MTC Air Conditioner Specifications

MTC Air Conditioner Specifications
MANUAL AIR CONDITIONER
J AIR CONDITIONER
SECTION
MTC
MANUAL AIR CONDITIONER
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CONTENTS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
CONTAMINATED REFRIGERANT ....................... 5
General Refrigerant 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
ELECTRICAL 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
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
Revision: 2006 July
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
Component Parts and Harness Connector Location... 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 INTAKE AIR ..................................... 36
CHECKING TEMPERATURE DECREASE ......... 36
CHECKING TEMPERATURE INCREASE .......... 36
CHECKING A/C SWITCH ................................... 36
Mode Door .............................................................. 37
INSPECTION FLOW ........................................... 37
Air Mix Door ............................................................ 38
INSPECTION FLOW ........................................
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Intake Door Motor Circuit ........................................ 39
INSPECTION FLOW ........................................... 39
COMPONENT DESCRIPTION ............................ 39
DIAGNOSIS PROCEDURE FOR INTAKE DOOR
MOTOR ............................................................... 40
Blower Motor Circuit ............................................... 42
INSPECTION FLOW ........................................... 42
DIAGNOSIS PROCEDURE FOR BLOWER
MOTOR ............................................................... 42
COMPONENT INSPECTION .............................. 45
Magnet Clutch Circuit ............................................. 46
INSPECTION FLOW ........................................... 46
DIAGNOSIS PROCEDURE FOR MAGNET
CLUTCH .............................................................. 47
ELECTRICAL COMPONENT INSPECTION ....... 51
Insufficient Cooling ................................................. 52
INSPECTION FLOW ........................................... 52
PERFORMANCE TEST DIAGNOSIS ................. 54
PERFORMANCE CHART ................................... 56
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE ................................................................... 57
Insufficient Heating ................................................. 60
INSPECTION FLOW ........................................... 60
Noise ...................................................................... 61
INSPECTION FLOW ........................................... 61
CONTROLLER .......................................................... 62
Removal and Installation of Heater Control Panel... 62
REMOVAL ........................................................... 62
INSTALLATION .................................................... 62
Disassembly and Assembly .................................... 62
BLOWER UNIT ......................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 63
INSTALLATION .................................................... 63
Disassembly and Assembly .................................... 64
BLOWER MOTOR .................................................... 65
Removal and Installation ........................................ 65
REMOVAL ........................................................... 65
INSTALLATION .................................................... 65
INTAKE DOOR MOTOR ........................................... 66
Removal and Installation ........................................ 66
REMOVAL ........................................................... 66
INSTALLATION .................................................... 66
BLOWER FAN RESISTOR ....................................... 67
Removal and Installation ........................................ 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 67
IN-CABIN MICROFILTER ......................................... 68
Removal and Installation ........................................ 68
FUNCTION .......................................................... 68
REPLACEMENT TIMING .................................... 68
REPLACEMENT PROCEDURES ....................... 68
HEATER & COOLING UNIT ASSEMBLY ................. 69
Removal and Installation ........................................ 69
REMOVAL ........................................................... 69
INSTALLATION .................................................... 70
Disassembly and Assembly .................................... 71
MODE DOOR ............................................................ 72
Mode Door Cable Adjustment ................................ 72
Revision: 2006 July
AIR MIX DOOR ..........................................................73
Air Mix Door Cable Adjustment ...............................73
HEATER CORE .........................................................74
Removal and Installation .........................................74
REMOVAL ............................................................74
INSTALLATION ....................................................74
DUCTS AND GRILLES .............................................75
Removal and Installation .........................................75
REMOVAL ............................................................75
INSTALLATION ....................................................78
REFRIGERANT LINES .............................................79
HFC-134a (R-134a) Service Procedure ..................79
SETTING OF SERVICE TOOLS AND EQUIPMENT ...................................................................79
Components ............................................................81
Removal and Installation of Compressor ................81
REMOVAL ............................................................81
INSTALLATION ....................................................82
Removal and Installation of Compressor Clutch .....83
REMOVAL ............................................................83
INSTALLATION ....................................................85
Removal and Installation of Low-pressure Flexible
Hose ........................................................................86
REMOVAL ............................................................86
INSTALLATION ....................................................86
Removal and Installation of High-pressure Flexible
Hose ........................................................................87
REMOVAL ............................................................87
INSTALLATION ....................................................87
Removal and Installation of High-pressure Pipe .....87
REMOVAL ............................................................87
INSTALLATION ....................................................88
Removal and Installation of Condenser ..................88
REMOVAL ............................................................88
INSTALLATION ....................................................89
Removal and Installation of Liquid Tank .................89
REMOVAL ............................................................89
INSTALLATION ....................................................89
Removal and Installation for Refrigerant Pressure
Sensor .....................................................................90
REMOVAL ............................................................90
INSTALLATION ....................................................90
Removal and Installation of Evaporator ..................90
REMOVAL ............................................................90
INSTALLATION ....................................................91
Removal and Installation of Expansion Valve .........91
REMOVAL ............................................................91
INSTALLATION ....................................................91
Checking for Refrigerant Leaks ..............................91
Checking System for Leaks Using the Fluorescent
Leak Detector ..........................................................92
Dye Injection ...........................................................92
Electrical Leak Detector ..........................................92
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .........................................................92
CHECKING PROCEDURE ..................................93
SERVICE DATA AND SPECIFICATIONS (SDS) ......95
Compressor ............................................................95
Lubricant .................................................................95
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Refrigerant ............................................................. 95
Engine Idling Speed ............................................... 95
Belt Tension ............................................................ 95
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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.
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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.
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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
CAUTION:
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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.
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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.
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The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:
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When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
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When installing refrigerant components to a vehicle, never 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.
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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.
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Never allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrene foam parts.
Damage may result.
Revision: 2006 July
MTC-4
2006 X-Trail
PRECAUTIONS
CONTAMINATED REFRIGERANT
If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, take appropriate steps
shown below:
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Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant
into the atmosphere.
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Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant
supply.
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Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
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In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never
recover contaminated refrigerant into the existing service equipment. If the facility does not have
dedicated recovery equipment, 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.
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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
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WARNING:
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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 meet- G
ing requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refrigerant and H
lubricant manufacturers.
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Never release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
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Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
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Never store or heat refrigerant containers above 52°C (126°F).
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Never 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.
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Never intentionally drop, puncture, or incinerate refrigerant containers.
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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.
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Never pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and 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 refrigerant M
manufacturers.
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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.
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Expansion valve to evaporator
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Refrigerant pressure sensor to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
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The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates 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 facilitating piping connections.
SHA815E
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PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
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RJIA3160E
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Never confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant may leak at the connection.
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O-Ring Part Numbers and Specifications
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Connection type
New
O-ring
size
8
Former
Former
New
10
12
Former
New
16
Former
SHA814E
New
19
Former
Part number
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mm (in)
W
mm (in)
92471 N8210
6.80 (0.2680)
1.85 (0.0728)
92470 N8200
6.07 (0.2390)
1.78 (0.0701)
J2476 89956
9.25 (0.3642)
1.78 (0.0701)
92472 N8210
10.90 (0.429)
2.43 (0.0957)
92475 71L00
11.00 (0.433)
2.40 (0.0940)
92473 N8210
13.60 (0.535)
2.43 (0.0957)
92475 72L00
14.30 (0.563)
2.30 (0.0910)
92474 N8210
16.50 (0.650)
2.43 (0.0957)
92477 N8200
17.12 (0.674)
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
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When the compressor is removed, store it in the same way at it is when mounted on the car. Failure to do so will cause lubricant to enter the low-pressure chamber.
When connecting tubes, always use a torque wrench and a back-up wrench.
After disconnecting tubes, immediately plug all openings to prevent entry of dust and moisture.
When installing an air conditioner in the vehicle, connect the pipes at the final stage of the operation. Never 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 tubes, apply lubricant to circle of the O-rings shown in illustration. Be careful
not to apply lubricant to threaded portion.
Name
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: Nissan A/C System Oil Type S
O-ring must be closely attached to the groove of tube.
When replacing the O-ring, be careful not to damage O-ring and tube.
Connect tube until a click can be heard, then tighten the nut or bolt by hand. Make sure that the Oring is installed to tube correctly.
After connecting line, perform 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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PRECAUTIONS
Precautions for Servicing Compressor
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AJS001MA
Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same way at 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 normal
operation.
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.
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ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
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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 hoseto-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.
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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 no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
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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.
SHA533D
Revision: 2006 July
MTC-9
2006 X-Trail
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.
RHA272D
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
RHA273D
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.
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
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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 electrical leak detector (SST: J-41995). The
fluorescent dye leak detector should be used in conjunction with an electrical leak detector (SST: J-41995)
to pin-point refrigerant leaks.
For the purpose of safety and customer’s satisfaction, read and follow all manufacture’s operating instructions and precautions prior to performing the work.
A compressor shaft seal should not necessarily be repaired because of dye seepage. The compressor
shaft seal should only be repaired after confirming the leak with an electrical leak detector (SST: J-41995).
Always remove any remaining dye from the leak area after repairs are completed to avoid a misdiagnosis
during a future service.
Revision: 2006 July
MTC-10
2006 X-Trail
PRECAUTIONS
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Never 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.
Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
Never 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. Never 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 three years or a little over unless a compressor malfunction occurs.
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IDENTIFICATION
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NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
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IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have the identification label on the front side of hood.
