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Shop manual ô tô NISSAN 2000 Xterra CONTENTS FRONT AXLE 2 Precautions 2 PRECAUTIONS .2 Preparation 2 SPECIAL SERVICE TOOLS 2 COMMERCIAL SERVICE TOOLS 2
HEATER &AIR CONDITIONERSECTIONHACONTENTSPRECAUTIONS .2Supplemental Restraint System (SRS) ″AIRBAG″ and ″SEAT BELT PRE-TENSIONER″ .2Precautions for Working with HFC-134a (R-134a) .3Contaminated Refrigerant 3General Refrigerant Precautions .3Precautions for Refrigerant Connection 4Precautions for Servicing Compressor 6Precautions for Service Equipment .7Wiring Diagrams and Trouble Diagnosis .9PREPARATION .10Special Service Tools 10HFC-134a (R-134a) Service Tools andEquipment 11Commercial Service Tool .13DESCRIPTION .14Refrigeration System .14Control Operation 15Discharge Air Flow .16Component Layout 17TROUBLE DIAGNOSES 19Component Location 19Circuit Diagram - Air Conditioner- .22Wiring Diagram - A/C - 23How to Perform Trouble Diagnoses for Quickand Accurate Repair 26Symptom Table 26Operational Check .27Blower Motor 29Mode Door .36Intake Door Motor 38Magnet Clutch 39Insufficient Cooling 50Insufficient Heating 58Noise 60SERVICE PROCEDURE 61HFC-134a (R-134a) Service Procedure 61Maintenance of Lubricant Quantity inCompressor .63Compressor .67Magnet Clutch 69Thermal Protector 73Refrigerant Lines .74Belt .78Fast Idle Control Device (FICD) 79Heater Core .79Evaporator Core 80SERVICE DATA AND SPECIFICATIONS (SDS) .81Manual .81GIMAEMLCECFECLMTATTFPDAXSUBRSTRSBTSCELIDX Supplemental Restraint System (SRS) “AIRBAG” and “SEAT BELT PRE-TENSIONER”NGHA0060The supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along witha seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types ofcollision. The Supplemental Restraint System consists of driver air bag module (located in the center of thesteering wheel), front passenger air bag module (located on the instrument panel on passenger side), seatbelt pre-tensioners, a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring har-ness and spiral cable.Information necessary to service the system safely is included in the RS section of this Service Manual.WARNING:¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or deathin the event of a collision which would result in air bag inflation, all maintenance must be performedby an authorized NISSAN dealer.¼ 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 AirBag Module, refer to RS-16.¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) cov-ered with yellow insulation either just before the harness connectors or for the complete harnessare related to the SRS.PRECAUTIONSSupplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”HA-2 Precautions for Working with HFC-134a(R-134a)=NGHA0061WARNING:¼ CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerantsare mixed, compressor failure is likely to occur, refer to “Contaminated Refrigerant”. To determinethe purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500–NI) and Refrigerant Identifier.¼ 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.¼ The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-lowing handling precautions must be observed:a) When removing refrigerant components from a vehicle, immediately cap (seal) the component tominimize the entry of moisture from the atmosphere.b) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until justbefore connecting the components. Connect all refrigerant loop components as quickly as pos-sible to minimize the entry of moisture into system.c) 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.d) Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, noseand throat. Remove R-134a from the A/C system, using certified service equipment meetingrequirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment).If accidental system discharge occurs, ventilate work area before resuming service. Additionalhealth and safety information may be obtained from refrigerant and lubricant manufacturers.e) Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.Damage may result.Contaminated RefrigerantNGHA0267If a refrigerant other than pure R-134a is identified in a vehicle, your options are:¼ Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant intothe atmosphere.¼ Explain that recovery of the contaminated refrigerant could damage your service equipment and refriger-ant supply.¼ Suggest the customer return the vehicle to the location of previous service where the contamination mayhave occurred.