NISSAN X-TRAIL 2003 Electronic Repair Manual

PREPARATION
ATC-13
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Recovery/Recycling
Recharging equipment (ACR4)Function:Refrigerant Recovery and
Recycling and Recharging
Electrical leak detectorPower supply:
lDC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses
(J-41459) Refrigerant dye injector
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
(J-42220)
Fluorescent dye leak detectorPower supply: DC 12V (Battery
terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system.
Includes: UV lamp and UV safety
glasses
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PA G o i l
Container: 1/4 ounce (7.4cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.) Tool number
To o l n a m eDescription
RJIA0195E
SHA705EB
SHA437F
SHA438F
SHA439F

ATC-14
PREPARATION
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
(J-43872)
Dye cleanerFor cleanig dye spills.
Manifold gauge set (with hoses
and couplers)
Identification:
lThe gauge face indicates R-134a.
Fitting size:Thread size
l1/22-16 ACME
Service hoses
lHigh side hose
lLow side hose
lUtility hose
Hose color:
lLow hose:Blue with black stripe
lHigh hose:Red with black stripe
lUtility hose:Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
l1/22-16 ACME
Service couplers
lHigh side coupler
lLow side coupler
Hose fitting to service hose:
lM14 x 1.5 fitting is optional or
permanently attached. Tool number
Tool nameDescription
SHA440F
SHA441F
RJIA0196E
S-NT201
S-NT202

PREPARATION
ATC-15
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Refrigerant weight scaleFor measuring of refrigerant
Fitting size:Thread size
l1/22-16 ACME
Vacuum pump
(Including the isolator valve)
Capacity:
lAir displacement:4 CFM
lMicron rating:20 microns
lOilcapacity:482g(17oz)
Fitting size:Thread size
l1/22-16 ACME Tool number
To o l n a m eDescription
S-NT200
S-NT203

ATC-16
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
PFP:KA990
Refrigerant CycleEJS000TD
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 (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)
Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the V-6 variable displacement compressor to
prevent freeze up.
Refrigerant System ProtectionEJS000TE
REFRIGERANT PRESSURE SENSOR (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)
The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sen-
sor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refriger-
ant 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
2,20psi).
DUAL-PRESSURE SWITCH (WITH DIESEL ENGINE: DKV-11G COMPRESSOR)
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pres-
sure switch opens to interrupt the compressor operation.
PRESSURE RELIEF VALVE (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)
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 abnormal level [more than 3,727 kPa (38 kg/

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

ATC-18
REFRIGERATION SYSTEM
The tilt of the swash plate allows the piston's stroke to change so that refrigerant discharge can be continu-
ously changed from 14.5 to 146 cm
3(0.885 to 8.91 cu in).
Operation
1. Operation Control Valve
Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response
to changes in refrigerant suction pressure.
Operation of the valve controls the internal pressure of the crankcase.
The angle of the swash plate is controlled between the crankcase's internal pressure and the piston cylin-
der pressure.
2. Maximum Cooling
Refrigerant pressure on the low-pressure side increases with an increase in heat loads.
When this occurs, the control valve's bellows compress to open the low-pressure side valve and close the
high-pressure side valve.
This causes the following pressure changes:
RHA037DD

REFRIGERATION SYSTEM
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lThe crankcase's internal pressure to equal the pressure on the low-pressure side;
lThe cylinder's internal pressure to be greater than the crankcase's internal pressure.
Under this condition, the swash plate is set to the maximum stroke position.
3. Capacity Control
lRefrigerant pressure on suction side is low during high speed driving or when ambient or interior tem
perature is low.
lThe bellows expands when refrigerant pressure on the suction pressure side drops below approxi
mately 177 kPa (1.8 kg/cm
2,26psi).
Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crank-
case pressure becomes high as high pressure enters the crankcase.
lThe force acts around the journal pin near the swash plate, and is generated by the pressure difference
before and behind the piston.
The drive lug and journal pin are located where the piston generates the highest pressure. Piston pres-
sure 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 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 swash plate.
RHA473C
RHA474C

ATC-20
REFRIGERATION SYSTEM
Component Layout
EJS000TG
RJIA0479E

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

ATC-22
LUBRICANT
4.CHECK ANY PART
Is there any part to be replaced? (Evaporator, condenser,liquid tank or in case there is evidence of a large
amount of lubricant leakage.)
Ye s o r N o
Ye s > > G o t oAT C - 2 2 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR".
No >> Carry out the A/C performance test.
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.
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
4. Drain the lubricant from the new compressor into a separate, clean container.
5. 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.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 ml [Litre] (0.2 Imp fl oz) of lubricant at this
time.
Do not add this 5 ml (0.2 Imp fl oz) of lubricant if only replacing the compressor.
Part replacedLubricant to be added to system
Remarks
Amount of lubricant
ml [Litre] (Imp fl oz)
Evaporator 75 (2.6) -
Condenser 35 (1.2) -
Liquid tank 10 (0.4) -
In case of refrigerant leak30 (1.1) Large leak
- Small leak *1