2003 NISSAN X-TRAIL charging

ATC-158
REFRIGERANT LINES

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

REFRIGERANT LINES
ATC-159
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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
REFRIGERANT LINES

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.

ATC-164
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)

MA-38
CHASSIS AND BODY MAINTENANCE

Changing M/T OilELS000BD
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
CAUTION:
Do not reuse gasket.
Checking A/T FluidELS000BV
1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD”
range on dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove dipstick and wipe clean lint-free paper.
CAUTION:
When wiping away the dipstick, always use lint-free paper, not cloth one.
e. Re-insert dipstick into charging pipe as far as it will go.
CAUTION:
To check fluid level, insert the dipstick until the cap contacts the end of the A/T fluid charging pipe,
with the dipstick reversed from the normal attachment conditions.
f. Remove dipstick and note reading. If reading is at low side of range, add fluid to the A/T fluid charging
pipe.
CAUTION:
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on dipstick.
CAUTION:

When wiping away the dipstick, always use lint-free paper, not cloth one.

To check fluid level, insert the dipstick until the cap contacts the end of the A/T fluid charging
pipe, with the dipstick reversed from the normal attachment conditions.Oil grade:
API GL-4
Viscosity:
Refer to MA-17, "
RECOMMENDED FLUIDS AND
LUBRICANTS"
Oil capacity:
Approx. 2.3 (4 lmp pt)
Filler plug and drain plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
SCIA0361E
SMA146B

CHASSIS AND BODY MAINTENANCE
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6. Check fluid condition.

If fluid is very dark or smells burned, refer to AT section for
checking operation of A/T. Flush cooling system after repair of
A/T.

If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to CO-12,
"RADIATOR" , CO-14, "RADIATOR (ALUMINUM TYPE)" .
7. Install the removed dipstick in the A/T fluid charging pipe.
Changing A/T FluidELS000BW
1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid from drain plug and refill with new A/T fluid.
Always refill same volume with drained fluid.
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to MA-38, "
Checking A/T Fluid" . If fluid is still dirty, repeat steps 2
through 5.
Checking Transfer OilELS000BT
Check for oil leakage and oil level.
CAUTION:
Never start engine while checking oil level.
Changing Transfer OilELS000BU
1. Drain oil from drain plug and refill with new gear oil.
SMA853B
Fluid grade:
Genuine Nissan ATF or equivalent. Refer to MA-
17, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
Fluid capacity (With torque converter):
Approx. 8.5 (7-1/2 lmp qt)
Drain plug:
: 34 N·m (3.5 kg-m, 25 ft-lb)
SMA052D
Filler plug:
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 - 173 in-lb)
SDIA0513E

SC-1
STARTING & CHARGING SYSTEM
K ELECTRICAL
CONTENTS
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STARTING & CHARGING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Wiring Diagrams and Trouble Diagnosis .................. 2
BATTERY .................................................................... 3
How to Handle Battery ............................................. 3
METHODS OF PREVENTING OVER-DIS-
CHARGE ............................................................... 3
CHECKING ELECTROLYTE LEVEL .................... 3
SPECIFIC GRAVITY CHECK ............................... 4
Battery Test and Charging Chart .............................. 5
CHART I ................................................................ 5
CHART II ............................................................... 6
A: SLOW CHARGE ............................................... 7
B: STANDARD CHARGE ...................................... 8
C: QUICK CHARGE ............................................ 10
Removal and Installation ......................................... 11
CHARGING SYSTEM ............................................... 12
System Description ................................................ 12
Wiring Diagram — CHARGE — /WITH GASOLINE
ENGINE ................................................................. 13
Wiring Diagram — CHARGE — /WITH DIESEL
ENGINE ................................................................. 14
Trouble Diagnoses ................................................. 15
WITH IC REGULATOR ....................................... 15
MALFUNCTION INDICATOR .............................. 15
Removal and Installation ........................................ 16
REMOVAL (QR ENGINE MODELS) ................... 16
REMOVAL (YD ENGINE MODELS) ................... 16
INSTALLATION ................................................... 16
Disassembly and Assembly ................................... 17
QR ENGINE MODELS ........................................ 17
YD ENGINE MODELS ........................................ 18
Disassembly ........................................................... 18
REAR COVER .................................................... 18REAR BEARING ................................................. 18
Inspection ............................................................... 19
ROTOR CHECK .................................................. 19
BRUSH CHECK .................................................. 19
PULLEY CHECK (WITH CLUTCH TYPE) ........... 19
STATOR CHECK ................................................. 19
Assembly ................................................................ 20
RING FITTING IN REAR BEARING .................... 20
REAR COVER INSTALLATION ........................... 20
STARTING SYSTEM ................................................. 21
System Description ................................................. 21
M/T MODELS ...................................................... 21
A/T MODELS ....................................................... 21
Wiring Diagram — START —/M/T models ............. 22
Wiring Diagram — START —/A/T models .............. 23
Trouble Diagnoses ................................................. 24
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
Disassembly and Assembly .................................... 26
QR ENGINE MODELS ........................................ 26
YD ENGINE MODELS ........................................ 28
Inspection ............................................................... 29
MAGNETIC SWITCH CHECK ............................. 29
PINION/CLUTCH CHECK ................................... 29
BRUSH CHECK .................................................. 29
YOKE CHECK ..................................................... 30
ARMATURE CHECK ........................................... 31
Assembly ................................................................ 32
PINION PROTRUSION LENGTH ADJUST-
MENT .................................................................. 32
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
Battery .................................................................... 34
Starter ..................................................................... 34
Alternator ................................................................ 34

BATTERY
SC-3
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BATTERY PFP:00011
How to Handle Battery EKS00313
CAUTION:

If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.

After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact.

Never add distilled water through the hole used to check specific gravity.
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.

The battery surface (particularly its top) should always be kept
clean and dry.

The terminal connections should be clean and tight.

At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”.

When the vehicle is not going to be used over a long period of
time, disconnect battery cable at negative terminal. (If the vehi-
cle has an extended storage switch, turn it off.)

Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep a
close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-
ing a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid con-
tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
MEL040F
ELA0349D
MEL042F