2003 NISSAN X-TRAIL clutch

ATC-2 INTAKE SWITCH ................................................. 31
A/C SWITCH ....................................................... 31
Discharge Air Flow ................................................. 32
System Description ................................................. 33
SWITCHES AND THEIR CONTROL FUNCTION ... 33
TROUBLE DIAGNOSIS ............................................ 34
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 34
WORK FLOW ...................................................... 34
SYMPTOM TABLE .............................................. 34
Component Parts and Harness Connector Location ... 35
ENGINE COMPARTMENT .................................. 35
PASSENGER COMPARTMENT .......................... 36
Schematic ............................................................... 37
WITH GASOLINE ENGINE ................................. 37
WITH DIESEL ENGINE ....................................... 38
Wiring Diagram —A/C— ......................................... 39
WITH GASOLINE ENGINE / LHD MODELS ....... 39
WITH GASOLINE ENGINE / RHD MODELS ...... 43
WITH DIESEL ENGINE / LHD MODELS ............ 47
WITH DIESEL ENGINE / RHD MODELS ............ 51
Auto Amp. Terminals and Reference Value ............ 55
PIN CONNECTOR TERMINAL LAYOUT ............ 55
TERMINALS AND REFERENCE VALUE FOR
AUTO AMP. ......................................................... 55
Self-diagnosis Function .......................................... 57
DESCRIPTION .................................................... 57
FUNCTION CONFIRMATION PROCEDURE ...... 59
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 63
AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER ........................................... 63
AUXILIARY MECHANISM: INLET PORT MEM-
ORY FUNCTION ................................................. 64
Operational Check .................................................. 65
CHECKING BLOWER ......................................... 65
CHECKING DISCHARGE AIR ............................ 65
CHECKING INTAKE DOOR ................................ 65
CHECKING TEMPERATURE DECREASE ......... 66
CHECKING TEMPERATURE INCREASE .......... 66
CHECKING A/C SWITCH ................................... 66
Power Supply and Ground Circuit for Auto Amp. ... 67
INSPECTION FLOW ........................................... 67
COMPONENT DESCRIPTION ............................ 67
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ... 68
LAN System Circuit ................................................ 69
DIAGNOSTIC PROCEDURE FOR LAN CIR-
CUIT .................................................................... 69
Mode Door Motor Circuit ........................................ 73
INSPECTION FLOW ........................................... 73
SYSTEM DESCRIPTION .................................... 74
COMPONENT DESCRIPTION ............................ 75
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 75
Air Mix Door Motor Circuit ...................................... 76
INSPECTION FLOW ........................................... 76
SYSTEM DESCRIPTION .................................... 77
COMPONENT DESCRIPTION ............................ 78
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR .................................................... 78
Intake Door Motor Circuit ........................................ 79
INSPECTION FLOW ............................................ 79
SYSTEM DESCRIPTION ..................................... 80
COMPONENT DESCRIPTION ............................ 81
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR .................................................... 81
Blower Motor Circuit ................................................ 82
INSPECTION FLOW ............................................ 82
SYSTEM DESCRIPTION ..................................... 83
COMPONENT DESCRIPTION ............................ 84
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ................................................................ 84
COMPONENT INSPECTION ............................... 87
Magnet Clutch Circuit .............................................. 88
INSPECTION FLOW ............................................ 88
SYSTEM DESCRIPTION ..................................... 89
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 89
COMPONENT INSPECTION ............................... 94
Insufficient Cooling .................................................. 96
INSPECTION FLOW ............................................ 96
PERFORMANCE TEST DIAGNOSIS .................. 98
PERFORMANCE CHART ..................................100
TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SURE .................................................................102
Insufficient Heating ...............................................105
INSPECTION FLOW ..........................................105
Noise .....................................................................107
INSPECTION FLOW ..........................................107
Self-diagnosis .......................................................108
INSPECTION FLOW ..........................................108
Ambient Sensor Circuit .........................................109
COMPONENT DESCRIPTION ..........................109
AMBIENT TEMPERATURE INPUT PROCESS .109
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ............................................................109
COMPONENT INSPECTION ............................. 111
In-vehicle Sensor Circuit ....................................... 111
COMPONENT DESCRIPTION .......................... 111
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR ............................................................112
COMPONENT INSPECTION .............................113
Sunload Sensor Circuit .........................................114
COMPONENT DESCRIPTION ..........................114
SUNLOAD INPUT PROCESS ...........................114
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR ............................................................114
COMPONENT INSPECTION .............................116
Intake Sensor Circuit .............................................117
COMPONENT DESCRIPTION ..........................117
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ...................................................................117
COMPONENT INSPECTION .............................119
CONTROLLER ........................................................120
Removal and Installation .......................................120
REMOVAL ..........................................................120
INSTALLATION ..................................................120

