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MTC


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J AIR CONDITIONER

                                                                                                                                                                    A


                                                                                                                                                                    B
                                                                               SECTION
                                                                      MANUAL AIR CONDITIONER                                                                        C


                                                                                                                                                                    D


                                                                                                                                                                    E
                                                               CONTENTS
PRECAUTIONS ......................................................... 4
                                                                     .         AIR CONDITIONER CONTROL .............................. 21                   .        F
 Precautions for Supplemental Restraint System                                  Description ............................................................. 21
                                                                                                                                                           .
 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                        Operation ............................................................... 21
                                                                                                                                                           .
 SIONER" ................................................................. 4
                                                                     .            AIR MIX DOOR CONTROL ................................ 21                 .        G
 Precautions for Working with HFC-134a (R-134a) 4                    .....        BLOWER SPEED CONTROL ............................ 21                     .
 Contaminated Refrigerant ....................................... 4  .            INTAKE DOORS CONTROL .............................. 21                   .
 General Refrigerant Precautions ............................. 5     .            MODE DOOR CONTROL .................................. 21                  .
                                                                                                                                                                    H
 Precautions for Leak Detection Dye ........................ 5       .            DEFROSTER DOOR CONTROL ....................... 21                        .
 A/C Identification Label ........................................... 6
                                                                     .            MAGNET CLUTCH CONTROL .......................... 21                      .
 Precautions for Refrigerant Connection .................. 6         .          Description of Control System ............................... 23           .
   FEATURES OF NEW TYPE REFRIGERANT                                             Control Operation .................................................. 24    .         I
   CONNECTION ..................................................... 6.            TEMPERATURE CONTROL DIAL (TEMPERA-
   O-RING AND REFRIGERANT CONNECTION..... 7                                       TURE CONTROL) .............................................. 24          .
 Precautions for Servicing Compressor .................... 9         .            RECIRCULATION () SWITCH ............................ 24                  .        MTC
 Precautions for Service Equipment ......................... 9       .            DEFROSTER SWITCH ...................................... 24               .
   RECOVERY/RECYCLING EQUIPMENT ............. 9                      .            REAR WINDOW DEFOGGER SWITCH ............ 24                              .
   ELECTRONIC LEAK DETECTOR ....................... 9                .            OFF SWITCH (BLOWER SPEED SET TO 0) .... 24                               .
                                                                                                                                                                    K
   VACUUM PUMP ................................................ 10   .            A/C SWITCH ...................................................... 24     .
   MANIFOLD GAUGE SET ................................... 10         .            MODE DIAL ........................................................ 24    .
   SERVICE HOSES .............................................. 10   .            BLOWER CONTROL DIAL ................................ 24                  .
   SERVICE COUPLERS ........................................11       .          Discharge Air Flow ................................................ 25     .        L
   REFRIGERANT WEIGHT SCALE ......................11                 .             ........................................................................... 25
                                                                                                                                                           .
   CHARGING CYLINDER ......................................11        .          System Description ................................................ 26     .
 Wiring Diagrams and Trouble Diagnosis ................11            .            SWITCHES AND THEIR CONTROL FUNCTION 26                                   ...      M
PREPARATION ........................................................ 12
                                                                     .         TROUBLE DIAGNOSIS ........................................... 27            .
 Special Service Tools ............................................ 12
                                                                     .          CONSULT-II Function (BCM) ................................ 27              .
 HFC-134a (R-134a) Service Tools and Equipment 12                    ...          CONSULT-II BASIC OPERATION ...................... 27                     .
 Commercial Service Tools ..................................... 15   .            DATA MONITOR ................................................ 28         .
REFRIGERATION SYSTEM .................................... 16         .          How to Perform Trouble Diagnosis for Quick and
 Refrigerant Cycle .................................................. 16
                                                                     .          Accurate Repair ..................................................... 29   .
   REFRIGERANT FLOW ...................................... 16        .            WORK FLOW ..................................................... 29       .
   FREEZE PROTECTION .................................... 16         .            SYMPTOM TABLE ............................................. 29           .
 Refrigerant System Protection .............................. 16     .          Component Parts and Harness Connector Location 30                          ...
   REFRIGERANT PRESSURE SENSOR ............ 16                       .            ENGINE COMPARTMENT ................................. 30                  .
   PRESSURE RELIEF VALVE .............................. 16           .            FRONT PASSENGER COMPARTMENT ........... 31                               .
 Component Layout ................................................ 17.          Schematic .............................................................. 32.
LUBRICANT ............................................................ 19
                                                                     .          Wiring Diagram -- A/C,M -- .................................. 33           .
 Maintenance of Lubricant Quantity in Compressor 19                  ...        Front Air Control Terminals and Reference Value... 36
   LUBRICANT ....................................................... 19
                                                                     .            PIN CONNECTOR TERMINAL LAYOUT ........... 36                             .
   CHECKING AND ADJUSTING .......................... 19              .            TERMINALS AND REFERENCE VALUE FOR


