Nissan Titan 2004 Owner's Manual
J AIR CONDITIONER
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SECTION
MANUAL AIR CONDITIONER
CONTENTS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a) ..... 4
Contaminated Refrigerant ........................................ 4
General Refrigerant Precautions .............................. 5
Precautions for Leak Detection Dye ......................... 5
A/C Identification Label ............................................ 6
Precautions for Refrigerant Connection ................... 6
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ................................ ...................... 6
O-RING AND REFRIGERANT CONNECTION ..... 7
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
CHARGING CYLINDER .......................................11
Wiring Diagrams and Trouble Diagnosis .................11
PREPARATION ......................................................... 12
Special Service Tools ............................................. 12
HFC-134a (R-134a) Service Tools and Equipment ... 12
Commercial Service Tools ...................................... 15
REFRIGERATION SYSTEM ....................... ....... ....... 16
Refrigerant Cycle ................................................... 16
REFRIGERANT FLOW ....................................... 16
Refrigerant System Protection ............................... 16
REFRIGERANT PRESSURE SENSOR ............. 16
PRESSURE RELIEF VALVE .............................. 17
Component Layout ................................................. 18
REFRIGERATION SYSTEM ............................... 18
LUBRICANT ............................................................. 20
Maintenance of Lubricant Quantity in Compressor ... 20
LUBRICANT ....................... ................................. 20
CHECKING AND ADJUSTING ........................... 20
AIR CONDITIONER CONTROL ............................... 22
Description ................... ...... ....... ...... ........................ 22
Operation .............. ................................. ................. 22
AIR MIX DOOR CONTROL ................................. 22
BLOWER SPEED CONTROL ............................. 22
INT AKE DOORS CONTROL ............................... 22
MODE DOOR CONTROL ................................... 22
DEFROSTER DOOR CONTROL ........................ 22
MAGNET CLUTCH CONTROL ........................... 22
SELF-DIAGNOSTIC SYSTEM ........... ...... ....... ....23
Description of Control System ................................24
Control Operation ................................................... 24
DISPLAY SCREEN (IF EQUIPPED) ...................25
TEMPERATURE SWITCH (TEMPERATURE
CONTROL) ............................ .......................... .... 25
RECIRCULATION () SWITCH .............................25
OFF SWITCH (BLOWER SPEED SET TO 0) .....25
A/C SWITCH ....................................................... 25
MODE SWITCH .................................................. 25
FRONT BLOWER SWITCH ................................ 25
Discharge Air Flow .................................................26
............................................................................26
System Description .................................................27
SWITCHES AND THEIR CONTROL FUNCTION ...27
CAN Communication System Description .............. 28
TROUBLE DIAGNOSIS ............................................ 29
CONSULT-II ................................................. ........... 29
CONSULT-II BASIC OPERATION .......................29
DATA MONITOR .................................................30
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ......................................................31
WORK FLOW ......................................................31
SYMPTOM TABLE .............................................. 31
Component Parts and Harness Connector Location ... 32
ENGINE COMPARTMENT .................................. 32
PASSENGER COMPARTMENT .........................33
Schematic .................... ....................................... ....34
Wiring Diagram —A/C— .........................................35
Front Air Control Terminals and Reference Value ... 41
PIN CONNECTOR TERMINAL LAYOUT ............41
TERMINALS AND REFERENCE VALUE FOR
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FRONT AIR CONTROL ....................................... 41
A/C System Self-diagnosis Function (With NAVI
Only) .......................................................................43
DESCRIPTION ....................................................43
Operational Check ..................................................45
CHECKING BLOWER .........................................45
CHECKING DISCHARGE AIR ............................45
CHECKING RECIRCULATION ............................45
CHECKING TEMPERATURE DECREASE .........46
CHECKING TEMPERATURE INCREASE ..........46
CHECK A/C SWITCH ..........................................46
Power Supply and Ground Circuit for Front Air Con-
trol ............................. .......................... .................... 47
INSPECTION FLOW ...........................................47
COMPONENT DESCRIPTION ............................48
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ...48
Mode Door Motor Circuit ........................................50
INSPECTION FLOW ...........................................50
SYSTEM DESCRIPTION .................................... 51
COMPONENT DESCRIPTION ............................51
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ...................................................51
Air Mix Door Motor Circuit ......................................54
INSPECTION FLOW ...........................................54
SYSTEM DESCRIPTION .................................... 55
COMPONENT DESCRIPTION ............................55
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR ...................................................55
Intake Door Motor Circuit ........................................ 58
INSPECTION FLOW ...........................................58
SYSTEM DESCRIPTION .................................... 59
