NISSAN X-TRAIL 2003 Service Repair Manual

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INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace the O-ring of high-pressure flexible hose with a new one, then apply compressor oil to it
when installing it.

When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure PipeEJS000VD
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove low-pressure flexible hose. Refer to ATC-153, "
Removal and Installation of Low-pressure Flexi-
ble Hose" .
3. Remove high-pressure pipe from clip.
4. Remove mounting bolt from high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Remove high-pressure pipe.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace the O-ring of high-pressure pipe with a new one, then apply compressor oil to it when
installing it.

When recharging refrigerant, check for leaks.
Removal and Installation of CondenserEJS0028A
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Disconnect high-pressure flexible hose and high-pressure pipe
from condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
3. Remove air duct (inlet). Refer to EM-15, "
AIR CLEANER AND
AIR DUCT" . (With QR engine)
4. Remove battery and battery tray.
RJIA3182E
RJIA2419E
RJIA2419E

ATC-156
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5. Disconnect refrigerant pressure sensor connector (With QR
engine) or dual-pressure switch connector (With YD engine).
6. Remove front grille and radiator mounting bracket.
7. Remove mounting nuts from condenser.
8. Remove radiator from lower mount, move it to engine side, and
then remove condenser between radiator and radiator core sup-
port.
CAUTION:
Be careful not to damage the core surface of condenser and
radiator.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace the O-rings of high-pressure pipe and high-pressure flexible hose with new ones, then
apply compressor oil to them after installing them.

When recharging refrigerant, check for leaks.
Removal and Installation of Liquid TankEJS0028C
REMOVAL
1. Remove condenser. Refer to ATC-155, "Removal and Installation of Condenser" .
2. Clean liquid tank and its surrounding area, and remove dirt and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
RJIA0690E
RJIA0691E
RJIA0081E
Condenser mounting nuts
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb)

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3. Remove mounting bolt for liquid tank.
CAUTION:
Cap or wrap joint of condenser pipe with a suitable material
such as a vinyl tape to avoid the entry of air.
4. Lift liquid tank upward. Remove bracket from protruding part of
condenser.
5. Slide liquid tank upward, and then remove liquid tank.
INSTALLATION
Installation liquid tank, and then install liquid tank bracket on con-
denser.
CAUTION:

Make sure liquid tank bracket is securely at protrusion of
condenser. (Make sure liquid tank bracket does not move to
a position below center of liquid tank.)

Replace the O-rings of condenser pipe with new ones, then
apply compressor oil to them after installing them.

When recharging refrigerant, check for leaks.
Removal and Installation of Refrigerant Pressure SensorEJS004GF
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove liquid tank. Refer to ATC-156, "
Removal and Installation of Liquid Tank" .
3. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Apply compressor oil to O-ling of refrigerant pressure sensor when installing it.

When recharging refrigerant, check for leaks.
RJIA2895E
RJIA1440E
RJIA1441E
RJIA2148E

ATC-158
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Removal and Installation of Dual-pressure SwitchEJS00289
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove liquid tank. Refer to ATC-156, "
Removal and Installation of Liquid Tank" .
3. Using a vise, secure liquid tank, and remove dual-pressure
switch.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Apply compressor oil to O-ling of dual pressure switch when installing it.

When recharging refrigerant, check for leaks.
Removal and Installation of EvaporatorEJS000VG
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove extension cowl top panel.
3. Disconnect low-pressure flexible hose and high-pressure pipe
from evaporator.
CAUTION:
Cap or wrap the joint of low-pressure flexible hose and
high-pressure pipe with a suitable material such as a vinyl
tape to avoid the entry of air.
4. Remove mounting screws, and then remove expansion valve
cover.
5. Remove mounting bolts, and then remove expansion valve.
6. Remove blower unit. Refer to ATC-125, "
BLOWER UNIT" .
RJIA0699E
Tightening torque :10.8 N·m (1.1 kg-m, 8.0 ft-lb)
RJIA0082E
RJIA2423E

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7. Remove foot duct (passenger side).
8. Remove mounting screws, and then remove evaporator cover.
9. Slide evaporator, and then remove it from heater & cooling unit.
10. Remove intake sensor from evaporator, and then remove evap-
orator.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace the O-rings of low-pressure flexible hose and high-pressure pipe with new ones, then
apply compressor oil to them when installing them.

Mark the mounting position of intake sensor bracket.

When recharging refrigerant, check for leaks.
Removal and Installation of Expansion ValveEJS004GG
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove extension cowl top panel.
3. Disconnect low-pressure flexible hose and high-pressure pipe from evaporator.
CAUTION:
Cap or wrap the joint of low-pressure flexible hose and high-pressure pipe with a suitable material
such as a vinyl tape to avoid the entry of air.
4. Remove mounting screws, and then remove expansion valve
cover.
5. Remove mounting bolts, and then remove expansion valve.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace the O-rings of expansion valve and piping with new ones, and then apply compressor oil
to them when installing them.

When recharging refrigerant, check for leaks.
RJIA0084E
RJIA0051E
RJIA2423E

ATC-160
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Checking for Refrigerant LeaksEJS000VJ
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS000VK
1. Check A/C system for leaks using the UV lamp and safety goggles (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionEJS000VL
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW-PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture's operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

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Electronic Refrigerant Leak DetectorEJS000VM
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service valves.
SHA705EB
SHA707EA
SHA706E
SHA708EA

ATC-162
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3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2 , 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal k). Refer to ATC-143, "
Components" . Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low- pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor or dual pressure switch.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7-10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Mode control dial: VENT (Ventilation)
c. Intake position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure on the high-pressure side will gradually drop after refrigerant
circulation stops and pressure on the low-pressure side will gradually
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high.
11. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent if necessary.
12. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
SHA839E

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13. Conduct A/C performance test to ensure system works properly.

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
CompressorEJS00281
LubricantEJS00282
RefrigerantEJS00283
Engine Idling SpeedEJS00284
Refer to EC-44, "Idle Speed and Ignition Timing Check" for QR engine (WITH EURO-OBD), EC-506, "Idle
Speed and Ignition Timing Check" for QR engine (WITHOUT EURO-OBD), EC-905, "Basic Inspection" for
YD engine (WITH EURO-OBD) or EC-905, "
Basic Inspection" for YD engine (WITHOUT EURO-OBD).
Belt TensionEJS00285
Refer to EM-13, "DRIVE BELTS" for QR engine or EM-131, "DRIVE BELTS" for YD engine.
ModelWith QR engine With YD engine
Calsonic Kansei make CWV-615MZEXEL VALEO CLIMATE CONTROL make
DKV-11G
Type V-6 variable displacement Vane rotary
Displacement
cm
3 (cu in)/revMax. 146 (8.91)
110 (6.71)
Min. 14.5 (0.885)
Cylinder bore × stroke
mm (in)37 (1.46) × [2.3 - 25.0 (0.091 - 0.984)] -
Direction of rotation Clockwise (viewed from drive end)
Drive beltPoly V
ModelWith QR engine With YD engine
Calsonic Kansei make CWV-615MZEXEL VALEO CLIMATE CONTROL
make DKV-11G
Name Nissan A/C System Oil Type S (DH-PS) Nissan A/C System Oil Type R (DH-PR)
Part number KLH00-PAGS0 KLH00-PAGR0
Capacity
m (lmp fl oz)Total in system 180 (6.3)
Compressor (Service part)
charging amount180 (6.3)
Ty p eHFC-134a (R-134a)
Capacity
kg (lb)0.55 (1.21)