Revision: February 2006                                                 MTC-1                                                                   2005 Xterra
   FRONT AIR CONTROL ...................................... 36               .        CONTROL UNIT .......................................................79  .
 Operational Check ................................................. 38      .          Removal and Installation ........................................79   .
   CHECKING BLOWER ........................................ 38               .            FRONT AIR CONTROL ......................................79          .
   CHECKING DISCHARGE AIR ........................... 38                     .        INTAKE SENSOR .....................................................80   .
   DISCHARGE AIR FLOW .................................... 38                .          Removal and Installation ........................................80   .
   CHECKING TEMPERATURE DECREASE ........ 39                                 .            REMOVAL ...........................................................80
                                                                                                                                                              .
   CHECKING TEMPERATURE INCREASE ......... 39                                .            INSTALLATION ...................................................80  .
   CHECK A/C SWITCH ......................................... 39             .        BLOWER MOTOR ....................................................81     .
 Power Supply and Ground Circuit for Front Air Con-                                     Components ...........................................................81
                                                                                                                                                              .
 trol .......................................................................... 40
                                                                             .          Removal and Installation ........................................81   .
   INSPECTION FLOW .......................................... 40             .            REMOVAL ...........................................................81
                                                                                                                                                              .
   COMPONENT DESCRIPTION ........................... 41                      .            INSTALLATION ...................................................81  .
   DIAGNOSTIC PROCEDURE FOR A/C SYSTEM 41                                    ...      IN-CABIN MICROFILTER .........................................82        .
 Mode Door Motor Circuit ....................................... 43          .          Removal and Installation ........................................82   .
   INSPECTION FLOW .......................................... 43             .            FUNCTION .........................................................82.
   SYSTEM DESCRIPTION ................................... 43                 .            REPLACEMENT TIMING ...................................82            .
   COMPONENT DESCRIPTION ........................... 44                      .            REPLACEMENT PROCEDURE .........................82                   .
   DIAGNOSTIC PROCEDURE FOR MODE                                                      HEATER & COOLING UNIT ASSEMBLY ................84                       .
   DOOR MOTOR .................................................. 45          .          Components ...........................................................84
                                                                                                                                                              .
 Air Mix Door Motor (Front) Circuit .......................... 47            .          Removal and Installation ........................................84   .
   INSPECTION FLOW .......................................... 47             .            REMOVAL ...........................................................84
                                                                                                                                                              .
   SYSTEM DESCRIPTION ................................... 48                 .            INSTALLATION ...................................................85  .
   COMPONENT DESCRIPTION ........................... 48                      .        HEATER CORE ........................................................86  .
   DIAGNOSTIC PROCEDURE FOR AIR MIX                                                     Components ...........................................................86
                                                                                                                                                              .
   DOOR MOTOR (FRONT) ................................... 49                 .          Removal and Installation ........................................86   .
 Intake Door Motor Circuit ....................................... 51        .            REMOVAL ...........................................................86
                                                                                                                                                              .
   INSPECTION FLOW .......................................... 51             .            INSTALLATION ...................................................86  .
   SYSTEM DESCRIPTION ................................... 52                 .        INTAKE DOOR MOTOR ...........................................87         .
   COMPONENT DESCRIPTION ........................... 52                      .          Removal and Installation ........................................87   .
   DIAGNOSTIC PROCEDURE FOR INTAKE                                                        REMOVAL ...........................................................87
                                                                                                                                                              .
   DOOR MOTOR .................................................. 53          .            INSTALLATION ...................................................87  .
 Front Blower Motor Circuit ..................................... 55         .        MODE DOOR MOTOR .............................................88         .
   INSPECTION FLOW .......................................... 55             .          Removal and Installation ........................................88   .
   SYSTEM DESCRIPTION ................................... 56                 .            REMOVAL ...........................................................88
                                                                                                                                                              .
   COMPONENT DESCRIPTION ........................... 56                      .            INSTALLATION ...................................................88  .
   DIAGNOSTIC PROCEDURE FOR BLOWER                                                    AIR MIX DOOR MOTOR ..........................................89         .
   MOTOR .............................................................. 57   .          Components ...........................................................89
                                                                                                                                                              .
   COMPONENT INSPECTION ............................. 61                     .          Removal and Installation ........................................89   .
 Magnet Clutch Circuit ............................................ 63       .            REMOVAL ...........................................................89
                                                                                                                                                              .
   INSPECTION FLOW .......................................... 63             .            INSTALLATION ...................................................89  .
   SYSTEM DESCRIPTION ................................... 64                 .        FRONT BLOWER MOTOR RESISTOR ...................90                       .
   DIAGNOSTIC PROCEDURE FOR MAGNET                                                      Removal and Installation ........................................90   .
   CLUTCH ............................................................. 64   .            REMOVAL ...........................................................90
                                                                                                                                                              .
 Insufficient Cooling ................................................ 68    .            INSTALLATION ...................................................90  .
   INSPECTION FLOW .......................................... 68             .        DUCTS AND GRILLES ............................................91        .
   PERFORMANCE TEST DIAGNOSES ............... 69                             .          Components ...........................................................91
                                                                                                                                                              .
   PERFORMANCE CHART .................................. 71                   .          Removal and Installation ........................................92   .
   TROUBLE DIAGNOSES FOR UNUSUAL PRES-                                                    DEFROSTER NOZZLE .......................................92          .
   SURE .................................................................. 72.            RH AND LH SIDE DEMISTER DUCTS ..............93                      .
 Insufficient Heating ................................................ 75    .            RH AND LH VENTILATOR DUCTS ....................93                   .
   INSPECTION FLOW .......................................... 75             .            CENTER VENTILATOR DUCT ...........................93                .
 Noise ..................................................................... 76
                                                                             .            FLOOR CONNECTOR DUCT ............................93                 .
   INSPECTION FLOW .......................................... 76             .            FRONT AND REAR FLOOR DUCTS .................93                      .
 Intake Sensor Circuit ............................................. 77      .            GRILLES .............................................................93
                                                                                                                                                              .
   COMPONENT DESCRIPTION ........................... 77                      .        REFRIGERANT LINES ............................................94        .
   DIAGNOSTIC PROCEDURE FOR INTAKE SEN-                                                 HFC-134a (R-134a) Service Procedure .................94               .
   SOR .................................................................... 77
                                                                             .            SETTING OF SERVICE TOOLS AND EQUIP-
   COMPONENT INSPECTION ............................. 78                     .            MENT ..................................................................94
                                                                                                                                                              .
                                                                                        Components ...........................................................96
                                                                                                                                                              .