COMPONENT DESCRIPTION ............................59
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ...................................................59
Defroster Door Motor Circuit ............................ .......61
SYMPTOM: ...................................... ...... ....... .......61
INSPECTION FLOW ...........................................61
SYSTEM DESCRIPTION .................................... 62
COMPONENT DESCRIPTION ............................62
DIAGNOSTIC PROCEDURE FOR
DEFROSTER DOOR MOTOR ............................62
Blower Motor Circuit ...............................................65
INSPECTION FLOW ...........................................65
SYSTEM DESCRIPTION .................................... 66
COMPONENT DESCRIPTION ............................66
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ...............................................................67
COMPONENT INSPECTION ..............................71
Magnet Clutch Circuit .............................................73
INSPECTION FLOW ...........................................73
SYSTEM DESCRIPTION .................................... 74
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 74
COMPONENT INSPECTION ..............................78
Insufficient Cooling .................................................79
INSPECTION FLOW ...........................................79
PERFORMANCE TEST DIAGNOSES ................80
PERFORMANCE CHART ...................................82
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE .............................. .....................................83
Insufficient Heating .................................................86
INSPECTION FLOW ....... ....... ...... ....... ...... ...........86
Noise ............................ ...........................................87
INSPECTION FLOW ....... ....... ...... ....... ...... ...........87
Self-diagnosis .........................................................88
INSPECTION FLOW ....... ....... ...... ....... ...... ...........88
Water Valve Circuit ....... ...... ....... ...... ....... .................89
COMPONENT DESCRIPTION ............................89
DIAGNOSTIC PROCEDURE FOR WATER
VALVE ....................... ...........................................89
COMPONENT INSPECTION ...............................91
Intake Sensor Circuit ...............................................91
COMPONENT DESCRIPTION ............................91
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR .....................................................................91
COMPONENT INSPECTION ...............................93
CONTROL UNIT .......................... ...... ....... ...... ....... ....94
Removal and Installation .........................................94
REMOVAL ........................................................ ....94
INSTALLATION ......... ...........................................94
INTAKE SENSOR .............................. ....... ...... ....... ....95
Removal and Installation .........................................95
REMOVAL ........................................................ ....95
INSTALLATION ......... ...........................................95
BLOWER MOTOR .....................................................96
Removal and Installation .........................................96
REMOVAL ........................................................ ....96
INSTALLATION ......... ...........................................96
IN-CABIN MICROFILTER ..........................................97
Removal and Installation .........................................97
FUNCTION ..........................................................97
REPLACEMENT TIMING ....................................97
REPLACEMENT PROCEDURE ..........................97
HEATER & COOLING UNIT ASSEMBLY .................99
Removal and Installation .........................................99
REMOVAL ........................................................ ....99
INSTALLATION ......... .........................................100
HEATER CORE .......................................................101
Removal and Installation .......................................101
REMOVAL ........................................................ ..102
INSTALLATION ......... .........................................102
DEFROSTER DOOR MOTOR .................................103
Removal and Installation .......................................103
REMOVAL ........................................................ ..103
INSTALLATION ......... .........................................103
INTAKE DOOR MOTOR ........................... ...... ....... ..104
Removal and Installation .......................................104
REMOVAL ........................................................ ..104
INSTALLATION ......... .........................................104
MODE DOOR MOTOR ............................. ...... ....... ..105
Removal and Installation .......................................105
REMOVAL ........................................................ ..105
INSTALLATION ......... .........................................105
AIR MIX DOOR MOTOR .........................................106
Removal and Installation .......................................106
REMOVAL ........................................................ ..106
INSTALLATION ......... .........................................106
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FRONT BLOWER MOTOR RESISTOR ................. 107
Removal and Installation ...................................... 107
REMOVAL ......................................................... 107
INSTALLATION ................................................. 107
DUCTS AND GRILLES .......................................... 108
Removal and Installation ...................................... 108
DEFROSTER NOZZLE ..................................... 109
RH AND LH SIDE DEMISTER DUCT ............... 109
RH AND LH VENTILATOR DUCT ..................... 109
CENTER VENTILATOR DUCT ..........................110
FLOOR DUCT ....................................................110
GRILLES ..................... .......................................110
