Nissan Xterra 2005 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
REFRIGERANT WEIGHT SCALE .......................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
FREEZE PROTECTION .......... ....... ...... ....... ....... 16
Refrigerant System Protection ............................... 16
REFRIGERANT PRESSURE SENSOR ............. 16
PRESSURE RELIEF VALVE ............................... 16
Component Layout ................................................. 17
LUBRICANT ............................................................. 19
Maintenance of Lubricant Quantity in Compressor ... 19
LUBRICANT ....................... ................................. 19
CHECKING AND ADJUSTING ........................... 19
AIR CONDITIONER CONTROL ...............................21
Description ................... ...... ....... ...... ........................ 21
Operation .............. ................................. ................. 21
AIR MIX DOOR CONTROL ................................. 21
BLOWER SPEED CONTROL ............................. 21
INT AKE DOORS CONTROL ............................... 21
MODE DOOR CONTROL ................................... 21
DEFROSTER DOOR CONTROL ........................ 21
MAGNET CLUTCH CONTROL ........................... 21
Description of Control System ................................23
Control Operation ................................................... 24
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE CONTROL) ...............................................24
RECIRCULATION () SWITCH .............................24
DEFROSTER SWITCH ....................................... 24
REAR WINDOW DEFOGGER SWITCH ............. 24
OFF SWITCH (BLOWER SPEED SET TO 0) .....24
A/C SWITCH ....................................................... 24
MODE DIAL ......................................................... 24
BLOWER CONTROL DIAL ................................. 24
Discharge Air Flow .................................................25
............................................................................25
System Description .................................................26
SWITCHES AND THEIR CONTROL FUNCTION ...26
TROUBLE DIAGNOSIS ............................................ 27
CONSULT-II Function (BCM) ............................. ....27
CONSULT-II BASIC OPERATION .......................27
DATA MONITOR .................................................28
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ......................................................29
WORK FLOW ......................................................29
SYMPTOM TABLE .............................................. 29
Component Parts and Harness Connector Location ... 30
ENGINE COMPARTMENT .................................. 30
FRONT PASSENGER COMPARTMENT ............31
Schematic .................... ....................................... ....32
Wiring Diagram — A/C,M — ...................................33
Front Air Control Terminals and Reference Value ... 36
PIN CONNECTOR TERMINAL LAYOUT ............36
TERMINALS AND REFERENCE VALUE FOR
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FRONT AIR CONTROL ....................................... 36
Operational Check ..................................................38
CHECKING BLOWER .........................................38
CHECKING DISCHARGE AIR ............................38
DISCHARGE AIR FLOW .....................................38
CHECKING TEMPERATURE DECREASE .........39
CHECKING TEMPERATURE INCREASE ..........39
CHECK A/C SWITCH ..........................................39
Power Supply and Ground Circuit for Front Air Con-
trol ............................. .......................... .................... 40
INSPECTION FLOW ...........................................40
COMPONENT DESCRIPTION ............................41
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ...41
Mode Door Motor Circuit ........................................43
INSPECTION FLOW ...........................................43
SYSTEM DESCRIPTION .................................... 43
COMPONENT DESCRIPTION ............................44
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ...................................................45
Air Mix Door Motor (Front) Circuit ........................... 47
INSPECTION FLOW ...........................................47
SYSTEM DESCRIPTION .................................... 48
COMPONENT DESCRIPTION ............................48
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (FRONT) ....................................49
Intake Door Motor Circuit ........................................ 51
INSPECTION FLOW ...........................................51
SYSTEM DESCRIPTION .................................... 52
COMPONENT DESCRIPTION ............................52
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ...................................................53
Front Blower Motor Circuit ...................................... 55
INSPECTION FLOW ...........................................55
SYSTEM DESCRIPTION .................................... 56
COMPONENT DESCRIPTION ............................56
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ...............................................................57
COMPONENT INSPECTION ..............................61
Magnet Clutch Circuit .............................................63
INSPECTION FLOW ...........................................63
SYSTEM DESCRIPTION .................................... 64
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 64
Insufficient Cooling .................................................68
INSPECTION FLOW ...........................................68
PERFORMANCE TEST DIAGNOSES ................69
PERFORMANCE CHART ...................................71
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ........................... ............. ............. ....... .......72
Insufficient Heating .................................................75
INSPECTION FLOW ...........................................75
Noise ......................................................................76
INSPECTION FLOW ...........................................76
Intake Sensor Circuit ..............................................77
COMPONENT DESCRIPTION ............................77
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ............................. ........................................ 77
COMPONENT INSPECTION ..............................78
CONTROL UNIT .......................... ...... ....... ...... ....... ....79
Removal and Installation .........................................79
FRONT AIR CONTROL .......................................79
INTAKE SENSOR .............................. ....... ...... ...........80
Removal and Installation .........................................80
REMOVAL ........................................................ ....80
