2003 NISSAN X-TRAIL engine

AT-458
[ALL]
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION
PFP:00000
RemovalECS004NC
CAUTION:
Before separating transaxle from engine, remove the crankshaft position sensor (Euro-OBD) from
transaxle. Be careful not to damage sensor.
1. Remove battery and bracket, air cleaner and air duct.
2. Remove air breather hose.
3. Disconnect A/T solenoid valve harness connector, PNP switch harness connector and revolution sensor
harness connector.
4. Remove crankshaft position sensor (Euro-OBD) from transaxle.
5. Disconnect control cable from transaxle.
6. Remove front exhaust tube.
7. Disconnect oil cooler hoses.
8. Remove drive shafts. Refer toFAX-11, "
FRONT DRIVE
SHAFT",RAX-9, "REAR DRIVE SHAFT".
9. Remove transfer. Refer toTF-12, "
TRANSFER ASSEMBLY".
10. Remove starter motor from transaxle.
11. Support transaxle with a jack.
SCIA0793E
ATM0479D

REMOVAL AND INSTALLATION
AT-459
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12. Remove center member, engine insulator and engine mounting
bracket.
lTighten center member fixing bolts to specified torque, Refer
toEM-61, "
ENGINE ASSEMBLY".
13. Remove suspension member. Refer toFSU-12, "
FRONT SUS-
PENSION MEMBER".
14. Remove dust cover from converter housing.
Rotate crankshaft to gain access to securing bolts.
15. Remove securing bolts between drive plate and torque con-
verter. when crank shaft rotates, turn to right at the front side of
engine.
16. Support engine with a jack.
17. Remove bolts fixing transaxle to engine.
18. Lower transaxle while supporting it with a jack.
InstallationECS004ND
1. Check drive plate runout.
CAUTION:
Do not allow any magnetic materials to contact the ring
gear teeth.
lIf this runout is out of allowance, replace drive plate with ring
gear.
2. When connecting torque converter to transaxle, measure dis-
tance “A” to be certain that they are correctly assembled.
SCIA0794E
AAT259A
Maximum allowable runout :
Refer to EM-´´, “FLYWHEEL/DRIVE PLATE RUNOUT”.
SAT977H
Distance “A”: 19 mm (0.626 in) or more
SAT573D

AT-460
[ALL]
REMOVAL AND INSTALLATION
3. Install torque converter to drive plate.
lWith converter installed, rotate crankshaft several turns
to check that transaxle rotates freely without binding.
4. Tighten belts fixing transaxle.
5. Reinstall any part removed.
6. Adjust control cable. Refer toAT-456, "
Control Cable Adjust-
ment".
7. Check continuity of PNP switch. Refer toAT-130, "
DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH".
8. Refill transaxle with ATF and check fluid level.
9. Move selector lever through all positions to be sure that tran-
saxle operates correctly. With parking brake applied, idle
engine. Move selector lever through “N” to “D”, to “2”, to “1” and
“R” positions. A slight shock should be felt through the hand
gripping the selector each time the transaxle is shifted.
10. Perform road test. Refer toAT-69, "
Road Test".
AAT266A
Bolt No.Tightening torque
N-m (kg-m, ft-lb)Bolt length “ L ”
mm (in)
1
69.6 - 79.4 (7.1 - 8.1, 51.4 - 58.6)49 (1.93)
245(1.77)
3
39.2 - 46.1 (4.0 - 4.7, 29.0 - 34.0)40 (1.57)
430(1.18)
5
30.4 - 40.2 (3.1 - 4.1, 22.4 - 29.7)40 (1.57)
645(1.97)
SCIA0795E
SAT638A