Revision: February 2006                                                        MTC-2                                                               2005 Xterra
  Removal and Installation for Compressor ............. 97                 .          REMOVAL ........................................................ 102
                                                                                                                                                         .
    COMPONENTS ................................................. 97        .          INSTALLATION ................................................ 102  .       A
    REMOVAL .......................................................... 97  .        Removal and Installation for Condenser ............. 102             .
    INSTALLATION .................................................. 97     .          REMOVAL ........................................................ 102
                                                                                                                                                         .
  Removal and Installation for Compressor Clutch ... 98                               INSTALLATION ................................................ 103  .       B
    REMOVAL .......................................................... 98  .        Removal and Installation for Evaporator ............. 104            .
    INSPECTION ..................................................... 99    .          REMOVAL ........................................................ 105
                                                                                                                                                         .
    INSTALLATION .................................................. 99     .          INSTALLATION ................................................ 105  .
    BREAK-IN OPERATION .................................. 101              .        Removal and Installation for Expansion Valve ..... 105               .       C
  Removal and Installation for High-pressure Flexible                                 REMOVAL ........................................................ 105
                                                                                                                                                         .
  A/C Hose ............................................................. 101
                                                                           .          INSTALLATION ................................................ 105  .
    REMOVAL ........................................................ 101   .        Checking for Refrigerant Leaks ........................... 105       .       D
    INSTALLATION ................................................ 101      .        Checking System for Leaks Using the Fluorescent
  Removal and Installation for High-pressure A/C                                    Dye Leak Detector ............................................... 105.
  Pipe ..................................................................... 101
                                                                           .        Dye Injection ........................................................ 106
                                                                                                                                                         .       E
    REMOVAL ........................................................ 101   .        Electronic Refrigerant Leak Detector ................... 106         .
    INSTALLATION ................................................ 101      .          PRECAUTIONS FOR HANDLING LEAK
  Removal and Installation for Low-pressure Flexible                                  DETECTOR ...................................................... 106.
  A/C Hose ............................................................. 101
                                                                           .          CHECKING PROCEDURE .............................. 107              .       F
    REMOVAL ........................................................ 101   .       SERVICE DATA AND SPECIFICATIONS (SDS) ... 109                         .
    INSTALLATION ................................................ 101      .        Service Data and Specifications (SDS) ............... 109            .
  Removal and Installation for Low-pressure A/C Pipe 102                   .          COMPRESSOR ............................................... 109     .       G
    REMOVAL ........................................................ 102   .          LUBRICANT ..................................................... 109.
    INSTALLATION ................................................ 102      .          REFRIGERANT ................................................ 109   .
  Removal and Installation for Refrigerant Pressure                                   ENGINE IDLING SPEED ................................. 109          .       H
  Sensor ................................................................. 102
                                                                           .          BELT TENSION ................................................ 109  .


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Revision: February 2006                                                     MTC-3                                                             2005 Xterra
                                              PRECAUTIONS

PRECAUTIONS                                                         PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER"                                                                                           EJS0043X


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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
G    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 per-
     formed by an authorized NISSAN/INFINITI dealer.
G    Improper 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.
G    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)                                                                EJS0043Y


WARNING:
G CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
  are mixed compressor failure is likely to occur. Refer to MTC-4, "Contaminated Refrigerant" . To
  determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant
  Recovery/Recycling Recharging equipment and Refrigerant Identifier.
G Use 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.
G The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
  lowing handling precautions must be observed:



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