INSTALLATION ......... ...........................................80
BLOWER MOTOR .....................................................81
Components ....................... .................... .................81
Removal and Installation .........................................81
REMOVAL ........................................................ ....81
INSTALLATION ......... ...........................................81
IN-CABIN MICROFILTER ..........................................82
Removal and Installation .........................................82
FUNCTION ..........................................................82
REPLACEMENT TIMING ....................................82
REPLACEMENT PROCEDURE ..........................82
HEATER & COOLING UNIT ASSEMBLY .................84
Components ....................... .................... .................84
Removal and Installation .........................................84
REMOVAL ........................................................ ....84
INSTALLATION ......... ...........................................85
HEATER CORE .........................................................86
Components ....................... .................... .................86
Removal and Installation .........................................86
REMOVAL ........................................................ ....86
INSTALLATION ......... ...........................................86
INTAKE DOOR MOTOR ........................... ...... ....... ....87
Removal and Installation .........................................87
REMOVAL ........................................................ ....87
INSTALLATION ......... ...........................................87
MODE DOOR MOTOR ............................. ...... ....... ....88
Removal and Installation .........................................88
REMOVAL ........................................................ ....88
INSTALLATION ......... ...........................................88
AIR MIX DOOR MOTOR ...........................................89
Components ....................... .................... .................89
Removal and Installation .........................................89
REMOVAL ........................................................ ....89
INSTALLATION ......... ...........................................89
FRONT BLOWER MOTOR RESISTOR ....................90
Removal and Installation .........................................90
REMOVAL ........................................................ ....90
INSTALLATION ......... ...........................................90
DUCTS AND GRILLES .............................................91
Components ....................... .................... .................91
Removal and Installation .........................................92
DEFROSTER NOZZLE ........................................92
RH AND LH SIDE DEMISTER DUCTS ...............93
RH AND LH VENTILATOR DUCTS .....................93
CENTER VENTILATOR DUCT ............................93
FLOOR CONNECTOR DUCT .............................93
FRONT AND REAR FLOOR DUCTS ..................93
GRILLES ......................... .....................................93
REFRIGERANT LINES .............................................94
HFC-134a (R-134a) Service Procedure ..................94
SETTING OF SERVICE TOOLS AND EQUIP-
MENT .............................. .....................................94
Components ....................... .................... .................96
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Removal and Installation for Compressor .............. 97
COMPONENTS .................................................. 97
REMOVAL ........................................................... 97
INSTALLATION ................................................... 97
Removal and Installation for Compressor Clutch ... 98
REMOVAL ........................................................... 98
INSPECTION ...................................................... 99
INSTALLATION ................................................... 99
BREAK-IN OPERATION ................................... 101
Removal and Installation for High-pressure Flexible
A/C Hose .............................................................. 101
REMOVAL ......................................................... 101
INSTALLATION ................................................. 101
Removal and Installation for High-pressure A/C
Pipe ...................................................................... 101
REMOVAL ......................................................... 101
INSTALLATION ................................................. 101
Removal and Installation for Low-pressure Flexible
A/C Hose .............................................................. 101
REMOVAL ......................................................... 101
INSTALLATION ................................................. 101
Removal and Installation for Low-pressure A/C Pipe . 102
REMOVAL ......................................................... 102
INSTALLATION ................................................. 102
Removal and Installation for Refrigerant Pressure
Sensor ...................... ............................................ 102
REMOVAL .........................................................102
INSTALLATION .................................................102
Removal and Installation for Condenser ..............102
REMOVAL .........................................................102
INSTALLATION .................................................103
Removal and Installation for Evaporator ..............104
REMOVAL .........................................................105
INSTALLATION .................................................105
Removal and Installation for Expansion Valve ......105
REMOVAL .........................................................105
INSTALLATION .................................................105
Checking for Refrigerant Leaks ............................105
Checking System for Leaks Using the Fluorescent
Dye Leak Detector ................................................105
Dye Injection .........................................................106
Electronic Refrigerant Leak Detector ....................106
PRECAUTIONS FOR HANDLING LEAK
DETECTOR ........................... ............................106
CHECKING PROCEDURE ...............................107
SERVICE DATA AND SPECIFICATIONS (SDS) ....109
Service Data and Specifications (SDS) ................109
COMPRESSOR ................................................109
LUBRICANT ......................................................109
REFRIGERANT ..................... ............................109
ENGINE IDLING SPEED ..................................109
BELT TENSION .................................................109
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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 BELT 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 .