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MTC-11
2006 X-Trail
PREPARATION
PREPARATION
Special Service Tools
PFP:00002
AJS001O8
The actual shapes of Kent-Moore tool may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
KV99106100
(J-41260)
Clutch disc wrench
Description
S-NT232
Removing shaft nut and clutch disc
SJIA1168E
KV99232340
(J-38874)
Clutch disc puller
Removing clutch disc
S-NT376
KV99106200
(J-41261)
Pulley installer
Installing pulley
S-NT235
Revision: 2006 July
MTC-12
2006 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.
Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.
Tool number
(Kent-Moore No.)
Tool name
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D
Description
E
Container color: Light blue
Container marking: HFC-134a (R134a)
Fitting size: Thread size
HFC-134a (R-134a) refrigerant
●
F
Large container 1/2″-16 ACME
S-NT196
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Type: Polyalkylene glycol oil (PAG),
type S (DH-PS)
Application:
HFC-134a (R-134a) wobble (swash)
plate compressors (Nissan only)
Capacity: 40 m (1.4 Imp fl oz)
Nissan A/C System Oil Type S
(DH-PS)
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S-NT197
(ACR2005-NI)
ACR5 A/C Service Center
Function: Refrigerant recovery,
recycling and recharging
MTC
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WJIA0293E
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Power supply:
DC 12 V (Battery terminal)
(J-41995)
Electrical leak detector
AHA281A
Revision: 2006 July
MTC-13
2006 X-Trail
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PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
(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
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleaner
Power supply:
DC 12 V (Battery terminal)
ZHA200H
Power supply:
DC 12 V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles
(J-42220)
UV lamp and UV safety goggles
SHA438F
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.)
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
SHA439F
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
For injecting 1/4 ounce of fluorescent
leak detection dye into A/C system
SHA440F
(J-43872)
Refrigerant dye cleaner
For cleaning dye spills
SHA441F
Identification:
●
(J-39183)
Manifold gauge set (with hoses
and couplers)
The gauge face indicates HFC-134a
(R-134a).
Fitting size: Thread size
●
1/2″-16 ACME
RJIA0196E
Revision: 2006 July
MTC-14
2006 X-Trail
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
Service hoses
Hose color:
A
(J-39501-72)
High-pressure side hose
●
Low hose: Blue with black stripe
●
High hose: Red with black stripe
●
(J-39502-72)
Low-pressure side hose
●
Utility hose: Yellow with black stripe
or green with black stripe
●
(J-39476-72)
Utility hose
●
B
C
Hose fitting to gauge:
S-NT201
●
1/2″-16 ACME
D
Service couplers
●
(J-39500-20)
High-pressure side coupler
●
(J-39500-24)
Low-pressure side coupler
Hose fitting to service hose:
M14 x 1.5 fitting is optional or
permanently attached.
E
F
S-NT202
G
For measuring of refrigerant
Fitting size: Thread size
1/2″-16 ACME
(J-39650)
Refrigerant weight scale
H
S-NT200
Capacity:
(J-39649)
Vacuum pump
(Including the isolator valve)
●
Air displacement: 4 CFM
●
Micron rating: 20 microns
●
Oil capacity: 482 g (17 oz)
I
MTC
Fitting size: Thread size
1/2″-16 ACME
S-NT203
Commercial Service Tools
AJS001OA
Tool name
K
Description
L
M
Checking for refrigerant purity and system contamination
Refrigerant identifier equipment
RJIA0197E
Power tool
For loosening bolts and nuts
PBIC0190E
Revision: 2006 July
MTC-15
2006 X-Trail
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Refrigerant Cycle
PFP:KA990
AJS001MG
REFRIGERANT FLOW
The refrigerant flows from the compressor, through the condenser with liquid tank, through the evaporator, and
back to the compressor. The refrigerant evaporation in the evaporator is controlled by an externally equalized
expansion valve, located inside the evaporator case.
FREEZE PROTECTION
To prevent evaporator frozen up, the evaporator air temperature is monitored, and the voltage signal to the
auto amp. will make the A/C relay go OFF and stop the compressor.
Refrigerant System Protection
AJS001MH
REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high- or 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: 2006 July
MTC-16
2006 X-Trail
REFRIGERATION SYSTEM
V-6 Variable Displacement Compressor
AJS001MI
A
GENERAL INFORMATION
1.
2.
3.
4.
5.
The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable compressor do not drop too far below 5°C (41°F) when:
Evaporator intake air temperature is less than 20°C (68°F).
Engine is running at speeds less than 1,500 rpm.
This is because the V-6 compressor provides a means of “capacity” control.
The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it
may not produce high refrigerant pressure discharge (compared to previous units) when used with air
conditioning systems.
A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt
angle of the wobble (swash) plate has changed and is not a malfunction.
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
when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.
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.
In previous compressors, however, suction pressure was reduced with increases in engine speed.
B
C
D
E
F
G
H
I
MTC
K
L
M
Revision: 2006 July
MTC-17
2006 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: 2006 July
MTC-18
2006 X-Trail
REFRIGERATION SYSTEM
Operation
1.
2.
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.
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.
A
B
C
D
E
F
G
H
I
MTC
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.
Revision: 2006 July
MTC-19
2006 X-Trail
K
L
M
REFRIGERATION SYSTEM
RHA474C
Revision: 2006 July
MTC-20
2006 X-Trail
REFRIGERATION SYSTEM
Component Layout
AJS001MJ
A
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA3092E
Revision: 2006 July
MTC-21
2006 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
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, never 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.
–
–
–
–
–
2.
3.
Start the engine, and set the following conditions:
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)
Perform lubricant return operation for about 10 minutes.
Stop the engine.
>> GO TO 3.
3. CHECK REPLACEMENT PART
Should the compressor be replaced?
YES >> GO TO MTC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" .
NO
>> GO TO MTC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR" .
Revision: 2006 July
MTC-22
2006 X-Trail
LUBRICANT
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR
A
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added:
B
Lubricant to be added to system
Part replaced
Amount of lubricant
m (Imp fl oz)
Remarks
Evaporator
75 (2.6)
—
Condenser
35 (1.2)
—
Liquid tank
10 (0.4)
—
30 (1.1)
Large leak
—
Small leak *1
In case of refrigerant leak
C
D
E
*1: If the refrigerant leak is small, no addition of lubricant is needed.
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Before connecting recovery/recycling recharging equipment to vehicle, check recovery/recycling recharg- F
ing equipment gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
Connect recovery/recycling recharging equipment to vehicle. Confirm refrigerant purity in supply tank G
using recovery/recycling recharging equipment and refrigerant identifier. If NG, refer to MTC-5, "CONTAMINATED REFRIGERANT" .
Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrig- H
erant identifier. If NG, refer to MTC-5, "CONTAMINATED REFRIGERANT" .
Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
I
Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
Drain the lubricant from the new compressor into a separate, clean container.
MTC
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.
Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
K
to new compressor through the suction port opening.
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 when replaces the compressor only.
L
M
Revision: 2006 July
MTC-23
2006 X-Trail
LUBRICANT
SJIA0596E
Revision: 2006 July
MTC-24
2006 X-Trail
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL
Control Operation
PFP:27500
A
AJS001ML
B
C
D
E
F
RJIA3132E
G
FAN CONTROL DIAL
This dial turns the fan ON and OFF, and controls fan speed.
H
TEMPERATURE CONTROL DIAL
This dial is to adjust the temperature of the discharge air.
I
MODE CONTROL DIAL
This dial controls the air flow outlet.
MTC
RECIRCULATION (REC) SWITCH
Recirculation (REC) position: Interior air is recirculated inside the vehicle. (The indicator lamp will illuminates.)
Fresh (FRE) position: Outlet air is drawn into the passenger compartment. (The indicator lamp will not illuminates.)
K
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 illuminates.
The air conditioner cooling function operates when the engine is running only.
L
M
Revision: 2006 July
MTC-25
2006 X-Trail
AIR CONDITIONER CONTROL
Discharge Air Flow
AJS001MM
SJIA0441E
Revision: 2006 July
MTC-26
2006 X-Trail
AIR CONDITIONER CONTROL
System Description
AJS001MN
A
SWITCHES AND THEIR CONTROL FUNCTION
B
C
D
E
F
G
H
I
RJIA3183E
MTC
K
L
M
RJIA0701E
Revision: 2006 July
MTC-27
2006 X-Trail
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
How to Perform Trouble Diagnoses for Quick and Accurate Repair
PFP:00004
AJS001MO
WORK FLOW
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-37, "Mode Door"
Discharge air temperature does not change.
Go to Trouble Diagnosis Procedure for Air Mix Door.
MTC-38, "Air Mix
Door"
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor.
Intake door motor does not operate normally.
MTC-39, "Intake Door
Motor Circuit"
Blower motor operation is malfunctioning.
Go to Trouble Diagnosis Procedure for Blower Motor.
MTC-42, "Blower
Motor Circuit"
Magnet clutch does not engage.
Go to Trouble Diagnosis Procedure for Magnet Clutch.
MTC-46, "Magnet
Clutch Circuit"
Insufficient cooling
Go to Trouble Diagnosis Procedure for Insufficient Cooling.
MTC-52, "Insufficient
Cooling"
Insufficient heating
Go to Trouble Diagnosis Procedure for Insufficient Heating.
MTC-60, "Insufficient
Heating"
Noise
Go to Trouble Diagnosis Procedure for Noise.