REFRIGERANT LINES ............................................111
HFC-134a (R-134a) Service Procedure ................ 111
SETTING OF SERVICE TOOLS AND EQUIP-
MENT .......................... ....................................... 111
Components ................................ ..........................113
Removal and Installation for Compressor .............114
REMOVAL ..........................................................114
INSTALLATION ..................................................115
Removal and Installation for Compressor Clutch ..115
REMOVAL ..........................................................115
INSPECTION .....................................................116
INSTALLATION ..................................................117
BREAK-IN OPERATION ....................................118
Removal and Installation for Low-pressure Flexible
Hose ............................... .......................................118
REMOVAL ..........................................................118
INSTALLATION ..................................................118
Removal and Installation for High-pressure Flexible
Hose ............................... .......................................118
REMOVAL ..........................................................118
INSTALLATION ..................................................118
Removal and Installation for High-pressure Pipe ..119
REMOVAL .........................................................119
INSTALLATION .................................................119
Removal and Installation for Low-pressure Pipe ..119
REMOVAL .........................................................119
INSTALLATION .................................................119
Removal and Installation for Refrigerant Pressure
Sensor ..................................................................119
REMOVAL .........................................................119
INSTALLATION .................................................119
Removal and Installation for Condenser ..............119
REMOVAL .........................................................119
INSTALLATION .................................................120
Removal and Installation for Front Evaporator .....121
REMOVAL .........................................................121
INSTALLATION .................................................122
Removal and Installation for Front Expansion Valve .122
REMOVAL .........................................................122
INSTALLATION .................................................122
Checking for Refrigerant Leaks ............................122
Checking System for Leaks Using the Fluorescent
Dye Leak Detector ................................................122
Dye Injection .........................................................123
Electronic Refrigerant Leak Detector ....................123
PRECAUTIONS FOR HANDLING LEAK
DETECTOR ........................... ............................123
CHECKING PROCEDURE ...............................124
SERVICE DATA AND SPECIFICATIONS (SDS) ....126
Service Data and Specifications (SDS) ................126
COMPRESSOR ................................................126
LUBRICANT ......................................................126
REFRIGERANT ..................... ............................126
ENGINE IDLING SPEED ..................................126
BELT TENSION .................................................126
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PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BE LT PRE-TENSIONER”, used along
with a front sea t belt , helps t o redu ce th e r isk or s everi ty of injury to th e driv er an d front passenge r for c ertain
types of collisi on . Thi s s ys te m in cludes seat belt swi tch inp uts an d du al stage front air bag modules . The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information ne ce ss ary t o se rvi ce th e sy stem saf e ly is i nclu de d in th e SR S and SB se ct i on of th is Ser vic e Manual.
WARNING:
● To avoid rendering the SRS inoperativ e, which cou ld increase the risk of persona l 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, in cluding incorrect removal a nd installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For rem ova l of Sp iral Ca ble an d Air
Bag Module, see the SRS section.
● Do not use electrical test equipme nt on any circuit related to the SRS unle ss instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors .
EJS0028X
Precautions for Working with HFC-134a (R-134a)
EJS0028Y
WARNING:
● CFC-12 (R-12) refrigeran t and HFC -134a (R -134a) refrige rant are not com patible. If the re friger ants
are mixed compressor failure is likely to occur. Refer MTC-4, "
Contaminated Refrigerant" . To
determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant
Recovery/Recycling Recharging equipment and Refrigerant Identifier.
● Use only specified lu bricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
– When removing refrigerant com ponents from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
– When installing refrigerant comp onents to a vehicle, do not remove the ca ps (unseal) until jus t
before connecting the comp onents. 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 lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
– Avoid breathing A/C refrigerant and lubricant vap or or mist. Expo sure ma y irritate eyes, no se and
throat. Re move H FC -13 4a ( R- 13 4a) f rom th e A /C s yst em u sin g c ert i fi ed s erv i ce eq u ipm en t meet i ng
requirements of SAE J2210 [HFC-134a (R-134a) recycling equipment], or J2209 [HFC-134a (R-134a)
recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming
service. Additional health and safety information may be obtained from refrigerant and lu bricant
manufacturers.
– Do not allow lubricant, NISSAN A/C System Lubricant Type S (DH-PS) or equivalent, to come in
contact with styrofoam parts. Damage may result.
Contaminated Refrigerant
EJS0028Z
If a refrigerant other than pure HFC-134a (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 recove ry of the contamin ated refri gerant co uld dam age your s ervice equ ipment a nd refriger -
ant supply.
