MTC - 4 8 15 16 23 42

J AIR CONDITIONER

SECTION

MANUAL AIR CONDITIONER

B

C

D

A

E

CONTENTS

PRECAUTIONS .......................................................... 3

Precautions for Supplemental Restraint System

(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-

SIONER” .................................................................. 3

Contaminated Refrigerant ........................................ 3

General Refrigerant Precautions .............................. 4

Precautions for Leak Detection Dye ......................... 4

A/C Identification Label ............................................ 4

Precautions for Refrigerant Connection ................... 5

FEATURES OF NEW TYPE REFRIGERANT

CONNECTION ...................................................... 5

O-RING AND REFRIGERANT CONNECTION ..... 6

Precautions for Servicing Compressor ..................... 9

Precautions for Service Equipment .......................... 9

RECOVERY/RECYCLING EQUIPMENT .............. 9

ELECTRONIC LEAK DETECTOR ........................ 9

VACUUM PUMP ................................................. 10

MANIFOLD GAUGE SET .................................... 10

SERVICE HOSES ............................................... 10

SERVICE COUPLERS .........................................11

REFRIGERANT WEIGHT SCALE .......................11

CALIBRATING ACR4 WEIGHT SCALE ...............11

CHARGING CYLINDER .......................................11

Wiring Diagrams and Trouble Diagnosis .................11

PREPARATION ......................................................... 12

Special Service Tools ............................................. 12

Commercial Service Tools ...................................... 15

REFRIGERATION SYSTEM ..................................... 16

Refrigeration Cycle ................................................. 16

REFRIGERANT FLOW ....................................... 16

REFRIGERANT SYSTEM PROTECTION .......... 16

Component Layout ................................................. 17

LUBRICANT ............................................................. 18

LUBRICANT ........................................................ 18

CHECKING AND ADJUSTING ........................... 18

AIR CONDITIONER CONTROL ............................... 21

Control Operation ................................................... 21

FAN CONTROL DIAL .......................................... 21

AIR CONTROL DIAL ........................................... 21

TEMPERATURE CONTROL DIAL ...................... 21

RECIRCULATION (REC) SWITCH ..................... 21

AIR CONDITIONER (A/C) SWITCH .................... 21

Discharge Air Flow ................................................. 22

System Description ................................................. 23

SWITCHES AND THEIR CONTROL FUNCTION ... 23

CAN Communication System Description .............. 23

FOR TCS MODELS ............................................ 23

FOR A/T MODELS .............................................. 25

FOR M/T MODELS ............................................. 26

TROUBLE DIAGNOSIS ............................................ 28

How to Perform Trouble Diagnoses for Quick and

Accurate Repair ...................................................... 28

WORK FLOW ...................................................... 28

SYMPTOM TABLE .............................................. 28

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ENGINE COMPARTMENT .................................. 29

PASSENGER COMPARTMENT ......................... 31

Circuit Diagram ....................................................... 32

Wiring Diagram — HEATER — .............................. 33

Wiring Diagram — A/C,M — ................................... 35

Operational Check .................................................. 38

CONDITIONS: ..................................................... 38

PROCEDURE: .................................................... 38

A/C System ............................................................. 40

DIAGNOSTIC PROCEDURE .............................. 40

Mode Door Motor Circuit ........................................ 42

INSPECTION FLOW ........................................... 42

SYSTEM DESCRIPTION .................................... 43

DIAGNOSTIC PROCEDURE .............................. 43

MODE DOOR ...................................................... 44

Air Mix Door ............................................................ 45

INSPECTION FLOW ........................................... 45

CONTROL LINKAGE ADJUSTMENT ................. 45

Intake Door Motor Circuit ........................................ 46

INSPECTION FLOW ........................................... 46

SYSTEM DESCRIPTON ..................................... 47

DIAGNOSTIC PROCEDURE .............................. 47

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Revision: May 2004

MTC-1

2002 Altima

CONTROL LINKAGE ADJUSTMENT ................. 48

Blower Motor Circuit ............................................... 49

INSPECTION FLOW ........................................... 49

DIAGNOSTIC PROCEDURE .............................. 49

ELECTRICAL COMPONENTS INSPECTION ..... 53

Magnet Clutch Circuit ............................................. 54

INSPECTION FLOW ........................................... 54

DIAGNOSTIC PROCEDURE .............................. 55

REFRIGERANT PRESSURE SENSOR .............. 57

Insufficient Cooling ................................................. 58

INSPECTION FLOW ........................................... 58

PERFORMANCE CHART ................................... 59

TROUBLE DIAGNOSES FOR ABNORMAL

PRESSURE ......................................................... 59

Insufficient Heating ................................................. 63

INSPECTION FLOW ........................................... 63

Noise ...................................................................... 64

INSPECTION FLOW ........................................... 64

Intake Sensor Circuit .............................................. 65

COMPONENT DESCRIPTION ............................ 65

DIAGNOSTIC PROCEDURE .............................. 65

CONTROL UNIT ........................................................ 67

Removal and Installation ........................................ 67

REMOVAL ........................................................... 67

INSTALLATION .................................................... 67

INTAKE SENSOR ..................................................... 68

Removal and Installation ........................................ 68

BLOWER UNIT ......................................................... 69

Removal and Installation ........................................ 69

REMOVAL ........................................................... 69

BLOWER MOTOR .................................................... 70

Removal and Installation ........................................ 70

INTAKE DOOR MOTOR ........................................... 71

Removal and Installation ........................................ 71

IN-CABIN MICROFILTER ......................................... 72

Removal and Installation ........................................ 72

FUNCTION .......................................................... 72

REPLACEMENT TIMING .................................... 72

REPLACEMENT PROCEDURES ....................... 72

HEATER & COOLING UNIT ASSEMBLY ................. 73

Removal and Installation ........................................ 73

REMOVAL ........................................................... 73

INSTALLATION ................................................... 73

HEATER CORE ......................................................... 74

Removal and Installation ........................................ 74

MODE DOOR MOTOR .............................................. 75

Removal and Installation ........................................ 75

DRIVER SIDE MODE DOOR MOTOR ................ 75

BLOWER FAN RESISTER ........................................ 76

Removal and Installation ........................................ 76

DUCTS AND GRILLES ............................................. 77

Removal and Installation ........................................ 77

Ventilator Duct, Defroster Nozzle and Defroster

Ducts ....................................................................... 77

Center Ventilator Grille ........................................... 77

Side Ventilator Grille LH ......................................... 77

Side Ventilator Grille RH ......................................... 78

Floor duct ................................................................ 78

REFRIGERANT LINES .............................................79

HFC-134a (R-134a) Service Procedure ..................79

SETTING OF SERVICE TOOLS AND EQUIP-

MENT ...................................................................79

Components ............................................................80

Removal and Installation for Compressor —

QR25DE Models .....................................................83

REMOVAL ...........................................................83

INSTALLATION ...................................................83

Removal and Installation for Compressor —

VQ35DE Models .....................................................84

REMOVAL ...........................................................84

INSTALLATION ...................................................84

Removal and Installation for Compressor Clutch ....85

REMOVAL ............................................................85

INSPECTION .......................................................86

INSTALLATION ....................................................86

BREAK-IN OPERATION ......................................87

Removal and Installation for Low-pressure Flexible

Hose ........................................................................87

REMOVAL ...........................................................87

INSTALLATION ...................................................87

Removal and Installation for High-pressure flexible hose ........................................................................88

REMOVAL ...........................................................88

INSTALLATION ...................................................88

Removal and Installation for High-pressure Pipe ....88

REMOVAL ...........................................................88

INSTALLATION ...................................................88

Removal and Installation for Refrigerant Pressure

Sensor .....................................................................88

Removal and Installation for Condenser .................88

REMOVAL ...........................................................88

INSTALLATION ...................................................89

Removal and Installation for Liquid Tank ................89

Removal and Installation for Evaporator .................90

REMOVAL ............................................................90

INSTALLATION ....................................................91

Removal and Installation for Expansion Valve ........91

REMOVAL ............................................................91

INSTALLATION ....................................................91

Checking for Refrigerant Leaks ..............................91

Checking System for Leaks Using the Fluorescent

Leak Detector ..........................................................92

Dye Injection ...........................................................92

Electronic Refrigerant Leak Detector ......................92

PRECAUTIONS FOR HANDLING LEAK

DETECTOR .........................................................92

CHECKING PROCEDURE ..................................93

SERVICE DATA AND SPECIFICATIONS (SDS) ......95

Service Data and Specifications (SDS) ..................95

COMPRESSOR ...................................................95

LUBRICANT .........................................................95

REFRIGERANT ...................................................95

ENGINE IDLING SPEED .....................................95

BELT TENSION ...................................................95

Revision: May 2004

MTC-2

2002 Altima

PRECAUTIONS

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT

BELT PRE-TENSIONER”

EJS000Z2

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 performed by an authorized NISSAN/INFINITI 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 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 harnesses or harness connectors.

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Precautions for Working with HFC-134a (R-134a)

EJS000Z3

WARNING:

CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed, compressor failure is likely to occur. Refer to

MTC-3, "Contaminated Refrigerant" . To

determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant

Recovery/Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier.

Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. 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 following 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 possible to minimize the entry of moisture into system.

Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. 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 R-134a from the A/C system using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment), or J2209 (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 DH-PS) to come in contact with styrofoam parts. Damage may result.

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Contaminated Refrigerant

EJS000Z4

If a refrigerant other than pure R-134a is identified in a vehicle, your options are:

Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere.

Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply.

Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred.

If you choose to perform the repair, recover the refrigerant using only dedicated equipment and contain-

ers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended.

Revision: May 2004

MTC-3

2002 Altima

PRECAUTIONS

If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance.

General Refrigerant Precautions

EJS000Z5

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 conditioning systems with compressed air during repair. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Precautions for Leak Detection Dye

EJS000Z6

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.

A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).

Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service.

Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed .

Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).

Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.

Leak detection dyes for R-134a and R-12 A/C systems are different. Do not use R-134a leak detection dye in R-12 A/C systems or R-12 leak detection dye in R-134a A/C systems or A/C system damage may result.

The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs.

A/C Identification Label

Vehicles with factory installed fluorescent dye have this identification label on the underside of hood.

NOTE:

Vehicles with factory installed fluorescent dye have a green label.

EJS000Z7

Revision: May 2004

MTC-4

WJIA0012E

2002 Altima

PRECAUTIONS

Precautions for Refrigerant Connection

EJS000Z8

A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.

Expansion valve to cooling unit

Evaporator pipes to evaporator (inside cooling unit)

Refrigerant pressure sensor

FEATURES OF NEW TYPE REFRIGERANT CONNECTION

The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics.

The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

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SHA815E

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Revision: May 2004

MTC-5

2002 Altima

PRECAUTIONS

O-RING AND REFRIGERANT CONNECTION

QR25DE Models

Revision: May 2004

MTC-6

WJIA0131E

2002 Altima

PRECAUTIONS

VQ35DE Models

WJIA0135E

CAUTION:

The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.