Revision: 2006 July
MTC-28
MTC-61, "Noise"
2006 X-Trail
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location
AJS001MP
A
ENGINE COMPARTMENT
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA3133E
Revision: 2006 July
MTC-29
2006 X-Trail
TROUBLE DIAGNOSIS
PASSENGER COMPARTMENT
RJIA3134E
Revision: 2006 July
MTC-30
2006 X-Trail
TROUBLE DIAGNOSIS
Schematic — A/C, M —
AJS001MQ
A
B
C
D
E
F
G
H
I
MTC
K
L
M
TJWB0039E
Revision: 2006 July
MTC-31
2006 X-Trail
TROUBLE DIAGNOSIS
Wiring Diagram — A/C, M —
AJS001OB
TJWB0164E
Revision: 2006 July
MTC-32
2006 X-Trail
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
MTC
K
L
M
TJWB0041E
Revision: 2006 July
MTC-33
2006 X-Trail
TROUBLE DIAGNOSIS
TJWB0042E
Revision: 2006 July
MTC-34
2006 X-Trail
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
MTC
K
L
M
TJWB0043E
Revision: 2006 July
MTC-35
2006 X-Trail
TROUBLE DIAGNOSIS
Operational Check
AJS001MS
The purpose of the operational check is to confirm that the system operates properly.
Conditions
: Engine running at normal operating temperature
CHECKING BLOWER
1. Turn fan control dial to 1st speed. Blower should operate on low speed.
2. Turn fan control dial to 2nd speed, and continue checking blower speed until all speeds are checked.
3. Leave blower on max. speed.
If NG, go to trouble diagnosis procedure for MTC-42, "Blower Motor Circuit" .
If OK, continue the check.
CHECKING DISCHARGE AIR
1.
2.
Turn mode control dial to each position.
Confirm that discharge air comes out according to the air distribution table. Refer to MTC-26, "Discharge Air Flow" .
If NG, go to trouble diagnosis procedure for MTC-37, "Mode Door" .
If OK, continue the check.
RJIA0492E
CHECKING INTAKE AIR
1. Press REC switch. Recirculation indicator should illuminate.
2. Press REC switch again. Recirculation indicator should not illuminate.
3. Listen for intake door position change (Slight change of blower sound can be heard.).
If NG, go to trouble diagnosis procedure for MTC-39, "Intake Door Motor Circuit" .
If OK, continue the check.
CHECKING TEMPERATURE DECREASE
1. Turn temperature control dial counterclockwise until full cold position.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for MTC-52, "Insufficient Cooling" .
If OK, continue the check.
CHECKING TEMPERATURE INCREASE
1. Turn temperature control dial clockwise until full hot position.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for MTC-60, "Insufficient Heating" .
If OK, continue the check.
CHECKING A/C SWITCH
1.
2.
Turn fan control dial to the desired (1st to 4th speed) position.
Press A/C switch. Then A/C switch indicator turns ON.
● Confirm that the compressor clutch engages (sound or visual inspection).
If NG, go to trouble diagnosis procedure for MTC-46, "Magnet Clutch Circuit" .
If all operational checks are OK (symptom cannot be duplicated), go to Incident Simulation Tests in GI-26,
"How to Perform Efficient Diagnosis for an Electrical Incident" and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to MTC-28, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures.
Revision: 2006 July
MTC-36
2006 X-Trail
TROUBLE DIAGNOSIS
Mode Door
AJS001MT
A
SYMPTOM: Air outlet does not change.
INSPECTION FLOW
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA3141E
*1
MTC-26, "Discharge Air Flow"
*4
MTC-28, "SYMPTOM TABLE"
Revision: 2006 July
*2
MTC-36, "Operational Check"
MTC-37
*3
MTC-72, "Mode Door Cable Adjustment"
2006 X-Trail
TROUBLE DIAGNOSIS
Air Mix Door
AJS001MU
SYMPTOM: Discharge air temperature does not change.
INSPECTION FLOW
RJIA3142E
*1
MTC-36, "Operational Check"
Revision: 2006 July
*2
MTC-73, "Air Mix Door Cable Adjust- *3
ment"
MTC-38
MTC-28, "SYMPTOM TABLE"
2006 X-Trail
TROUBLE DIAGNOSIS
Intake Door Motor Circuit
AJS001MV
A
SYMPTOM
●
Intake door does not change.
●
Intake door motor does not operate normally.
B
INSPECTION FLOW
C
D
E
F
G
H
I
MTC
SJIA1108E
*1
MTC-36, "Operational Check"
*2
MTC-39, "Intake Door Motor Circuit"
*3
K
MTC-28, "SYMPTOM TABLE"
COMPONENT DESCRIPTION
Intake Door Motor
L
The intake door motor is attached to the blower unit. It rotates so that
air is drawn from inlets set by the heater control panel. Motor rotation
is conveyed to a lever which activates the intake door.
M
RJIA3100E
Revision: 2006 July
MTC-39
2006 X-Trail
TROUBLE DIAGNOSIS
DIAGNOSIS PROCEDURE FOR INTAKE DOOR MOTOR
SYMPTOM: Intake door motor does not operate normally.
RJIA0595E
1. CHECK POWER SUPPLY FOR HEATER CONTROL PANEL
1.
2.
3.
Disconnect heater control panel connector.
Turn ignition switch ON.
Check voltage between heater control panel harness connector
M55 terminal 1 and ground.
1 – Ground
: Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> Check power supply circuit and 10A fuse [No. 15,
located in the fuse block (J/B)]. Refer to PG-51, "FUSE
BLOCK - JUNCTION BOX (J/B)" .
● If fuse is OK, check harness for open circuit. Repair or replace if necessary.
● If fuse is NG, check harness for short circuit and replace fuse.
RJIA2923E
2. CHECK GROUND CIRCUIT FOR HEATER CONTROL PANEL
1.
2.
Turn ignition switch OFF.
Check continuity between heater control panel harness connector M55 terminal 5 and ground.
5 – Ground
: Continuity should exist.
OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.
RJIA2924E
3. CHECK RECIRCULATION SWITCH CIRCUIT
1.
2.
Press REC (recirculation) switch.
Check continuity between heater control panel harness connector M55 terminal 1 and 5.
1–5
: Continuity should exist.
OK or NG
OK
>> GO TO 4.
NG
>> Replace heater control panel.
RJIA2925E
Revision: 2006 July
MTC-40
2006 X-Trail
TROUBLE DIAGNOSIS
4. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR
1.
2.
3.
A
Reconnect heater control panel connector.
Turn ignition switch ON.
Check voltage between intake door motor harness connector M48 terminal 1 and 2.
B
C
D
E
RJIA3144E
F
Terminals
(+)
Intake door motor
connector
(−)
Condition
Terminal No.
Intake door motor
connector
Terminal No.
M48
2
M48
1
REC switch: ON
M48
1
M48
2
REC switch: OFF
Voltage
G
Approx. 12 V
H
OK or NG
OK
>> Replace intake door motor.
NG
>> GO TO 5.
I
5. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND INTAKE DOOR MOTOR
1.
2.
3.
MTC
Turn ignition switch OFF.
Disconnect heater control panel connector and intake door motor connector.
Check continuity between heater control panel harness connector M55 terminal 10, 11 and intake door
K
motor harness connector M48 terminal 2, 1.
L
M
RJIA3145E
10 – 2
11 – 1
: Continuity should exist.
: Continuity should exist.
OK or NG
OK
>> Replace heater control panel.
NG
>> Repair harness or connector.
Revision: 2006 July
MTC-41
2006 X-Trail
TROUBLE DIAGNOSIS
Blower Motor Circuit
AJS001MW
SYMPTOM: Blower motor operation is malfunctioning.
INSPECTION FLOW
RJIA3146E
*1
MTC-36, "Operational Check"
*2
MTC-42, "DIAGNOSIS PROCEDURE FOR BLOWER MOTOR"
*3
MTC-28, "SYMPTOM TABLE"
DIAGNOSIS PROCEDURE FOR BLOWER MOTOR
SYMPTOM: Blower motor operation is malfunctioning.
RJIA0602E
Revision: 2006 July
MTC-42
2006 X-Trail
TROUBLE DIAGNOSIS
1. CHECK POWER SUPPLY FOR BLOWER MOTOR
1.
2.
3.
A
Disconnect blower motor connector.
Turn ignition switch ON.
Check voltage between blower motor harness connector M65
terminal 1 and ground.
1 – Ground
B
: Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> Check power supply circuit and 15A fuses [Nos. 19 and
24, located in the fuse block (J/B)]. Refer to PG-51,
"FUSE BLOCK - JUNCTION BOX (J/B)" .
● If fuses are OK, check harness for open circuit. Repair or replace if necessary.
● If fuses are NG, check harness for short circuit and replace fuse.
C
D
RJIA2929E
E
2. CHECK GROUND CIRCUIT FOR BLOWER MOTOR
1.
2.
3.
F
Turn ignition switch OFF.
Turn fan control dial to 1st speed.
Check continuity between blower motor harness connector M65
terminal 2 and ground.
2 – Ground
G
: Continuity should exist.
H
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.
I
RJIA2930E
3. CHECK BLOWER MOTOR
MTC
Refer to MTC-45, "Blower Motor" .
OK or NG
OK
>> INSPECTION END
NG
>> Replace blower motor.
K
4. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND FAN RESISTOR
L
1.
2.
Disconnect fan resistor connector.