● Suggest the customer return the ve hicle to the location of previous service where the contami nation ma y
have occurred.
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PRECAUTIONS
● If you choose to p erfor m th e rep ai r, recover the refri ger ant usi ng on ly 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.
● If the vehicle is within the warranty period, the air con ditioner warranty is void. Pleas e contact NISSAN
Customer Affairs for furthe r assis tance .
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EJS00290
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 a nd hand protection (goggles and glove s) 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 r e frige r an t c ontainer with an open flame; i f container warming is requ ired, place the
bottom of the container in a warm pail of water.
● Do not intentionally drop, puncture, or incinerate refrigerant containers.
● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during re pair. Some mixtures of air and HF C-134a (R-134a)
have been show n to be combusti ble at elevated pressu res. The se mixtu res, i f ignited, may ca use
injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
Precautions for Leak Detection Dye
● The A/C system cont a ins a fluor esce nt le ak de tecti on dye used f or loc ati ng r efrig erant lea ks. An ul trav iole t
EJS00291
(UV) lamp is required to illuminate the dy e when inspecting for leaks.
● Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
● The fluorescen t dy e le ak de te ct o r is no t a re pl a cem en t for a n e le ct ron i c r efr i ge ran t le ak de tec to r. The fluo-
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-
41995).
● For your safety and the cus tomer's sa tisfaction , read and f ollow all m anufacturer' s operating instruction s
and precautions prior to performing work.
● 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 immedia tely w ith the ap prov ed dy e clea ner. Fluorescent dy e left on a s urfa ce fo r an exten ded p eriod
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 refrigera nt dye bottle (1 /4 ounce / 7.4 cc) per A/C system.
● Leak detectio n dyes for HFC-134a (R-13 4a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C systems or CFC-12 (R-12) leak detection
dye in R-134a A/C systems or A/C system dam age may result.
● The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.
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PRECAUTIONS
A/C Identification Label
EJS00292
Vehicles with factory installed fluorescent dye have this identification
label on the underside of hood.
WJIA0672E
Precautions for Refrigerant Connection
EJS00293
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 sens or
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
● The O-ring has been relocated. It has also been provided with a groove for proper installation. This
reduces the possibility 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 facil-
itating piping connec tio ns .
SHA815E
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PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
A/C Compressor and Condenser
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WJIA1020E
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PRECAUTIONS
1. High-pressure service valve 2. Grommet 3. High-pressure pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible hose 8. Low-pressure flexible hose 9. Low-pressure service valve
10. Low-pressure pipe 11. Expansion valve 12. Drain hose
CAUTION:
The new and former refrigerant co nnections 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.
O-Ring Part Numbers and Specifications
Connection type
New 8 92471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
SHA814E
*: Always check with the Parts Department for the latest parts information.
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)
WARNING:
Make sure all refrigera nt is disc ha rg ed into the rec yc ling equi pm ent a nd the pr es su re in the sy ste m 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 re moved, s tore it in the same pos ition as it i s when moun ted on the c ar.
Failure to do so will cause lubricant to enter the low pressure chamber.
● When connect ing tubes, always use a torque wrench and a back-up wrench.
● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and mo isture.
● When installing an air conditioner in the veh icl e, c onne ct the pip es as the final stage of the opera -
tion. Do not remove the seal ca ps 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 Lubricant Type S (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.
O-ring
size
12
16
19
Part number* D mm (in) W mm (in)
92472 N8210 10.9 (0.429) 2.43 (0.0957)
92473 N8210 13.6 (0.535) 2.43 (0.0957)
92474 N8210 16.5 (0.650) 2.43 (0.0957)
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PRECAUTIONS
● After connecting li ne, conduct leak test a nd ma ke s ure that there is no lea ka ge from c onn ec tion s.
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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Precautions for Servicing Compressor
● 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 Lub ricant Quanti ty in Compres-
sor” exactly. Refer to MTC-20, "
● Keep friction su rfaces between clutc h and pulley clean. If the surface is contaminated w ith lubri-
Maintenance of Lubricant Quantity in Compressor" .
EJS00294
cant, wipe it off by using a clean waste cloth moistened with thinner.
● After compressor service operation, turn the compressor shaft by hand more than 5 turns in both
directions. This will e qually distribute lubricant inside the compresso r. After the compresso r is
installed, let the engine idle and operate the compressor for 1 hour.