EJS0043X
Precautions for Working with HFC-134a (R-134a) EJS0043Y
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 compress or failure is likely to occur. Refer to MTC-4, "
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 lubricant for the HFC-134a (R-134a) A/ C system and H FC-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 S AE J2210 [HFC-134a (R-134a) recyclin g equipment], or SAE J2209 [HFC-134a (R134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before
resuming service. Additional he alth and safety informatio n may be obtained from refrigerant and
lubricant manufacturers.
– Do not allow lubricant, Genuine NISSAN A/C System Lubricant Type R (DH-PS), part number
KLH00-PAGR0 or equivalent, to come in contact with styrofoam parts. Damage may result.
Contaminated Refrigerant" . To
Contaminated Refrigerant EJS0043Z
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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General Refrigerant Precauti on s EJS00440
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 EJS00441
● 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
(UV) lamp is required to illuminate the dye 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 remaining 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 c leaning 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 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 HFC-134a (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.
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PRECAUTIONS
A/C Identification Label EJS00442
Vehicles with factory installed fluorescent dye have this identification
label on the underside of hood.
WJIA1235E
Precautions for Refrigerant Connection EJS00443
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
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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MTC-6
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
A/C Compressor and Condenser
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WJIA1481E
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MTC-7
PRECAUTIONS
1. High-pressure service valve 2. Clip 3. High-pressure A/C pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible A/C hose 8. Low-pressure flexible A/C hose 9. Low-pressure service valve
10. Low-pressure A/C pipe 11. Expansion valve 12. A/C drain
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-u p wrench.
● After disconnecting tu bes, immediately plug all openings to pr event entry of dirt and mois ture.
● 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: Genuine NISSAN A/C System Lubricant Type R (DH-PS) or equivalent
Part number: KLH00-PAGR0
● 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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MTC-8
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 refrigerant 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 EJS00444
● 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-19, "
● Keep friction su rfaces between clutc h and pulley clean. If the surface is contaminated w ith lubri-
Maintenance of Lubricant Quantity in Compressor" .
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 clutc h, apply voltage to the new one and check for normal
operation. Refer to MTC-98, "
Removal and Installation for Compressor Clutch" .
Precautions for Service Equipment EJS00445
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 maintenance.
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PRECAUTIONS
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 recomm ended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a (R-134a). Make
sure the gauge set h as 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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MTC-10
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, dis c harging and contamination may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
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RHA273D
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC134a (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.
RHA274D
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 EJS00446
When you read wiring diagrams, refer to the following:
● GI-16, "How to Read Wiring Diagrams"
● PG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble diagnosis, refer to the following:
● GI-11, "How to Follow Trouble Diagnoses"
● GI-28, "How to Perform Efficient Diagnosis for an Electrical Incident"
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PREPARATION
PREPARATION PFP:00002 Special Service Tools EJS00447
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
Description
Installing pulley
Removing pulley
HFC-134a (R-134a) Service Tools and Equipment EJS00448
Never mix HFC- 134a (R-134a) refrigerant and/or the specified lubricant with CFC-12 (R-12) refrigerant and/or
the 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 refrigerants/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
S-NT196
KLH00-PAGR0
(—)
NISSAN A/C System Lubricant
Type R (DH-PS)
Description
Container color: Light blue
Container marking: HFC-134a (R134a)
Fitting size: Thread size
● large container 1/2”-16 ACME
Type: Poly alkylene glycol oil (PAG),
type R (DH-PS)
Application: HFC-134a (R-134a) vane
rotary compresso rs (NISSAN only)
Lubricity: 40 m (1.4 US fl oz, 1.4 Imp
fl oz)
S-NT197
KV991J0130
(ACR2005-NI)
ACR5 A/C Service Center
WJIA0293E
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MTC-12
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)
HFC-134a (R-134a) Fluorescent
leak detection dye (box of 24, 1/4
ounce bottles)
(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 (battery terminal)
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) Refrigerant
dye injector
Use with J-41447, 1/4 ounce bottle
SHA440F
—
(J-43872)
Refrigerant dye cleaner
SHA441F
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MTC-13
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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MTC-14
PREPARATION
Commercial Service Tools EJS00449
Tool name Description
(J-41810-NI)
Refrigerant identifier equipment (R134a)
RJIA0197E
Power tool Loosening bolts and nuts
For checking refrigerant purity and
system contamination
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(J-44614)
Clutch disc holding tool
PBIC0190E
WHA230
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Clutch disc holding tool
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REFRIGERATION SYSTEM
REFRIGERATION SYSTEM PFP:KA990 Refrigerant Cycle EJS0044A
WJIA1482E
REFRIGERANT FLOW
The refriger ant fl ows in t he st a ndard pa tter n. Ref riger ant flow s thro ugh the com presso r, condenser , liq uid ta nk,
expansion valve, 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.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
evaporator coil temperature falls below a specified point, the intake sensor interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the intake sensor allows compressor
operation.