Check continuity between fan resistor harness connector M66
terminal 1 and blower motor harness connector M65 terminal 2.
1–2
M
: Continuity should exist.
OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connector.
RJIA2931E
5. CHECK FAN RESISTOR
Refer to MTC-45, "Fan Resistor" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace fan resistor.
Revision: 2006 July
MTC-43
2006 X-Trail
TROUBLE DIAGNOSIS
6. CHECK CIRCUIT CONTINUITY BETWEEN FAN RESISTOR AND HEATER CONTROL PANEL
1.
2.
Disconnect heater control panel connector.
Check continuity between fan resistor harness connector M66
terminal 2, 3 or 4 and heater control panel harness connector
M54 terminal 16, 15 or 14.
2 – 16
3 – 15
4 – 14
: Continuity should exist.
: Continuity should exist.
: Continuity should exist.
OK or NG
OK
>> GO TO 7.
NG
>> Repair harness or connector.
RJIA2932E
7. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND HEATER CONTROL PANEL
Check continuity between blower motor harness connector M65 terminal 2 and heater control panel harness connector M54 terminal
17.
2 – 17
: Continuity should exist.
OK or NG
OK
>> GO TO 8.
NG
>> Repair harness or connector.
RJIA2933E
8. CHECK FAN SWITCH
Refer to MTC-45, "Fan Switch" .
OK or NG
OK
>> GO TO 9.
NG
>> Replace fan switch.
9. CHECK GROUND CIRCUIT
Check continuity between heater control panel harness connector
M54 terminal 13 and ground.
13 – Ground
: Continuity should exist.
OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
RJIA2934E
Revision: 2006 July
MTC-44
2006 X-Trail
TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Blower Motor
A
Confirm smooth rotation of the blower motor.
●
Ensure that there are no foreign particles inside the blower unit.
B
C
D
RJIA3147E
Fan Switch
E
Check continuity between heater control panel connector M54 terminals at each switch position.
Switch position
Terminals
Continuity
OFF
13 - 14, 15, 16, 17
No
1
13 - 14
2
13 - 15
3
13 - 16
4
13 - 17
F
G
Yes
H
RJIA0610E
Fan Resistor
I
Check resistance between fan resistor connector M66 terminals.
Terminals
1
Resistance (Ω)
2
0.25 - 0.31
3
0.58 - 0.70
4
1.33 - 1.63
MTC
K
L
RJIA3148E
M
Revision: 2006 July
MTC-45
2006 X-Trail
TROUBLE DIAGNOSIS
Magnet Clutch Circuit
AJS001MX
SYMPTOM: Magnet clutch does not engage.
INSPECTION FLOW
SJIA1102E
*1
MTC-36, "Operational Check"
*2
EM-11, "Checking Drive Belt"
*4
MTC-28, "SYMPTOM TABLE"
*5
MTC-91, "Checking for Refrigerant
Leaks"
Revision: 2006 July
MTC-46
*3
MTC-47, "DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH"
2006 X-Trail
TROUBLE DIAGNOSIS
DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
A
SYMPTOM: Magnet clutch does not engage when A/C switch and fan control dial are ON.
1. CHECK POWER SUPPLY FOR COMPRESSOR
1.
2.
3.
4.
B
Disconnect compressor connector.
Start the engine.
Turn fan control dial and A/C switch to ON.
Check voltage between compressor harness connector E34 terminal 1 and ground.
1 – Ground
C
: Battery voltage
OK or NG
OK
>> GO TO 2.
>> GO TO 3.
D
RJIA2869E
E
2. CHECK MAGNET CLUTCH CIRCUIT
Check for operation sound when applying battery voltage direct current to terminal.
OK or NG
OK
>> 1. Repair harness or connector.
2. Go to operational check. Refer to MTC-36, "CHECKING A/C SWITCH" . Confirm that magnet clutch operation is usual.
NG
>> 1. Replace magnet clutch.
2. Go to operational check. Refer to MTC-36, "CHECKING A/C SWITCH" . Confirm that magnet clutch operation is usual.
F
G
H
I
RJIA2005E
3. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR
1.
2.
3.
MTC
Turn ignition switch OFF.
Disconnect A/C relay connector.
Check continuity between A/C relay harness connector E5 terminal 5 and compressor harness connector E34 terminal 1.
5–1
K
L
: Continuity should exist.
OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.
M
RJIA2870E
Revision: 2006 July
MTC-47
2006 X-Trail
TROUBLE DIAGNOSIS
4. CHECK POWER SUPPLY FOR A/C RELAY
1.
2.
Turn ignition switch ON.
Check voltage between A/C relay harness connector E5 terminal 1 and ground, and also terminal 3 and ground.
1 – Ground
3 – Ground
: Battery voltage
: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> Check power supply circuit and 10A fuse [No. 15
located in the fuse block (J/B)]. Refer to PG-51, "FUSE
BLOCK - JUNCTION BOX (J/B)" .
● If fuse is OK, check harness for open circuit. Repair or replace if necessary.
● If fuse is NG, check harness for short circuit and replace fuse.
RJIA2871E
5. CHECK A/C RELAY
Refer to MTC-51, "A/C Relay" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace A/C relay.
6. CHECK COIL SIDE CIRCUIT OF A/C RELAY
1.
2.
3.
Reconnect A/C relay connector.
Turn ignition switch ON.
Check voltage between ECM harness connector M118 terminal
105 and ground.
105 – Ground
: Approx. 12 V
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
RJIA2936E
7. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM
1.
2.
3.
Turn ignition switch OFF.
Disconnect A/C relay connector and ECM connector.
Check continuity between A/C relay connector E5 terminal 2
and ECM harness connector M118 terminal 105.
2 – 105
: Continuity should exist.
OK or NG
OK
>> Check ECM. Refer to EC-104, "ECM Terminals and Reference Value" .
NG
>> Repair harness or connector.
Revision: 2006 July
MTC-48
RJIA2937E
2006 X-Trail
TROUBLE DIAGNOSIS
8. CHECK COMPRESSOR ON SIGNAL
A
Check voltage between heater control panel harness connector M55
terminal 7 and ground.
B
Terminals
(+)
Condition
Heater control
panel connector
Terminal No.
M55
7
Voltage
(−)
Ground
C
A/C switch: ON
(Blower motor operates.)
Approx. 0 V
A/C switch: OFF
Approx. 5 V
D
RJIA2938E
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 15.
E
9. CHECK COMPRESSOR FEEDBACK SIGNAL
F
Check voltage between heater control panel harness connector M55
terminal 12 and ground.
12 – Ground
G
: Approx. 0 V
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 16.
H
I
RJIA2939E
10. CHECK REFRIGERANT PRESSURE SENSOR
MTC
Refer to EC-634, "REFRIGERANT PRESSURE SENSOR" .
OK or NG
OK
>> GO TO 11.
NG
>> Replace refrigerant pressure sensor.
K
L
11. CHECK A/C SWITCH
1.
2.
3.
4.
Turn ignition switch OFF.
Disconnect heater control panel connector.
Press A/C switch.
Check continuity between heater control panel connector M55
terminal 7 and 8.
7–8
: Continuity should exist.
OK or NG
OK
>> GO TO 12.
NG
>> Replace heater control panel.
Revision: 2006 July
M
RJIA2940E
MTC-49
2006 X-Trail
TROUBLE DIAGNOSIS
12. CHECK HEATER CONTROL PANEL CIRCUIT
Check continuity between heater control panel harness connector
M55 terminal 8 and heater control panel harness connector M54 terminal 18.
8 – 18
: Continuity should exist.
OK or NG
OK
>> GO TO 13.
NG
>> Repair harness or connector.
RJIA2941E
13. CHECK FAN SWITCH
Check continuity between heater control panel connector M54 terminal 18 and 13.
Terminals
Heater control panel
connector
Terminal No.
M54
18
Heater control panel
connector
Terminal No.
M54
13
Condition
Continuity
Fan control dial:
ON (Blower motor
operates.)
Yes
Fan control dial:
OFF
No
RJIA2942E
OK or NG
OK
>> GO TO 14.
NG
>> Replace fan switch.
14. CHECK GROUND CIRCUIT
Check continuity between heater control panel harness connector
M54 terminal 13 and ground.
13 – Ground
: Continuity should exist.
OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
RJIA2934E
15. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND HEATER CONTROL PANEL
1.
2.
3.
Turn ignition switch OFF.
Disconnect ECM and heater control panel connector.
Check continuity between heater control panel harness connector M55 terminal 7 and ECM harness connector M118 terminal
110.
7 – 110
: Continuity should exist.
OK or NG
OK
>> Replace ECM.
NG
>> Repair harness or connector.
Revision: 2006 July
RJIA2944E
MTC-50
2006 X-Trail
TROUBLE DIAGNOSIS
16. CHECK CIRCUIT CONTINUITY BETWEEN COMBINATION METER AND HEATER CONTROL
PANEL
1.
2.
3.
Turn ignition switch OFF.
Disconnect combination meter connector and heater control
panel connector.
Check continuity between heater control panel harness connector M55 terminal 12 and combination meter harness connector
M44 terminal 32.
12 – 32
A
B
C
: Continuity should exist.
D
OK or NG
OK
>> Replace combination meter.
NG
>> Repair harness or connector.
RJIA2945E
E
ELECTRICAL COMPONENT INSPECTION
A/C Relay
F
Check circuit continuity between terminal Nos. 3 and 5.