¼ If you choose to perform the repair, recover the refrigerant using only dedicated equipment and contain-ers. Do not recover contaminated refrigerant into your existing service equipment. If your facilitydoes not have dedicated recovery equipment, you may contact a local refrigerant product retailer foravailable service. This refrigerant must be disposed of in accordance with all federal and local regulations.In addition, replacement of all refrigerant system components on the vehicle is recommended.¼ If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NissanCustomer Affairs for further assistance.General Refrigerant PrecautionsNGHA0062WARNING:¼ Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture therefrigerant every time an air conditioning system is discharged.¼ Always wear eye and hand protection (goggles and gloves) when working with any refrigerant orair conditioning system.¼ Do not store or heat refrigerant containers above 52°C (125°F).¼ Do not heat a refrigerant container with an open flame; if container warming is required, place thebottom of the container in a warm pail of water.¼ Do not intentionally drop, puncture, or incinerate refrigerant containers.¼ Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.¼ Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to preventsuffocation.¼ Do 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 beenGIMAEMLCECFECLMTATTFPDAXSUBRSTRSBTSCELIDXPRECAUTIONSPrecautions for Working with HFC-134a (R-134a)HA-3 shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury orproperty damage. Additional health and safety information may be obtained from refrigerant manu-facturers.Precautions for Refrigerant ConnectionNGHA0063A new type refrigerant connection has been introduced to all refrigerant lines except the following portion.¼ Front evaporator core connections.FEATURES OF NEW TYPE REFRIGERANT CONNECTIONNGHA0063S01¼ The O-ring is relocated in a groove for proper installation. This eliminates the chance of the O-ring beingcaught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in rela-tion to the contacting surface of the mating part to improve sealing characteristics.¼ The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, therebyfacilitating piping connections.AHA534APRECAUTIONSPrecautions for Refrigerant ConnectionHA-4 O-RING AND REFRIGERANT CONNECTION=NGHA0063S02LHA239CAUTION:Refrigerant connections in some systems use different O-ring configurations. Do not confuse O-ringssince they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around,the connection.O-Ring Part Numbers and SpecificationsNGHA0063S0201Connec-tion typeO-ringsizePart number D mm (in) W mm (in)SHA814ENew892471 N8210 6.8 (0.268) 1.85 (0.0728)Former 92470 N8200 6.07 (0.23990) 1.78 (0.0701)New1292472 N8210 10.9 (0.429) 2.43 (0.0957)Former 92475 71L00 11.0 (0.433) 2.4 (0.094)New 16 92473 N8210 13.6 (0.535) 2.43 (0.0957)New 19 92474 N8210 16.5 (0.650) 2.43 (0.0957)*: Always check with the Parts Department for the latest parts information.WARNING:Make sure all refrigerant is discharged into the recycling equipment and the pressure in the systemis less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and removeit.CAUTION:When replacing or cleaning refrigerant cycle components, observe the following.¼ When 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.¼ When connecting tubes, always use a torque wrench and a back-up wrench.¼ After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.¼ 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 forconnection.¼ Allow components stored in cool areas to warm to working area temperature before removing sealGIMAEMLCECFECLMTATTFPDAXSUBRSTRSBTSCELIDXPRECAUTIONSPrecautions for Refrigerant Connection (Cont’d)HA-5 caps. This prevents condensation from forming inside A/C components.¼ Thoroughly remove moisture from the refrigeration system before charging the refrigerant.¼ Always replace used O-rings.¼ When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful notto apply lubricant to threaded portion.Lubricant name: Nissan A/C System Lubricant Type RPart number: KLH00-PAGR1¼ O-ring must be closely attached to inflated portion of tube.¼ After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.¼ After connecting line, conduct leak test and make sure that there is no leakage. When the gasleaking point is found, disconnect that line and replace the O-ring. Then tighten connections of sealseat to the specified torque.AHA514APrecautions for Servicing CompressorNGHA0064¼ Plug all openings to prevent moisture and foreign matter from entering.¼ Do not keep the compressor in the upside down position or laid on its side for more than 10 min-utes.¼ When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-sor” exactly. Refer to HA-63.