Revision: May 2004

MTC-7

2002 Altima

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PRECAUTIONS

O-Ring Part Numbers and Specifications

Connection type

New

Former

New

Former

New

Former

O-ring size

8

10

12

16

Part number*

92471 N8210

J2476 89956

92472 N8210

92475 71L00

92473 N8210

92475 72L00

D mm (in)

6.8 (0.268)

9.25 (0.3642)

10.9 (0.429)

11.0 (0.433)

13.6 (0.535)

14.3 (0.563)

W mm (in)

1.85 (0.0728)

1.78 (0.0701)

2.43 (0.0957)

2.4 (0.094)

2.43 (0.0957)

2.3 (0.091)

SHA814E

New 19 92474 N8210 16.5 (0.650) 2.43 (0.0957)

*: Always check with the Parts Department for the latest parts information.

WARNING:

Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.

CAUTION:

When replacing or cleaning refrigerant cycle components, observe the following.

When the compressor is removed, store it in the same position as it is when mounted on the car.

Failure to do so will cause lubricant to enter the low pressure chamber.

When connecting tubes, always use a torque wrench and a back-up wrench.

After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.

When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. 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 DH-PS

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.

Revision: May 2004

MTC-8

2002 Altima

PRECAUTIONS

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.

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RHA861F

Precautions for Servicing Compressor

EJS000Z9

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 Compressor” exactly. Refer to

MTC-18, "Maintenance of Lubricant Quantity in Compressor" .

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 5 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 1 hour.

After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation. [Gap between clutch disc and pulley is 0.3 - 0.6 mm (0.012 - 0.024 in)]

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Precautions for Service Equipment

RECOVERY/RECYCLING EQUIPMENT

EJS000ZA

Follow the manufacturer's instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

Follow the manufacturer's instructions for tester operation and tester maintenance.

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Revision: May 2004

MTC-9

2002 Altima

PRECAUTIONS

VACUUM PUMP

The 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.

MANIFOLD GAUGE SET

Be certain that the gauge face indicates R-134a or 134a. Make sure the gauge set has 1/2

-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-

134a (R-134a) along with specified lubricant.

SERVICE HOSES

Be certain that the service hoses display the markings described

(colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

Revision: May 2004

MTC-10

RHA270D

SHA533D

RHA272D

2002 Altima

PRECAUTIONS

SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to a

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.

Shut-off valve rotation

Clockwise

Counterclockwise

A/C service valve

Open

Close

REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2

-16

ACME.

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RHA273D

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RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale every three months.

To calibrate the weight scale on the ACR4 (J-39500-NI):

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 36.3 kg (10 and 80 lb) on the center of the weight scale.

6.

Enter the known weight using four digits. (Example 10 lbs = 10.00, 10.5 lbs = 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. Press Shift/Reset to return the ACR4 to the program mode.

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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.

Wiring Diagrams and Trouble Diagnosis

EJS000ZB

When you read wiring diagrams, refer to the following:

GI-12, "How to Read Wiring Diagrams"

PG-5, "Wiring Diagram — POWER —"

When you perform trouble diagnosis, refer to the following:

GI-9, "How to Follow Trouble Diagnoses"

GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident"

Revision: May 2004

MTC-11

2002 Altima

PREPARATION

PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

PFP:00002

EJS000ZC

Tool number

(Kent-Moore No.)

Tool name

KV99234330

(J-38873)

Pulley installer

Description

Installing pulley

LHA171

KV99233130

(J-29884)

Pulley puller

Removing pulley

LHA172

HFC-134a (R-134a) Service Tools and Equipment

EJS000ZD

Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant.

Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.

Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant.

Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor failure will result.

Tool number

(Kent-Moore No.)

Tool name

HFC-134a (R-134a) refrigerant

Description

Container color:Light blue

Container marking:HFC-134a (R-

134a)

Fitting size: Thread size

● large container 1/2

2

-16 ACME

S-NT196

KLH00-PAGS0

( - )

Nissan A/C System Oil Type DH-

PS

Type:Poly alkylene glycol oil (PAG), type DH-PS

Application:HFC-134a (R-134a) vane rotary compressors (Nissan only)

Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz)

S-NT197

Revision: May 2004

MTC-12

2002 Altima

Tool number

(Kent-Moore No.)

Tool name

(J-39500-NI)

Recovery/Recycling

Recharging equipment (ACR4)

(J-41995)

Electronic refrigerant leak detector

(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 cleaner

(J-42220)

Fluorescent dye leak detector

(J-41447)

HFC-134a (R-134a) Fluorescent leak detection dye

(Box of 24, 1/4 ounce bottles)

PREPARATION

RJIA0195E

Description

Function:Refrigerant Recovery and

Recycling and Recharging

Power supply:

DC 12V (Cigarette lighter)

AHA281A

Power supply:

DC 12V (Battery terminal)

SHA438F

SHA437F

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Power 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

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Application: For HFC-134a (R-134a)

PAG oil

Container: 1/4 ounce (7.4cc) bottle

(Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)

SHA439F

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Revision: May 2004

MTC-13

2002 Altima

Service hoses

High side hose

(J-39500-72B)

Low side hose

(J-39500-72R)

Utility hose

(J-39500-72Y)

Service couplers

High side coupler

(J-39500-20A)

Low side coupler

(J-39500-24A)

(J-39699)

Refrigerant weight scale

(J-39649)

Vacuum pump

(Including the isolator valve)

Revision: May 2004

Tool number

(Kent-Moore No.)

Tool name

(J-41459)

HFC-134a (R-134a) Dye injector

Use with J-41447, 1/4 ounce bottle

(J-43872)

Dye cleaner

PREPARATION

Description

For injecting 1/4 ounce of fluorescent leak detection dye into A/C system.

SHA440F

For cleaning dye spills.

(J-39183-C)

Manifold gauge set (with hoses and couplers)

SHA441F

Identification:

The gauge face indicates R-134a.

Fitting size: Thread size

1/2

2

-16 ACME

MTC-14

S-NT201

RJIA0196E

Hose color:

Low side hose:Blue with black stripe

High side hose:Red with black stripe

Utility hose:Yellow with black stripe or green with black stripe

Hose fitting to gauge:

1/2

2

-16 ACME

Hose fitting to service hose:

M14 x 1.5 fitting is optional or permanently attached.

S-NT202

For measuring of refrigerant

Fitting size: Thread size

1/2

2

-16 ACME

S-NT200

S-NT203

Capacity:

Air displacement: 4 CFM

Micron rating: 20 microns

Oil capacity: 482 g (17 oz)

Fitting size: Thread size

1/2

2

-16 ACME

2002 Altima

Commercial Service Tools

Tool name

(J-41810-NI)

Refrigerant identifier equipment-

(R-134a)

Power tool

(J-44614)

Clutch disc holding tool

PREPARATION

PBIC0190E

RJIA0197E

EJS000ZE

Description

Checks refrigerant purity and for system contamination

A

B

Loosening bolts and nuts

C

D

E

Clutch disc holding tool

F

G

H

WHA230

K

L

M

I

MTC

Revision: May 2004

MTC-15

2002 Altima

REFRIGERATION SYSTEM

REFRIGERATION SYSTEM

PFP:KA990

Refrigeration Cycle

REFRIGERANT FLOW

EJS000ZF

The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.

REFRIGERANT SYSTEM PROTECTION

Refrigerant Pressure Sensor

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.

ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm

2

, 398 psi) or below about 120 kPa

(1.22 kg/cm

2

, 17.4 psi).

Pressure Relief Valve

The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.

When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38 kg/ cm

2

, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

Revision: May 2004

MTC-16

LJIA0015E

2002 Altima

Component Layout

REFRIGERATION SYSTEM

EJS000ZG

A

B

C

D

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-17

WJIA0287E

2002 Altima

LUBRICANT

LUBRICANT

Maintenance of Lubricant Quantity in Compressor

PFP:KLG00

EJS000ZH

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage has occurred. It is important to maintain the specified amount.

If lubricant quantity is not maintained properly, the following malfunctions may result:

Lack of lubricant: May lead to a seized compressor

Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT

Name: Nissan A/C System Oil Type DH-PS

Part number: KLH00-PAGS0

CHECKING AND ADJUSTING

Adjust 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.

Yes or No

Yes >> 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 switch: ON

Blower speed: Max. position

Temp. control: Optional [Set so that intake air temperature is 25 to 30

°

C (77 to 86

°

F).]

Intake position: Recirculation (REC)

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?

Yes or No

Yes >> GO TO

MTC-19, "Lubricant Adjustment Procedure for Compressor Replacement" .

No >> GO TO 4.

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.)

Yes or No

Yes

>> GO TO MTC-19, "Lubricant Adjusting Procedure for Component Replacement Except Compres-

No

sor" .

>> Carry out the A/C performance test.

Revision: May 2004

MTC-18

2002 Altima

LUBRICANT

Lubricant Adjusting Procedure for Component Replacement Except Compressor

After replacing any of the following major components, add the correct amount of lubricant to the system.

Amount of lubricant to be added

A

Part replaced

Evaporator

Condenser

Liquid tank

Lubricant to be added to system

Amount of lubricant m (US fl oz, Imp fl oz)

75 (2.5, 2.6)

75 (2.5, 2.6)

5 (0.2, 0.2)

Remarks

Add if compressor is not replaced.

In case of refrigerant leak

30 (1.0, 1.1)

Large leak

Small leak *1

*1: If refrigerant leak is small, no addition of lubricant is needed.

B

C

D

E

Lubricant Adjustment Procedure for Compressor Replacement

1.

Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If

OK, recover refrigerant from equipment lines.

2.

Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. If NG, refer to

MTC-3, "Contaminated Refrigerant"

.

3.

Connect ACR4 to vehicle. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant

identifier. If NG, refer to MTC-3, "Contaminated Refrigerant"

.

4.

Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling equipment.

5.

Drain the lubricant from the “old” (removed) compressor into a graduated container and recover the amount of lubricant drained.

6.

Drain the lubricant from the “new” compressor into a separate, clean container.

7.

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.

8.

Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compressor through the suction port opening.

9.

If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time.

Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-19

2002 Altima

LUBRICANT

RHA065DD

Revision: May 2004

MTC-20

2002 Altima

AIR CONDITIONER CONTROL

Control Operation

AIR CONDITIONER CONTROL

PFP:27500

EJS000ZI

A

B

C

D

E

F

G

WJIA0133E

FAN CONTROL DIAL

This dial turns the fan ON and OFF, and controls fan speed.

H

AIR CONTROL DIAL

This dial allows control of the outlet air flow.

In , or mode, the intake door is set to "FRESH".

The compressor turns on when the dial is moved to "MAX A/C" or .

TEMPERATURE CONTROL DIAL

This dial allows adjustment of the temperature of the outlet air.