Conditions
Continuity
12 V direct current supply between terminal Nos. 1 and 2.
Yes
No current supply.
No
G
If NG, replace A/C relay.
H
RHA638H
I
Refrigerant Pressure Sensor
The refrigerant pressure sensor is attached to the liquid tank.
Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure. Refer to EC-634, "REFRIGERANT PRESSURE
SENSOR" .
MTC
K
L
RJIA0690E
RJIA2954E
Revision: 2006 July
MTC-51
2006 X-Trail
M
TROUBLE DIAGNOSIS
Insufficient Cooling
AJS001MY
SYMPTOM: Insufficient cooling
INSPECTION FLOW
SJIA1065E
*1
MTC-36, "Operational Check"
Revision: 2006 July
*2
EM-11, "Checking Drive Belt"
MTC-52
*3
MTC-38, "Air Mix Door"
2006 X-Trail
TROUBLE DIAGNOSIS
*4
MTC-57, "TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE"
*5
MTC-28, "SYMPTOM TABLE"
*7
MTC-54, "PERFORMANCE TEST
DIAGNOSIS"
*8
MTC-5, "CONTAMINATED REFRIGERANT"
*6
EC-480, "SYSTEM DESCRIPTION"
A
B
C
D
E
F
G
H
I
MTC
K
L
M
Revision: 2006 July
MTC-53
2006 X-Trail
TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSIS
SJIA1226E
Revision: 2006 July
MTC-54
2006 X-Trail
TROUBLE DIAGNOSIS
*1
MTC-56, "PERFORMANCE CHART" *2
*4
MTC-38, "Air Mix Door"
MTC-56, "PERFORMANCE CHART" *3
MTC-57, "TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE"
A
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA3107E
*1
MTC-83, "Removal and Installation
of Compressor Clutch"
Revision: 2006 July
*2
MTC-42, "Blower Motor Circuit"
MTC-55
*3
EM-11, "Checking Drive Belt"
2006 X-Trail
TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition
Testing must be performed as follows:
Vehicle location
Indoors or in the shade (in a well-ventilated place)
Doors
Closed
Door windows
Open
Hood
Open
TEMP.
Max. COLD
Mode control dial
(Ventilation) set
Recirculation (REC) switch
(Recirculation) set
Max. speed set
Fan (blower) speed
Engine speed
Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading
Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Relative humidity
%
Discharge air temperature at center ventilator
°C (°F)
Air temperature
°C (°F)
50 - 60
60 - 70
25 (77)
10.0 - 11.6 (50 - 53)
30 (86)
13.9 - 16.2 (57 - 61)
35 (95)
17.8 - 21.4 (64 - 71)
25 (77)
11.6 - 13.9 (53 - 57)
30 (86)
16.2 - 18.9 (61- 66)
35 (95)
21.4 - 24.5 (71 - 76)
Ambient Air Temperature-to-operating Pressure Table
Ambient air
Relative humidity
%
50 - 70
Revision: 2006 July
Air temperature
°C (°F)
High-pressure (Discharge side)
Low-pressure (Suction side)
(kg/cm2
kPa (kg/cm2 , psi)
kPa
, psi)
30 (86)
980 - 1,180
(9.99 - 12.04, 142 - 171)
230 - 270
(2.35 - 2.75, 33 - 39)
35 (95)
1,180 - 1,390
(12.04 - 14.18, 171 - 202)
260 - 310
(2.65 - 3.16, 38 - 45)
40 (104)
1,400 - 1,580
(14.28 - 16.12, 203 - 229)
300 - 350
(3.06 - 3.57, 44 - 51)
MTC-56
2006 X-Trail
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
Whenever system’s high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the
standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-to-operating pressure table).
A
B
Both High and Low-pressure Sides are Too High
Gauge indication
Refrigerant cycle
Probable cause
Corrective action
The pressure is reduced soon
after water is splashed on condenser.
Excessive refrigerant charge in
refrigeration cycle.
Reduce refrigerant until specified pressure is obtained.
Air suction by cooling fan is
insufficient.
Insufficient condenser cooling
performance.
↓
1. Condenser fins are clogged.
D
●
Clean condenser.
●
Check and repair cooling fan
as necessary.
2. Improper fan rotation of cooling fan.
Both high- and low-pressure
sides are too high.
●
●
AC359A
Low-pressure pipe is not
cold.
When compressor is stopped
high-pressure value quickly
drops by approximately 196
kPa (1.96 bar, 2 kg/cm2 , 28
psi). It then decreases gradually thereafter.
Engine tends to overheat.
●
●
An area of the low-pressure
pipe is colder than areas
near the evaporator outlet.
Low-pressure pipe is sometimes covered with frost.
C
E
F
Poor heat exchange in condenser.
(After compressor operation
stops, high-pressure decreases
too slowly.)
↓
Air in refrigeration cycle.
Evacuate repeatedly and
recharge system.
Engine cooling systems malfunction.
Check and repair each engine
cooling system.
●
Excessive liquid refrigerant
on low-pressure side.
●
Excessive refrigerant discharge flow.
●
Expansion valve is open a little compared with the specification.
G
H
I
MTC
Replace expansion valve.
K
↓
Improper expansion valve
adjustment.
L
High-pressure Side is Too High and Low-pressure Side is Too Low
Gauge indication
Refrigerant cycle
Probable cause
Corrective action
M
High-pressure side is too high and
low-pressure side is too low.
Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.
High-pressure tube or parts
located between compressor
and condenser are clogged or
crushed.
●
Check and repair or replace
malfunctioning parts.
●
Check lubricant for contamination.
AC360A
Revision: 2006 July
MTC-57
2006 X-Trail
TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High
Gauge indication
High-pressure side is too low and
low-pressure side is too high.
Refrigerant cycle
Probable cause
Corrective action
High- and low-pressure sides
become equal soon after compressor operation stops.
Compressor pressure operation is improper.
↓
Damaged inside compressor
packings.
Replace compressor.
No temperature difference
between high- and low-pressure sides.
Compressor pressure operation is improper.
↓
Damaged inside compressor
packings.
Replace compressor.
AC356A
Both High and Low-pressure Sides are Too Low
Gauge indication
Refrigerant cycle
●
●
Liquid tank inlet and expansion valve are frosted.
●
Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank.
●
●
Both high- and low-pressure sides
are too low.
AC353A
There is a big temperature
difference between liquid
tank outlet and inlet. Outlet
temperature is extremely
low.
Expansion valve inlet is
frosted.
Probable cause
Liquid tank inside is slightly
clogged.
High-pressure pipe located
between liquid tank and
expansion valve is clogged.
Corrective action
●
Replace liquid tank.
●
Check lubricant for contamination.
●
Check and repair malfunctioning parts.
●
Check lubricant for contamination.
Temperature difference
occurs somewhere in highpressure side.
Expansion valve and liquid
tank are warm or slightly cool
when touched.
There is a big temperature difference between expansion
valve inlet and outlet while the
valve itself is frosted.
Low refrigerant charge.
↓
Leaking fittings or components.
Expansion valve closes a little
compared with the specification.
↓
1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.
Check refrigerant for leaks.
Refer to MTC-91, "Checking
for Refrigerant Leaks" .
●
Remove foreign particles by
using compressed air.
●
Replace expansion valve.
●
Check lubricant for contamination.
●
Check and repair malfunctioning parts.
●
Check lubricant for contamination.
●
Replace compressor.
●
Repair evaporator fins.
●
Replace evaporator.
●
Refer to MTC-42, "Blower
Motor Circuit" .
3. Outlet and inlet may be
clogged.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.
Air flow volume is not enough
or is too low.
Revision: 2006 July
Low-pressure pipe is clogged
or crushed.
Evaporator is frozen.
MTC-58
2006 X-Trail
TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative
Gauge indication
Low-pressure side sometimes
becomes negative.
Refrigerant cycle
●
●
AC354A
Air conditioning system
does not function and does
not cyclically cool the compartment air.
The system constantly functions for a certain period of
time after compressor is
stopped and restarted.
Probable cause
Refrigerant does not discharge cyclically.
↓
Moisture is frozen at expansion valve outlet and inlet.
↓
Water is mixed with refrigerant.
Corrective action
A
B
●
Drain water from refrigerant
or replace refrigerant.
●
Replace liquid tank.
C
D
Low-pressure Side Becomes Negative
Gauge indication
Refrigerant cycle
Probable cause
Corrective action
Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
●
Low-pressure side becomes negative.
Liquid tank or front/rear side of
expansion valve’s pipe is
frosted or wet with dew.
High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted.
●
AC362A
●
If water is the cause, initially
cooling is okay. Then the
water freezes causing a
blockage. Drain water from
refrigerant or replace refrigerant.
If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed air
(not shop air).
If either of the above methods cannot correct the malfunction, replace expansion
valve.
●
Replace liquid tank.
●
Check lubricant for contamination.
E
F
G
H
I
MTC
K
L
M
Revision: 2006 July
MTC-59
2006 X-Trail
TROUBLE DIAGNOSIS
Insufficient Heating
AJS001MZ
SYMPTOM: Insufficient heating
INSPECTION FLOW
SJIA1066E
*1
MTC-36, "Operational Check"
*2
CO-8, "Changing Engine Coolant"
*3
CO-12, "Checking Radiator Cap"
*4
EC-201, "DTC P0117, P0118 ECT
SENSOR" and CO-22, "THERMOSTAT AND WATER CONTROL
VALVE" .
