Engine cooling system NISSAN X-TRAIL 2005 Service Manual PDF
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2005, Model line: X-TRAIL, Model: NISSAN X-TRAIL 2005Pages: 4555, PDF Size: 88.09 MB
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ATC-3
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AMBIENT SENSOR ................................................ 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 121
IN-VEHICLE SENSOR ............................................ 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSTALLATION ................................................. 122
SUNLOAD SENSOR .............................................. 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSTALLATION ................................................. 123
INTAKE SENSOR ................................................... 124
Removal and Installation ...................................... 124
REMOVAL ......................................................... 124
INSTALLATION ................................................. 124
BLOWER UNIT ....................................................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSTALLATION ................................................. 125
Disassembly and Assembly ................................. 126
BLOWER MOTOR .................................................. 127
Removal and Installation ...................................... 127
REMOVAL ......................................................... 127
INSTALLATION ................................................. 127
INTAKE DOOR MOTOR ......................................... 128
Removal and Installation ...................................... 128
REMOVAL ......................................................... 128
INSTALLATION ................................................. 128
FAN CONTROL AMPLIFIER .................................. 129
Removal and Installation ...................................... 129
REMOVAL ......................................................... 129
INSTALLATION ................................................. 129
AIR CONDITIONER FILTER ................................... 130
Removal and Installation ...................................... 130
FUNCTION ........................................................ 130
REPLACEMENT TIMING .................................. 130
REPLACEMENT PROCEDURES ..................... 130
HEATER & COOLING UNIT ASSEMBLY .............. 131
Removal and Installation ...................................... 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
Disassembly and Assembly ................................. 132
MODE DOOR MOTOR ........................................... 134
Removal and Installation ...................................... 134
REMOVAL ......................................................... 134
INSTALLATION ................................................. 134
AIR MIX DOOR MOTOR ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSTALLATION ................................................. 135
HEATER CORE ...................................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSTALLATION ................................................. 136
DUCTS AND GRILLES .......................................... 137
Removal and Installation ...................................... 137
REMOVAL ......................................................... 137
INSTALLATION ................................................. 140REFRIGERANT LINES ...........................................141
HFC-134a (R-134a) Service Procedure ...............141
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................141
Components .........................................................143
WITH GASOLINE ENGINE ...............................143
WITH DIESEL ENGINE .....................................144
Removal and Installation of Compressor ..............144
REMOVAL .........................................................144
INSTALLATION .................................................146
Removal and Installation of Compressor Clutch ..146
REMOVAL .........................................................146
INSTALLATION .................................................150
Removal and Installation of Low-pressure Flexible
Hose .....................................................................153
REMOVAL .........................................................153
INSTALLATION .................................................154
Removal and Installation of High-pressure Flexible
Hose .....................................................................154
REMOVAL .........................................................154
INSTALLATION .................................................155
Removal and Installation of High-pressure Pipe ..155
REMOVAL .........................................................155
INSTALLATION .................................................155
Removal and Installation of Condenser ................155
REMOVAL .........................................................155
INSTALLATION .................................................156
Removal and Installation of Liquid Tank ...............156
REMOVAL .........................................................156
INSTALLATION .................................................157
Removal and Installation of Refrigerant Pressure
Sensor ..................................................................157
REMOVAL .........................................................157
INSTALLATION .................................................157
Removal and Installation of Dual-pressure Switch .158
REMOVAL .........................................................158
INSTALLATION .................................................158
Removal and Installation of Evaporator ................158
REMOVAL .........................................................158
INSTALLATION .................................................159
Removal and Installation of Expansion Valve .......159
REMOVAL .........................................................159
INSTALLATION .................................................159
Checking for Refrigerant Leaks ............................160
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................160
Dye Injection .........................................................160
Electronic Refrigerant Leak Detector ....................161
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................161
CHECKING PROCEDURE ...............................161
SERVICE DATA AND SPECIFICATIONS (SDS) ....164
Compressor ..........................................................164
Lubricant ...............................................................164
Refrigerant ............................................................164
Engine Idling Speed .............................................164
Belt Tension ..........................................................164
Page 3186 of 4555
ATC-8
PRECAUTIONS
With Diesel Engine
NOTE:
This illustration is for RHD models. The blower and heater & cooling unit layouts for LHD models are symmet-
rically opposite.
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.
