2004 NISSAN TERRANO air condition

HEATER & AIR CONDITIONERSECTION
HA
CONTENTS
PRECAUTIONS ...............................................................2
Supplemental Restraint System (SRS) ²AIR
BAG² and²SEAT BELT PRE-TENSIONER² ...............2
Introduction ..................................................................2
Identification .................................................................3
Precautions for Working with HFC-134a (R-134a) .....4
General Refrigerant Precautions .................................4
Precautions for Refrigerant Connection ......................5
Precautions for Servicing Compressor ........................6
DESCRIPTION - Overall System ...................................7
Control Operation ........................................................7
Component Layout ......................................................8
Air Flow ........................................................................\
9
DESCRIPTION - Refrigeration System .......................10
Refrigeration Cycle ....................................................10
PREPARATION .............................................................. 11
Special Service Tools ................................................ 11
HFC-134a (R-134a) Service Tools and
Equipment ..................................................................12
Precautions for Service Equipment ...........................14
SERVICE PROCEDURES .............................................16
HFC-134a (R-134a) Service Procedure ....................16
Refrigerant Lines .......................................................18
Compressor Mounting ...............................................22
Belt Tension ...............................................................22
LUBRICATION OIL - Checking and Adjusting ...........23
Lubrication Oil ............................................................23 Maintenance of Oil Quantity in Compressor .............23
Checking and Adjusting .............................................23
COMPRESSOR - Model DKS-17CH (ZEXEL
make) ........................................................................\
.....25
Compressor Clutch ....................................................25
DIAGNOSES - Overall System ....................................28
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................28
Operation Check ........................................................29
Performance Chart ....................................................31
Performance Test Diagnoses ....................................32
TROUBLE DIAGNOSES ...............................................37
Symptom Chart ..........................................................37
Preliminary Check......................................................38
Harness Layout for A/C System ................................40
Wiring Diagram - Heater............................................42
Wiring Diagram ..........................................................44
Main Power Supply and Ground Circuit Check ........52
Diagnostic Procedure 1 .............................................53
Diagnostic Procedure 2 .............................................55
Diagnostic Procedure 3 .............................................60
Electrical Components Inspection .............................61
Control Linkage Adjustment.......................................62
SERVICE DATA AND SPECIFICATIONS (SDS) ..........65
General Specifications ...............................................65
Inspection and Adjustment ........................................65
When you read wiring diagrams:
I Read GI section, ªHOW TO READ WIRING DIAGRAMSº.
I See EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSESº.
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Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The 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 composition which is available to NISSAN MODEL R20 is as follows (The composition
varies according to the destination and optional equipment.):
IFor 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.
I 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).
WARNING:
I 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.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
I 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.
Introduction
To prevent the ozone layer from being destroyed, the HFC-134a (R-134a) refrigerant has replaced the previ-
ously used CFC-12 (R-12).
The new and previous service tools, refrigerant, lubricant, etc. are not interchangeable due to differences in
their physical properties and characteristics.
Always service the HFC-134a (R-134a) air conditioning system using the specified tools, lubricant and
refrigerant, observing the following precautions:
PRECAUTIONS
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Precautions for Working with HFC-134a
(R-134a)
WARNING:I CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant must never be mixed, even in the
smallest amounts, as they are incompatible with each other. If the refrigerants are mixed, com-
pressor failure is likely to occur.
I Use only specified lubrication oil for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a)
components. If lubrication oil other than that specified is used, compressor failure is likely to
occur.
I The specified HFC-134a (R-134a) lubrication oil absorbs moisture from the atmosphere at a rapid
rate, therefore the following 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. Also, complete the connection of all refrigerant loop
components as quickly as possible to minimize the entry of moisture into the system.
c: Use the specified lubrication oil from a sealed container only. Containers must be re-sealed immediately after dispensing the lubrication oil. Lubrication oil in containers which are not
properly sealed will become moisture saturated, and such lubrication oil is no longer suitable
for use and should be properly disposed of.
d: 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)
system. 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 lubrication oil (Nissan A/C System Oil Type S or Type R) to come in contact with styrofoam parts. Damage may result.
General Refrigerant Precautions
WARNING:
I Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
I Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
I Do not store or heat refrigerant containers above 52ÉC (125ÉF).
I 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.
I Do not drop, puncture, or incinerate refrigerant containers.
I Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
I Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
I Do not introduce compressed air to any refrigerant container or refrigerant component.
PRECAUTIONS
HA-4
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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.
I When connecting tubes, always use a torque wrench and a back-up wrench.
I After disconnecting tubes, plug all openings immediately to prevent entrance of dirt and moisture.
I When 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.
I To 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.
I Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
I Always replace used O-rings.
I When 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 S
Part number: KLH00-PAGS0
I O-ring must be closely attached to inflated portion of tube.
I After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
I 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.
SHA525D
PRECAUTIONS
HA-5
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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.
I When the compressor is removed, store it under the same condition as it is when mounted on the
car.
I When replacing or repairing compressor, be sure to remove oil from the compressor and check
the oil quantity extracted.
I When 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.
I Pay 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.
I After 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.
I When 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-6
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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-7
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Set the recovery/recycling/rechargingequipment.
Recovered lubrication oilRefer to LUBRICATION
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-17
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Lubrication Oil
Name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
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
I Excessive 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.
I There 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:
I 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 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 replaced Oil 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
leak 30 (1.1)
Large leak
Ð Small leak *2
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LUBRICATION OIL Ð Checking and Adjusting
HA-23
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