RECIRCULATION (REC) SWITCH

OFF position: Outside air is drawn into the passenger compartment.

ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.

Recirculation is canceled when , or is selected, and resumes when another mode is chosen.

If the refrigerant pressure sensor input signal is high, recirculation is canceled, when , and mode is selected.

AIR CONDITIONER (A/C) SWITCH

The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp will also light.

The air conditioner cooling function operates only when the engine is running.

I

MTC

K

L

M

Revision: May 2004

MTC-21

2002 Altima

Discharge Air Flow

AIR CONDITIONER CONTROL

EJS000ZJ

Revision: May 2004

MTC-22

WJIA0016E

2002 Altima

System Description

AIR CONDITIONER CONTROL

SWITCHES AND THEIR CONTROL FUNCTION

EJS000ZK

A

B

C

D

E

I

WJIA0134E

CAN Communication System Description

EJS000ZL

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.

Each control unit transmits/receives data but selectively reads required data only.

FOR TCS MODELS

System diagram

MTC

K

L

M

F

G

H

Input/output signal chart

Signals

Engine speed signal

Engine coolant temperature signal

Revision: May 2004

ECM

T

T

TCM

MTC-23

COMBINA-

TION

METER

R

R

BCM

LKIA0015E

T: Transmit R: Receive

ABS/TCS control unit

IPDM E/R

R

2002 Altima

Signals

Accelerator pedal position signal

Fuel consumption monitor signal

A/T warning lamp signal

A/T position indicator signal

ABS operation signal

TCS operation signal

Air conditioner switch signal

Air conditioner compressor signal

A/C compressor request signal

Cooling fan motor operation signal

Cooling fan speed request signal

Position lights request

Position lights status

Low beam request

Low beam status

High beam request

High beam status

Front fog lights request

Front fog light status

OD cancel switch signal

Brake switch signal

Vehicle speed signal

Oil pressure switch

Sleep request1

Sleep request2

N range switch signal

P range switch signal

Seat belt buckle switch signal

Door switch signal

Tail lamp request

Turn indicator signal

Buzzer output signal

Trunk switch signal

ASCD main switch signal

ASCD cruise signal

Wiper operation

Wiper stop position signal

Rear window defogger switch signal

Rear window defogger control signal

ECM

T

T

R

R

R

T

R

R

R

T

R

R

R

R

T

T

R

AIR CONDITIONER CONTROL

TCM

T

T

R

R

R

R

R

R

R

T

R

T

T

R

R

R

R

T

T

T

T

R

R

COMBINA-

TION

METER

R

R

R

BCM

R

(R range only)

ABS/TCS control unit

IPDM E/R

R

T

T

T

R

R

T

R

T

R

T

R

T

R

T

R

T

R

T

R

T

R

R

R

T

R

T

R

T

T

R

T

T

T

T

T

T

R

R

R

R

R

T

R

T

T

R

T

Revision: May 2004

MTC-24

2002 Altima

AIR CONDITIONER CONTROL

FOR A/T MODELS

System diagram

Input/output signal chart

Signals

Engine speed signal

Engine coolant temperature signal

Accelerator pedal position signal

Fuel consumption monitor signal

A/T warning lamp signal

A/T position indicator signal

Air conditioner switch signal

Air conditioner compressor signal

A/C compressor request signal

Blower fan switch signal

Cooling fan motor operation signal

Cooling fan speed request signal

Position lights request

Position lights status

Low beam request

Low beam status

High beam request

High beam status

Front fog lights request

Front fog light status

OD cancel switch signal

Brake switch signal

Vehicle speed signal

Oil pressure switch

Sleep request1

Sleep request2

N range switch signal

P range switch signal

Seat belt buckle switch signal

Door switch signal

Revision: May 2004

A

B

C

ECM

T

T

T

T

R

R

R

T

R

(QR25DE)

R

T

R

R

R

R

TCM

T

T

R

R

R

R

MTC-25

R

R

T

T

T

T

T

R

T

T

COMBINATION

METER

R

R

R

R

R

BCM

R

(R range only)

T

LKIA0017E

T: Transmit R: Receive

IPDM E/R

R

D

E

F

G

H

T

R

I

R

R

T

T

T

R

T

R

T

R

T

R

T

R

T

R

R

R

T

R

T

R

MTC

K

L

M

R

T

T

R

T

T

R

R

2002 Altima

Signals

Tail lamp request

Turn indicator signal

Buzzer output signal

Trunk switch signal

ASCD main switch signal

ASCD cruise signal

Wiper operation

Wiper stop position signal

Rear window defogger switch signal

Rear window defogger control signal

FOR M/T MODELS

System diagram

AIR CONDITIONER CONTROL

ECM

T

T

TCM

COMBINATION

METER

R

R

R

R

R

R

R

BCM

T

T

T

T

T

R

R

R

IPDM E/R

R

R

T

T

T

Input/output signal chart

Signals

Engine speed signal

Engine coolant temperature signal

Fuel consumption monitor signal

Air conditioner switch signal

Air conditioner compressor signal

A/C compressor request signal

Blower fan switch signal

Cooling fan motor operation signal

Cooling fan speed request signal

Position lights request

Position lights status

Low beam request

Low beam status

High beam request

High beam status

Front fog lights request

Front fog light status

Vehicle speed signal

Oil pressure switch

Revision: May 2004

R

R

R

ECM

T

T

T

R

R

T

R

(QR25DE)

R

T

COMBINATION

METER

R

BCM

LKIA0018E

T: Transmit R: Receive

IPDM E/R

T

T

R

T

R

T

R

T

R

T

R

T

R

MTC-26

T

R

T

R

T

R

T

T

R

R

T

T

R

2002 Altima

Signals

Sleep request1

Sleep request2

Seat belt buckle switch signal

Door switch signal

Tail lamp request

Turn indicator signal

Buzzer output signal

Trunk switch signal

ASCD main switch signal

ASCD cruise signal

Wiper operation

Wiper stop position signal

Rear window defogger switch signal

Rear window defogger control signal

AIR CONDITIONER CONTROL

ECM

T

T

COMBINATION

METER

R

R

R

R

R

R

R

T

R

R

BCM

T

T

T

T

R

T

T

T

T

R

R

R

IPDM E/R

R

R

R

R

T

T

T

F

G

H

I

MTC

K

L

M

C

D

E

A

B

Revision: May 2004

MTC-27

2002 Altima

TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS

How to Perform Trouble Diagnoses for Quick and Accurate Repair

WORK FLOW

PFP:00004

EJS000ZM

*1:

MTC-38, "Operational Check"

SYMPTOM TABLE

Symptom

A/C system does not come on.

Air outlet does not change.

Mode door motor does not operate normally.

Reference Page

Go to Trouble Diagnosis Procedure for A/C system.

Go to Trouble Diagnosis Procedure for Mode Door Motor.

Air Mix door does not change.

Intake door does not change.

Intake door motor does not operate normally.

Go to Trouble Diagnosis Procedure for Air Mix Door.

Go to Trouble Diagnosis Procedure for Intake Door Motor.

Blower motor operation is malfunctioning.

Go to Trouble Diagnosis Procedure for Blower Motor.

Magnet clutch does not engage.

Go to Trouble Diagnosis Procedure for Magnet Clutch.

Insufficient cooling.

Insufficient heating.

Noise.

Go to Trouble Diagnosis Procedure for Insufficient Cooling.

Go to Trouble Diagnosis Procedure for Insufficient Heating.

Go to Trouble Diagnosis Procedure for Noise.

SHA900E

MTC-40

MTC-42

MTC-45

MTC-46

MTC-49

MTC-54

MTC-58

MTC-63

MTC-64

Revision: May 2004

MTC-28

2002 Altima

TROUBLE DIAGNOSIS

Component Parts and Harness Connector Location

ENGINE COMPARTMENT

QR25DE Models

EJS000ZN

A

B

C

D

E

F

G

H

I

MTC

K

L

M

WJIA0136E

Revision: May 2004

MTC-29

2002 Altima

TROUBLE DIAGNOSIS

VQ35DE Models

Revision: May 2004

MTC-30

WJIA0137E

2002 Altima

PASSENGER COMPARTMENT

TROUBLE DIAGNOSIS

Revision: May 2004

MTC-31

WJIA0138E

2002 Altima

F

G

H

I

MTC

K

L

M

C

D

E

A

B

Circuit Diagram

TROUBLE DIAGNOSIS

EJS000ZO

Revision: May 2004

MTC-32

WJWA0011E

2002 Altima

TROUBLE DIAGNOSIS

Wiring Diagram — HEATER —

EJS000ZP

A

B

C

D

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-33

WJWA0012E

2002 Altima

TROUBLE DIAGNOSIS

Revision: May 2004

MTC-34

WJWA0013E

2002 Altima

Wiring Diagram — A/C,M —

TROUBLE DIAGNOSIS

EJS000ZQ

A

B

C

D

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-35

WJWA0014E

2002 Altima

TROUBLE DIAGNOSIS

Revision: May 2004

MTC-36

WJWA0015E

2002 Altima

Revision: May 2004

TROUBLE DIAGNOSIS

MTC-37

WJWA0016E

2002 Altima

F

G

H

I

MTC

K

L

M

C

D

E

A

B

TROUBLE DIAGNOSIS

Operational Check

EJS000ZR

The purpose of the operational check is to confirm that the system operates as it should. The systems which are checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase.

CONDITIONS:

Engine running at normal operating temperature.

PROCEDURE:

1. Check Blower

1.

Turn fan control dial to 1-speed.

Blower should operate on 1-speed.

2.

Then turn fan control dial to 2-speed.

3.

Continue checking blower speed until all four speeds are checked.

4.

Leave blower on 4-speed.

If NG, go to MTC-49, "Blower Motor Circuit" .

If OK, continue with next check.

WJIA0139E

2. Check Discharge Air

1.

Turn air control dial to each position.

2.

Confirm air discharge at all air outlets.

If NG, go to MTC-42, "Mode Door Motor Circuit" .

If OK, continue with next check.

WJIA0140E

3. Check Recirculation

1.

Press recirculation switch.

Recirculation indicator should light.

2.

Listen for intake door position change (you should hear blower sound change slightly).

NOTE:

Confirm that the RECIRCULATION (REC) switch is canceled in the FOOT ( ), D/F ( ) and DEF ( ) modes.

If NG, go to MTC-46, "Intake Door Motor Circuit" .

If OK, continue with next check.

4. Check Temperature Decrease

1.

Turn fan control dial to 1-speed.

2.

Turn temperature control dial to full cold.

3.

Check for cold air at discharge air outlets.

If NG, go to MTC-58, "Insufficient Cooling" .

If OK, continue with next check.

WJIA0141E

Revision: May 2004

MTC-38

WJIA0142E

2002 Altima

TROUBLE DIAGNOSIS

5. Check Temperature Increase

1.

Turn temperature control dial to full hot.

2.

Check for hot air at discharge air outlets.