RJIA2818E
Connec-
tion typeO-ring
sizePart number D mm (in) W mm (in)
New
892471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New
1292472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
1692473 N8210 13.6 (0.535) 2.43 (0.0957)
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
1992474 N8210 16.5 (0.650) 2.43 (0.0957)
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
SHA814E
Page 3202 of 4555
ATC-24
LUBRICANT
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 refrigerant leakage occurred. It is important to maintain the
specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
Lack of lubricant: May lead to a seized compressor
Excessive 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?
A/C system works properly.
There is no evidence of a large amount of lubricant leakage.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
OK or NG
OK >> GO TO 2.
NG >> 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 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.
>> GO TO 3.
3. CHECK REPLACEMENT PART
Should the compressor be replaced?
YES >> GO TO AT C - 2 5 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
NO >> GO TO AT C - 2 5 , "
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACE-
MENT EXCEPT COMPRESSOR" . 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
Page 3274 of 4555
ATC-96
TROUBLE DIAGNOSIS
Insufficient CoolingEJS004H2
SYMPTOM: Insufficient cooling
INSPECTION FLOW
*1ATC-65, "Operational Check".*2ATC-59, "FUNCTION CONFIRMA-
TION PROCEDURE", see No. 1.*3AT C - 5 9 , "
FUNCTION CONFIRMA-
TION PROCEDURE", see No. 5 to 7.
*4 QR engine; EM-13, "
Checking Drive
Belts" or YD engine; EM-140,
"Checking Drive Belts" .*5ATC-76, "
Air Mix Door Motor Circuit".*6ATC-100, "Test Reading (QR
Engine)" or ATC-101, "Test Reading
(YD Engine)" .
*7ATC-63, "
AUXILIARY MECHA-
NISM: TEMPERATURE SETTING
TRIMMER".*8ATC-59, "
FUNCTION CONFIRMA-
TION PROCEDURE", see No. 9.*9AT C - 6 9 , "
LAN System Circuit".
SJIA0408E
Page 3280 of 4555
ATC-102
TROUBLE DIAGNOSIS
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 con-
denser.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 cool-
ing 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 (1.96 bar, 2 kg/cm
2 , 28
psi). It then decreases gradu-
ally thereafter.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-pressure
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 lit-
tle compared with the specifi-
cation.
↓
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
Page 3309 of 4555
HEATER & COOLING UNIT ASSEMBLY
ATC-131
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HEATER & COOLING UNIT ASSEMBLYPFP:27110
Removal and InstallationEJS000UT
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Drain coolant from cooling system. Refer to CO-9, "
Changing Engine Coolant" for QR engine or CO-32,
"Changing Engine Coolant" for YD engine.
3. Disconnect two heater hoses from heater core pipe.
4. Remove mounting bolt from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Remove the blower unit. Refer to ATC-125, "
BLOWER UNIT" .
6. Remove clips of vehicle harness from steering member.
7. Remove mounting nuts, and then remove instrument stay.
8. Remove mounting bolts from heater & cooling unit.
RJIA0060E
RJIA0061E
RJIA2444E
Page 3340 of 4555
ATC-162
REFRIGERANT LINES
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
Page 3951 of 4555
HEATER UNIT
MTC-27
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HEATER UNITPFP:27100
Removal and InstallationEJS001F9
REMOVAL
1. Drain coolant from cooling system. Refer to CO-9, "Changing Engine Coolant" for QR engine or CO-32,
"Changing Engine Coolant" for YD engine.
2. Disconnect two heater hoses from heater core pipe.
3. Remove instrument panel. Refer to IP-11, "
Removal and Installation" .
4. Remove blower unit. Refer to MTC-22, "
BLOWER UNIT" .
5. Remove clips of vehicle harness from steering member.
6. Remove mounting nuts, and then remove instrument stay.
7. Remove mounting bolts from heater (& cooling) unit.
RJIA0060E
RJIA0061E
RJIA2444E
Page 4481 of 4555
HARNESS
PG-65
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Wiring Diagram Codes (Cell Codes) EKS0032J
Use the chart below to find out what each wiring diagram code stands for.
Refer to the wiring diagram code in the alphabetical index to find the location (page number) of each wiring
diagram.
