Nissan XTrail T30 2005 User Manual

J AIR CONDITIONER

SECTION MTC

MANUAL AIR CONDITIONER

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CONTENTS

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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 ......................	5
General Refrigerant Precautions .............................	5
Lubricant Precautions .............................................	5
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 ..................................................	9
MANIFOLD GAUGE SET .....................................	9
SERVICE HOSES ..............................................	10
SERVICE COUPLERS .......................................	10
REFRIGERANT WEIGHT SCALE .....................	10
CHARGING CYLINDER .....................................	10
Precautions for Leak Detection Dye ......................	10
IDENTIFICATION ................................................	11
IDENTIFICATION LABEL FOR VEHICLE ...........	11
Wiring Diagrams and Trouble Diagnosis ................	11
PREPARATION ........................................................	12
Special Service Tools ............................................	12
HFC-134a (R-134a) Service Tools and Equipment...	13
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
V-6 Variable Displacement Compressor ................	17
GENERAL INFORMATION ................................	17

DESCRIPTION ...................................................	18
Component Layout ................................................	21
LUBRICANT .............................................................	22
Maintenance of Lubricant Quantity in Compressor... 22
LUBRICANT .......................................................	22
LUBRICANT RETURN OPERATION .................	22
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................	23
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ......................	23
AIR CONDITIONER CONTROL ..............................	25
Control Operation ..................................................	25
FAN CONTROL DIAL .........................................	25
TEMPERATURE CONTROL DIAL .....................	25
MODE CONTROL DIAL .....................................	25
RECIRCULATION (REC) SWITCH ....................	25
A/C SWITCH ......................................................	25
Discharge Air Flow .................................................	26
System Description ................................................	27
SWITCHES AND THEIR CONTROL FUNCTION... 27
TROUBLE DIAGNOSIS ...........................................	28
How to Perform Trouble Diagnoses for Quick and
Accurate Repair .....................................................	28
WORK FLOW .....................................................	28
SYMPTOM TABLE .............................................	28
ComponentPartsandHarnessConnectorLocation... 29
ENGINE COMPARTMENT .................................	29
PASSENGER COMPARTMENT ........................	30
Schematic —A/C, M— .........................................	... 31
Wiring Diagram — A/C, M — ...............................	... 32
Operational Check .................................................	36
CHECKING BLOWER ........................................	36
CHECKING DISCHARGE AIR ...........................	36
CHECKING RECIRCULATION ..........................	36
CHECKING TEMPERATURE DECREASE ........	37
CHECKING TEMPERATURE INCREASE .........	37
CHECKING A/C SWITCH ..................................	37
Mode Door .............................................................	38
INSPECTION FLOW ........................................

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Air Mix Door ...........................................................	39
INSPECTION FLOW ..........................................	39
Intake Door Motor Circuit .......................................	40
INSPECTION FLOW ..........................................	40
COMPONENT DESCRIPTION ...........................	40
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ..................................................	41
Blower Motor Circuit ..............................................	43
INSPECTION FLOW ..........................................	43
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ..............................................................	43
COMPONENT INSPECTION .............................	46
Magnet Clutch Circuit ............................................	47
INSPECTION FLOW ..........................................	47
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................	48
ELECTRICAL COMPONENT INSPECTION ......	52
Insufficient Cooling ................................................	54
INSPECTION FLOW ..........................................	54
PERFORMANCE TEST DIAGNOSIS ................	55
PERFORMANCE CHART ..................................	57
TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SURE ..................................................................	58
Insufficient Heating ................................................	61
INSPECTION FLOW ..........................................	61
Noise .....................................................................	62
INSPECTION FLOW ..........................................	62
CONTROLLER ..........................................................	63
Removal and Installation .......................................	63
REMOVAL ..........................................................	63
INSTALLATION ...................................................	63
Disassembly and Assembly ...................................	63
BLOWER UNIT ........................................................	64
Removal and Installation .......................................	64
REMOVAL ..........................................................	64
INSTALLATION ...................................................	64
Disassembly and Assembly ...................................	65
BLOWER MOTOR ...................................................	66
Removal and Installation .......................................	66
REMOVAL ..........................................................	66
INSTALLATION ...................................................	66
INTAKE DOOR MOTOR ..........................................	67
Removal and Installation .......................................	67
REMOVAL ..........................................................	67
INSTALLATION ...................................................	67
BLOWER FAN RESISTOR ......................................	68
Removal and Installation .......................................	68
REMOVAL ..........................................................	68
INSTALLATION ...................................................	68
IN-CABIN MICROFILTER ........................................	69
Removal and Installation .......................................	69
FUNCTION .........................................................	69
REPLACEMENT TIMING ...................................	69
REPLACEMENT PROCEDURES ......................	69
HEATER & COOLING UNIT ASSEMBLY ................	70
Removal and Installation .......................................	70
REMOVAL ..........................................................	70
INSTALLATION ...................................................	71
Disassembly and Assembly ...................................	72

