evaporator INFINITI FX35 2004 Service Manual

ATC-3
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2004 November 2004 FX35/FX45COMPONENT INSPECTION ............................. 112
Intake Sensor Circuit ............................................. 113
COMPONENT DESCRIPTION .......................... 113
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ................................................................... 113
COMPONENT INSPECTION ............................. 114
CONTROLLER ........................................................115
Removal and Installation of A/C and AV Switch .... 115
REMOVAL .......................................................... 115
INSTALLATION .................................................. 115
AUTO AMP ..............................................................116
Removal and Installation of Unified Meter and A/C
Amp. ...................................................................... 116
REMOVAL .......................................................... 116
INSTALLATION .................................................. 116
AMBIENT SENSOR .................................................117
Removal and Installation ....................................... 117
REMOVAL .......................................................... 117
INSTALLATION .................................................. 117
IN-VEHICLE SENSOR .............................................118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
SUNLOAD SENSOR ...............................................119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION .................................................. 119
INTAKE SENSOR ................................................... 120
Removal and Installation ...................................... 120
REMOVAL ......................................................... 120
INSTALLATION ................................................. 120
BLOWER UNIT ....................................................... 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 121
Disassembly and Assembly ................................. 122
BLOWER MOTOR .................................................. 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSTALLATION ................................................. 123
INTAKE DOOR MOTOR ......................................... 124
Removal and Installation ...................................... 124
REMOVAL ......................................................... 124
INSTALLATION ................................................. 124
IN-CABIN MICROFILTER ....................................... 125
Removal and Installation ...................................... 125
FUNCTION ........................................................ 125
REPLACEMENT TIMING .................................. 125
REPLACEMENT PROCEDURES ..................... 125
HEATER & COOLING UNIT ASSEMBLY .............. 126
Removal and Installation ...................................... 126
REMOVAL ......................................................... 126
INSTALLATION ................................................. 127
Disassembly and Assembly ................................. 128
MODE DOOR MOTOR ........................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130AIR MIX DOOR MOTOR .........................................131
Removal and Installation ......................................131
REMOVAL .........................................................131
INSTALLATION .................................................131
HEATER CORE .......................................................132
Removal and Installation ......................................132
REMOVAL .........................................................132
INSTALLATION .................................................132
DUCTS AND GRILLES ...........................................133
Removal and Installation ......................................133
REMOVAL .........................................................133
INSTALLATION .................................................136
REFRIGERANT LINES ...........................................137
HFC-134a (R-134a) Service Procedure ...............137
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................137
Components .........................................................139
VK45DE .............................................................139
VQ35DE ............................................................140
Removal and Installation of Compressor ..............140
REMOVAL .........................................................140
INSTALLATION .................................................142
Removal and Installation of Compressor Clutch ..143
REMOVAL .........................................................143
INSTALLATION .................................................145
Removal and Installation of Low-pressure Flexible
Hose .....................................................................147
REMOVAL .........................................................147
INSTALLATION .................................................148
Removal and Installation of High-pressure Flexible
Hose .....................................................................148
REMOVAL .........................................................148
INSTALLATION .................................................149
Removal and Installation of Low-pressure Pipe 1
(Engine Compartment) .........................................149
REMOVAL .........................................................149
INSTALLATION .................................................150
Removal and Installation of High-pressure Pipe 1
and 2 (Engine Compartment) ...............................150
REMOVAL .........................................................150
INSTALLATION .................................................151
Removal and Installation of Low-pressure Pipe 2
and High-pressure Pipe 3 .....................................151
REMOVAL .........................................................151
INSTALLATION .................................................152
Removal and Installation of Liquid Tank ...............153
REMOVAL .........................................................153
INSTALLATION .................................................153
Removal and Installation of Condenser ................154
REMOVAL .........................................................154
INSTALLATION .................................................154
Removal and Installation of Refrigerant Pressure
Sensor ..................................................................155
REMOVAL .........................................................155
INSTALLATION .................................................155
Removal and Installation of Evaporator ................155
REMOVAL .........................................................155
INSTALLATION .................................................155
Removal and Installation of Expansion Valve .......156

ATC-8
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
Precautions for Refrigerant ConnectionAJS0013Y
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.

Expansion valve to evaporator

Refrigerant pressure sensor to condenser
ABOUT ONE-TOUCH JOINT
Description

One-touch joints are pipe joints which do not require tools during piping connection.

Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at
connection point is not necessary.