● After replaci ng the compressor magnet clutch, apply voltage to the new one and check for normal
operation. Refer to MTC-115, "
Precautions for Service Equipment
Removal and Installation for Compressor Clutch".
EJS00295
RECOVERY/ RECYCLING EQUIPMENT
Follow the man uf ac turer's instructio ns for machine op era tion and machi ne m ai nte na nc e . N e ve r i ntroduce any
refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Follow the manufacturer's instructions for tester operation and tester maintenanc e.
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VACUUM PUMP
The lubricant contained inside the vac uum pump is not co mpatible
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 vacuu m pump l ubric ant ma y migra te ou t of th e pump in to
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 man-
ual shut-off valve near th e pump end. Clo se the valv e 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 co ndition. Such valves ma y restrict the pump's
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a (R-134a or
134a). Make sure the ga uge 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.
RHA270D
SHA533D
RHA272D
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PRECAUTIONS
SERVICE COUPLERS
Never attempt to conn ect HFC-134a (R-1 34a) service coupl ers 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. If an improper
connection is attempted, discharging and contamination may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
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RHA273D
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 sc ale or of quality recycle/recharge equipment.
Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the following:
● GI-15, "How to Read Wiring Diagrams"
● PG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble dia gnosis, refer to the following:
● GI-9, "How to Follow Trouble Diagnoses"
● GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident"
EJS00296
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PREPARATION
PREPARATION PFP:00002 Special Service Tools
EJS00297
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
—
(J-38873-A)
Pulley installer
LHA171
KV99233130
(J-29884)
Pulley puller
LHA172
HFC-134a (R-134a) Service Tools and Equipment
Description
Installing pulley
Removing pulley
EJS00298
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 containe r fittings, service hose fitti ngs and service equipment fit tings (equipment which handle s
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerant s/lubricant.
Adapters that convert one size fitting to another must never be used refrigerant/lubricant contamination will
occur and compress or fai lure will result.
Tool number
(Kent-Moore No.)
Tool name
HFC-134a (R-134a) refrigerant Container color: Light blue
Description
Container marking: HFC-134a (R134a)
Fitting size: Thread size
● large container 1/2”-16 ACME
S-NT196
KLH00-PAGS0
( — )
NISSAN A/C System Lubricant
Type S (DH-PS)
S-NT197
(J-43600)
Recovery/Recycling
Recharging equipment (ACR2000)
WJIA0293E
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Type: Poly alkylene glycol oil (PAG),
type S (DH-PS)
Application: HFC-134a (R-134a)
swash plate compressors (NISSAN
only)
Lubricity: 40 m (1.4 US fl oz, 1.4 Imp
fl oz)
Refrigerant Recovery and Recycling
and Recharging
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
(J-41995)
Electronic refrigerant leak detector
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
goggles
(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)
SHA438F
AHA281A
ZHA200H
Description
Power supply:
● DC 12V (Cigarette lighter)
Power supply:
● DC 12V (Battery terminal)
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 goggles
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.)
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SHA439F
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce bottle
SHA440F
(J-43872)
Dye cleaner
SHA441F
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For injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
For cleaning dye spills.
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PREPARATION
Tool number
(Kent-Moore No.)
Tool name
(J-39183-C)
Manifold gauge set (with hoses
and couplers)
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)
S-NT201
Description
Identification:
● The gauge face indicates R-134a.
Fitting size-Thread size
● 1/2”-16 ACME
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”-16 ACME
Hose fitting to service hose:
● M14 x 1.5 fitting is optional or perma-
nently attached.
(J-39699)
Refrigerant weight scale
(J-39649)
Vacuum pump
(Including the isolator valve)
S-NT202
For measuring of refrigerant
Fitting size-Thread size
● 1/2”-16 ACME
S-NT200
Capacity:
● Air displacement: 4 CFM
● Micron rating: 20 microns
● Oil capacity: 482 g (17 oz)
Fitting size-Thread size
● 1/2”-16 ACME
S-NT203
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PREPARATION
Commercial Service Tools
Tool name Description
(J-41810-NI)
Refrigerant identifier equipment (R134a)
RJIA0197E
Power tool Loosening bolts and nuts
PBIC0190E
(J-44614)
Clutch disc holding tool
For checking refrigerant purity and
system contamination
Clutch disc holding tool
EJS00299
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REFRIGERATION SYSTEM
REFRIGERATION SYSTEM PFP:KA990 Refrigerant Cycle
EJS0029A
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evapor ator, and back to the compres sor. The refrigerant ev apora tion th rough the evap orato r coils
are controlled by externally equalized expansion valve, located inside the evaporator case.