If NG, go to

MTC-63, "Insufficient Heating" .

If OK, continue with next check.

6. Check Air Conditioner Switch

Turn fan control dial to the desired (1- to 4-speed) position and push the air conditioner switch (if equipped) to turn ON the air conditioner.

The indicator light should come on when air conditioner is ON.

If NG, go to

MTC-40, "A/C System" .

If all operational checks are OK (symptom can not be duplicated), go to “Incident Simulation Tests” ( GI-25 ) and perform tests as outlined to simulate driving conditions environment. If symptom appears,

refer to MTC-28, "SYMPTOM TABLE"

and perform applicable trouble diagnosis procedures.

C

WJIA0143E

D

E

A

B

F

G

WJIA0144E

H

I

MTC

K

L

M

Revision: May 2004

MTC-39

2002 Altima

A/C System

SYMPTOM:

A/C system does not come on.

TROUBLE DIAGNOSIS

INSPECTION FLOW

EJS000ZS

*1:

MTC-39, "6. Check Air Conditioner

Switch"

*2:

MTC-38, "Operational Check"

DIAGNOSTIC PROCEDURE

SYMPTOM:

A/C system does not come on.

1.

CHECK POWER SUPPLY CIRCUIT FOR A/C CONTROL UNIT

WJIA0145E

*3:

MTC-40, "DIAGNOSTIC PROCE-

DURE"

Terminal

(+) (-)

Connector

M51-2

Wire color

G

Body ground

OK or NG

OK

NG

>> GO TO 2.

>> Check 10A fuse (No. 12) at fuse block (J/B).

Voltage (V)

(Approx.)

12V

WJIA0147E

Revision: May 2004

MTC-40

2002 Altima

TROUBLE DIAGNOSIS

2.

CHECK BODY GROUND CIRCUIT FOR A/C CONTROL UNIT

Connector

M51-3

Terminal

Wire color

B

Body ground

If OK, check harness for short.

OK or NG

OK

NG

>> INSPECTION END

>> If NG, repair harness or connector.

Continuity

Yes

WJIA0146E

C

D

E

A

B

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-41

2002 Altima

TROUBLE DIAGNOSIS

Mode Door Motor Circuit

SYMPTOM:

Air outlet does not change.

Mode door motor does not operate normally.

INSPECTION FLOW

EJS000ZT

*1

MTC-44, "MODE DOOR"

*2

MTC-38, "Operational Check"

*3

MTC-28, "SYMPTOM TABLE"

*4

MTC-22, "Discharge Air Flow"

WJIA0205E

*5

MTC-43, "DIAGNOSTIC PROCE-

DURE"

Revision: May 2004

MTC-42

2002 Altima

TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION

Mode Door Motor

The mode door motor is installed on the heater unit. Using a link it operates the mode door. When the air control dial is turned to each position, the mode door motor moves the mode door to control air flow direction.

DIAGNOSTIC PROCEDURE

SYMPTOM: Mode door motor does not operate normally.

1.

CHECK BODY GROUND CIRCUIT FOR MODE DOOR MOTOR

Connector

M40-2

Terminals

Wire color

B

Continuity should exist.

Body ground

If OK, check harness for short.

OK or NG

OK

NG

>> GO TO 2.

>> Repair harness or connector.

Continuity

Yes

Revision: May 2004

MTC-43

WJIA0208E

2002 Altima

WJIA0206E

C

D

E

A

B

F

G

WJIA0200E

H

I

MTC

K

WJIA0207E

L

M

TROUBLE DIAGNOSIS

2.

CHECK CIRCUIT CONTINUITY BETWEEN EACH TERMINAL ON A/C CONTROL UNIT AND ON

MODE DOOR MOTOR

Connectors

M51-9

M51-12

Terminals

Wire colors Connectors

L/B

L/R

M40-3

M40-1

Continuity should exist.

Wire colors

L/B

L/R

Continuity

Yes

If OK, check harness for short.

OK or NG

OK

NG

>> GO TO 3.

>> Repair harness or connector.

3.

CHECK FOR A/C CONTROL UNIT OUTPUT

1.

Reconnect mode door motor connector.

2.

Measure voltage across A/C control unit harness connector M51 terminals 9 (L/B) and 12 (L/R) while turning air control dial to each position.

Voltage (V)

OK or NG

OK

NG

>> Replace mode door motor.

>> Replace A/C control unit.

: Approx. 12V

WJIA0209E

WJIA0210E

MODE DOOR

1.

Install mode door motor on heater unit.

Ensure that the linkage is properly attached.

2.

Connect mode door motor harness connector.

3.

Turn ignition switch ON.

4.

Check that the mode door operates properly when air control dial is turned to each position.

WJIA0200E

Revision: May 2004

MTC-44

2002 Altima

Air Mix Door

SYMPTOM: Air mix door does not change.

INSPECTION FLOW

TROUBLE DIAGNOSIS

*1

MTC-38

*2

MTC-28

CONTROL LINKAGE ADJUSTMENT

Temperature control cable

1.

Attach temperature control cable.

2.

Rotate control knob to full cold position.

3.

Remove slack from cable and install temperature control cable clamp.

After positioning control cable, check for proper operation.

*3

MTC-45

EJS001LH

A

B

C

D

E

F

G

H

I

WJIA0288E

MTC

K

L

M

WJIA0192E

Revision: May 2004

MTC-45

2002 Altima

TROUBLE DIAGNOSIS

Intake Door Motor Circuit

Symptom:

Intake door does not change.

Intake door motor does not operate normally.

INSPECTION FLOW

EJS000ZU

*1:

MTC-46, "Intake Door Motor Circuit"

*2:

MTC-38, "Operational Check"

WJIA0148E

*3:

MTC-28, "SYMPTOM TABLE"

Revision: May 2004

MTC-46

2002 Altima

TROUBLE DIAGNOSIS

SYSTEM DESCRIPTON

Intake Door Motor

The intake door motor is installed on the blower unit. Using a link it opens and closes the intake door.

When RECIRCULATION switch is at REC (except DEF and D/F modes), the A/C control unit sets the intake door at the “RECIRCU-

LATION” position.

DIAGNOSTIC PROCEDURE

SYMPTOM: Intake door does not change. Intake door motor does not operate normally.

1.

CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR

Connector

M58-2

Terminals

Wire color

B

Body ground

Continuity should exist.

If OK, check harness for short.

OK or NG

OK

NG

>> GO TO 2.

>> Repair harness or connector.

Continuity

Yes

Revision: May 2004

MTC-47

WJIA0152E

2002 Altima

WJIA0149E

C

D

E

A

B

F

G

WJIA0150E

H

K

WJIA0151E

L

I

MTC

M

TROUBLE DIAGNOSIS

2.

CHECK CIRCUIT CONTINUITY BETWEEN EACH TERMINAL ON A/C CONTROL UNIT AND ON

INTAKE DOOR MOTOR

Connectors

M51-9

M51-12

Terminals

Wire colors Connectors

L/B

L/R

M58-3

M58-1

Continuity should exist.

Wire colors

L/B

L/R

Continuity

Yes

If OK, check harness for short.

OK or NG

OK

NG

>> GO TO 3.

>> Repair harness or connector.

3.

CHECK FOR A/C CONTROL UNIT OUTPUT

Measure voltage across A/C control unit harness terminals and body ground.

Terminals

RECIRCU-

LATION

(+) (-)

Connectors Wire colors

M51-9 L/B

REC(ON)

FRE(OFF)

M51-12

M51-9

M51-12

L/R

L/B

L/R

OK or NG

OK

NG

>> Replace intake door motor.

>> Replace A/C control unit.

Body ground

Condition

REC

FRE

Voltage (V)

(Approx.)

12V

0V

0V

12V

CONTROL LINKAGE ADJUSTMENT

1.

Install intake door motor on blower unit.

Ensure that the intake door motor lever is fitted into the slit portion of intake door link.

2.

Connect the intake door motor harness connector.

3.

Turn ignition switch to ON.

4.

Check that intake door operates properly when RECIRCULA-

TION switch is turned ON and OFF.

WJIA0154E

WJIA0150E

Revision: May 2004

MTC-48

2002 Altima

TROUBLE DIAGNOSIS

Blower Motor Circuit

Symptom:

Blower motor operation is malfunctioning.

INSPECTION FLOW

*1:

MTC-49, "Blower Motor Circuit"

*2:

MTC-38, "Operational Check"

DIAGNOSTIC PROCEDURE

SYMPTOM:

Blower motor operation is malfunctioning.

Test group No.

1

2

3

4

5

INCIDENT

Fan fails to rotate.

Fan does not rotate at 1-speed.

Fan does not rotate at 2-speed.

Fan does not rotate at 3-speed.

Fan does not rotate at 4-speed.

EJS000ZV

A

B

C

D

E

WJIA0156E

*3:

MTC-28, "SYMPTOM TABLE"

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-49

2002 Altima

TROUBLE DIAGNOSIS

1.

DIAGNOSTIC PROCEDURE

Check if blower motor rotates properly at each fan speed.

Conduct checks as per table above.

1

>> GO TO 2.

2, 3, 4 >> GO TO 8.

5

>> GO TO 10.

2.

CHECK POWER SUPPLY FOR BLOWER MOTOR

Disconnect blower motor harness connector.

Terminals

Voltage (V)

(Approx.)

(+) (-)

Connector

M62-1

Wire color

W/L

Body ground

12V

Yes or No

Yes >> GO TO 3.

No >>

Check 15A fuses (No. 10 and No. 11) at fuse block (J/

B).

WJIA0159E

Check blower relay [located in fuse block (J/B)]. Refer to PG-5, "Wiring Diagram — POWER —

" .

3.

CHECK CIRCUIT CONTINUITY FOR BLOWER MOTOR

Turn fan control switch to any position except OFF.

Terminals

Voltage (V)

(Approx.)

(+) (-)

Connector

M62-2

Wire color

L/W Body ground

12V

Continuity should exist.

OK or NG

OK

NG

>> GO TO 4.

>> GO TO 5.

4.

CHECK BLOWER MOTOR

(Refer to Electrical Components Inspection.)

(

MTC-53, "Blower motor"

)

OK or NG

OK

NG

>> INSPECTION END

>> Replace blower motor.

WJIA0160E

Revision: May 2004

MTC-50

2002 Altima

TROUBLE DIAGNOSIS

5.

CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR

Reconnect blower motor harness connector.

Terminals

(+)

Connector

M63-1

Yes or No

Yes >> GO TO 7.

No >> GO TO 6.

Wire color

L/W

(-)

Body ground

Voltage (V)

(Approx.)

12V

6.

CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND RESISTOR

Disconnect blower motor and resistor harness connectors.

Connector

M63-1

Terminals

Wire color Connector

L/W M62-2

Continuity should exist.

Wire color

L/W

Continuity

Yes

If OK, check harness for short.

OK or NG

OK

NG

>> INSPECTION END

>> Repair harness or connector.