MODE DOOR ...........................................................	73
Control Linkage Adjustment ...................................	73
MODE DOOR CONTROL CABLE ......................	73
AIR MIX DOOR .........................................................	74
Control Linkage Adjustment ...................................	74
AIR MIX DOOR CONTROL CABLE ...................	74
HEATER CORE ........................................................	75
Removal and Installation ........................................	75
REMOVAL ...........................................................	75
INSTALLATION ...................................................	75
DUCTS AND GRILLES ............................................	76
Removal and Installation ........................................	76
REMOVAL ...........................................................	76
INSTALLATION ...................................................	79
REFRIGERANT LINES ............................................	80
HFC-134a (R-134a) Service Procedure .................	80
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ..................................................................	80
Components ...........................................................	82
Removal and Installation of Compressor ...............	82
REMOVAL ...........................................................	82
INSTALLATION ...................................................	83
Removal and Installation of Compressor Clutch ....	84
REMOVAL ...........................................................	84
INSTALLATION ...................................................	86
Removal and Installation of Low-Pressure Flexible
Hose .......................................................................	87
REMOVAL ...........................................................	87
INSTALLATION ...................................................	87
Removal and Installation of High-Pressure Flexible
Hose .......................................................................	88
REMOVAL ...........................................................	88
INSTALLATION ...................................................	88
Removal and Installation of High-Pressure Pipe	...88
REMOVAL ...........................................................	88
INSTALLATION ...................................................	89
Removal and Installation of Condenser .................	89
REMOVAL ...........................................................	89
INSTALLATION ...................................................	90
Removal and Installation of Liquid Tank ................	90
REMOVAL ...........................................................	90
INSTALLATION ...................................................	90
Removal and Installation for Refrigerant Pressure
Sensor ....................................................................	91
REMOVAL ...........................................................	91
INSTALLATION ...................................................	91
Removal and Installation of Evaporator .................	91
REMOVAL ...........................................................	91
INSTALLATION ...................................................	92
Removal and Installation of Expansion Valve ........	92
REMOVAL ...........................................................	92
INSTALLATION ...................................................	92
Checking for Refrigerant Leaks .............................	92
Checking System for Leaks Using the Fluorescent
Leak Detector .........................................................	93
Dye Injection ..........................................................	93
Electronic Refrigerant Leak Detector .....................	93
PRECAUTIONS FOR HANDLING LEAK

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DETECTOR .......................................................	93	Lubricant ................................................................	96
CHECKING PROCEDURE ................................	94	Refrigerant .............................................................	96
SERVICE DATA AND SPECIFICATIONS (SDS) .....	96	Engine Idling Speed ..............................................	96
Compressor ...........................................................	96	Belt Tension ...........................................................	96

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	PRECAUTIONS
PRECAUTIONS	PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” AJS001M5

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.

WARNING:

●To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.

●Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section.

●Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

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

AJS001OH

WARNING:

●CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed and compressor malfunction is likely to occur, refer to “CONTAMINATED REFRIGERANT” below. 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 lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur.

●The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:

–When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere.

–When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.

–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.

–Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R- 134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

–Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result.

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PRECAUTIONS

CONTAMINATED REFRIGERANT

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 recovery of the contaminated refrigerant could damage your service equipment and refriger-
	ant supply.
●	Suggest the customer return the vehicle to the location of previous service where the contamination may
	have occurred.

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●If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. 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 conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance.

General Refrigerant Precautions

AJS001M7

WARNING:

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●Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged.

●Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system.

●Do not store or heat refrigerant containers above 52° C (125° F).

●Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water.