¼ Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, withlubricant, wipe it off by using a clean waste cloth moistened with thinner.¼ After compressor service operation, turn the compressor shaft by hand more than five turns inboth directions. This will equally distribute lubricant inside the compressor. After the compressoris installed, let the engine idle and operate the compressor for one hour.¼ After replacing the compressor magnet clutch, apply voltage to the new one and check for normaloperation.PRECAUTIONSPrecautions for Refrigerant Connection (Cont’d)HA-6 Precautions for Service EquipmentNGHA0065RECOVERY/RECYCLING EQUIPMENTNGHA0065S01Follow the manufacturer’s instructions for machine operation andmachine maintenance. Never introduce any refrigerant other thanthat specified into the machine.ELECTRONIC LEAK DETECTORNGHA0065S02Follow the manufacture’s instructions for tester operation andtester maintenance.AHA559AVACUUM PUMPNGHA0065S03The lubricant contained inside the vacuum pump is not compatiblewith the specified lubricant for HFC-134a (R-134a) A/C systems.The vent side of the vacuum pump is exposed to atmosphericpressure. So the vacuum pump lubricant may migrate out of thepump into the service hose. This is possible when the pump isswitched off after evacuation (vacuuming) and hose is connectedto it.To prevent this migration, use a manual valve situated near thehose-to-pump connection, as follows.¼ Usually vacuum pumps have a manual isolator valve as partof the pump. Close this valve to isolate the service hose fromthe pump.¼ For pumps without an isolator, use a hose equipped with amanual shut-off valve near the pump end. Close the valve toisolate the hose from the pump.¼ If the hose has an automatic shut off valve, disconnect thehose from the pump: when the hose is connected, the valve isopen and lubricating oil may migrate.Some one-way valves open when vacuum is applied and closeunder a no vacuum condition. Such valves may restrict the pump’sability to pull a deep vacuum and are not recommended.SHA533DMANIFOLD GAUGE SETNGHA0065S04Be certain that the gauge face indicates R-134a or 134a. Makesure the gauge set has 1/2″-16 ACME threaded connections forservice hoses. Confirm the set has been used only with refrigerantHFC-134a (R-134a) along with specified lubricant.AHA560ASERVICE HOSESNGHA0065S05Be certain that the service hoses display the markings described(colored hose with black stripe). All hoses must include positiveshut off devices (either manual or automatic) near the end of thehoses opposite the manifold gauge.GIMAEMLCECFECLMTATTFPDAXSUBRSTRSBTSCELIDXPRECAUTIONSPrecautions for Service EquipmentHA-7 RHA273DSERVICE COUPLERSNGHA0065S06Never attempt to connect HFC-134a (R-134a) service couplers toan CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplerswill not properly connect to the CFC-12 (R-12) system. However, ifan improper connection is attempted, discharging and contamina-tion may occur.Shut-off valve rotation A/C service valveClockwise OpenCounterclockwise CloseRHA274DREFRIGERANT WEIGHT SCALENGHA0065S07Verify that no refrigerant other than HFC-134a (R-134a) and speci-fied lubricants have been used with the scale. If the scale controlsrefrigerant flow electronically, the hose fitting must be 1/2″-16ACME.Calibrate the scale every 3 months.To calibrate the weight scale on the ACR4 (J-39500–NI):1. Press Shift/Reset and Enter at the same time.2. Press 8787. “A1” will be displayed.3. Remove all weight from the scale.4. Press 0, then press Enter. “0.00” will be displayed andchanged to “A2”.5. Place a known weight (dumbbell or similar weight), between 10and 19 lbs., on the center of the weight scale.6. Enter the known weight using 4 digits (Example 10 lbs = 10.00,10.5 lbs = 10.50).7. Press Enter — the display returns to the vacuum mode.8. Press Shift/Reset and Enter at the same time.9. Press 6 — the known weight on the scale is displayed.10. Remove the known weight from the scale. “0.00” will be dis-played.11. Press Shift/Reset to return the ACR4 to the program mode.CHARGING CYLINDERNGHA0065S08Using a charging cylinder is not recommended. Refrigerant may bevented into air from cylinder’s top valve when filling the cylinderwith refrigerant. Also, the accuracy of the cylinder is generally lessthan that of an electronic scale or of quality recycle/recharge equip-ment.AHA274THERMOMETER AND HYGROMETERNGHA0065S09An etched stem-type thermometer and a hygrometer can be usedto check the air conditioning system performance. A hygrometer isused because the air conditioning performance depends on thehumidity.PRECAUTIONSPrecautions for Service Equipment (Cont’d)HA-8 Wiring Diagrams and Trouble DiagnosisNGHA0066When you read wiring diagrams, refer to the followings:¼ “HOW TO READ WIRING DIAGRAMS” refer to GI-10.