7.

CHECK GROUND CIRCUIT FOR FAN SWITCH

Disconnect fan switch harness connector.

Check circuit continuity between fan switch harness terminal and body ground.

Terminals

(+) (-)

Connector

M41-5

Wire color

B Body ground

OK or NG

OK

NG

>> GO TO 8.

>> Repair harness or connector.

8.

CHECK BLOWER MOTOR RESISTOR

Refer to

MTC-53, "Blower Motor Resistor" .

Voltage (V)

(Approx.)

12V

OK or NG

OK

NG

>> GO TO 9.

>> Replace blower motor resistor.

WJIA0161E

C

D

E

A

B

F

G

H

WJIA0162E

I

MTC

K

L

M

WJIA0163E

Revision: May 2004

MTC-51

2002 Altima

TROUBLE DIAGNOSIS

9.

CHECK RESISTOR HARNESS CONNECTOR

Reconnect resistor harness connector.

OK or NG

1

>> GO TO 12.

2, 3, 4 >> GO TO 10.

10.

CHECK FAN SWITCH CIRCUIT

Do approx. 12 volts exist between each fan switch harness connector terminal and body ground?

Terminal

Test group No.

2

3

Connector

M41-4

M41-3

4

5

M41-2

M41-1

Yes or No

Yes >> GO TO 12.

No >> GO TO 11.

(+)

Wire color

L/B

L/R

L/Y

L/W

(-)

Body ground

Voltage (V)

(Approx.)

12V

WJIA0164E

11.

CHECK CIRCUIT CONTINUITY BETWEEN FAN SWITCH HARNESS TERMINAL AND RESISTOR

HARNESS TERMINAL

Terminal No.

Fan switch

Connectors

M41-4

M41-3

M41-2

M41-1

Wire colors

L/B

L/R

L/Y

L/W

Connectors

M63-4

M63-3

M63-2

M63-1

OK or NG

OK

NG

>> Check harness for short.

>> Repair harness or connector.

12.

CHECK FAN SWITCH

Resistor

Wire colors

L/B

L/R

L/Y

L/W

Refer to MTC-53, "Fan Switch" .

OK or NG

OK

NG

>> INSPECTION END

>> Replace fan switch.

Continuity

Yes

WJIA0165E

Revision: May 2004

MTC-52

2002 Altima

TROUBLE DIAGNOSIS

ELECTRICAL COMPONENTS INSPECTION

Fan Switch

Check continuity between terminals at each switch position.

Continuity between terminals SWITCH POSITION

OFF

1

2

3

4

4 — 5 — 6

3 — 5 — 6

2 — 5 — 6

1 — 5 — 6

Blower motor

Confirm smooth rotation of the blower motor.

Ensure that there are no foreign particles inside the intake unit.

Blower Motor Resistor

Check resistance between terminals.

(+)

3

4

2

Terminal No.

(

)

1

Resistance (

)

(Approx.)

0.9 - 1.1

2.27 - 2.78

0.3 - 0.38

WJIA0157E

C

D

E

A

B

I

WJIA0158E

MTC

K

L

M

F

G

H

Revision: May 2004

MTC-53

2002 Altima

TROUBLE DIAGNOSIS

Magnet Clutch Circuit

Symptom:

Magnet clutch does not engage when A/C switch and fan switch are ON.

INSPECTION FLOW

EJS000ZW

*1:

MTC-91, "Checking for Refrigerant

Leaks"

*4:

MTC-28, "SYMPTOM TABLE"

*2:

MTC-55, "DIAGNOSTIC PROCE-

DURE"

*5: MA-14, "Checking Drive Belts"

WJIA0166E

*3:

MTC-38, "Operational Check"

Revision: May 2004

MTC-54

2002 Altima

TROUBLE DIAGNOSIS

DIAGNOSTIC PROCEDURE

SYMPTOM:

Magnet clutch does not engage when A/C switch and fan switch are ON.

1.

CHECK POWER SUPPLY FOR COMPRESSOR

Disconnect compressor harness connector.

A

B

Terminals

(+)

Connector

F3-1

OK or NG

OK

NG

>> GO TO 2.

>> GO TO 3.

Wire color

Y/B

(-)

Body ground

Voltage (V)

(Approx.)

12V

WJIA0167E

2.

CHECK MAGNET CLUTCH COIL

Check magnet clutch coil.

OK or NG

OK

NG

>> Check compressor mounting points for looseness or corrosion and repair as necessary.

>> Replace magnet clutch. Refer to

MTC-85, "Removal and Installation for Compressor Clutch" .

3.

CHECK MAGNET CLUTCH COIL POWER SUPPLY FROM IPDM E/R

Reconnect compressor harness connector.

C

D

E

F

G

H

I

Terminals

(+)

Voltage (V)

(Approx.)

(-)

Connector Wire color

E124-28 Y/B Body ground 12V

OK or NG

OK

NG

>> Repair harness or connector between IPDM E/R and compressor.

>> GO TO 4.

4.

CHECK INTAKE SENSOR CIRCUIT

Refer to

MTC-65, "Intake Sensor Circuit" .

OK or NG

OK

NG

>> GO TO 5.

>> Repair as necessary.

5.

CHECK REFRIGERANT PRESSURE SENSOR

WJIA0065E

Refer to EC-595, "REFRIGERANT PRESSURE SENSOR" (QR25DE models) or EC-1266, "REFRIGERANT

PRESSURE SENSOR" (VQ35DE models).

OK or NG

OK

NG

>> GO TO 6.

>> Repair as necessary.

MTC

K

L

M

Revision: May 2004

MTC-55

2002 Altima

TROUBLE DIAGNOSIS

6.

CHECK FAN ON SIGNAL TO A/C CONTROL UNIT AND BCM

1.

Disconnect A/C control unit harness connector M51.

2.

Measure voltage between A/C control unit and body ground.

3.

Reconnect A/C control unit harness connector M51 and disconnect BCM harness connector M18.

4.

Measure voltage between BCM and body ground.

Connectors

Terminals

(+)

Wire colors

G/B

M51-5

M18-65

G/B

G/B

G/B

OK or NG

OK

NG

>> GO TO 8.

>> GO TO 7.

7.

CHECK FAN SWITCH

(-)

Body ground

Condition

FAN SW: OFF

FAN SW: ON

FAN SW: OFF

FAN SW: ON

Voltage (V)

(Approx.)

5V

0V

5V

0V

Check fan switch. Refer to MTC-53, "Fan Switch"

.

OK or NG

OK

NG

>> Repair harness or connectors between fan switch and A/C control unit and BCM.

>> Replace fan switch.

8.

CHECK COMPRESSOR ON SIGNAL

1.

Reconnect A/C control unit harness connector.

2.

With fan switch ON, measure voltage between A/C control unit and body ground with A/C switch OFF and ON.

Terminals

(+) (-)

Connector

M51-1

Wire color

L/W

L/W

Body ground

OK or NG

OK

NG

>> GO TO 9.

>> Replace A/C control unit.

Condition

A/C SW: OFF

A/C SW: ON

9.

CHECK COMPRESSOR ON SIGNAL CIRCUIT

1.

Disconnect A/C control unit harness connector.

2.

Check continuity between A/C control unit and BCM.

Voltage (V)

(Approx.)

9V

0V

Connector

M18-58

Terminals

Wire color Connector

L/W M51-1

If OK, check harness for short.

OK or NG

OK

NG

>> GO TO 10.

>> Repair harness or connectors.

Wire color

L/W

Continuity

Yes

WJIA0211E

WJIA0213E

WJIA0170E

Revision: May 2004

MTC-56

2002 Altima

TROUBLE DIAGNOSIS

10.

CHECK CAN COMMUNICATION CIRCUITS

Check CAN communication circuits between BCM to ECM and between ECM to IPDM E/R. Refer to LAN-3,

"CAN COMMUNICATION" .

OK or NG

OK

NG

>> ECM is malfunctioning.

>> Repair or replace component based on diagnosis.

REFRIGERANT PRESSURE SENSOR

Make sure that higher A/C refrigerant pressure results in higher refrigerant pressure sensor output voltage.

Low-pressure side

High-pressure side

OFF kPa (kg/cm

2

, psi)

Decreasing to 0.18 (0.00184, 0.03)

Increasing to 2.74 (0.0279, 0.40)

Refer to EC-595, "REFRIGERANT PRESSURE SENSOR"

(QR25DE models) or EC-1266, "REFRIGERANT PRESSURE SEN-

SOR" (VQ35DE models).

BBIA0027E

A

B

C

D

E

F

G

H

I

SHA315F

MTC

K

L

M

Revision: May 2004

MTC-57

2002 Altima

Insufficient Cooling

Symptom:

Insufficient cooling.

INSPECTION FLOW

TROUBLE DIAGNOSIS

EJS000ZX

WJIA0175E

*1: MA-14, "Checking Drive Belts"

(QR25DE) or MA-21, "Checking

Drive Belts" (VQ35DE)

*2:

MTC-46, "Intake Door Motor Circuit"

*4:

MTC-3, "Contaminated Refrigerant"

*5:

MTC-79, "HFC-134a (R-134a) Service Procedure"

*8:

MTC-38, "Operational Check"

*7:

MTC-83, "Removal and Installation for Compressor — QR25DE Models"

or

MTC-84, "Removal and Installation for Compressor — VQ35DE

Models"

*3: EC Section

*6:

*9

MTC-59, "Performance Chart"

MTC-28, "SYMPTOM TABLE"

Revision: May 2004

MTC-58

2002 Altima

TROUBLE DIAGNOSIS

A

PERFORMANCE CHART

Test Condition

Testing must be performed as follows:

Doors

Door window

Vehicle location

Hood

TEMP.

Closed

Open

Open

Max. COLD

Indoors or in the shade (in a well-ventilated place)

Mode switch

(Ventilation) set

Intake switch

(Recirculation) set

(blower) speed

Engine speed

Max. speed set

Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading

Recirculating-to-discharge Air Temperature Table

Inside air (Recirculating air) at blower assembly inlet

Relative humidity

%

Air temperature

°

C (

°

F)

50 - 60

25 (77)

30 (86)

35 (95)

60 - 70

25 (77)

30 (86)

35 (95)

Discharge air temperature at center ventilator

°

C (

°

F)

10.0 - 12.3 (50 - 54)

13.2 - 15.3 (56 - 60)

17.2 - 21.0 (63 - 70)

12.3 - 14.9 (54 - 59)

15.3 - 19.3 (60 - 67)

21.0 - 24.4 (70 - 76)

Ambient Air Temperature-to-operating Pressure Table

Relative humidity

%

Ambient air

Air temperature

°

C (

°

F)

High-pressure (Discharge side) kPa (kg/cm2, psi)

50 - 70

30 (86)

35 (95)

40 (104)

1,220 - 1,500

(12.44 - 15.30, 176.9 - 217.5)

1,360 - 1,690

(13.87 - 17.24, 197.2 - 245.1)

1,500 - 1,830

(12.44 - 18.67, 176.9 - 265.4)

Low-pressure (Suction side) kPa (kg/cm2, psi)

240 - 295

(2.45 - 3.01, 34.8 - 42.8)

275 - 335

(2.81 - 3.42, 39.9 - 48.6)

310 - 375

(3.16 - 3.83, 45.0 - 54.4)

TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE

Whenever system's high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the standard (normal) pressure, differs from vehicle to vehicle, refer to Ambient Air Temperature-to-operating Pressure

Table above.