Code Section Wiring Diagram Name
1STSIG AT A/T 1st Signal
2NDSIG AT A/T 2nd Signal
3RDSIG AT A/T 3rd Signal
4THSIG AT A/T 4th Signal
4WD TF 4WD Control system
A/C ATC Air Conditioner
ABS BRC Anti-Lock Brake System
APP1PW EC Accelerator Pedal Position Sensor 1 Power Supply
APP2PW EC Accelerator Pedal Position Sensor 2 Power Supply
APPS1 EC Accelerator Pedal Position Sensor
APPS2 EC Accelerator Pedal Position Sensor
APPS3 EC Accelerator Pedal Position Sensor
ASC/BS EC Automatic Speed Control Device (ASCD) Brake Switch
ASC/SW EC Automatic Speed Control Device (ASCD) Steering Switch
ASCBOF EC Automatic Speed Control Device (ASCD) Brake Switch
ASCIND EC Automatic Speed Control Device (ASCD) Indicator
AT/IND DI A/T Indicator Lamp
AUDIO AV Audio
BA/FTS AT A/T Fluid Temperature Sensor and TCM Power Supply
BACK/L LT Back-Up Lamp
BOOST EC Turbocharger Boost Sensor
BRK/SW EC Brake Switch
CAN AT CAN Communication Line
CAN EC CAN Communication Line
CAN LAN CAN System
CHARGE SC Charging System
CHIME DI Warning Chime
CIGAR WW Cigarette Lighter
CKPS EC Crankshaft Position Sensor
CLOCK DI Clock
CMPS EC Camshaft Position Sensor
COOL/F EC Cooling Fan Control
D/LOCK BL Power Door Lock
DEF GW Rear Window Defogger
DTRL LT Headlamp - With Daytime Light System
ECM/PW EC ECM Power Supply for Back-Up
ECMRLY EC ECM Relay
ECTS EC Engine Coolant Temperature Sensor
EGRVLV EC EGR Volume Control Valve
EGVC/V EC EGR Volume Control Valve
ENGSS AT Engine Speed Signal
Page 4497 of 4555
MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTION MA
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MAINTENANCE
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
DESCRIPTION ............................................................ 4
Pre-Delivery Inspection Items .................................. 4
GENERAL MAINTENANCE ....................................... 6
General Maintenance ............................................... 6
PERIODIC MAINTENANCE ....................................... 7
Periodic Maintenance ............................................... 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................... 7
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ....... 8
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) ................ 9
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................. 12
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ..... 13
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) .............. 14
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) ............................ 14
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 15
RECOMMENDED FLUIDS AND LUBRICANTS ...... 17
Fluids and Lubricants ............................................. 17
SAE Viscosity Number ........................................... 18
GASOLINE ENGINE ........................................... 18
DIESEL ENGINE ................................................. 18
Engine Coolant Mixture Ratio ................................ 19
ENGINE MAINTENANCE (QR20DE·QR25DE) ........ 20
Checking Drive Belts .............................................. 20
Tension Adjustment ................................................ 20Changing Engine Coolant ....................................... 20
DRAINING ENGINE COOLANT .......................... 20
REFILLING ENGINE COOLANT ......................... 21
FLUSHING COOLING SYSTEM ......................... 22
Checking Cooling System ...................................... 22
CHECKING COOLING SYSTEM HOSES ........... 22
CHECKING RADIATOR ...................................... 22
CHECKING RADIATOR CAP .............................. 22
CHECKING RADIATOR SYSTEM FOR LEAKS ... 23
Checking Fuel Lines ............................................... 24
Changing Air Cleaner Filter .................................... 24
VISCOUS PAPER TYPE ..................................... 24
Changing Engine Oil ............................................... 24
Changing Oil Filter .................................................. 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
INSPECTION AFTER INSTALLATION ................ 26
Checking and Changing Spark Plugs ..................... 26
REMOVAL ........................................................... 26
INSPECTION AFTER REMOVAL (EXCEPT FOR
RUSSIA) .............................................................. 26
INSPECTION AFTER REMOVAL (FOR RUS-
SIA) ..................................................................... 27
INSTALLATION ................................................... 28
Checking EVAP Vapor Lines .................................. 28
ENGINE MAINTENANCE (YD22DDTI) .................... 29
Checking Drive Belts .............................................. 29
Tension Adjustment ................................................ 29
A/C COMPRESSOR BELT .................................. 30
ALTERNATOR AND WATER PUMP BELT .......... 30
Changing Engine Coolant ....................................... 30
DRAINING ENGINE COOLANT .......................... 30
REFILLING ENGINE COOLANT ......................... 31
FLUSHING COOLING SYSTEM ......................... 32
Checking Cooling System ...................................... 32
CHECKING COOLING SYSTEM HOSES ........... 32
CHECKING RADIATOR ...................................... 32
CHECKING RADIATOR CAP .............................. 33
CHECKING RADIATOR SYSTEM FOR LEAKS ... 33
Checking Fuel Lines ............................................... 34