SERVICE DATA AND SPECIFICATIONS (SDS)
AT-563
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS004MI
Shift ScheduleECS004MJ
VEHICLE SPEED WHEN SHIFTING GEARS THROTTLE POSITION
VEHICLE SPEED WHEN PERFORMING AND RELEASING LOCK-UP
Unit: km/h (MPH)
NOTE:
lLock-up vehicle speed indicates the speed in D4position.
lPerform lock-up inspection after warming up engine.
lLock-up vehicle speed may vary depending on the driving conditions and circumstances.
Stall RevolutionECS004MK
Line PressureECS004ML
EngineQR20DE
Automatic transaxle model RE4F04B(4WD)
Automatic transaxle assembly Model code number 85X23
Transaxle gear ratio1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Reverse 2.272
Final drive 3.789
Recommended fluid Gemuine Nissan ATF or equiualent,*1
Fluid capacity (Imp qt)9.4 (8-1/4)
Throttle posi-
tionShift patternVehicle speed km/h (MPH)
D
1®D2D2®D3D3®D4D4®D3D3®D2D2®D1
Full throttleComfort53 - 61
(33 - 38)99 - 107
(62 - 67)156 - 164
(97 - 102)152 - 160
(94 - 99)89 - 97
(53 - 60)41 - 49
(25 - 30)
Auto power53 - 61
(33 - 38)99 - 107
(62 - 67)156 - 164
(97 - 102)152 - 160
(94 - 99)89 - 97
(55 - 60)41 - 49
(25 - 30)
Half throttleComfort34 - 42
(21 - 26)64 - 72
(40 - 45)124 - 138
(77 - 82)82 - 90
(51 - 56)41 - 49
(25 - 30)5-13
(3 - 8)
Auto power38 - 46
(24 - 29)70 - 78
(44 - 48)124 - 132
(77 - 82)81 - 89
(50 - 55)44 - 53
(27 - 33)5-13
(3 - 8)
Model code No. 85X23
Vehicle speed Throttle position 1/8 58 - 66 (36 - 41)
EngineStall revolution
rpm
QR20DE 2,450 - 2,950
Engine speed
rpmLine pressure kPa (kg/cm2,psi)
D, 2 and 1 positions R position
Idle 500 (5.1, 73) 772 (7.9, 113)
Stall 1,233 (12.6, 179) 1,918 (19.6, 278)

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION
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AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
General Refrigerant Precautions .............................. 4
Lubricant Precautions .............................................. 5
Precautions for Refrigerant Connection ................... 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 5
O-RING AND REFRIGERANT CONNECTION..... 6
Precautions for Servicing Compressor ..................... 7
Precautions for Service Equipment .......................... 8
RECOVERY/RECYCLING EQUIPMENT .............. 8
ELECTRONIC LEAK DETECTOR ........................ 8
VACUUM PUMP ................................................... 8
MANIFOLD GAUGE SET ...................................... 8
SERVICE HOSES ................................................. 9
SERVICE COUPLERS .......................................... 9
REFRIGERANT WEIGHT SCALE ........................ 9
CALIBRATING ACR4 WEIGHT SCALE ................ 9
CHARGING CYLINDER ...................................... 10
Precautions for Leak Detection Dye ....................... 10
IDENTIFICATION ................................................ 10
IDENTIFICATION LABEL FOR VEHICLE ........... 10
Wiring Diagrams and Trouble Diagnosis ................ 10
PREPARATION ..........................................................11
Special Service Tools ..............................................11
WITH GASOLINE ENGINE (CWV-615M COM-
PRESSOR) ..........................................................11
WITH DIESEL ENGINE (DKV-11G COMPRES-
SOR) ....................................................................11
HFC-134a (R-134a) Service Tools and Equipment... 12
REFRIGERATION SYSTEM ..................................... 16
Refrigerant Cycle ................................................... 16
REFRIGERANT FLOW ....................................... 16
FREEZE PROTECTION (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 16
Refrigerant System Protection ............................... 16
REFRIGERANT PRESSURE SENSOR (WITHGASOLINE ENGINE: CWV-615M COMPRES-
SOR) ................................................................... 16
DUAL-PRESSURE SWITCH (WITH DIESEL
ENGINE: DKV-11G COMPRESSOR) .................. 16
PRESSURE RELIEF VALVE (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 16
V-6 Variable Displacement Compressor (With Gas-
oline Engine: CWV-165M Compressor) .................. 17
GENERAL INFORMATION ................................. 17
DESCRIPTION .................................................... 17
Component Layout ................................................. 20
LUBRICANT .............................................................. 21
Maintenance of Lubricant Quantity in Compressor... 21
LUBRICANT ........................................................ 21
LUBRICANT RETURN OPERATION .................. 21
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 22
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 22
AIR CONDITIONER CONTROL ............................... 24
Overview Air Conditioner LAN Control System ...... 24
System Construction .............................................. 24
OPERATION ........................................................ 24
TRANSMISSION DATA AND TRANSMISSION
ORDER ............................................................... 25
AIR MIX DOOR CONTROL (AUTOMATIC TEM-
PERATURE CONTROL) ..................................... 25
FAN SPEED CONTROL ...................................... 26
INTAKE DOOR CONTROL ................................. 26
OUTLET DOOR CONTROL ................................ 26
MAGNET CLUTCH CONTROL ........................... 26
SELF-DIAGNOSTIC SYSTEM ............................ 26
Overview of Control system .................................... 26
Control Operation ................................................... 27
DISPLAY SCREEN .............................................. 27
AUTO SWITCH ................................................... 27
TEMPERATURE DIAL (POTENTIO TEMPERA-
TURE CONTROL) ............................................... 27
A/C SWITCH ....................................................... 27