B

C

D

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-59

2002 Altima

TROUBLE DIAGNOSIS

Both High and Low-pressure Sides are Too High

Gauge indication

Both high and low-pressure sides are too high.

AC359A

Refrigerant cycle

Pressure is reduced soon after water is splashed on condenser.

Probable cause

Excessive refrigerant charge in refrigeration cycle

Air suction by cooling fan is insufficient.

Engine tends to overheat.

An area of the low-pressure pipe is colder than areas near the evaporator outlet.

Plates are sometimes covered with frost.

Insufficient condenser cooling performance

1. Condenser fins are clogged.

2. Improper fan rotation of cooling fan

Low-pressure pipe is not cold.

When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (2 kg/cm

2

, 28 psi). It then decreases gradually thereafter.

Poor heat exchange in condenser

(After compressor operation stops, high pressure decreases too slowly.)

Air in refrigeration cycle

Engine cooling systems malfunction.

Excessive liquid refrigerant on low-pressure side

Excessive refrigerant discharge flow

Expansion valve is open a little compared with the specification.

1. Improper thermal valve installation

2. Improper expansion valve adjustment

Corrective action

Reduce refrigerant until specified pressure is obtained.

Clean condenser.

Check and repair cooling fan as necessary.

Evacuate repeatedly and recharge system.

Check and repair each engine cooling system.

Replace expansion valve.

High-pressure Side is Too High and Low-pressure Side is Too Low

Gauge indication Refrigerant cycle Probable cause

High-pressure side is too high and low-pressure side is too low.

Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot.

Corrective action

High-pressure tube or parts located between compressor and condenser are clogged or crushed.

Check and repair or replace malfunctioning parts.

Check lubricant for contamination.

AC360A

High-pressure Side is Too Low and Low-pressure Side is Too High

Gauge indication Refrigerant cycle

High-pressure side is too low and low-pressure side is too high.

AC356A

High and low-pressure sides become equal soon after compressor operation stops.

No temperature difference between high and low-pressure sides

Probable cause

Compressor pressure operation is improper.

Damaged inside compressor packings

Compressor pressure operation is improper.

Damaged inside compressor packings.

Corrective action

Replace compressor.

Replace compressor.

Revision: May 2004

MTC-60

2002 Altima

TROUBLE DIAGNOSIS

Both High- and Low-pressure Sides are Too Low

Gauge indication

Both high- and low-pressure sides are too low.

Refrigerant cycle

There is a big temperature difference between receiver drier outlet and inlet. Outlet temperature is extremely low.

Liquid tank inlet and expansion valve are frosted.

Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank.

Expansion valve inlet may be frosted.

Temperature difference occurs somewhere in highpressure side

Expansion valve and liquid tank are warm or only cool when touched.

AC353A

There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.

An area of the low-pressure pipe is colder than areas near the evaporator outlet.

Air flow volume is not enough or is too low.

Probable cause

Liquid tank inside is slightly clogged.

High-pressure pipe located between receiver drier and expansion valve is clogged.

Corrective action

Replace desiccant assy.

Check lubricant for contamination.

Check and repair malfunctioning parts.

Check lubricant for contamination.

Low refrigerant charge

Leaking fittings or components

Expansion valve closes a little compared with the specification.

1. Improper expansion valve adjustment

2. Malfunctioning thermal valve

3. Outlet and inlet may be clogged.

Check refrigerant for leaks.

Refer to

MTC-91, "Checking for Refrigerant Leaks"

.

Remove foreign particles by using compressed air.

Check lubricant for contamination.

Low-pressure pipe is clogged or crushed.

Evaporator is frozen.

Check and repair malfunctioning parts.

Check lubricant for contamination.

Check intake sensor operation. Refer to

MTC-68,

"INTAKE SENSOR" .

Replace compressor.

Low-pressure Side Sometimes Becomes Negative

Refrigerant cycle Gauge indication

Low-pressure side sometimes becomes negative.

Air conditioning system does not function and does not cyclically cool the compartment air.

The system constantly functions for a certain period of time after compressor is stopped and restarted.

Probable cause

Refrigerant does not discharge cyclically.

Moisture is frozen at expansion valve outlet and inlet.

Water is mixed with refrigerant.

AC354A

Corrective action

Drain water from refrigerant or replace refrigerant.

Replace desiccant assy.

A

B

C

D

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-61

2002 Altima

TROUBLE DIAGNOSIS

Low-pressure Side Becomes Negative

Gauge indication Refrigerant cycle

Low-pressure side becomes negative.

AC362A

Probable cause

Liquid tank or front/rear side of expansion valve's pipe is frosted or dewed.

High-pressure side is closed and refrigerant does not flow.

Expansion valve or liquid tank is frosted.

Corrective action

Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles.

If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant.

If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air

(not shop air).

If either of the above methods cannot correct the problem, replace expansion valve.

Replace desiccant assy.

Check lubricant for contamination.

Revision: May 2004

MTC-62

2002 Altima

Insufficient Heating

SYMPTOM: Insufficient heating

INSPECTION FLOW

TROUBLE DIAGNOSIS

*1: MA-14, "Changing Engine Coolant"

(QR25DE) or MA-22, "Changing

Engine Coolant" (VQ35DE)

*4:

*7:

CO-20, "Removal and Installation"

(QR25DE) or EC-1110, "Overall

Function Check" (VQ35DE)

MTC-38, "Operational Check"

*2: CO-11, "CHECKING RADIATOR

CAP" (QR25DE) or CO-33,

"CHECKING RADIATOR CAP"

(VQ35DE)

*5: MA-16, "FLUSHING COOLING SYS-

TEM" (QR25DE) or MA-23, "FLUSH-

ING COOLING SYSTEM"

(VQ35DE)

*8

MTC-28, "SYMPTOM TABLE"

*3:

WJIA0176E

MTC-46, "Intake Door Motor Circuit"

*6: CO-11, "Refilling Engine Coolant"

(QR25DE) or CO-33, "Refilling

Engine Coolant" (VQ35DE)

Revision: May 2004

MTC-63

2002 Altima

EJS000ZY

A

B

C

D

E

F

G

H

I

MTC

K

L

M

Noise

SYMPTOM: Noise

INSPECTION FLOW

TROUBLE DIAGNOSIS

EJS000ZZ

Revision: May 2004

MTC-64

SHA331F

2002 Altima

TROUBLE DIAGNOSIS

*1

MTC-85, "Removal and Installation for Compressor Clutch"

*3

MTC-18, "Maintenance of Lubricant

Quantity in Compressor"

*5 MA-14, "Checking Drive Belts"

(QR25DE) or MA-21, "Checking

Drive Belts" (VQ35DE)

*4

MTC-38, "Operational Check"

*2

MTC-86, "INSTALLATION"

Intake Sensor Circuit

COMPONENT DESCRIPTION

Intake Sensor

The intake sensor is located on the heater and cooling unit. It converts temperature of air after it passes through the evaporator into a resistance value which is then input to the A/C control unit.

After disconnecting intake sensor harness connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below.

EJS00100

Temperature

°

C (

°

F)

-15 (5)

-10 (14)

-5 (23)

0 (32)

5 (41)

10 (50)

15 (59)

20 (68)

25 (77)

30 (86)

35 (95)

40 (104)

45 (113)

Resistance k

12.34

9.62

7.56

6.00

4.80

3.87

3.15

2.57

2.12

1.76

1.47

1.23

1.04

If NG, replace intake sensor.

DIAGNOSTIC PROCEDURE

SYMPTOM: Intake sensor circuit is open or shorted.

WJIA0091E

A

B

C

D

E

F

G

H

I

MTC

K

L

M

WJIA0177E

Revision: May 2004

MTC-65

2002 Altima

TROUBLE DIAGNOSIS

1.

CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND BODY GROUND

Disconnect intake sensor harness connector.

Connector

M53-1

Terminal

Wire color

B

Body ground

OK or NG

OK

NG

>> GO TO 2.

>> Repair harness or connector.

Continuity

Yes

2.

CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND A/C CONTROL UNIT

Disconnect A/C control unit harness connector.

Terminals

Connector

M53-2

Wire color

R/G

Connector

M51-6

OK or NG

OK

NG

>> GO TO 3.

>> Repair harness or connector.

Wire color

R/G

Continuity

Yes

WJIA0178E

WJIA0179E

3.

CHECK INTAKE SENSOR

Refer to MTC-65, "Intake Sensor" .

OK or NG

OK

NG

>> Replace A/C control unit.

>> Replace intake sensor.

Revision: May 2004

MTC-66

2002 Altima

CONTROL UNIT

Removal and Installation

REMOVAL

CONTROL UNIT

1.

Remove cluster lid C. Refer to IP-12, "Cluster Lid C" .

2.

Remove audio unit. Refer to AV-22, "AUDIO UNIT" .

3.

Remove the temperature control cable clamp and then remove the cable from the air mix door lever.

4.

Remove the A/C control unit screws and then remove it from the instrument panel.

5.

Disconnect the A/C control unit connectors and then remove it.

INSTALLATION

Installation is in the reverse order of removal.

Adjustment

1.

Attach temperature control cable.

2.

Rotate control knob to full cold position.

3.

Remove slack from cable and install temperature control cable clamp.

After positioning control cable, check for proper operation.

PFP:27500

EJS00101

A

B

WJIA0192E

F

G

H

C

D

E

WJIA0191E

I

MTC

K

L

M

Revision: May 2004

MTC-67

2002 Altima

INTAKE SENSOR

INTAKE SENSOR

Removal and Installation

1.

Remove the evaporator. Refer to

MTC-90, "Removal and Installation for Evaporator" .

2.

Remove the intake sensor clip and then the sensor.

CAUTION:

Be careful not to damage the core surface.

PFP:27723

EJS00102

WJIA0100E

Revision: May 2004

MTC-68

2002 Altima

BLOWER UNIT

BLOWER UNIT

Removal and Installation

REMOVAL

1.

Remove the glove box assembly. Refer to IP-15, "Glove Box" .

2.

Remove the ECM.

3.

Disconnect the blower motor, intake door motor and fan control amp. connector.

4.

Remove the 2 bolts and 1 screw from the blower unit, then remove it.

PFP:27200

EJS00103

A

B

C

D

E

WJIA0101E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-69

2002 Altima

BLOWER MOTOR

BLOWER MOTOR

Removal and Installation

1.