When removing a pipe joint, use a disconnector.
COMPONENT PARTS
FUNCTIONS OF COMPONENT PARTS
NOTE:

Garter spring cannot be removed from cage of male-side piping.

Indicator ring remains near piping connection point, however, this is not a malfunction. (This is to check
piping connection during factory assembly.)
Pipe (Male side)
Retains O-rings.

Retains garter spring in cage.
Garter spring Anchors female side piping.
Indicator ringWhen connection is made properly, this is ejected from male-side piping. (This part is no longer neces-
sary after connection.)
O-ring Seals connection point. (Not reusable)
Pipe (Female side)

Seals connection by compressing O-rings.

Anchors piping connection using flare and garter spring.
RJIA0970E

ATC-12
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-Ring Part Numbers and Specifications
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.

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

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

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

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

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

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

Always replace used O-rings.

When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0

O-ring must be closely attached to dented portion of tube.

When replacing the O-ring, be careful not to damage O-ring and tube.

Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
Connection type Piping connection point Part number QTY O-ring size
NewLow-pressure pipe 1 to low-pressure pipe 2 (One-touch joint) 92473 N8221 2 16
Low-pressure pipe 2 to expansion valve 92473 N8210 1 16
High-pressure pipe 1 to high-pressure pipe 2 (One-touch joint) 92471 N8221 2 8
High-pressure pipe 3 to expansion valve 92471 N8210 1 8
High-pressure pipe 2 to high-pressure pipe 3 (One-touch joint) 92471 N8221 2 8
Condenser to high-pressure flexible hose (One-touch joint) 92472 N8221 2 12
Condenser to high-pressure pipe 1 (One-touch joint) 92471 N8221 2 8
Low-pressure flexible hose to low-pressure pipe 1 (One-touch
joint)92473 N8221 2 16
Compressor to low-pressure flexible hose 92474 N8210 1 19
Compressor to high-pressure flexible hose 92472 N8210 1 12
Liquid tank to condenser pipeInlet
92471 N82101
8
Outlet 1
FormerRefrigerant pressure sensor to condenser J2476 89956 1 10
Expansion valve to evaporatorInlet 92475 71L00 1 12
Outlet 92475 72L00 1 16

REFRIGERATION SYSTEM
ATC-21
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2004 November 2004 FX35/FX45
REFRIGERATION SYSTEMPFP:KA990
Refrigerant CycleAJS00146
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up.
Refrigerant System ProtectionAJS00147
REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high- or low-pressure by the refrigerant pressure sen-
sor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrig-
erant 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/cm
2 , 398 psi), or below about 134 kPa
(1.4 kg/cm
2 , 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/cm
2
, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the
atmosphere.
RJIA0849E

ATC-22
REFRIGERATION SYSTEM
Revision: 2004 November 2004 FX35/FX45
V-6 Variable Displacement CompressorAJS001BE
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.

ATC-28
LUBRICANT
Revision: 2004 November 2004 FX35/FX45
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-
PRESSOR
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
*1: If refrigerant leak is small, no addition of lubricant is needed.Part replacedLubricant to be added to system
Remarks
Amount of lubricant
m (US fl oz., Imp fl oz.)
Evaporator 75 (2.5, 2.6) -
Condenser 35 (1.2, 1.2) -
Liquid tank 10 (0.3, 0.4) -
In case of refrigerant leak30 (1.0, 1.1) Large leak
- Small leak *1

ATC-96
TROUBLE DIAGNOSIS
Revision: 2004 November 2004 FX35/FX45
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 tempera-
ture-to-operating pressure table).
Both High- and Low-pressure Sides are Too High
High-pressure Side is Too High and Low-pressure Side is Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure sides
are too high.Pressure is reduced soon
after water is splashed on
condenser.Excessive refrigerant charge
in refrigeration cycleReduce refrigerant until speci-
fied pressure is obtained.
Air suction by cooling fan is
insufficient.Insufficient condenser cooling
performance
↓
1. Condenser fins are clogged.
2. Improper fan rotation of
cooling fan

Clean condenser.

Check and repair cooling fan
as necessary.

Low-pressure pipe is not
cold.

When compressor is
stopped high-pressure
value quickly drops by
approximately 196 kPa (2
kg/cm
2 , 28 psi). It then
decreases gradually there-
after.Poor heat exchange in con-
denser
(After compressor operation
stops, high-pressure
decreases too slowly.)
↓
Air in refrigeration cycleEvacuate repeatedly and
recharge system.
Engine tends to overheat.Engine cooling systems mal-
function.Check and repair each engine
cooling system.