●Do not intentionally drop, puncture, or incinerate refrigerant containers.

●Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.

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●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- MTC tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)

have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause

injury or property damage. Additional health and safety information may be obtained from refriger- K ant manufacturers.

Lubricant Precautions

AJS001M8

●Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur.

●The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:

–When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere.

–When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.

–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.

●Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment] or J-2209 [HFC-134a (R-134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

●Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result.

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PRECAUTIONS

Precautions for Refrigerant Connection

AJS001M9

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

●Expansion valve to cooling unit

●Refrigerant pressure sensor to liquid tank

FEATURES OF NEW TYPE REFRIGERANT CONNECTION

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

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

SHA815E

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PRECAUTIONS

O-RING AND REFRIGERANT CONNECTION

RJIA3160E

CAUTION:

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

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O-Ring Part Numbers and Specifications

	Connec-		O-ring	Part number	D mm (in)		W	mm (in)
	tion type		size
	New		8	92471 N8210	6.8 (0.268)		1.85	(0.0728)
	Former			92470 N8200	6.07 (0.2390)		1.78	(0.0701)
	Former	10		J2476 89956	9.25 (0.3642)		1.78	(0.0701)
	New		12	92472 N8210	10.9	(0.429)	2.43	(0.0957)
	Former			92475 71L00	11.0 (0.433)		2.4	(0.094)
	New		16	92473 N8210	13.6	(0.535)	2.43	(0.0957)
	Former			92475 72L00	14.3	(0.563)	2.3	(0.091)
SHA814E	New		19	92474 N8210	16.5	(0.650)	2.43	(0.0957)
	Former			92477 N8200	17.12	(0.6740)	1.78	(0.0701)

WARNING:

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

CAUTION:

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

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PRECAUTIONS

●When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low-pressure chamber.

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

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

●When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection.

●Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components.

●Thoroughly remove moisture from the refrigeration system before charging the refrigerant.

●Always replace used O-rings.

●When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion.

Lubricant name	: Nissan A/C System Oil Type S
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.

●After connecting line, conduct leak test and make sure that there is no leakage from connections. 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.

RHA861F

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2005 X-Trail

PRECAUTIONS

Precautions for Servicing Compressor

AJS001MA

●Plug all openings to prevent moisture and foreign matter from entering.

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

●When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to MTC-22, "Maintenance of Lubricant Quantity in Compressor" .

●Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner.

●After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour.

●After replacing the compressor magnet clutch, apply voltage to the new one and check for usual operation.

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Precautions for Service Equipment

AJS001MB

RECOVERY/RECYCLING EQUIPMENT

Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.

VACUUM PUMP

The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it.

To prevent this migration, use a manual valve placed near the hose- to-pump connection, as follows.

●Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump.

●For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump.

●If the hose has an automatic shut-off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate.

Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended.

RHA270DA

MANIFOLD GAUGE SET

Be certain that the gauge face indicates HFC-134a or R-134a. Be sure the gauge set has 1/2″ -16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.

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PRECAUTIONS

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.

SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.

Shut-off valve rotation	A/C service valve
Clockwise	Open
Counterclockwise	Close

REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″ -16 ACME.

RHA272D

RHA273D

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 scale or of quality recycle/recharge equipment.

Precautions for Leak Detection Dye

AJS001MC

●The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks.

●Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye.

●The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J- 41995) pin-point refrigerant leaks.

●For your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions and precautions prior to performing the 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.

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MTC-10

2005 X-Trail

PRECAUTIONS

●Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,

clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed.

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

●	Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.
●	Leak detection dyes for HFC-134a (R-134a) 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 system or CFC-12 (R-12) leak detection
	dye in HFC-134a (R-134a) A/C system or A/C system damage may result.

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

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IDENTIFICATION

NOTE:

Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label.

IDENTIFICATION LABEL FOR VEHICLE

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

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following:

●GI-14, "How to Read Wiring Diagrams" in GI section.

●PG-3, "Wiring Diagram - POWER -" in PG section. When you perform trouble diagnosis, refer to the following:

●GI-10, "How to Follow Trouble Diagnoses" in GI section.