*5
MTC-28, "SYMPTOM TABLE"
*6
MTC-73, "Air Mix Door Cable Adjustment"
Revision: 2006 July
MTC-60
2006 X-Trail
TROUBLE DIAGNOSIS
Noise
AJS001N0
A
SYMPTOM: Noise
INSPECTION FLOW
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA3108E
*1
Compressor clutch, MTC-83,
"REMOVAL" .
*2
Compressor clutch, MTC-85,
"INSTALLATION" .
*4
MTC-36, "Operational Check"
*5
EM-11, "Checking Drive Belt"
Revision: 2006 July
MTC-61
*3
MTC-22, "Maintenance of Lubricant
Quantity in Compressor"
2006 X-Trail
CONTROLLER
CONTROLLER
Removal and Installation of Heater Control Panel
PFP:27500
AJS001N1
REMOVAL
1.
2.
3.
4.
Remove mode door cable and air mix door cable from heater unit.
Remove cluster lid C. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove mounting screws from heater control panel.
Disconnect connector, and then remove heater control panel.
RJIA0089E
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Adjust the door cables during installation. Refer to MTC-72, "Mode Door Cable Adjustment" and MTC73, "Air Mix Door Cable Adjustment" .
Disassembly and Assembly
AJS001N2
RJIA3153E
1.
Mode door cable
2.
Clamp
3.
Case assembly
4.
Heater panel
5.
Finisher
6.
Dial
7.
Air mix door cable
8.
Fan switch
9.
Bulb
Revision: 2006 July
MTC-62
2006 X-Trail
BLOWER UNIT
BLOWER UNIT
Removal and Installation
PFP:27200
A
AJS001N3
REMOVAL
1.
2.
3.
4.
5.
6.
Remove glove box, glove box cover and instrument passenger lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove NAVI control unit. Refer to AV-63, "Removal and Installation of NAVI Control Unit" .
Remove ECM mounting bolt, and then remove ECM with ECM
bracket attached.
Remove instrument panel mounting screw.
Remove blower unit mounting bolt and screws.
Disconnect blower motor connector and fan control amp. connector.
B
C
D
E
SJIA1063E
7.
8.
Disconnect intake door motor connector, and then remove harness clips.
Remove blower unit.
CAUTION:
Move blower unit rightward, and remove locating pins (2
parts) and joint. Then remove blower unit downward.
F
G
H
I
SJIA1064E
INSTALLATION
MTC
Installation is basically the reverse order of removal.
CAUTION:
Make sure locating pins (2 parts) are securely installed.
K
L
M
Revision: 2006 July
MTC-63
2006 X-Trail
BLOWER UNIT
Disassembly and Assembly
AJS001N4
RJIA3187E
1.
Upper case 2
4.
Fan resistor
7.
Washer
2.
In-cabin microfilter
3.
Filter cover
5.
Screw
6.
Blower fan motor assembly
8.
Cooling hose
9.
Intake door motor
10. Motor bracket
11. Intake door link
12. Intake door lever 2
13. Upper case 1
14. Intake door 2
15. Intake door 1
16. Nut
17. Blower fan
18. Bell mouth
19. Intake door lever 1
CAUTION:
If retaining tabs are damaged while disassembling blower unit,
use 9 screws (27111-2Y000) to assemble blower unit.
RJIA3155E
Revision: 2006 July
MTC-64
2006 X-Trail
BLOWER MOTOR
BLOWER MOTOR
Removal and Installation
PFP:27226
A
AJS001N5
REMOVAL
1.
2.
Remove blower unit. Refer to MTC-63, "BLOWER UNIT" .
Separate blower motor from blower unit.
B
C
D
E
RJIA3164E
3.
Remove cooling hose, blower fan resistor and blower fan.
F
G
H
RJIA3154E
I
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
If retaining tabs are damaged while disassembling blower unit,
use 9 screws (27111-2Y000) to assemble blower unit.
MTC
K
L
M
RJIA3155E
Revision: 2006 July
MTC-65
2006 X-Trail
INTAKE DOOR MOTOR
INTAKE DOOR MOTOR
Removal and Installation
PFP:27730
AJS001N7
REMOVAL
1.
2.
Remove blower unit. Refer to MTC-63, "BLOWER UNIT" .
Remove mounting screws, and then remove intake door motor
from blower unit.
RJIA3115E
INSTALLATION
Installation is basically the reverse order of removal.
Revision: 2006 July
MTC-66
2006 X-Trail
BLOWER FAN RESISTOR
BLOWER FAN RESISTOR
Removal and Installation
PFP:27150
A
AJS001N6
REMOVAL
1.
2.
Remove glove box, glove box cover and instrument passenger lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove mounting screws, and then remove fan resistor.
CAUTION:
Do not repair the thermal fuse of the fan resistor.
B
C
D
E
RJIA3156E
INSTALLATION
F
Installation is basically the reverse order of removal.
G
H
I
MTC
K
L
M
Revision: 2006 July
MTC-67
2006 X-Trail
IN-CABIN MICROFILTER
IN-CABIN MICROFILTER
Removal and Installation
PFP:27277
AJS001N8
FUNCTION
Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing in-cabin microfilter into blower unit.
RJIA3117E
REPLACEMENT TIMING
Replace in-cabin microfilter.
Refer to MA-8, "CHASSIS AND BODY MAINTENANCE" in Schedule 1 and MA-9, "CHASSIS AND BODY
MAINTENANCE" Schedule 2.
When replacing filter, affix a caution label inside the glove box.
REPLACEMENT PROCEDURES
1.
2.
3.
4.
5.
Remove glove box cover. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove filter cover.
Take out in-cabin microfilter from blower unit.
Replace with new one and reinstall on blower unit.
Reinstall glove box cover.
RJIA3130E
Revision: 2006 July
MTC-68
2006 X-Trail
HEATER & COOLING UNIT ASSEMBLY
HEATER & COOLING UNIT ASSEMBLY
Removal and Installation
PFP:27110
A
AJS001N9
REMOVAL
1.
2.
3.
4.
5.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Drain coolant from cooling system. Refer to CO-8, "Changing Engine Coolant" .
Disconnect two heater hoses from heater core pipe.
Remove mounting bolt from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of low-pressure flexible hose and
high-pressure pipe with suitable material such as vinyl tape
to avoid the entry of air.
Remove blower unit. Refer to MTC-63, "BLOWER UNIT" .
B
C
D
E
RJIA3166E
6.
7.
8.
F
Remove instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove clips of vehicle harness from steering member.
Remove mounting nuts, and then remove instrument stay.
G
H
I
RJIA3167E
9.
MTC
Remove mounting bolts from heater & cooling unit.
K
L
M
RJIA3168E
Revision: 2006 July
MTC-69
2006 X-Trail
HEATER & COOLING UNIT ASSEMBLY
RJIA3169E
10. Remove column shaft mounting nuts.
11. Remove steering member mounting bolts and nuts.
12. Remove steering member, and then remove heater & cooling unit assembly.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of low-pressure flexible hose and high-pressure pipe with new ones, and then
apply compressor oil to it when installing it.
●
When recharging refrigerant, check for leaks.
●
Adjust the door cables during installation. Refer to MTC-72, "Mode Door Cable Adjustment" and
MTC-73, "Air Mix Door Cable Adjustment" .
NOTE:
●
When filling radiator with coolant, refer to CO-8, "Changing Engine Coolant" .
●
Recharge the refrigerant.
Revision: 2006 July
MTC-70
2006 X-Trail
HEATER & COOLING UNIT ASSEMBLY
Disassembly and Assembly
AJS001NA
A
B
C
D
E
F
G
H
I
MTC
RJIA3157E
1.
Heater & cooling unit case (left)
2.
Defroster door
3.
Heater & cooling unit case (right)
4.
Foot duct (right)
5.
Screw
6.
Heater core cover
7.
Evaporator cover
8.
Evaporator
9.
Expansion valve
10. Bolt
11. Expansion valve cover
12. Cooler grommet
13. Heater pipe support
14. Insulator
15. Ventilator door link 2
16. Ventilator door link 1
17. Ventilator door lever
18. Foot duct (left)
19. Defroster door lever
20. Ventilator door
21. Max. cool door
22. Heater core
23. Slide door unit (Air mix door)
24. Max. cool door lever
25. Main link
26. Harness bracket
Revision: 2006 July
MTC-71
K
L
M
2006 X-Trail
MODE DOOR
MODE DOOR
Mode Door Cable Adjustment
PFP:27181
AJS001NC
1.
2.
Set mode control dial to VENT position.
Move side link by hand and hold mode door in VENT position.
3.
Pull on the cable cover in the direction of the arrow ( ), and
then clamp it.
NOTE:
After positioning control cable, make sure it operates properly.
RJIA3158E
Revision: 2006 July
MTC-72
2006 X-Trail
AIR MIX DOOR
AIR MIX DOOR
Air Mix Door Cable Adjustment
PFP:27180
A
AJS001ND
1.
2.
Set temperature control dial to full cold position.
Move air mix door lever by hand and hold it at the full cold position.
3.
Pull on the cable cover in the direction of the arrow ( ), and
then clamp it.
NOTE:
After positioning control cable, make sure it operates properly.
B
C
D
RJIA3159E
E
F
G
H
I
MTC
K
L
M
Revision: 2006 July
MTC-73
2006 X-Trail
HEATER CORE
HEATER CORE
Removal and Installation
PFP:27140
AJS001NB
REMOVAL
1.