ATC-2
DEFROSTER (DEF) SWITCH ............................. 27
MODE SWITCH ................................................... 27
FAN SWITCH ...................................................... 27
OFF SWITCH ...................................................... 27
FRESH (FRE) SWITCH ....................................... 27
RECIRCULATION (REC) SWITCH ..................... 27
Discharge Air Flow ................................................. 28
System Description ................................................. 29
SWITCHES AND THEIR CONTROL FUNCTION... 29
TROUBLE DIAGNOSIS ............................................ 30
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 30
WORK FLOW ...................................................... 30
SYMPTOM TABLE .............................................. 30
Component Parts and Harness Connector Location... 31
ENGINE COMPARTMENT .................................. 31
PASSENGER COMPARTMENT .......................... 32
Circuit Diagram ....................................................... 33
WITH GASOLINE ENGINE ................................. 33
WITH DIESEL ENGINE ....................................... 34
Wiring Diagram ....................................................... 35
WITH DASOLINE ENGINE ................................. 35
WITH DIESEL ENGINE ....................................... 38
Auto Amp. Terminals and Reference Value ............ 41
PIN CONNECTOR TERMINAL LAYOUT ............ 41
AUTO AMP. INSPECTION TABLE ...................... 41
Self-diagnosis Function .......................................... 42
DESCRIPTION .................................................... 42
PROCEDURE ...................................................... 43
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 49
AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER ........................................... 50
AUXILIARY MECHANISM: INLET PORT MEM-
ORY FUNCTION (FOR LHD MODELS) .............. 51
Operational Check .................................................. 51
CHECKING MEMORY FUNCTION ..................... 51
CHECKING BLOEWER ....................................... 52
CHECKING DISCHARGE AIR ............................ 52
CHECKING RECIRCULATION ............................ 52
CHECKING TEMPERATURE DECREASE ......... 53
CHECKING TEMPERATURE INCREASE .......... 53
CHECKING AUTO MODE ................................... 53
Power Supply and Ground Circuit for Auto Amp. ... 53
INSPECTION FLOW ........................................... 54
COMPONENT DESCRIPTION ............................ 54
DIAGNOSTIC PROCEDURE .............................. 55
LAN System Circuit ................................................ 56
DIAGNOSTIC PROCEDURE .............................. 56
Mode Door Motor Circuit ........................................ 58
INSPECTION FLOW ........................................... 59
SYSTEM DESCRIPTION .................................... 60
COMPONENT DESCRIPTION ............................ 61
DIAGNOSTIC PROCEDURE .............................. 61
Air Mix Door Motor Circuit ...................................... 61
INSPECTION FLOW ........................................... 62
SYSTEM DESCRIPTION .................................... 62
COMPONENT DESCRIPTION ............................ 64DIAGNOSTIC PROCEDURE ...............................64
Intake Door Motor Circuit ........................................64
INSPECTION FLOW ............................................65
SYSTEM DESCRIPTION .....................................65
COMPONENT DESCRIPTION ............................66
DIAGNOSTIC PROCEDURE ...............................67
Blower Motor Circuit ................................................67
INSPECTION FLOW ............................................68
SYSTEM DESCRIPTION .....................................69
COMPONENT DESCRIPTION ............................70
DIAGNOSTIC PROCEDURE ...............................70
COMPONENT INSPECTION ...............................73
Magnet Clutch Circuit ..............................................73
INSPECTION FLOW ............................................74
SYSTEM DESCRIPTION .....................................74
DIAGNOSTIC PROCEDURE ...............................75
COMPONENT INSPECTION ...............................80
Insufficient Cooling ..................................................81
INSPECTION FLOW ............................................82
PERFORMANCE TEST DIAGNOSES ................83
PERFORMANCE CHART ....................................84
TROUBLE DIAGNOSES FOR ABNORMAL
PRESSURE .........................................................86
Insufficient Heating .................................................89
INSPECTION FLOW ............................................90
Noise .......................................................................91
INSPECTION FLOW ............................................91
Self-diagnosis .........................................................92
INSPECTION FLOW ............................................92
Memory Function ....................................................92
INSPECTION FLOW ............................................93
Ambient Sensor Circuit ...........................................93
COMPONENT DESCRIPTION ............................93
AMBIENT TEMPERATURE INPUT PROCESS...93
DIAGNOSTIC PROCEDURE ...............................94
COMPONENT INSPECTION ...............................95
In-vehicle Sensor Circuit .........................................95
COMPONENT DESCRIPTION ............................95
DIAGNOSTIC PROCEDURE ...............................96
COMPONENT INSPECTION ...............................97
Sunload Sensor Circuit ...........................................98
COMPONENT DESCRIPTION ............................98
SUNLOAD INPUT PROCESS .............................98
DIAGNOSTIC PROCEDURE ...............................98
COMPONENT INSPECTION ............................. 100
Intake Sensor Circuit ............................................. 101
COMPONENT DESCRIPTION .......................... 101
DIAGNOSTIC PROCEDURE ............................. 101
CONTROLLER ........................................................ 104
Removal and Installation ....................................... 104
Disassembly and Assembly .................................. 104
AMBIENT SENSOR ................................................ 105
Removal and Installation ....................................... 105
IN-VEHICLE SENSOR ............................................ 106
Removal and Installation ....................................... 106
SUNLOAD SENSOR ............................................... 107
Removal and Installation ....................................... 107