Refrigerant System Protect ion EJS0044B
REFRIGERANT PRESSURE SENSOR
The refriger ant sy stem i s prot ect ed ag ains t exces sive ly hi gh- or low- pres sure s by t he ref rige ran t pres sure se nsor , l oc at ed on t he co nden ser. If the syste m pr ess ure r is es abov e o r fa lls be lo w t he sp ecif ic at i ons, t he ref ri ge 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).
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 th an 2,990 kPa (30 .5 kg/
2
, 433.6 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant
cm
into the atm osphere.
2
, 398 psi), or below
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REFRIGERATION SYSTEM
Component Layout EJS0044C
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WJIA1260E
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
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REFRIGERATION SYSTEM
7. Front heater and cooling unit assembly 8. Floor connector duct grilles 9. Floor connector duct
10. Front floor ducts 11. Rear floor ducts
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LUBRICANT
LUBRICANT PFP:KLG00
Maintenance of Lubricant Quantity in Compressor EJS0044D
The lubricant in the co mpressor circ ulates through the system wi th the refrigera nt. Add lubric ant 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 lubri c ant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name: NISSAN A/C System Lubricant Type R (DH-PS) or equivalent
Part number: KLH00-PAGR0
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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
● Temp. control: Optional [Set so that intake air temperature is 25° to 30° C (77 ° to 86°F)]
● Intake po sition: 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 foll ow in g ma jo r com po ne nts, add the co rrec t am ount of lubricant to the system.
Amount of Lubricant to be Added
Lubricant to be added to system
Part replaced
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 lubr ic ant is nee ded.
Amount of lubricant
m (US fl oz, Imp fl oz)
30 (1.0, 1.1) Large leak
— Small leak *1
Remarks
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Lubricant Adjustment Procedure for Compressor Replacement
1. Before connecting recovery/recyclin g equipme nt to vehicle, c heck recovery /recycling eq uipment ga uges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Connect recovery/recycling equipment to vehicle. Confirm refrigerant purity 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 dra ine d.
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” comp re ss or thro ug h the suct io n po rt ope ni ng .
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MTC-19
Contaminated Refrigerant" .
LUBRICANT
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.
RHA065DD
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MTC-20
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL PFP:27500
Description EJS0044E
The front air control provides regula tion of the v ehicle's inter ior temperature. The system is based on the position of the front air control temperature switch selected by the driver. This is done by utilizing a microcomputer,
also referred to as the front air control, which receives input signals from the following two sensors:
● Intake sensor
● PBR (position balanced resistor).
The front air control uses these signals (including the set position of the temperature switch) to control:
● Outlet air volume
● Air temperature
● Air distribution
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Operation EJS0044F
AIR MIX DOOR CONTROL
The air mix door is c on trol le d s o th at in-vehicle temp era tu re is ch anged based on th e po s iti on of th e temperature switch.
BLOWER SPEED CONTROL
Blower speed is controlled based on front blower switch settings.
When blower sw itch is turned, the blower motor starts and increases a ir flow volume each time the blower
switch is turned clockwise, and decreases air flow volume each time the blower switch is turned counterclockwise.
INTAKE DOORS CONTROL
The intake doors are c ontrolled by the recirculation switch setting, a nd the mode (def roster and floo r) switch
setting.
MODE DOOR CONTROL
The mode door is controlled by the position of the mode dial.
DEFROSTER DOOR CONTROL
The defroster door is controlled by the mode dial (set to defroster).
MAGNET CLUTCH CONTROL
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WJIA1629E
Compressor can only operate with engine running and blower ON (speed 1-4).
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.
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AIR CONDITIONER CONTROL
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle sensor, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line.
Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.
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MTC-22
AIR CONDITIONER CONTROL
Description of Control System EJS0044G
The control system consists of input sensors, switches, the front air control (microcomputer) and outputs.