2.
3.
4.
Remove heater & cooling unit assembly. Refer to MTC-69, "HEATER & COOLING UNIT ASSEMBLY" .
Remove heater pipe support.
Remove mounting screws, and then remove foot duct and
heater core cover.
Remove heater core from heater & cooling unit assembly.
RJIA3125E
INSTALLATION
Installation is basically the reverse order of removal.
Revision: 2006 July
MTC-74
2006 X-Trail
DUCTS AND GRILLES
DUCTS AND GRILLES
Removal and Installation
PFP:27860
A
AJS001NE
REMOVAL
B
C
D
E
F
G
H
I
RJIA3170E
1.
Side defroster duct (right)
2.
Defroster nozzle
3.
4.
Side ventilator duct (left)
5.
Front speaker grille (left)
6.
Cup holder (left)
7.
Side ventilator grille (left)
8.
Multi-box (Instrument center lower
panel)
9.
Side ventilator grille (right)
MTC
Side defroster duct (left)
10. Cup holder (right)
11. Front speaker grille (right)
12. Side ventilator duct (right)
13. Adaptor
14. Multi-box duct 2
15. Driver ventilator grille
16. Center ventilator grille (left)
17. Center ventilator grille (right)
18. Instrument panel
K
L
19. Multi-box duct 1
Removal of Center Ventilator Grilles
1.
2.
M
Remove cluster lid C. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove mounting clips, and then remove center ventilator
grilles.
RJIA2407E
Revision: 2006 July
MTC-75
2006 X-Trail
DUCTS AND GRILLES
Removal of Side Ventilator Grilles
1.
2.
3.
Remove instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove side ventilator ducts. Refer to MTC-76, "Removal of Defroster Nozzle, Ducts and Side Ventilator
Ducts" .
Remove mounting screws, and then remove side ventilator
grilles.
RJIA3122E
Removal of Driver Ventilator Grille
1.
2.
3.
Remove instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove side ventilator duct (left). Refer to MTC-76, "Removal of Defroster Nozzle, Ducts and Side Ventilator Ducts" .
Remove mounting screws, and then remove driver ventilator
grille.
RJIA3171E
Removal of Defroster Nozzle, Ducts and Side Ventilator Ducts
1.
2.
Remove instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove mounting screws, and then remove side defroster ducts with defroster nozzle.
3.
Remove mounting screws, and then remove side ventilator ducts.
RJIA3123E
Revision: 2006 July
MTC-76
2006 X-Trail
DUCTS AND GRILLES
Removal of Adaptor
1.
2.
3.
Remove heater & cooling unit assembly. Refer to MTC-69, "HEATER & COOLING UNIT ASSEMBLY" .
Remove mounting screw and clip.
Slide adaptor toward vehicle front, and then remove adaptor.
A
B
C
D
RJIA3124E
Removal of Multi-box Duct
1.
2.
3.
4.
E
Remove instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Remove mounting screws, and then disconnect multi-box duct
from heater & cooling unit assembly.
Remove mounting bolts, and then remove heater & cooling unit
bracket (right).
Remove multi-box duct from passenger side.
F
G
H
RJIA3172E
I
Removal of Foot Duct
1.
2.
Remove multi-box duct. Refer MTC-77, "Removal of Multi-box Duct" .
Remove mounting screws, and then remove foot duct.
MTC
K
L
RJIA3125E
Revision: 2006 July
MTC-77
2006 X-Trail
M
DUCTS AND GRILLES
Removal of Floor Ducts
1.
2.
3.
4.
Remove front seats. Refer to SE-17, "FRONT SEAT" .
Remove multi-box (Instrument center lower panel). Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Peel back the floor trim to a point where the floor duct is visible.
Remove mounting bolts and clips, and then remove rear floor ducts.
RJIA3131E
5.
Remove mounting clips, and then remove front floor duct.
RJIA3173E
INSTALLATION
Installation is basically the reverse order of removal.
Revision: 2006 July
MTC-78
2006 X-Trail
REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service Procedure
PFP:92600
A
AJS001NF
SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant
B
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from A/C system, using certified service equipment meeting
requirements of SAE 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.
C
D
E
F
G
H
I
WJIA0614E
MTC
Evacuating System and Charging Refrigerant
K
L
M
WJIA0615E
Revision: 2006 July
MTC-79
2006 X-Trail
REFRIGERANT LINES
SJIA1275E
*1
MTC-22, "LUBRICANT RETURN
OPERATION"
*2
MTC-91, "Checking for Refrigerant
Leaks"
*4
MTC-54, "PERFORMANCE TEST
DIAGNOSIS"
*5
MTC-5, "CONTAMINATED
REFRIGERANT"
Revision: 2006 July
MTC-80
*3
MTC-93, "CHECKING PROCEDURE"
2006 X-Trail
REFRIGERANT LINES
Components
AJS001NG
A
Refer to MTC-6, "Precautions for Refrigerant Connection" .
B
C
D
E
F
G
H
I
MTC
RJIA3174E
Removal and Installation of Compressor
K
AJS001NH
REMOVAL
L
M
RJIA3185E
1.
2.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove engine undercover, using power tools.
Revision: 2006 July
MTC-81
2006 X-Trail
REFRIGERANT LINES
3.
4.
5.
Remove compressor-alternator belt. Refer to EM-11, "Removal and Installation" or EM-12, "Removal and
Installation of Drive Belt Auto-Tensioner" .
Remove mounting bolt from high-pressure flexible hose.
Remove mounting nut from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of low-pressure flexible hose and
high-pressure flexible hose with suitable material such as
vinyl tape to avoid the entry of air.
RJIA3175E
6.
7.
8.
Disconnect compressor connector.
Remove mounting bolts from compressor.
Remove compressor from the lower side of the vehicle.
RJIA3176E
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with new ones, and
then apply compressor oil to it when installing it.
●
When recharging refrigerant, check for leaks.
Revision: 2006 July
MTC-82
2006 X-Trail
REFRIGERANT LINES
Removal and Installation of Compressor Clutch
AJS001OJ
A
REMOVAL
Overhaul
1.
When removing center bolt, hold clutch disc with clutch disc
wrench (SST).
B
C
D
RHA136EB
E
F
G
H
RHA399F
2.
I
Remove clutch disc using clutch disc puller (SST).
MTC
K
RHA124F
3.
L
Remove snap ring using external snap ring pliers.
M
RHA138E
Revision: 2006 July
MTC-83
2006 X-Trail
REFRIGERANT LINES
4.
Position the center pulley puller on the end of the drive shaft,
and remove pulley assembly using any commercially available
pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
RHA139E
5.
Remove field coil harness clip using a pair of pliers.
RHA125F
6.
Remove snap ring using external snap ring pliers.
RHA145E
Inspection
Clutch disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.
Pulley
Check the appearance of the pulley assembly. If the contact surface
of pulley shows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.
RHA126F
Revision: 2006 July
MTC-84
2006 X-Trail
REFRIGERANT LINES
INSTALLATION
1.
2.
A
Install field coil.
Be sure to align the coil’s pin with the hole in the compressor’s
front head.
Install field coil harness clip using a screwdriver.
B
C
RHA142E
3.
Install pulley assembly using pulley installer (SST) and a hand
press, and then install snap ring using snap ring pliers.
D
E
F
G
RHA143EA
4.
H
Install clutch disc on drive shaft, together with original shim(s).
Press the clutch disc down by hand.
I
MTC
K
RHA127F
5.
Using the holder to prevent clutch disc rotation.
L
: 14 N·m (1.4 kg-m, 10 ft-lb)
After tightening the bolt, check that the pulley rotates smoothly.
M
RHA086E
Revision: 2006 July
MTC-85
2006 X-Trail
REFRIGERANT LINES
6.
Check clearance around the entire periphery of clutch disc.
Disc to pulley clearance
: 0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
RHA087E
Break-In Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque.
Removal and Installation of Low-pressure Flexible Hose
AJS001NJ
REMOVAL
1.
2.
3.
4.
5.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove extension cowl top panel.
Remove the clips from low-pressure flexible hose.
Remove mounting bolts from low-pressure flexible hose bracket.
Remove harness bracket mounting bolt.
RJIA3177E
6.
Remove mounting nut from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of compressor and low-pressure flexible hose with suitable material such as vinyl tape to avoid
the entry of air.
RJIA3178E
7.
Remove mounting bolt, and then remove low-pressure flexible
hose.
CAUTION:
Cap or wrap the joint of evaporator and low-pressure flexible hose with suitable material such as vinyl tape to avoid
the entry of air.
RJIA3179E
INSTALLATION
Installation is basically the reverse order of removal.
Revision: 2006 July
MTC-86
2006 X-Trail
REFRIGERANT LINES
CAUTION:
●
Replace O-rings of low-pressure flexible hose with new ones, and then apply compressor oil to it
when installing it.
●
When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure Flexible Hose
AJS001NK
A
B
REMOVAL
1.
2.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove high-pressure flexible hose mounting clip.
C
D
E
F
RJIA3181E
3.
Remove mounting bolt from high-pressure flexible hose, and
then remove it.
CAUTION:
Cap or wrap the joint of compressor and high-pressure flexible hose with suitable material such as vinyl tape to avoid
the entry of air.
G
H
I
RJIA3180E
MTC
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of high-pressure flexible hose with new ones, and then apply compressor oil to it
when installing it.