ATC-3
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AT C INTAKE SENSOR CIRCUIT ................................... 108
Removal and Installation ...................................... 108
BLOWER UNIT ....................................................... 109
Removal and Installation ...................................... 109
REMOVAL ......................................................... 109
INSTALLATION ................................................. 109
Disassembly and Assembly ................................. 109
BLOWER MOTOR ................................................... 111
Removal and Installation ...................................... . 111
INTAKE DOOR MOTOR .......................................... 112
Removal and Installation ....................................... 112
FAN CONTROL AMPLIFIER ................................... 113
Removal and Installation ....................................... 113
VENTILATION AIR FILTER ..................................... 114
Removal and Installation ....................................... 114
Function ................................................................ 114
Replacement Timing ............................................. 114
Replacement Procedures ...................................... 114
HEATER & COOLING UNIT ASSEMBLY ............... 115
Removal and Installation ....................................... 115
REMOVAL .......................................................... 115
INSTALLATION .................................................. 116
Disassembly and Assembly .................................. 116
MODE DOOR MOTOR ............................................ 118
Removal and Installation ....................................... 118
AIR MIX DOOR MOTOR .......................................... 119
Removal and Installation ....................................... 119
HEATER CORE ...................................................... 120
Removal and Installation ...................................... 120
DUCTS AND GRILLES .......................................... 121
Removal and Installation ...................................... 121
Ventilator Duct, Defroster Nozzle and Defroster
Ducts .................................................................... 121
Center Ventilator Grille ......................................... 121
Side Ventilator Grille ............................................. 121
Foot Duct .............................................................. 122
Floor duct ............................................................. 122
REFRIGERANT LINES ........................................... 123
HFC-134a (R-134a) Service Procedure ............... 123
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................ 123
Components ......................................................... 125
Removal and Installation for Compressor ............ 126REMOVAL .........................................................126
INSTALLATION .................................................128
Removal and Installation for Compressor Clutch . 129
REMOVAL .........................................................129
INSTALLATION .................................................132
Removal and Installation for Low-pressure flexible
hose ......................................................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
Removal and Installation for High-pressure flexible
hose ......................................................................136
REMOVAL .........................................................136
INSTALLATION .................................................136
Removal and Installation for High-pressure pipe ..137
REMOVAL .........................................................137
INSTALLATION .................................................137
Removal and Installation for Refrigerant Pressure
Sensor ..................................................................137
Removal and Installation for Dual-pressure Switch.138
Removal and Installation for Condenser ..............138
REMOVAL .........................................................138
INSTALLATION .................................................138
Removal and Installation for Evaporator ..............139
REMOVAL .........................................................139
INSTALLATION .................................................139
Removal and Installation for Expansion Valve ......140
Removal and Installation for Desiccant Assembly. 140
REMOVAL .........................................................140
INSTALLATION .................................................140
Checking for Refrigerant Leaks ............................140
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................141
Dye Injection .........................................................141
Electronic Refrigerant Leak Detector ....................141
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................141
CHECKING PROCEDURE ...............................142
Service Data and Specifications (SDS) ................143
COMPRESSOR ................................................143
LUBRICANT ......................................................144
REFRIGERANT .................................................144
ENGINE IDLING SPEED ..................................144
BELT TENSION .................................................144

PRECAUTIONS
ATC-7
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CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
lWhen 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.
lWhen connecting tubes, always use a torque wrench and a back-up wrench.
lAfter disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
lWhen 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 for
connection.
lAllow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
lThoroughly remove moisture from the refrigeration system before charging the refrigerant.
lAlways replace used O-rings.
lWhen connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
lO-ring must be closely attached to dented portion of tube.
lWhen replacing the O-ring, be careful not to damage O-ring and tube.
lConnect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
lAfter connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.
Precautions for Servicing CompressorEJS000T5
lPlug all openings to prevent moisture and foreign matter from entering.
lWhen the compressor is removed, store it in the same position as it is when mounted on the car.
lWhen replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer toATC-21, "
Maintenance of Lubricant Quantity in Compressor".
lKeep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.
lAfter compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
RHA861F