2003 NISSAN X-TRAIL gas type

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION
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AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
General Refrigerant Precautions .............................. 4
Lubricant Precautions .............................................. 5
Precautions for Refrigerant Connection ................... 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 5
O-RING AND REFRIGERANT CONNECTION..... 6
Precautions for Servicing Compressor ..................... 7
Precautions for Service Equipment .......................... 8
RECOVERY/RECYCLING EQUIPMENT .............. 8
ELECTRONIC LEAK DETECTOR ........................ 8
VACUUM PUMP ................................................... 8
MANIFOLD GAUGE SET ...................................... 8
SERVICE HOSES ................................................. 9
SERVICE COUPLERS .......................................... 9
REFRIGERANT WEIGHT SCALE ........................ 9
CALIBRATING ACR4 WEIGHT SCALE ................ 9
CHARGING CYLINDER ...................................... 10
Precautions for Leak Detection Dye ....................... 10
IDENTIFICATION ................................................ 10
IDENTIFICATION LABEL FOR VEHICLE ........... 10
Wiring Diagrams and Trouble Diagnosis ................ 10
PREPARATION ..........................................................11
Special Service Tools ..............................................11
WITH GASOLINE ENGINE (CWV-615M COM-
PRESSOR) ..........................................................11
WITH DIESEL ENGINE (DKV-11G COMPRES-
SOR) ....................................................................11
HFC-134a (R-134a) Service Tools and Equipment... 12
REFRIGERATION SYSTEM ..................................... 16
Refrigerant Cycle ................................................... 16
REFRIGERANT FLOW ....................................... 16
FREEZE PROTECTION (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 16
Refrigerant System Protection ............................... 16
REFRIGERANT PRESSURE SENSOR (WITHGASOLINE ENGINE: CWV-615M COMPRES-
SOR) ................................................................... 16
DUAL-PRESSURE SWITCH (WITH DIESEL
ENGINE: DKV-11G COMPRESSOR) .................. 16
PRESSURE RELIEF VALVE (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 16
V-6 Variable Displacement Compressor (With Gas-
oline Engine: CWV-165M Compressor) .................. 17
GENERAL INFORMATION ................................. 17
DESCRIPTION .................................................... 17
Component Layout ................................................. 20
LUBRICANT .............................................................. 21
Maintenance of Lubricant Quantity in Compressor... 21
LUBRICANT ........................................................ 21
LUBRICANT RETURN OPERATION .................. 21
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 22
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 22
AIR CONDITIONER CONTROL ............................... 24
Overview Air Conditioner LAN Control System ...... 24
System Construction .............................................. 24
OPERATION ........................................................ 24
TRANSMISSION DATA AND TRANSMISSION
ORDER ............................................................... 25
AIR MIX DOOR CONTROL (AUTOMATIC TEM-
PERATURE CONTROL) ..................................... 25
FAN SPEED CONTROL ...................................... 26
INTAKE DOOR CONTROL ................................. 26
OUTLET DOOR CONTROL ................................ 26
MAGNET CLUTCH CONTROL ........................... 26
SELF-DIAGNOSTIC SYSTEM ............................ 26
Overview of Control system .................................... 26
Control Operation ................................................... 27
DISPLAY SCREEN .............................................. 27
AUTO SWITCH ................................................... 27
TEMPERATURE DIAL (POTENTIO TEMPERA-
TURE CONTROL) ............................................... 27
A/C SWITCH ....................................................... 27

ATC-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS000T0
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.
WAR NIN G:
lTo 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 per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo 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 harness connectors.
Precautions for Working with HFC-134a (R-134a)EJS000T1
WAR NIN G:
lUse only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
lThe specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
–When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
bletominimizetheentryofmoistureintosystem.
–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a from the A/C system, using certified service equipment meeting require-
ments of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If acci-
dental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
–Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
General Refrigerant PrecautionsEJS000T2
WAR NIN G:
lDo not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
lAlways wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
lDo not store or heat refrigerant containers above 52°C(125°F).
lDo not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
lDo not intentionally drop, puncture, or incinerate refrigerant containers.
lKeep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
lRefrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
lDo not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or

PRECAUTIONS
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CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
lWhen the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
lWhen connecting tubes, always use a torque wrench and a back-up wrench.
lAfter disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
lWhen installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
lAllow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
lThoroughly remove moisture from the refrigeration system before charging the refrigerant.
lAlways replace used O-rings.
lWhen connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
lO-ring must be closely attached to dented portion of tube.
lWhen replacing the O-ring, be careful not to damage O-ring and tube.
lConnect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
lAfter connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.
Precautions for Servicing CompressorEJS000T5
lPlug all openings to prevent moisture and foreign matter from entering.
lWhen the compressor is removed, store it in the same position as it is when mounted on the car.
lWhen replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer toATC-21, "
Maintenance of Lubricant Quantity in Compressor".
lKeep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.
lAfter 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.
RHA861F