●GI-26, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

SHA436FA

AJS001MD

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MTC-11

2005 X-Trail

	PREPARATION
PREPARATION	PFP:00002
Special Service Tools	AJS001O8

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

Tool number

(Kent-Moore No.) Description Tool name

KV99106100

S-NT232

(J-41260) Removing shaft nut and clutch disc Clutch disc wrench

RJIA0194E

KV99232340

(J-38874) Removing clutch disc Clutch disc puller

S-NT376

KV99106200

(J-41261) Installing pulley Pulley installer

S-NT235

Revision: 2005 March

MTC-12

2005 X-Trail

PREPARATION

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

AJS001O9

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

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

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

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

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	Tool number
	(Kent-Moore No.)	Description
	Tool name
		Container color: Light blue
		Container marking: HFC-134a (R-
	HFC-134a (R-134a) refrigerant	134a)
		Fitting size: Thread size
		● Large container 1/2″ -16 ACME
		S-NT196
		Type: Polyalkylene glycol oil (PAG),
	KLH00-PAGS0	type S (DH-PS)
		Application: HFC-134a (R-134a)
	Nissan A/C System Oil Type S
		wobble (swash) plate compressors
	(DH-PS)
		(Nissan only)
		Lubricity: 40 m (1.4 Imp fl oz)
		S-NT197
	(ACR2005-NI)	Function: Refrigerant recovery,
	ACR5 A/C Service Center	recycling and recharging
		WJIA0293E

(J-41995)	Power supply:
Electrical leak detector	DC 12V (Battery terminal)

AHA281A

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MTC-13

2005 X-Trail

PREPARATION

Tool number
(Kent-Moore No.)			Description
Tool name
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector			Power supply:
Use with J-41447, 1/4 ounce
			DC 12V (Battery terminal)
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)		ZHA200H
Refrigerant dye cleaner
			Power supply:
			DC 12V (Battery terminal)
(J-42220)			For checking refrigerant leak when
			fluorescent dye is installed in A/C
UV lamp and UV safety goggles
			system
			Includes:
	SHA438F		UV lamp and UV safety goggles
			Application:
			For HFC-134a (R-134a) PAG oil
(J-41447)			Container:
HFC-134a (R-134a) fluorescent			1/4 ounce (7.4cc) bottle
leak detection dye			(Includes self-adhesive dye
(Box of 24, 1/4 ounce bottles)			identification labels for affixing to
			vehicle after charging system with
	SHA439F		dye.)
(J-41459)
HFC-134a (R-134a) dye injector			For injecting 1/4 ounce of fluorescent
Use with J-41447, 1/4 ounce			leak detection dye into A/C system
bottle
	SHA440F
(J-43872)			For cleaning dye spills
Refrigerant dye cleaner
	SHA441F
			Identification:
(J-39183)			● The gauge face indicates HFC-134a
Manifold gauge set (with hoses			(R-134a).
and couplers)			Fitting size: Thread size
			● 1/2″ -16 ACME
		RJIA0196E

Revision: 2005 March

MTC-14

2005 X-Trail

PREPARATION

	Tool number
	(Kent-Moore No.)		Description
	Tool name
	Service hoses		Hose color:
	● (J-39501-72)		● Low hose: Blue with black stripe
	High-pressure side hose		● High hose: Red with black stripe
	● (J-39502-72)		● Utility hose: Yellow with black stripe
	Low-pressure side hose		or green with black stripe
	● (J-39476-72)		Hose fitting to gauge:
	Utility hose	S-NT201	● 1/2″ -16 ACME
	Service couplers
	● (J-39500-20)		Hose fitting to service hose:
	High-pressure side coupler		M14 x 1.5 fitting is optional or
	● (J-39500-24)		permanently attached.
	Low-pressure side coupler
		S-NT202
	(J-39650)		For measuring of refrigerant
			Fitting size: Thread size
	Refrigerant weight scale
			1/2″ -16 ACME
		S-NT200
			Capacity:
	(J-39649)		● Air displacement: 4 CFM
			● Micron rating: 20 microns
	Vacuum pump
			● Oil capacity: 482 g (17 oz)
	(Including the isolator valve)
			Fitting size: Thread size
		S-NT203	1/2″ -16 ACME
Commercial Service Tools			AJS001OA

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Description

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Refrigerant identifier equipment

Checking for refrigerant purity and system contamination

RJIA0197E

Power tool	For loosening bolts and nuts
	PBIC0190E

Revision: 2005 March

MTC-15

2005 X-Trail

REFRIGERATION SYSTEM

REFRIGERATION SYSTEM

Refrigerant Cycle

REFRIGERANT FLOW

PFP:KA990

AJS001MG

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

FREEZE PROTECTION

Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the V-6 variable displacement compressor to prevent freeze up.