ATC-3
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AMBIENT SENSOR ................................................ 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 121
IN-VEHICLE SENSOR ............................................ 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSTALLATION ................................................. 122
SUNLOAD SENSOR .............................................. 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSTALLATION ................................................. 123
INTAKE SENSOR ................................................... 124
Removal and Installation ...................................... 124
REMOVAL ......................................................... 124
INSTALLATION ................................................. 124
BLOWER UNIT ....................................................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSTALLATION ................................................. 125
Disassembly and Assembly ................................. 126
BLOWER MOTOR .................................................. 127
Removal and Installation ...................................... 127
REMOVAL ......................................................... 127
INSTALLATION ................................................. 127
INTAKE DOOR MOTOR ......................................... 128
Removal and Installation ...................................... 128
REMOVAL ......................................................... 128
INSTALLATION ................................................. 128
FAN CONTROL AMPLIFIER .................................. 129
Removal and Installation ...................................... 129
REMOVAL ......................................................... 129
INSTALLATION ................................................. 129
VENTILATION AIR FILTER .................................... 130
Removal and Installation ...................................... 130
FUNCTION ........................................................ 130
REPLACEMENT TIMING .................................. 130
REPLACEMENT PROCEDURES ..................... 130
HEATER & COOLING UNIT ASSEMBLY .............. 131
Removal and Installation ...................................... 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
Disassembly and Assembly ................................. 132
MODE DOOR MOTOR ........................................... 134
Removal and Installation ...................................... 134
REMOVAL ......................................................... 134
INSTALLATION ................................................. 134
AIR MIX DOOR MOTOR ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSTALLATION ................................................. 135
HEATER CORE ...................................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSTALLATION ................................................. 136
DUCTS AND GRILLES .......................................... 137
Removal and Installation ...................................... 137
REMOVAL ......................................................... 137
INSTALLATION ................................................. 140REFRIGERANT LINES ...........................................141
HFC-134a (R-134a) Service Procedure ...............141
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................141
Components .........................................................143
WITH GASOLINE ENGINE ...............................143
WITH DIESEL ENGINE .....................................144
Removal and Installation of Compressor ..............144
REMOVAL .........................................................144
INSTALLATION .................................................146
Removal and Installation of Compressor Clutch ..146
REMOVAL .........................................................146
INSTALLATION .................................................150
Removal and Installation of Low-pressure Flexible
Hose .....................................................................153
REMOVAL .........................................................153
INSTALLATION .................................................154
Removal and Installation of High-pressure Flexible
Hose .....................................................................154
REMOVAL .........................................................154
INSTALLATION .................................................155
Removal and Installation of High-pressure Pipe ..155
REMOVAL .........................................................155
INSTALLATION .................................................155
Removal and Installation of Condenser ................155
REMOVAL .........................................................155
INSTALLATION .................................................156
Removal and Installation of Liquid Tank ...............156
REMOVAL .........................................................156
INSTALLATION .................................................157
Removal and Installation of Refrigerant Pressure
Sensor ..................................................................157
REMOVAL .........................................................157
INSTALLATION .................................................157
Removal and Installation of Dual-pressure Switch .158
REMOVAL .........................................................158
INSTALLATION .................................................158
Removal and Installation of Evaporator ................158
REMOVAL .........................................................158
INSTALLATION .................................................159
Removal and Installation of Expansion Valve .......159
REMOVAL .........................................................159
INSTALLATION .................................................159
Checking for Refrigerant Leaks ............................160
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................160
Dye Injection .........................................................160
Electronic Refrigerant Leak Detector ....................161
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................161
CHECKING PROCEDURE ...............................161
SERVICE DATA AND SPECIFICATIONS (SDS) ....164
Compressor ..........................................................164
Lubricant ...............................................................164
Refrigerant ............................................................164
Engine Idling Speed .............................................164
Belt Tension ..........................................................164

ATC-10
PRECAUTIONS

Precautions for Servicing CompressorEJS000T5

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

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

When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to AT C - 2 4 , "
Maintenance of Lubricant Quantity in Compressor" .

Keep 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.

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

After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.
Precautions for Service EquipmentEJS000T6
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.

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

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

If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
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 ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.
RHA270DA
SHA533D

ATC-14
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsEJS001F1
WITH GASOLINE ENGINE (CWV-615M COMPRESSOR)
WITH DIESEL ENGINE (DKV-11G COMPRESSOR)
Tool number
Tool nameDescription
KV99106100
Clutch disc wrenchRemoving shaft nut and clutch disc
KV99232340
Clutch disc pullerRemoving clutch disc
KV99106200
Pulley installerInstalling pulley
S-NT232
RJIA0194E
S-NT376
S-NT235
Tool number
Tool nameDescription
KV99231260
Clutch disc wrenchRemoving shaft nut and clutch disc
KV992T0001
Clutch disc pullerRemoving clutch disc
RJIA0475E
RJIA0476E

REFRIGERATION SYSTEM
ATC-19
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V-6 Variable Displacement Compressor (With Gasoline Engine: CWV-615M
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 wobble (swash) plate has changed and is not a malfunction.
4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system
main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or
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 (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm
2 , 21 to 26 psi) under varying con-
ditions.
In previous compressors, however, suction pressure was reduced with increases in engine speed.