Refrigerant System Protection
EJS0029B
REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high or low pressure s by the refrigerant pressure sensor , l oc at ed on t he co nd enser. If the syste m p ress ur e r is es ab ov e or fa lls be lo w t he sp eci fic at i on s, t he ref r ige rant pressure sensor detects the pressure inside the refrigerant line and sends a voltage signal to the ECM.
The ECM de-energizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high
pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm
about 120 kPa ( 1 .22 kg/cm
2
, 17.4 psi).
2
, 398 psi), or below
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REFRIGERATION SYSTEM
PRESSURE RELIEF VALVE
The refrige rant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrig erant in the system increases to an abnorma l level [more than 2,990 kPa (30.5 kg/
2
cm
, 433.6 psi)], the release p ort on the pressure relief valv e automatically open s and releases refrigerant
into the atmosphere.
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REFRIGERATION SYSTEM
Component Layout
REFRIGERATION SYSTEM
EJS0029C
LJIA0141E
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REFRIGERATION SYSTEM
1. Defroster nozzle 2. LH side demister duct 3. LH ventilator duct
4. RH side demister duct 5. RH ventilator duct 6. Center ventilator duct
7. Front heater and cooling unit assembly 8. Floor duct 9. Clips
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LUBRICANT
LUBRICANT PFP:KLG00 Maintenance of Lubricant Quantity in Compressor
EJS0029D
The lubricant in the c ompressor circulates thro ugh the syst em with the refrig erant. Add lubr icant to compre ssor when repl ac in g an y c omp on en t or a f te r a la rge r e fri ge ran t le ak ag e h as occu r red . It is im po rtant 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 Lubricant Type S (DH-PS)
Part number: KLH00-PAGS0
CHECKING AND ADJUSTING
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
Start the engine and set the following conditions:
test condition
● Engine speed: Idling to 1,200 rpm
● A/C switch: On
● Blower speed : Max. position
● Temperature control: Optional [set so that intake air temperature is 25° to 30° C (77° to 86°F).]
● Intake position: Recirculation ( )
● Perform lubricant return operation for about ten minutes
Adjust the lubricant quantity according to the following table.
Lubricant Adjusting Procedure for Components 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:
Lubricant to be added to system
Part replaced
Front evaporator 75 (2.5, 2.6) —
Condenser 75 (2.5, 2.6) —
Liquid tank 5 (0.2, 0.2) Add if compressor is not replaced.
In case of refrigerant leak
*1: If refrigerant leak is small, no addition of lubricant is needed.
Amount of lubricant
m (US fl oz , Imp fl oz)
30 (1.0, 1.1) Large leak
— Small leak *1
Remarks
Lubricant Adjustment Procedure for Compressor Replacement
1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure s hould be displayed. If NG, recover refrigerant from equipment lines.
2. Connect recovery/recyc ling equipment to vehicle. Confirm refrigerant pur ity in supply tank using recovery/
recycling equipment and refrigerant identifier. If NG, refer to MTC - 4, "
3. Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identifier. If NG, refer to MTC-4, "
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.
Contaminated Refrigerant" .
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LUBRICANT
8. Measure an amount o f n ew l ub ric an t eq ua l to t h e a mou nt r e cover e d d uri ng di sc har gi ng. A d d thi s l u bri can t
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.
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AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL PFP:27500 Description
EJS0029E
The front air control provides regulation of the vehicle's interior temperature. The system is based on the position of the front air controls temperature switch, mode switch, front blower switch, A/C switch, and recirculation
switch positions selected by the driver. This is done by utilizing a microcomputer, also referred to as the front
air control, which receives input signals f rom the following two sensors:
● Intake sensor
● PBR (Position Balanced Resistor).
The front air control then sends outputs to the defroster door motor, mode door motor, air mix door motor, and
intake door motor, as necessary to control:
● Outlet air volume
● Air temperature
● Air distribution
Operation
EJS0029F
AIR MIX DOOR CONTROL
The air mix door is controlled so that in-vehicle temperature changed based on the position of the temperature
switch.
BLOWER SPEED CONTROL
Blower speed is controlled based on front blower switch settings.