Remove the blower unit. Refer to

MTC-69, "Removal and Installation"

.

2.

Release the 8 tabs attaching blower motor to blower unit case and then remove it.

PFP:27226

EJS00104

WJIA0104E

Revision: May 2004

MTC-70

2002 Altima

INTAKE DOOR MOTOR

INTAKE DOOR MOTOR

Removal and Installation

1.

Remove the blower unit. Refer to

MTC-69, "Removal and Installation" .

2.

Remove the screws and then the intake door motor from the blower unit.

PFP:27730

EJS00105

A

B

C

D

WJIA0105E

E

F

G

H

I

MTC

K

L

M

Revision: May 2004

MTC-71

2002 Altima

IN-CABIN MICROFILTER

IN-CABIN MICROFILTER

Removal and Installation

FUNCTION

Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing in-cabin microfilter into blower unit.

REPLACEMENT TIMING

Replace in-cabin microfilter.

Refer to MA-7, "SCHEDULE 1" and MA-10, "SCHEDULE 2" .

Caution label is fixed inside the glove box.

REPLACEMENT PROCEDURES

1.

Remove glove box assembly. Refer to IP-15, "Glove Box" .

2.

Remove in-cabin microfilter cover.

3.

Take out the ventilation air filter from blower unit.

4.

Replace with new in-cabin microfilter and reinstall on blower unit.

5.

Reinstall glove box assembly.

PFP:27277

EJS001LK

LJIA0012E

SHA868E

LJIA0013E

Revision: May 2004

MTC-72

2002 Altima

HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY

PFP:27110

Removal and Installation

REMOVAL

1.

Discharge refrigerant from A/C system. Refer to MTC-79, "HFC-134a (R-134a) Service Procedure" .

EJS00106

2.

Drain coolant from cooling system. Refer to MA-14, "Changing Engine Coolant" (QR25DE models) or

MA-22, "Changing Engine Coolant" (VQ35DE models).

3.

Disconnect heater hoses from heater core pipes.

4.

Disconnect refrigerant lines from evaporator.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid entry of air.

5.

Remove the instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .

6.

Remove the blower unit. Refer to

MTC-69, "Removal and Installation" .

7.

Remove the temperature control cable clamp and then remove the cable from the air mix door lever.

A

B

C

D

E

F

G

WJIA0192E

H

8.

Disconnect mode door motor connector.

9.

Remove the heater and cooling unit.

I

MTC

K

WJIA0200E

INSTALLATION

Install in the reverse order of removal.

NOTE:

When filling radiator with coolant, refer to CO-11, "Refilling Engine Coolant" (QR25DE models) or CO-33,

"Refilling Engine Coolant" (VQ35DE models). Recharge the A/C system. Refer to

MTC-79, "HFC-134a (R-

134a) Service Procedure" .

L

M

Revision: May 2004

MTC-73

2002 Altima

HEATER CORE

HEATER CORE

Removal and Installation

1.

Remove heater and cooling unit. Refer to

MTC-73, "Removal and Installation" .

2.

Remove heater core pipe support screws and then remove it.

PFP:27140

EJS00107

WJIA0185E

3.

Remove heater core cover screws and then remove it.

WJIA0127E

4.

Remove heater core.

WJIA0186E

Revision: May 2004

MTC-74

2002 Altima

MODE DOOR MOTOR

MODE DOOR MOTOR

PFP:27731

Removal and Installation

DRIVER SIDE MODE DOOR MOTOR

EJS00108

1.

Remove the driver lower instrument panel assembly. Refer to IP-13, "Driver Lower Instrument Panel" .

2.

Disconnect the mode door motor connector.

3.

Remove the mode door motor screws and then remove it.

A

B

C

D

WJIA0200E

E

F

G

H

K

L

M

I

MTC

Revision: May 2004

MTC-75

2002 Altima

BLOWER FAN RESISTER

BLOWER FAN RESISTER

Removal and Installation

1.

Disconnect blower motor resistor connector.

2.

Remove blower motor resistor screws and then remove it.

PFP:27150

EJS00109

WJIA0193E

Revision: May 2004

MTC-76

2002 Altima

DUCTS AND GRILLES

DUCTS AND GRILLES

Removal and Installation

Ventilator Duct, Defroster Nozzle and Defroster Ducts

Center Ventilator Grille

1.

Remove cluster lid D. Refer to IP-13, "Cluster Lid D" .

2.

Release the tabs to remove center ventilator grille.

Side Ventilator Grille LH

1.

Remove cluster lid A. Refer to IP-13, "Cluster Lid A" .

2.

Remove side ventilator grille LH.

PFP:27860

EJS0010A

A

EJS0010B

B

C

D

E

I

WJIA0112E

EJS0010C

MTC

K

L

M

F

G

H

WJIA0113E

EJS0010D

Revision: May 2004

MTC-77

WJIA0114E

2002 Altima

DUCTS AND GRILLES

Side Ventilator Grille RH

1.

Remove glove box assembly. Refer to IP-15, "Glove Box" .

2.

Remove side ventilator grille RH screw and then remove it.

Floor duct

1.

Remove the carpet. Refer to EI-32, "FLOOR TRIM" .

2.

Release foam tape and slide floor duct rearward to release from clips.

EJS0010E

WJIA0108E

EJS0010F

WJIA0115E

Revision: May 2004

MTC-78

2002 Altima

REFRIGERANT LINES

REFRIGERANT LINES

PFP:92600

HFC-134a (R-134a) Service Procedure

SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant

EJS0010G

WARNING:

Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment) or J2201 (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.

A

B

C

D

E

Evacuating System and Charging Refrigerant

F

G

H

SHA179FD

I

MTC

K

L

M

Revision: May 2004

MTC-79

SHA180FD

2002 Altima

REFRIGERANT LINES

*1

MTC-18, "LUBRICANT"

*2

MTC-91, "Checking for Refrigerant

Leaks"

*3

MTC-91, "Checking for Refrigerant

Leaks"

*4

MTC-59, "Performance Chart"

SHA251F

*5

MTC-3, "Contaminated Refrigerant"

Components

Refer to MTC-5, "Precautions for Refrigerant Connection"

.

Revision: May 2004

MTC-80

EJS0010H

2002 Altima

Revision: May 2004

REFRIGERANT LINES

QR25DE Models

MTC-81

WJIA0180E

2002 Altima

F

G

H

I

MTC

K

L

M

C

D

E

A

B

REFRIGERANT LINES

VQ35DE Models

Revision: May 2004

MTC-82

WJIA0116E

2002 Altima

REFRIGERANT LINES

Removal and Installation for Compressor — QR25DE Models

F

WJIA0182E

G

REMOVAL

1.

Discharge the refrigerant. Refer to MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the drive belt.

Refer to MA-14, "ENGINE MAINTENANCE (QR25DE ENGINE)" .

3.

Disconnect the compressor connector.

4.

Remove the high-pressure flexible hose and low-pressure flexible hose.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

5.

Remove the mounting bolts from compressor using power tools.

INSTALLATION

CAUTION:

Replace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new one, then apply compressor oil to it when installing it.

When charging refrigerant, check for leaks.

H

I

MTC

K

L

Bolts mounting the compressor

Tightening torque

Tightening torque

: 28.4 - 33.3 N·m (2.9 - 3.4 kg-m, 21 - 24 ft-lb)

: 59.8 - 69.6 N·m (6.1 - 7.0 kg-m, 45 - 51 ft-lb)

Bolt mounting the high- and low-pressure flexible hoses

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

M

EJS0010I

A

B

C

D

E

Revision: May 2004

MTC-83

2002 Altima

REFRIGERANT LINES

Removal and Installation for Compressor — VQ35DE Models

EJS0010J

WJIA0117E

REMOVAL

1.

Discharge the refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the drive belt.

Refer to MA-21, "ENGINE MAINTENANCE (VQ35DE ENGINE)" .

3.

Remove the coolant pipe bracket bolt.

4.

Remove compressor mounting stud.

5.

Disconnect the compressor connector.

6.

Remove the high-pressure flexible hose and low-pressure flexible hose.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

7.

Remove the mounting bolts and nut from compressor using power tools.

INSTALLATION

CAUTION:

Replace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new one, then apply compressor oil to it when installing it.

When charging refrigerant, check for leaks.

Bolts mounting the compressor (rear side)

Tightening torque : 56.9 - 65.7 N·m (5.8 - 6.8 kg-m, 42 - 48 ft-lb)

Bolt mounting the compressor (front side)

Tightening torque : 28.4 - 33.3 N·m (2.9 - 3.4 kg-m, 21 - 24 ft-lb)

Nut mounting the compressor (front side)

Tightening torque : 59.8 - 69.6 N·m (6.1 - 7.0 kg-m, 45 - 51 ft-lb)

Bolt mounting the high- and low-pressure flexible hoses

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

Revision: May 2004

MTC-84

2002 Altima

Removal and Installation for Compressor Clutch

REMOVAL

When removing center bolt, hold clutch disc with clutch disc tool.

Remove the clutch disc.

Clutch disc holding tool:

(J-44614) Commercial service tool

REFRIGERANT LINES

Remove the snap ring using external snap ring pliers.

Pulley removal:

WHA212

Use a pulley puller with small adapter. Position the small adapter on the end of the drive shaft and the center of the puller on the small adapter. Remove the pulley assembly with the puller.

To prevent deformation of the pulley groove, the puller claws should be hooked under (not into) the pulley groove.

Remove the snap ring using external snap ring pliers.

Remove the magnet coil harness clip using a screwdriver, remove the three magnet coil fixing screws and remove the magnet coil.

Revision: May 2004

MTC-85

2002 Altima

EJS0010K

A

B

WHA228

C

D

E

F

G

RHA072C

H

I

MTC

LHA173

K

L

M

REFRIGERANT LINES

INSPECTION

Clutch Disc

WHA183

If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Pulley

Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

Coil

Check magnet coil for loose connection or cracked insulation.

INSTALLATION

Install the magnet coil.

Be sure to align the magnet coil pin with the hole in the compressor front head.

Install the magnet coil harness clip using a screwdriver.

WHA213

Install the pulley assembly using the installer and a wrench, and then install the snap ring using snap ring pliers.

LHA174

Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand.

Revision: May 2004

MTC-86

WHA184

2002 Altima

REFRIGERANT LINES

Using the clutch disc tool to prevent clutch disc rotation, tighten the bolt to 12 N·m (1.2 kg-m, 9 ft-lb).

After tightening the bolt, check that the pulley rotates smoothly.

WHA229

C

D

E

A

B

Check clearance all the way around the clutch disc.

Clutch disc-to-pulley clearance

: 0.3 - 0.6 mm (0.012 - 0.024 in)

If the specified clearance is not obtained, replace adjusting spacer and readjust.

WHA194

BREAK-IN OPERATION

When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.

Removal and Installation for Low-pressure Flexible Hose

REMOVAL

1.