The relationship of these components is shown in the figure below:
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WJIA1495E
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AIR CONDITIONER CONTROL
Control Operation EJS0044H
Front air control
WJIA1510E
1 Temperature control dial 2 Blower control dial 3 A/C switch
4 Rear window defogger switch 5 Recirculation switch 6 Mode dial
TEMPERATURE CONTROL DIAL (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, air inlet is set to fresh. REC mode can be re-entered by pressing REC
switch again.
● REC switch is not operated when DEF switch is turned ON, at the D/F position or at the floor position.
DEFROSTER SWITCH
Positions the air outle t doo rs to the defros t po sitio n. Also positi on s the intake doo rs to the o utside air po siti on
and compressor is enabled.
REAR WINDOW DEFOGGER SWITCH
When switch is ON, rear window i s defogged.
OFF SWITCH (BLOWER SPEED SET TO 0)
The compressor and blower are OFF.
A/C SWITCH
The compressor i s ON or OFF.
MODE DIAL
Controls the air discharge outlets.
BLOWER CONTROL DIAL
Manually controls the four blower speeds and turns blower off and on.
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MTC-24
AIR CONDITIONER CONTROL
Discharge Air Flow EJS0044I
WJIA1296E
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B
C
D
Mode door position
Air outlet/distribution
Vent Foot Defroster
95% 5% —
60% 40% —
20% 55% 25%
15% 50% 35%
7% 15% 78%
Airflow always present at driver and passenger side dem ister s
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AIR CONDITIONER CONTROL
System Description EJS0044J
SWITCHES AND THEIR CONTROL FUNCTION
WJIA1496E
WJIA1497E
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MTC-26
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS PFP:00004
CONSULT-II Function (BCM) EJS0045Y
CONSULT-II can display each diag nostic item usin g the diagnostic test modes shown following.
BCM diagnostic
test item
Inspection by part
Diagnostic mode Description
Supports inspections and adjustments. Commands ar e transm i tted t o the BCM
WORK SUPPORT
DATA MONITOR Displays BCM input/output data in real time.
ACTIVE TEST Operation of electrical loads can be checked by sendi ng dr ive sig nal to them .
SELF-DIAG RESULTS Displays BCM self-diagnosis results.
CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read.
ECU PART NUMBER BCM part number can be read.
CONFIGURATION Perfor m s BCM con figur at i on rea d/wri te functi ons.
for setting the status suitable for required operation, input/outp ut signals are
received from the BCM and received data is displayed.
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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 carries out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, and turn the
ignition switch ON.
BBIA0538E
2. Touch “START (NISSAN BASED VHCL)”.
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BCIA0029E
3. Touc h “BCM” on “SELECT SYSTEM” scree n.
If “BCM” is not indi cated, go to GI-39, "
CONSULT-II Data Link
Connector (DLC) Circuit" .
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 SIGNA LS” or “ SEL E CT ION FR OM MENU ” on
“DATA MONITOR” screen.
All signals Monitors all the items.
Selection from menu Selects and monitors the individual item selected.
4. When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the items
will be monitored.
5. Touch “START”.
6. Touch “RECORD” while monitoring, then the status of the moni-
WJIA0469E
tored item can be recorded. To stop recording, touch “STOP”.
Display Item List
Monitor item name
“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 f rom ai r cond itioner sw itch sign al.
FAN ON SIG “ON/OFF” D i splays “FAN (ON)/FAN (OFF)” status as judged from blower motor switch signal.
Contents
Revision: February 2006 2005 Xterra
MTC-28
TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis for Quick and Accurate Repair EJS0045Z
WORK FLOW
SHA900E
*1 MTC-38, "Operational Check".
SYMPTOM TABLE
Symptom Reference Page
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System. MTC-40
Air outlet does not change.
Mode door motor is malfunctioning.
Discharge air temperature does not chang e.
Air mix door motor (front) is ma l functioning.
Intake door does not change.
Intake door motor is malfunctioning.
Front blower motor operation is malfunction-
ing.
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutc h. MTC-63
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling. MTC-68
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating. MTC-75
Noise Go to Trouble Diagnosis Procedure for Noise. MTC-76
Go to Trouble Diagnosis Procedure for Mode Door Motor. MTC-43
Go to Trouble Diagnosis Procedure for Air Mix Door Motor
(front).
Go to Trouble Diagnosis Procedure for Intake Door Motor. MTC-51
Go to Trouble Diagnosis Procedure for Front Blower Motor. MTC-55
MTC-47
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TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location EJS00460
ENGINE COMPARTMENT
WJIA1489E
Revision: February 2006 2005 Xterra
MTC-30
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