When blower swit ch is turned, the blower m otor starts and increases air flow v olume each time the blowe r
switch is turned counterclockwise, and decreases air flow volume each time the blower switch is turned counterclockwise.
When engine coola nt tempe rature is low, the blower motor oper ation is de layed to prevent coo l air from f lowing.
INTAKE DOORS CONTROL
The intake door s are controlled by the recirc ulation switch setting, ma x. A/C switch setting, and the mode
(defroster) switch setting.
MODE DOOR CONTROL
The mode door is controlled by the position of the mode switch.
DEFROSTER DOOR CONTROL
The defroster door is controlled by: Turning the mode dial to front defroster.
MAGNET CLUTCH CONTROL
WJIA0682E
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AIR CONDITIONER CONTROL
When the A/C switch is pressed, or the mode switch is turned to the defroster position, the front air control outputs a compressor ON signal to BCM.
The BCM then sends a compressor ON signal to ECM, via CAN communication line.
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle an gle sensor, etc.). If it judges compres s or ca n b e turn ed ON , it sends compresso r ON si gnal to IPDM E/R, via CAN communication line.
Upon receipt of comp ressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.
SELF-DIAGNOSTIC SYSTEM
The self-diagnosti c system is buil t into the front air control to qu ickly locate the cause of symptom s. Refer to
MTC-43, "
A/C System Self-diagnosis Function (With NAVI Only)" .
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AIR CONDITIONER CONTROL
Description of Control Syste m
The control sy stem consists of input sensors, switches, the front air control (microcomputer) and outputs.
The relation ship of these components i s shown in the figure below:
EJS0029G
Control Operation
WJIA0683E
EJS0029H
Front air control
WJIA0684E
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AIR CONDITIONER CONTROL
DISPLAY SCREEN (IF EQUIPPED)
Displays the operational status of the system.
TEMPERATURE SWITCH (TEMPERATURE CONTROL)
Increases or decreases the set temperature.
RECIRCULATION () SWITCH
● When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
● When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automati-
cally turned OFF. REC mode can be re-entered by pressing REC switch again.
● REC switch is not operated when DEF switch is turned ON, or at th e D/F position.
● Recirculation mode is on in MAX A/C position.
OFF SWITCH (BLOWER SPEED SET TO 0)
The compressor and blower are OFF and the intake door is set to the outside air position.
A/C SWITCH
The compressor is ON or OFF.
MODE SWITCH
Controls the air discharge outlets through control of the mode and de froster doors.
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FRONT BLOWER SWITCH
Manually contro l the blower speed. Four s peeds are available for m anual control [as shown o n the display
screen (if equipped)].
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AIR CONDITIONER CONTROL
Discharge Air Flow
EJS0029I
WJIA0540E
WJIA0528EWJIA0709E
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AIR CONDITIONER CONTROL
System Description
SWITCHES AND THEIR CONTROL FUNCTION
EJS0029J
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AIR CONDITIONER CONTROL
CAN Communication System Description
Refer to LAN-8, "CAN COMMUNICATION" .
EJS0029L
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TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS PFP:00004
CONSULT-II
CONSULT-II can display each diagnostic ite m using the diagnostic test modes shown following.
System part Check item , diag nosis m ode Description
BCM Data monitor Displays BCM input data in real time.
EJS0029M
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CONSULT-II BASIC OPERATION
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and “CON-
SULT-II convert er” to the data link conn ector, and turn the ignition switch ON.
BBIA0369E
2. T ouch “START (NISSAN BASED VHCL)”.
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3. T ouch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not
indicated, go to GI-38, "
CONSULT-II Data Link Connector (DLC)
Circuit" .
BCIA0029E
BCIA0030E
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TROUBLE DIAGNOSIS
DATA MONITOR
Operation Procedure
1. Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen.
2. Touch “DATA MONITOR” on “SELECT DIAG MODE” screen.
WJIA0468E
BCIA0031E
3. Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on
“DATA MONITOR” screen.
All signals Monitors all the items.
Selection from menu Selects and monitors the individual item selected.
4. Touch “START”.
5. When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the ite ms
will be monitored.
6. Touch “RECORD” while monitoring, then the status of the moni-
WJIA0469E
tored item can be recorded. To stop recording, to uch “STOP”.
Display Item List
Monitor it em na me “operation or
unit”
IGN ON SW “ON/OFF” Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal.
COMP ON SIG “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal.
FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower motor switch signal.
Contents
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