................................... 132
HFC-134a (R-134a) Service Procedure ............... 132
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................ 132Components .........................................................134
Compressor ..........................................................136
REMOVAL .........................................................136
INSTALLATION .................................................137
Compressor Clutch .............................................. .138
REMOVAL .........................................................138
INSTALLATION .................................................139
Low-pressure Flexible Hose .................................141
REMOVAL .........................................................141
INSTALLATION .................................................141
High-pressure Flexible Hose ................................141
REMOVAL .........................................................141
INSTALLATION .................................................142
High-pressure Pipe ...............................................142
REMOVAL .........................................................142
INSTALLATION .................................................142
Refrigerant Pressure Sensor ................................142
REMOVAL AND INSTALLATION ......................142
Dual-pressure Switch ...........................................143
REMOVAL AND INSTALLATION ......................143
Condenser Assembly ...........................................143
REMOVAL .........................................................143
INSTALLATION .................................................143
Evaporator ............................................................144
REMOVAL .........................................................144
INSTALLATION .................................................144
Expansion Valve ...................................................144
REMOVAL .........................................................144
INSTALLATION .................................................144
Checking for Refrigerant Leaks ............................145
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................145
Dye Injection .........................................................146
Electronic Refrigerant Leak Detector ....................146
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................146
CHECKING PROCEDURE ...............................147
SERVICE DATA AND SPECIFICATIONS (SDS) ....149
Compressor ..........................................................149
Lubricant ...............................................................149
Refrigerant ............................................................149
Engine Idling Speed .............................................149
Belt Tension ..........................................................149

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NISSAN ALMERA N16 2003 Electronic Repair Manual ATC-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS001YP
The Supplemental Restraint System such as �

ATC-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS001YP
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
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 must be per-
formed by an authorized NISSAN/INFINITI 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 SRS 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 and/or orange harness connec-
tors.
Precautions for Working with HFC-134a (R-134a)EJS001YQ
WARNING:
●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 malfunction 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:
–When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–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 possi-
ble to minimize the entry of moisture into system.
–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.
–Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meet-
ing requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (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.
–Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
General Refrigerant PrecautionsEJS001YR
WARNING:
●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.
●Do not store or heat refrigerant containers above 52°C (125°F).
●Do 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.
●Do not intentionally drop, puncture, or incinerate refrigerant containers.
●Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
●Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
●Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)

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