AIR CONDITIONER CONTROL
ATC-29
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Stop Signal:
At the end of each transmission, a stop operation, in-operation, or internal malfunction message is delivered to
the auto amp. This completes one data transmission and control cycle.
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.
FAN SPEED CONTROL
Blower speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle tempera-
ture, intake temperature, amount of sunload and air mix door position.
With FAN control dial set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing.
INTAKE DOOR CONTROL
The intake doors are automatically controlled by the temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and ON-OFF operation of the compressor.
OUTLET DOOR CONTROL
The outlet door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temper-
ature, intake temperature and amount of sunload.
MAGNET CLUTCH CONTROL
The ECM controls compressor operation using input signals from the throttle position sensor, refrigerant pres-
sure sensor (or dual-pressure switch) and auto amp.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amp. to quickly locate the cause of symptoms.
RHA352H

ATC-34
TROUBLE DIAGNOSIS

TROUBLE DIAGNOSISPFP:00004
How to Perform Trouble Diagnoses for Quick and Accurate RepairEJS004GO
WORK FLOW
SYMPTOM TABLE
*1ATC-65, "Operational Check".
SHA900E
Symptom Reference Page
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System.ATC-67, "
Power
Supply and
Ground Circuit for
Auto Amp."
Air outlet does not change.
Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN)ATC-73, "Mode
Door Motor Cir-
cuit"Mode door motor does not operate normally.
Discharge air temperature does not change.
Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN)AT C - 7 6 , "
Air Mix
Door Motor Cir-
cuit"Air mix door motor does not operate nor-
mally.
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN)AT C - 7 9 , "
Intake
Door Motor Cir-
cuit"Intake door motor does not operate normally.
Blower motor operation is malfunctioning.
Go to Trouble Diagnosis Procedure for Blower Motor.AT C - 8 2 , "
Blower
Motor Circuit"Blower motor operation is malfunctioning
under out of starting fan speed control.
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch.AT C - 8 8 , "
Magnet
Clutch Circuit"
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.ATC-96, "Insuffi-
cient Cooling"
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating.ATC-105, "Insuffi-
cient Heating"
Noise Go to Trouble Diagnosis Procedure for Noise.ATC-107, "Noise"
Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis.ATC-108, "Self-
diagnosis"

TROUBLE DIAGNOSIS
ATC-61
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8. CHECK ACTUATORS
Refer to the following chart and confirm discharge air flow, air tem-
perature, blower motor voltage and compressor operation.
Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for
improper operation.
*1: Step No. 41 to 46 are for differentiation and will not be displayed.
*2: FOOT position during automatic control. Refer to AT C - 6 3 , "
AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER" .
OK or NG
OK >> 1. Turn ignition switch OFF or intake switch ON.
2. INSPECTION END
NG >>

Air outlet does not change.
Go to Mode Door Motor Circuit. Refer to AT C - 7 3 , "
Mode Door Motor Circuit" .

Intake door does not change.
Go to Intake Door Motor Circuit. Refer to AT C - 7 9 , "
Intake Door Motor Circuit" .

Blower motor operation is malfunctioning.
Go to Blower Motor Circuit. Refer to AT C - 8 2 , "
Blower Motor Circuit" .

Magnet clutch does not engage.
Go to Magnet Clutch Circuit. Refer to AT C - 8 8 , "
Magnet Clutch Circuit" .

Discharge air temperature does not change.
Go to Air Mix Door Motor Circuit. Refer to AT C - 7 6 , "
Air Mix Door Motor Circuit" .
RJIA0492E
Mode control dial position
STEP-No.
*1STEP-41 STEP-42 STEP-43 STEP-44 STEP-45 STEP-46
Mode control dial posi-
tionAUTO VENT B/LFOOT or
FOOT2D/F or D/F2 DEF
Mode door position VENT VENT B/L
FOOT
*2D/F DEF
Intake door position REC REC REC FRE FRE FRE
Air mix door position FULL COLD FULL COLD FULL COLD FULL HOT FULL HOT FULL HOT
Blower motor voltage Approx. 4.5V Approx. 10.5V Approx. 8.5V Approx. 8.5V Approx. 8.5V Approx. 12V
Compressor ON ON OFF OFF ON ON