ATC-12
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment
EJS000TB
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-
cant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor failure will result.
KV992T0002
Pulley installerInstalling pulley
KV99233130
Pulley pullerRemoving pulley Tool number
Tool nameDescription
RJIA0477E
RJIA0478E
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color:Light blue
Container marking:HFC-134a (R-
134a)
Fitting size:Thread size
llarge container 1/22-16 ACME
Gasoline engine (CWV-615M):
KLH00-PAGS0
Nissan A/C System Oil Type S
Diesel engine (DKV-11G):
KLH00-PAGR0
Nissan A/C System Oil Type RGasoline engine (CWV-615M):
Type: Poly alkylene glycol oil (PAG),
type S
Application: HFC-134a (R-134a)
swash plate compressors (Nissan
only)
Diesel engine (DKV-11G):
Type: Poly alkylene glycol oil (PAG),
type R
Application: HFC-134a (R-134a) vane
rotary compressors (Nissan only)
Lubricity: 40 ml [Litre] (1.4 Imp fl oz)
S-NT196
S-NT197

REFRIGERATION SYSTEM
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cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into
the atmosphere.
V-6 Variable Displacement Compressor (With Gasoline Engine: CWV-165M
Compressor)
EJS000TF
GENERAL INFORMATION
1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable com-
pressor do not drop too far below 5°C(41°F) when:
Evaporator intake air temperature is less than 20°C(68°F).
Engine is running at speeds less than 1,500 rpm.
This is because the V-6 compressor provides a means of "capacity" control.
2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it
may not produce high refrigerant pressure discharge (compared to previous units) when used with air
conditioning systems.
3. A "clanking" sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt
angle of the swash plate has changed and is not a problem.
4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system
main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or
when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.
5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It
normally ranges from 147 to 177 kPa (1.5 to 1.8 kg/cm
2, 21 to 26 psi) under varying conditions.
In previous compressors, however, suction pressure was reduced with increases in engine speed.
DESCRIPTION
General
The variable compressor is basically a swash plate type that changes piston stroke in response to the required
cooling capacity.
RJIA0198E

LUBRICANT
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LUBRICANTPFP:KLG00
Maintenance of Lubricant Quantity in CompressorEJS000TH
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci-
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
lLack of lubricant: May lead to a seized compressor
lExcessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
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?
lA/C system works properly.
lThere is no evidence of a large amount of lubricant leakage.
Ye s o r N o
Yes >>GOTO2.
No >> GO TO 3.
2.PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:
1. Start engine, and set the following conditions:
–Test condition
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
Blower speed: Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
Intake position: Recirculation (REC)
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
>> GO TO 3.
3.CHECK COMPRESSOR
Should the compressor be replaced?
Ye s o r N o
Ye s > > G o t oAT C - 2 2 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT".
No >> GO TO 4.With gasoline engine
(CWV-615M Compressor)With diesel engine
(DKV-11G Compressor)
Name Nissan A/C System Oil Type S Nissan A/C System Oil Type R
Part number KLH00-PAGS0 KLH00-PAGR0

REFRIGERANT LINES
ATC-143
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Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent 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 engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Face mode
c. Intake position: Recirculation
d. Max cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure 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.
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity.
12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Conduct A/C performance test to ensure system works properly.
Service Data and Specifications (SDS)EJS000VN
COMPRESSOR
SHA708EA
ModelWith gasoline engine With diesel engine
CALSONIC KANSEI make V-6 ZEXEL VALEO make DKV-11G
Type V-6 variable displacement Vane rotary

ATC-144
REFRIGERANT LINES
LUBRICANT
REFRIGERANT
ENGINE IDLING SPEED
Refer toATC-144, "ENGINE IDLING SPEED".
BELT TENSION
Refer to,EM-13, "Tension Adjustment"QR engine;EM-110, "Tension Adjustment"YD engine.
Displacement
cm3 (cu. in)/revMax. 184 (11.228)
110 (6.71)
Min. 14.5 (0.885)
Cylinder bore´stroke
mm (in)37 (1.46)´[2.3 - 28.6 (0.091 - 1.126)] -
Direction of rotation Clockwise (viewed from drive end)
Drive beltPoly V
ModelWith gasoline engine With diesel engine
CALSONIC KANSEI make V-6 ZEXEL VALEO make DKV-11G
Name Nissan A/C System Oil Type S Nissan A/C System Oil Type R
Part number KLH00-PAGS0 KLH00-PAGR0
Capacity
ml (lmp fl oz)Total in system 180 (6.3)
Compressor (Service part) charging
amount180 (6.3)
Ty p eHFC-134a (R-134a)
Capacity
kg (lb)0.50 (1.10)