Discharge the refrigerant. Refer to MTC-79, "HFC-134a (R-134a) Service Procedure" .

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

2.

Remove the low-pressure flexible hose. Refer to

MTC-80, "Components" .

EJS0010L

INSTALLATION

CAUTION:

Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to it when installing it.

When charging refrigerant, check for leaks.

Bolt mounting the low-pressure flexible hose (evaporator side)

Tightening torque : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)

Bolt mounting the low-pressure flexible hose (compressor side)

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

K

L

M

F

G

H

I

MTC

Revision: May 2004

MTC-87

2002 Altima

REFRIGERANT LINES

Bolt connecting the low-pressure flexible hose in-line connection (VQ35DE models)

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

Removal and Installation for High-pressure flexible hose

REMOVAL

1.

Discharge the refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the high-pressure flexible hose. Refer to MTC-80, "Components" .

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

EJS0010M

INSTALLATION

CAUTION:

Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to it when installing it.

When charging refrigerant, check for leaks.

Bolts mounting the high-pressure flexible hose

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

Removal and Installation for High-pressure Pipe

REMOVAL

1.

Discharge the refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the high-pressure pipe. Refer to

MTC-80, "Components"

.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

EJS0010N

INSTALLATION

CAUTION:

Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when installing it.

When charging refrigerant, check for leaks.

Bolt mounting the high-pressure pipe (evaporator side)

Tightening torque : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)

Bolt mounting the high-pressure pipe (condenser side)

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

Removal and Installation for Refrigerant Pressure Sensor

1.

Discharge the refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Disconnect the refrigerant pressure sensor connector and remove the refrigerant pressure sensor from condenser.

CAUTION:

Please be careful not to damage the condenser fins.

Apply compressor oil to the O-ring of the refrigerant pressure sensor when installing it.

EJS0010O

Tightening torque

: 9.8 - 11.7 N·m (1.0 - 1.2 kg-m, 7.3 - 8.6 ftlb)

WJIA0123E

EJS0010P

Removal and Installation for Condenser

REMOVAL

1.

Discharge the refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the radiator. Refer to CO-34, "RADIATOR" .

CAUTION:

Be careful not to damage the core surface of the condenser and the radiator.

Revision: May 2004

MTC-88

2002 Altima

REFRIGERANT LINES

3.

Disconnect the high-pressure flexible hose and the high-pressure pipe from the condenser.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

4.

Disconnect the refrigerant pressure sensor connector.

5.

Remove the front fascia. Refer to EI-13, "FRONT BUMPER" .

6.

Remove the mounting nuts from condenser mounting brackets.

C

WJIA0124E

D

E

A

B

F

G

WJIA0125E

INSTALLATION

CAUTION:

Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones, then apply compressor oil to them after installing them.

When charging refrigerant, check for leaks.

High-pressure flexible hose and pipe mounting bolt

Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 69 - 173 in-lb)

Condenser mounting nuts

Tightening torque : 5.0 - 6.79 N·m (0.51 - 0.69 kg-m, 45 - 60 in-lb)

Removal and Installation for Liquid Tank

EJS0010Q

H

I

MTC

K

L

M

WJIA0183E

1.

Discharge the refrigerant. Refer to MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Remove the battery.

Revision: May 2004

MTC-89

2002 Altima

REFRIGERANT LINES

3.

Remove the hood switch (if equipped).

4.

Remove the engine undercover using power tools.

5.

Remove the bolt and line clamp.

6.

Loosen the tank clamp and remove the liquid tank.

Removal and Installation for Evaporator

REMOVAL

EJS00317

1.

Evacuate and recover the A/C system refrigerant. Refer to MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Disconnect the battery negative terminal.

3.

Disconnect the air cleaner to electronic throttle control actuator tube. Refer to EM-16, "AIR CLEANER

AND AIR DUCT" (QR25DE), EM-112, "AIR CLEANER AND AIR DUCT" (VQ35DE).

NOTE:

The tube is located between the air cleaner assembly and the intake manifold and is removed to access the expansion valve.

4.

Disconnect the A/C pipe from the expansion valve.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

5.

Remove the cooler grommet.

6.

Remove the expansion valve.

7.

Remove the center console side finisher RH. Refer to IP-16,

"Center Console" .

8.

Remove the glove box assembly. Refer to IP-15, "Glove Box" .

9.

Remove the ECM.

Disconnect the ECM connector.

Remove the wire harness from the ECM mounting bracket.

Remove the two ECM mounting bracket nuts and disconnect the ground wire.

10. Remove the blower unit. Refer to

MTC-69, "BLOWER UNIT" .

WJIA0128E

11. Remove the heater core cover.

WJIA0127E

12. Remove the evaporator cover.

Revision: May 2004

MTC-90

WJIA0188E

2002 Altima

REFRIGERANT LINES

13. Remove the evaporator.

Remove the thermo control amplifier.

Remove the intake sensor.

CAUTION:

Mark the mounting position of the intake sensor and thermo control amplifier.

A

B

C

WJIA0190E

INSTALLATION

Installation is in the reverse order of removal.

Expansion valve mounting bolts : 2.9 - 5.0 N·m (0.29 - 0.51 kg-m, 26 - 44 in-lb)

CAUTION:

Replace the O-rings with new ones, then apply compressor oil to them when installing them.

D

E

Removal and Installation for Expansion Valve

REMOVAL

EJS00318

1.

Evacuate and recover the A/C system refrigerant. Refer to

MTC-79, "HFC-134a (R-134a) Service Procedure" .

2.

Disconnect the air cleaner to electronic throttle control actuator tube. Refer to EM-16, "AIR CLEANER

AND AIR DUCT" (QR25DE), EM-112, "AIR CLEANER AND AIR DUCT" (VQ35DE).

NOTE:

The tube is located between the air cleaner assembly and the intake manifold and is removed to access the expansion valve.

3.

Disconnect the A/C pipe from the expansion valve.

CAUTION:

Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

4.

Remove the cooler grommet.

5.

Remove the expansion valve.

F

G

H

I

MTC

K

L

WJIA0128E

INSTALLATION

Installation is in the reverse order of removal.

Expansion valve mounting bolts : 2.9 - 5.0 N·m (0.29 - 0.51 kg-m, 26 - 44 in-lb)

CAUTION:

Replace the O-rings with new ones, then apply compressor oil to them when installing them.

Checking for Refrigerant Leaks

EJS0010T

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector.

If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned.

When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections.

M

Revision: May 2004

MTC-91

2002 Altima

REFRIGERANT LINES

When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the component.

CAUTION:

Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak.

Checking System for Leaks Using the Fluorescent Leak Detector

EJS0010U

1.

Check A/C system for leaks using the UV lamp and safety glasses (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or TXV) leak.

2.

If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residue.

3.

After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiagnosis.

4.

Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector.

NOTE:

Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean.

Clean with a dry cloth or blow off with shop air.

Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings and may damage the detector.

Dye Injection

EJS0010V

(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 (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 manufacturer's operating 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 connection 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 Detector

PRECAUTIONS FOR HANDLING LEAK DETECTOR

When performing a refrigerant leak check, use a J-41995 A/C leak detector or equivalent. Ensure that the instrument is calibrated and set properly per the operating instructions.

The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance.

EJS0010W

Revision: May 2004

MTC-92

SHA196FA

2002 Altima

REFRIGERANT LINES

1.

Position probe approximately 5 mm (3/16 in) away from point to be checked.

2.

When testing, circle each fitting completely with probe.

C

SHA707EA

D

E

A

B

3.

Move probe along component approximately 25 to 50 mm (1 to

2 in)/sec.

SHA706E

F

G

H

I

MTC

SHA708EA

CHECKING PROCEDURE

To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed.

1.

Turn engine OFF.

2.

Connect a suitable A/C manifold gauge set to the A/C service ports.

3.

Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm

2

, 50 psi) above 16

°

C (61

°

F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.

NOTE:

At temperatures below 16

°

C (61

°

F), leaks may not be detected since the system may not reach 345 kPa (3.54

kg/cm

2

, 50 psi).

4.

Conduct the leak test from the high side (compressor discharge a to evaporator inlet f) to the low side

[evaporator drain hose g to shaft seal k (QR25DE models) or l (VQ35DE models)]. Refer to MTC-80 . Per-

form a leak check for the following areas carefully. Clean the component to be checked and move the leak detected probe completely around the connection/component.

Compressor

Check the fitting of high- and low-pressure hoses, relief valve and shaft seal.

Liquid tank

Check the refrigerant pressure sensor.

Service valves

Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks).

Revision: May 2004

MTC-93

2002 Altima

K

L

M

REFRIGERANT LINES

NOTE:

After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any false readings by leak detector.

Cooling unit (Evaporator)

With engine OFF, turn blower fan on "High" for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer's recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose.

Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose.

5.

If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above.

6.

Do not stop when one leak is found. Continue to check for additional leaks at all system components.

If no leaks are found, perform steps 7 - 10.

7.

Start engine.

8.

Set the heater A/C control as follows; a.

A/C switch: ON b.

Face mode c.

Intake position: Recirculation d.

Max cold temperature e.

Fan speed: High

9.

Run engine at 1,500 rpm for at least 2 minutes.

10. Turn engine off and perform leak check again following steps 4 through 6 above.

Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high.

SHA839E

11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity.

12. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier.

13. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier.

14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component as necessary.

15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.

16. Conduct A/C performance test to ensure system works properly.

Revision: May 2004

MTC-94

2002 Altima

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Service Data and Specifications (SDS)

COMPRESSOR

PFP:00030

EJS0010X

A

Model

Type

Displacement cm3 (cu in)/rev

Cylinder bore

×

stroke mm (in)

Direction of rotation

Drive belt

LUBRICANT

CALSONIC KANSEI make

DKS-17D

175.5 (10.7)/rev

30.5 (1.201) x 21.4 (0.84)

Clockwise (viewed from drive end)

Poly V

B

C

D

E

Model

Name

Part number

CALSONIC KANSEI make DKS-17D

Nissan A/C System Oil Type DH-PS

KLH00-PAGS0

150 (5.03, 5.3)

F

Capacity m (US fl oz, lmp fl oz)

Total in system

Compressor (Service part) charging amount

150 (5.03, 5.3)

G

REFRIGERANT

H

Type

Capacity kg (lb)

HFC-134a (R-134a)

0.475 - 0.525 (1.045 - 1.155)

I

ENGINE IDLING SPEED

Refer to EC-38, "Idle Speed and Ignition Timing Check" (QR25DE models) or EC-656, "Idle Speed and Ignition Timing Check" (VQ35DE models).

MTC

BELT TENSION

Refer to MA-14, "ENGINE MAINTENANCE (QR25DE ENGINE)" or MA-21, "ENGINE MAINTENANCE

(VQ35DE ENGINE)" .

K

L

M

Revision: May 2004

MTC-95

2002 Altima

SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: May 2004

MTC-96

2002 Altima

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