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Case Study: Full Air-Conditioning Restoration – 2020 Nissan Patrol

When the owner of this 2020 Y62 Nissan Patrol visited Rawson Motors, they reported that the air-conditioning system was no longer working. Given the size of the vehicle and its dual-zone A/C system, proper cooling throughout the cabin is essential—especially for families and long-distance touring.

Rawson Motors Full AC Restoration – 2020 Nissan Patrol

Our team had previously carried out diagnostic testing and confirmed the fault:
The A/C lines had become dislodged from their mountings and were rubbing, causing a leak. We identified the leak was located between the body and the chassis of the vehicle. Repairing these lines requires extensive access that is not possible with standard in-situ methods.

1. Initial Findings & Diagnosis

  • A/C completely inoperative
  • Confirmed line failure and refrigerant loss
  • Leak located within rear A/C pipework running between the body and chassis sections
  • Repairs required major disassembly and body-lift procedures to access affected components
Rawson Motors Full AC Restoration – 2020 Nissan Patrol - Line failure, leaks, refrigerant loss

2. Vehicle Preparation & Fluid Management

Before separating the cab from the chassis, all connected fluids and dependent systems must be safely drained or isolated:

  • Drained coolant
  • Drained power steering fluid
  • Drained brake fluid
  • Vacuumed the A/C system
  • Ensured all lines were depressurised and safe to disconnect

3. Disassembly & Cab-Lift Process

To access the A/C pipework, a large portion of the body structure required removal. The team undertook the following:

External & Structural Component Removal

  • Removed rear bumper cover and accessories
  • Removed front bumper cover and accessories
  • Removed inner guard liners
  • Removed relevant trims
  • Removed core support and reinforcement systems
  • Removed thermo fan shroud

Mechanical & System Disconnections

  • Disconnected battery cables
  • Disconnected handbrake cable
  • Disconnected transmission cables
  • Disconnected fuel filler neck
  • Removed intake airbox and related assemblies

Wiring, Brake & Cooling System Disconnections

  • Disconnected wiring harnesses
  • Disconnected brake hoses where required
  • Disconnected cooling system hoses
  • Disconnected wheel speed sensors
  • Disconnected breathers and body harnesses

Body-to-Chassis Separation

  • Loosened and removed all body mounts
  • Completed the full body-from-chassis lift to expose the A/C lines routed between the chassis rails and underbody structures

This provided the clear access required to safely replace the damaged lines.

Rawson Motors Full AC Restoration – 2020 Nissan Patrol - Dissasembly & Cab Off

4. A/C & Heater Line Replacement

With the body lifted:

  • Located and replaced the failed A/C pipes
  • Replaced an additional heater pipe discovered to be degraded
  • Ensured all mounting points, insulation and grommets were correctly fitted to prevent future wear
Rawson Motors Full AC Restoration – 2020 Nissan Patrol - AC Heater Lines

5. Reassembly & System Restoration

The vehicle was then reassembled with the same level of care and precision:

  • Reversed the entire disassembly procedure
  • Reconnected all wiring, mechanical systems and lines
  • Refilled, bled and calibrated all fluids: Coolant, Brake fluid, Power steering fluid
  • Re-evacuated and re-gassed the A/C system
  • Performed full leak testing and operational verification

6. The Final Result

After thorough testing, the Patrol’s air-conditioning systems were fully restored, with strong, consistent cooling throughout the cabin. No leaks were detected and all vehicle systems operated as intended.

This repair required significant expertise, specialist equipment and a structured workflow to ensure the vehicle was returned to factory-level performance.

At Rawson Motors, we’re equipped and experienced to handle even the most complex repairs with excellent attention to detail. Sometimes the little things, are the big things. Book in your vehicle with us today, use the booking form below or call us directly.

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