Refrigerant System Protection

AJS001MH

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively highor low-pressures by the refrigerant pressure sensor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side

detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm2 , 398 psi), or below about 134 kPa (1.4 kg/cm2 , 20 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 unusual level [more than 3,727 kPa (38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

RJIA1552E

Revision: 2005 March

MTC-16

2005 X-Trail

REFRIGERATION SYSTEM

V-6 Variable Displacement Compressor	AJS001MI
GENERAL INFORMATION	A

1.The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable com-

	pressor do not drop too far below 5° C (41° F) when:
	Evaporator intake air temperature is less than 20° C (68° F).	B
	Engine is running at speeds less than 1,500 rpm.
	This is because the V-6 compressor provides a means of “capacity” control.
	2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it	C
	may not produce high refrigerant pressure discharge (compared to previous units) when used with air
	conditioning systems.

3.A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt D angle of the wobble (swash) plate has changed and is not a malfunction.

4.For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system

main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or	E
when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.

5.A constant range of suction pressure is maintained when engine speed is greater than a certain value. It

normally ranges from 147 to 177 kPa (1.5 to 1.8 kg/cm2 , 21 to 26 psi) under varying conditions.	F
In previous compressors, however, suction pressure was reduced with increases in engine speed.
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Revision: 2005 March

MTC-17

2005 X-Trail

REFRIGERATION SYSTEM

DESCRIPTION General

The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity.

The tilt of the wobble (swash) plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 13.5 to 146 cm3 (0.824 to 8.91 cu in).

SJIA0631E

Revision: 2005 March

MTC-18

2005 X-Trail

REFRIGERATION SYSTEM

Operation

1.Operation Control Valve

Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure.

Operation of the valve controls the internal pressure of the crankcase.

The angle of the wobble (swash) plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure.

2.Maximum Cooling

Refrigerant pressure on the low-pressure side increases with an increase in heat loads.

When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve.

This causes the following pressure changes:

●The crankcase’s internal pressure to equal the pressure on the low-pressure side;

●The cylinder’s internal pressure to be greater than the crankcase’s internal pressure.

Under this condition, the wobble (swash) plate is set to the maximum stroke position.

RHA473C

3.Capacity Control

●Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low.

●The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.8 kg/cm2 , 26 psi).

Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high-pressure enters the crankcase.

●The force acts around the journal pin near the wobble (swash) plate, and is generated by the pressure difference between before and behind the piston.

The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the wobble (swash) plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the wobble (swash) plate.

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MTC-19

2005 X-Trail

REFRIGERATION SYSTEM

RHA474C

Revision: 2005 March

MTC-20

2005 X-Trail

REFRIGERATION SYSTEM

Component Layout

AJS001MJ

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RJIA3092E

Revision: 2005 March

MTC-21

2005 X-Trail

LUBRICANT

LUBRICANT

Maintenance of Lubricant Quantity in Compressor

PFP:KLG00

AJS001MK

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

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

●Lack of lubricant: May lead to a seized compressor.

●Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT

Name	: Nissan A/C System Oil Type S
Part number	: KLH00-PAGS0

LUBRICANT RETURN OPERATION

Adjust the lubricant quantity according to the test group shown below.

1. CHECK LUBRICANT RETURN OPERATION

Can lubricant return operation be performed?

●A/C system works properly.

●There is no evidence of a large amount of lubricant leakage.

CAUTION:

If excessive lubricant leakage is noted, do not perform the lubricant return operation.

OK or NG

OK	>> GO TO 2.
NG	>> GO TO 3.

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS

1.Start engine, and set the following conditions:

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–

–

–

–

Engine speed: Idling to 1,200 rpm A/C switch: ON

Blower speed: Max. position

Temp. control: Optional [Set so that intake air temperature is 25 to 30° C (77 to 86° F).] Intake position: Recirculation (REC)

2.Perform lubricant return operation for about 10 minutes.