●
When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure Pipe
K
L
AJS001NL
REMOVAL
1.
2.
3.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove low-pressure flexible hose. Refer to MTC-86, "Removal and Installation of Low-pressure Flexible
Hose" .
Remove high-pressure pipe from clip.
RJIA3182E
Revision: 2006 July
MTC-87
2006 X-Trail
M
REFRIGERANT LINES
4.
5.
Remove mounting bolt from high-pressure pipe.
CAUTION:
Cap or wrap the joint of evaporator, condenser and highpressure pipe with suitable material such as vinyl tape to
avoid the entry of air.
Remove high-pressure pipe.
RJIA2419E
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of high-pressure pipe with new ones, and then apply compressor oil to it when
installing it.
●
When recharging refrigerant, check for leaks.
Removal and Installation of Condenser
AJS001NM
REMOVAL
1.
2.
3.
4.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Disconnect high-pressure flexible hose and high-pressure pipe
from the condenser.
CAUTION:
Cap or wrap the joint of condenser, high-pressure pipe and
high-pressure flexible hose with suitable material such as
vinyl tape to avoid the entry of air.
Remove air duct (inlet). Refer to EM-14, "AIR CLEANER AND
AIR DUCT" .
Remove battery and battery tray. Refer to SC-4, "BATTERY" .
RJIA2419E
5.
Disconnect refrigerant pressure sensor connector.
RJIA0690E
6.
7.
8.
Remove front grille and radiator mounting bracket. Refer to EI18, "FRONT GRILLE" and CO-11, "RADIATOR" .
Remove mounting nuts from condenser.
Remove radiator from lower mount, move it to engine side, and
then remove condenser between radiator and radiator core support.
CAUTION:
Be careful not to damage the core surface of condenser and
radiator.
RJIA0081E
Revision: 2006 July
MTC-88
2006 X-Trail
REFRIGERANT LINES
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of high-pressure pipe and high-pressure flexible hose with new ones, and then
apply compressor oil to them after installing them.
●
When recharging refrigerant, check for leaks.
Condenser mounting nuts
: 4.2 N·m (0.43 kg-m, 37 in-lb)
A
B
C
Removal and Installation of Liquid Tank
AJS001NN
D
REMOVAL
1.
2.
3.
Remove condenser. Refer to MTC-88, "Removal and Installation of Condenser" .
Clean liquid tank and its surrounding area, and remove dust and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
Remove mounting bolts from liquid tank.
CAUTION:
Cap or wrap the joint of condenser pipe with a suitable
material such as a vinyl tape to avoid the entry of air.
E
F
G
H
RJIA2895E
4.
5.
Lift liquid tank bracket upward. Remove bracket from protruding
part of condenser.
Slide liquid tank upward, and then remove liquid tank.
I
MTC
K
L
RJIA1440E
M
INSTALLATION
Install liquid tank, and then install liquid tank bracket on condenser.
CAUTION:
●
Make sure liquid tank bracket is securely installed at protrusion of condenser.
●
Make sure liquid tank bracket does not move to position
below center of liquid tank.
●
Replace O-rings of the condenser pipe with new ones, and
then apply compressor oil to them when installing them.
●
When recharging refrigerant, check for leaks.
RJIA1441E
Revision: 2006 July
MTC-89
2006 X-Trail
REFRIGERANT LINES
Removal and Installation for Refrigerant Pressure Sensor
AJS001NO
REMOVAL
1.
2.
3.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove liquid tank. Refer to MTC-89, "Removal and Installation of Liquid Tank" .
Using a vise, secure liquid tank, and remove refrigerant pressure sensor.
RJIA2148E
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Apply compressor oil to O-ring of refrigerant pressure sensor when installing it.
●
When recharging refrigerant, check for leaks.
Removal and Installation of Evaporator
AJS001NQ
REMOVAL
1.
2.
3.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove extension cowl top panel.
Disconnect low-pressure flexible hose and high-pressure pipe
from evaporator.
CAUTION:
Cap or wrap the joint of evaporator, low-pressure flexible
hose and high-pressure pipe with a suitable material such
as a vinyl tape to avoid the entry of air.
RJIA3182E
4.
5.
Remove mounting screw, and then remove expansion valve
cover.
Remove mounting bolts, and then remove expansion valve.
RJIA3127E
6.
Remove blower unit. Refer to MTC-63, "BLOWER UNIT" .
Revision: 2006 July
MTC-90
2006 X-Trail
REFRIGERANT LINES
7.
8.
9.
Remove foot duct (passenger side).
Remove mounting screws, and then remove evaporator cover.
Slide evaporator, and then remove it from heater & cooling unit
assembly.
A
B
C
RJIA3126E
D
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of low-pressure flexible hose and high-pressure pipe with new ones, and then
apply compressor oil to them when installing them.
●
When recharging refrigerant, check for leaks.
Removal and Installation of Expansion Valve
E
F
AJS001OD
REMOVAL
1.
2.
3.
4.
5.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove extension cowl top panel.
Disconnect low-pressure flexible hose and high-pressure pipe from evaporator.
CAUTION:
Cap or wrap the joint of expansion valve, low-pressure flexible hose and high-pressure pipe with a
suitable material such as a vinyl tape to avoid the entry of air.
Remove mounting screw, and then remove expansion valve
cover.
Remove mounting bolts, and then remove expansion valve.
G
H
I
MTC
K
RJIA3127E
L
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of expansion valve and low-pressure flexible hose and high-pressure pipe with
new ones, and then apply compressor oil to them when installing them.
●
When recharging refrigerant, check for leaks.
Checking for Refrigerant Leaks
AJS001NS
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electrical leak detector or fluorescent dye leak
detector (SST: J-42220).
If dye is observed, confirm the leak with an electrical leak detector. It is possible a prior leak was repaired and
not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electrical leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
Revision: 2006 July
MTC-91
2006 X-Trail
M
REFRIGERANT LINES
CAUTION:
Moving the electrical leak detector probe slower and closer to the suspected leak area will improve the
chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak Detector
AJS001NT
1.
Check A/C system for leaks using the UV lamp and safety goggles (SST: J-42220) in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (SST: J-43872) to prevent future
misdiagnosis.
4. Perform a system performance check and verify the leak repair with an approved electrical leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye Injection
AJS001NU
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1.
2.
3.
4.
5.
6.
7.
8.
Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50
psi).
Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J-41459).
Connect the injector tool to the A/C low-pressure side service valve.
Start engine and switch A/C ON.
When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture’s
operating instructions).
With the engine still running, disconnect the injector tool from the service valve.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Attach a blue label as necessary.
Electrical Leak Detector
AJS001NV
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance.
SHA196FA
Revision: 2006 July
MTC-92
2006 X-Trail
REFRIGERANT LINES
1.
Position probe approximately 5 mm (3/16 in) away from point to
be checked.
A
B
C
SHA707EA
D
2.
When testing, circle each fitting completely with probe.
E
F
G
SHA706E
3.
Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
H
I
MTC
SHA708EA
K
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Stop the engine.
2. Connect a suitable A/C manifold gauge set (SST: J-39183) to the A/C service valves.
3.
4.
2
Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm , 50 psi) above 16°C (61°F). If less
than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa
(3.52 kg/cm2 , 50 psi).
Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal k). Refer to MTC-81, "Components" . Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure hoses, relief valve and shaft seal.
Condenser
Check the fitting of high-pressure hose and pipe.
Liquid tank
Check the fitting of refrigerant pressure sensor.
Service valves
Revision: 2006 July
MTC-93
2006 X-Trail
L
M
REFRIGERANT LINES
Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start the engine.
8. Set the A/C control as follows;
a. A/C switch: ON
b. Mode door position: VENT (ventilation)
c. Intake door position: Recirculation
d. Temperature setting: Max. cold
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Stop the engine and perform leak check again following steps 4
through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
SHA839E
11. Before connecting recovery/recycling recharging equipment to vehicle, check recovery/recycling recharging equipment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover
refrigerant from equipment lines and then check refrigerant purity.
12. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant
identifier.
13. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrigerant identifier.
14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component as necessary.
15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
16. Perform A/C performance test to ensure system works properly.
Revision: 2006 July
MTC-94
2006 X-Trail
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor
PFP:00030
A
AJS001NW
Model
Calsonic Kansei make CWV-615M
Type
V-6 variable displacement
Displacement
Max.
146 (8.91)
cm3 (cu in)/rev
Min.
13.5 (0.824)
Cylinder bore × stroke
mm (in)
B
C
35.2 (1.386) × [2.3 - 25.0 (0.091 - 0.984)]
Direction of rotation
D
Clockwise (viewed from drive end)
Drive belt
Poly V
Lubricant
AJS001NX
Model
Calsonic Kansei make CWV-615M
Name
Capacity
m (Imp fl oz)
E
Nissan A/C System Oil Type S (DH-PS)
Total in system
180 (6.3)
Compressor (Service part) charging
amount
180 (6.3)
Refrigerant
F
G
AJS001NY
Type
H
HFC-134a (R-134a)
Capacity
kg (lb)
0.55 (1.21)
I
Engine Idling Speed
AJS001NZ
Refer to EC-661, "Idle Speed and Ignition Timing" .
MTC
Belt Tension
AJS001O0
Refer to EM-11, "DRIVE BELTS" .
K
L
M
Revision: 2006 July
MTC-95
2006 X-Trail
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2006 July
MTC-96
2006 X-Trail
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