¼ “POWER SUPPLY ROUTING” for power distribution circuit refer to EL-9.When you perform trouble diagnosis, refer to the followings:¼ “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” refer to GI-34.¼ “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” refer to GI-23.GIMAEMLCECFECLMTATTFPDAXSUBRSTRSBTSCELIDXPRECAUTIONSWiring Diagrams and Trouble DiagnosisHA-9 Special Service Tools=NGHA0286The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescriptionKV99231260(J-38874)Clutch disc wrenchNT204Removing shaft nut and clutch discKV99232340(J-38874)Clutch disc pullerNT206Removing clutch discKV99234330(J-39024)Pulley installerNT207Installing pulleyKV99233130(J-39023)Pulley pullerNT208Removing pulleyPREPARATIONSpecial Service ToolsHA-10 [...]... fitting to gauge: ¼ 1/2 -1 6 ACME Service hoses ¼ High side hose (J-3950 1-7 2) ¼ Low side hose (J-3950 2-7 2) ¼ Utility hose (J-3947 6-7 2) NT201 Hose fitting to service hose: ¼ M14 x 1.5 fitting is optional or permanently attached Service couplers ¼ High side coupler (J-3950 0-2 0) ¼ Low side coupler (J-3950 0-2 4) NT202 For measuring of refrigerant Fitting size: Thread size ¼ 1/2 -1 6 ACME (J-39650) Refrigerant... Thread size ¼ large container 1/2 -1 6 ACME HFC-134a (R-134a) refrigerant CL MT NT196 Type: Polyalkylene glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz) KLH00-PAGR1 ( — ) Nissan A/C System Lubricant Type R AT TF NT197 Function: Refrigerant Recovery and Recycling and Recharging (J-39500-NI) Recovery/Recycling Recharging...PREPARATION HFC-134a (R-134a) Service Tools and Equipment HFC-134a (R-134a) Service Tools and Equipment =NGHA0068 Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant... (+) (–) Resistance Ω 2 3 Approx 2.0 - 2.4 Check resistance between terminals AHA458A FE Approx 0.8 - 1.0 4 1 Approx 0.2 - 0.3 EC CL MT AT TF PD AX SU BR ST RS BT SC EL HA-35 IDX TROUBLE DIAGNOSES Mode Door Mode Door TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR =NGHA0240 Symptom: ¼ Mode door does not change Inspection Flow AHA480A *1: HA-16 *2: HA-37 *3: HA-27 *4: HA-26 HA-36 ... Function: Checks for refrigerant leaks (J-41995) Electrical leak detector ST RS BT AHA281A SC EL HA-11 IDX PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name Description (J-39183) Manifold gauge set (with hoses and couplers) Identification: ¼ The gauge face indicates R-134a Fitting size: Thread size ¼ 1/2 -1 6 ACME NT199 Hose color: ¼ Low hose: Blue... 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 Tool number (Kent-Moore No.) Tool name GI MA EM LC EC Description FE Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size:... GI MA EM LC EC FE CL MT AT TF PD AHA461A *1: HA-30 *2: HA-27 AX *3: HA-26 SU BR ST RS BT SC EL HA-29 IDX TROUBLE DIAGNOSES Blower Motor (Cont’d) BLOWER MOTOR CIRCUIT =NGHA0089 SYMPTOM: ¼ Blower motor does not rotate 1 DIAGNOSTIC PROCEDURE Check if blower motor rotates properly at each fan speed Does not rotate at any speed ᮣ GO TO 2 Does not rotate at 1-3 speed ᮣ GO TO 6 Does not rotate at 4 speed ᮣ... HA-23 EL IDX TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) AHA517A HA-24 TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC LHA288 EL HA-25 IDX TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair How to Perform Trouble Diagnoses for Quick and Accurate Repair NGHA0075 WORK FLOW NGHA0075S01 AHA454A *1: HA-27 *2: HA-26... Fitting size: Thread size ¼ 1/2 -1 6 ACME (J-39649) Vacuum pump (Including the isolator valve) NT203 HA-12 PREPARATION Commercial Service Tool Commercial Service Tool Tool name Description =NGHA0067 Note Refrigerant Identifier Equipment Checking refrigerant purity and for system contamination GI MA EM LC EC NT765 For details of handling methods, refer to the Instruction Manual attached to the service... PROCEDURE FOR BLOWER MOTOR CIRCUIT” HA-29 ¼ Mode door does not change positions ¼ Go to “TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR” HA-36 ¼ Intake door position does not change ¼ Go to “TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR” HA-38 ¼ Magnet clutch does not engage when A/C switch and fan switch are ON ¼ Go to “TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH ” HA-39 ¼ Insufficient cooling ¼ Go to “TROUBLE . and “SEAT BELT PRE-TENSIONER”HA-2 Precautions for Working with HFC-134a(R-134a)=NGHA0061WARNING:¼ CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant. ToolsHA-10 HFC-134a (R-134a) Service Tools andEquipment=NGHA0068Never mix HFC-134a (R-134a) refrigerant and/or its specified lubri-cant with CFC-12 (R-12)