3.Stop engine.

>>GO TO 3.

3.CHECK REPLACEMENT PART

Should the compressor be replaced?

YES	>> GO TO MTC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
	MENT" .
NO	>> GO TO MTC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACE-
	MENT EXCEPT COMPRESSOR" .

Revision: 2005 March

MTC-22

2005 X-Trail

LUBRICANT

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		Remarks
		Amount of lubricant
		m (Imp fl oz)
	Evaporator	75 (2.6)	-
	Condenser	35 (1.2)	-
	Liquid tank	10 (0.4)	-
	In case of refrigerant leak	30 (1.1)	Large leak
		-	Small leak *1

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

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LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

1.Before connecting recovery/recycling recharging equipment to vehicle, check recovery/recycling recharging equipment gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.

2.Connect recovery/recycling recharging equipment to vehicle. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant identifier. If NG, refer to MTC-5, "CONTAMINATED REFRIGERANT" .

3.Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrigerant identifier. If NG, refer to MTC-5, "CONTAMINATED REFRIGERANT" .

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

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

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

7.Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening.

8.Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant

to new compressor through the suction port opening.

9.If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m (0.2 Imp fl oz) of lubricant only when replaces the compressor.

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Revision: 2005 March

MTC-23

2005 X-Trail

LUBRICANT

SJIA0596E

Revision: 2005 March

MTC-24

2005 X-Trail

AIR CONDITIONER CONTROL

AIR CONDITIONER CONTROL

Control Operation

PFP:27500

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AJS001ML

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RJIA3132E

FAN CONTROL DIAL

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

TEMPERATURE CONTROL DIAL

This dial allows you to adjust the temperature of the discharge air.

MODE CONTROL DIAL

This dial controls the outlet air flow.

RECIRCULATION (REC) SWITCH

Recirculation (REC) position: Interior air is recirculated inside the vehicle. (The indicator lamp will light.) Fresh (FRE) position: Outlet air is drawn into the passenger compartment. (The indicator lamp will not light.)

A/C SWITCH

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

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

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Revision: 2005 March

MTC-25

2005 X-Trail

AIR CONDITIONER CONTROL

Discharge Air Flow

AJS001MM

SJIA0441E

Revision: 2005 March

MTC-26

2005 X-Trail

AIR CONDITIONER CONTROL

System Description

SWITCHES AND THEIR CONTROL FUNCTION

AJS001MN

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RJIA3183E

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RJIA0701E

Revision: 2005 March

MTC-27

2005 X-Trail

TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS

How to Perform Trouble Diagnoses for Quick and Accurate Repair

WORK FLOW

PFP:00004

AJS001MO

SHA900E

*1 MTC-36, "Operational Check"

SYMPTOM TABLE

	Symptom	Reference Page
	Air outlet does not change.	Go to Trouble Diagnosis Procedure for Mode Door.	MTC-38, "Mode Door"
	Discharge air temperature does not change.	Go to Trouble Diagnosis Procedure for Air Mix Door.	MTC-39, "Air Mix
			Door"
	Intake door does not change.	Go to Trouble Diagnosis Procedure for Intake Door Motor.	MTC-40, "Intake Door
			Motor Circuit"
	Intake door motor does not operate normally.
	Blower motor operation is malfunctioning.	Go to Trouble Diagnosis Procedure for Blower Motor.	MTC-43, "Blower
			Motor Circuit"
	Magnet clutch does not operate when A/C	Go to Trouble Diagnosis Procedure for Magnet Clutch.	MTC-47, "Magnet
	switch and fan switch are ON.		Clutch Circuit"
	Insufficient cooling	Go to Trouble Diagnosis Procedure for Insufficient Cooling.	MTC-54, "Insufficient
			Cooling"
	Insufficient heating	Go to Trouble Diagnosis Procedure for Insufficient Heating.	MTC-61, "Insufficient
			Heating"
	Noise	Go to Trouble Diagnosis Procedure for Noise.	MTC-62, "Noise"

Revision: 2005 March

MTC-28

2005 X-Trail

TROUBLE DIAGNOSIS

Component Parts and Harness Connector Location	AJS001MP
ENGINE COMPARTMENT	A

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RJIA3133E

Revision: 2005 March

MTC-29

2005 X-Trail