An area of the low-pres-
sure pipe is colder than
areas near the evaporator
outlet.

Plates are sometimes cov-
ered with frost.

Excessive liquid refrigerant
on low-pressure side

Excessive refrigerant dis-
charge flow

Expansion valve is open a
little compared with the
specification.
↓
Improper expansion valve
adjustmentReplace expansion valve.
AC359A
Gauge indication Refrigerant cycle Probable cause Corrective action
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 contami-
nation.
AC360A

TROUBLE DIAGNOSIS
ATC-97
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2004 November 2004 FX35/FX45
High-pressure Side is Too Low and Low-pressure Side is Too High
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low and
low-pressure side is too high.High- and low-pressure sides
become equal soon after com-
pressor operation stops.Compressor pressure opera-
tion is improper.
↓
Damaged inside compressor
packingsReplace compressor.
No temperature difference
between high- and low-pres-
sure sidesCompressor pressure opera-
tion is improper.
↓
Damaged inside compressor
packings.Replace compressor.
AC356A
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure sides
are too low.

There is a big temperature
difference between receiver
drier outlet and inlet. Outlet
temperature is extremely
low.

Liquid tank inlet and expan-
sion valve are frosted.Liquid tank inside is slightly
clogged.

Replace liquid tank.

Check lubricant for contami-
nation.

Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank.

Expansion valve inlet may
be frosted.

Temperature difference
occurs somewhere in high-
pressure side.High-pressure pipe located
between receiver drier and
expansion valve is clogged.

Check and repair malfunc-
tioning parts.

Check lubricant for contami-
nation.
Expansion valve and liquid
tank are warm or only cool
when touched.Low refrigerant charge
↓
Leaking fittings or componentsCheck refrigerant for leaks.
Refer to ATC-157, "
Checking
for Refrigerant Leaks" .
There is a big temperature dif-
ference between expansion
valve inlet and outlet while the
valve itself is frosted.Expansion valve closes a little
compared with the specifica-
tion.
↓
1. Improper expansion valve
adjustment
2. Malfunctioning expansion
valve
3. Outlet and inlet may be
clogged.

Remove foreign particles by
using compressed air.

Check lubricant for contami-
nation.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.Low-pressure pipe is clogged
or crushed.

Check and repair malfunc-
tioning parts.

Check lubricant for contami-
nation.
Air flow volume is not enough
or is too low.Evaporator is frozen.

Check intake sensor circuit.
Refer to AT C - 11 3 , "
Intake
Sensor Circuit" .

Replace compressor.
AC353A

TROUBLE DIAGNOSIS
ATC-113
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2004 November 2004 FX35/FX45
Intake Sensor CircuitAJS00157
COMPONENT DESCRIPTION
Intake Sensor
The intake sensor is located on the heater & cooling unit. It converts
temperature of air after it passes through the evaporator into a resis-
tance value which is then input to the unified meter and A/C amp.
DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR
SYMPTOM: Intake sensor circuit is open or shorted. (24 or −24 is
indicated on unified meter and A/C amp. as a result of performing
Self-diagnosis STEP-2.)
1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND
1. Disconnect intake sensor connector.
2. Turn ignition switch ON.
3. Check voltage between intake sensor harness connector M254
terminal 2 (R) and ground.
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between intake sensor harness connector
M254 terminal 1 (W) and unified meter and A/C amp. harness
connector M57 terminal 49 (W/G).
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector.
RJIA0928E
RJIA1458E
2 – Ground : Approx. 5V
RJIA2031E
1 – 49 : Continuity should exist.
RJIA2032E

ATC-120
INTAKE SENSOR
Revision: 2004 November 2004 FX35/FX45
INTAKE SENSORPFP:27723
Removal and InstallationAJS0015D
REMOVAL
1. Set the temperature at 18°C (60°F), and then disconnect the battery negative cable.
2. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
3. Remove the mounting bolt, and then remove the low-pressure pipe 2 and high-pressure pipe 3. Refer to
ATC-151, "
Removal and Installation of Low-pressure Pipe 2 and High-pressure Pipe 3" .
CAUTION:
Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere.
4. Slide the evaporator to passenger side, and then remove the
intake sensor.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace O-rings for A/C piping with new ones. Before installing, apply compressor oil to them.

Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.

Insert one-touch joint connection point securely until it clicks.

After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.

When recharging refrigerant, check for leaks.
RJIA0928E