NISSAN NAVARA 2005 Repair Workshop Manual

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5. Remove the pulley using Tool with a small adapter. Position the
small adapter on the end of the drive shaft and the center of the
puller on the small adapter.
CAUTION:
To prevent deformation of the pulley groove, the puller
claws should be hooked under the pulley groove and not
into the pulley groove.
6. Remove the magnet coil harness clip using a screwdriver,
remove the three magnet coil fixing screws and remove the
magnet coil.
INSPECTION
Clutch Disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.
Pulley
Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving,
replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable
solvent before reinstallation.
Coil
Check magnet coil for loose connections or any cracked insulation.
INSTALLATION
1. Install the magnet coil.
CAUTION:
Be sure to align the magnet coil pin with the hole in the
compressor front head.
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2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
4. Install the clutch disc on the compressor shaft, together with the
original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc
from turning and tighten the bolt to specification. Refer toMTC-
120, "Components".
CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as
shown.
7. If the specified clearance is not obtained, replace the adjusting
spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer toEM-12, "
DRIVE BELTS".
10. Install the engine under cover and the splash shield.Tool number : KV99106200
MJIB0290E
WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
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BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-pressure Flexible HoseEJS005HE
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
3. Remove the cowl top extension. Refer toEI-20, "
COWL TOP".
4. Discharge the refrigerant. Refer toMTC-118, "
HFC-134a (R-134a) Service Procedure".
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 low-pressure flexible hose. Refer toMTC-120, "
Components".
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lReplace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseEJS005HF
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT"
3. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
4. Remove the high-pressure flexible hose. Refer toMTC-120, "
Components".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lReplace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeEJS005HG
REMOVAL
1. Remove the cowl top extension. Refer toEI-20, "COWL TOP".
2. Disconnect the battery negative cable.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer toWT-5, "
Rotation".
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer toMTC-118, "
HFC-134a (R-134a) Service Procedure".
7. Remove the low pressure pipe. Refer toMTC-127, "
Removal and Installation for Low-pressure Pipe".
8. Remove the high-pressure pipe. Refer toMTC-120, "
Components".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".

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CAUTION:
lReplace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Low-pressure PipeEJS005HH
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the cowl top and the cowl top extension. Refer toEI-20, "
COWL TOP".
3. Remove the low-pressure pipe. Refer toMTC-120, "
Components".
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lReplace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Refrigerant Pressure SensorEJS005HI
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the refrigerant pressure sensor electrical connector
and remove the refrigerant pressure sensor from the condenser.
CAUTION:
Be careful not to damage the condenser fins.
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lBe careful not to damage the condenser fins.
lApply compressor oil to the O-ring of the refrigerant pressure sensor when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for CondenserEJS005HJ
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the radiator. Refer toCO-11, "
RADIATOR".
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
3. Disconnect the high-pressure flexible hose and the high-pressure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
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4. Disconnect the refrigerant pressure sensor connector.
lRemove the refrigerant pressure sensor from the condenser
as necessary.
5. Lift the condenser out of the mounting grommets to remove the
condenser.
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lReplace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
lAfter charging refrigerant, check for leaks.
lReplace the grommets as necessary.
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Removal and Installation for EvaporatorEJS005HK
Heater and Cooling Unit Assembly
MJIB0252E
1. Heater core cover 2. Heater core pipe bracket 3. Heater core
4. Upper bracket 5. Upper heater and cooling unit case 6. A/C evaporator
7. Lower heater and cooling unit case 8. Blower motor 9. Blower motor resistor

MTC-130
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REMOVAL
1. Remove the heater core. Refer toMTC-106, "HEATER CORE".
2. Remove the defroster mode door arm.
3. Separate the heater core and cooling unit case.
4. Remove the evaporator.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace the O-rings on the low-pressure flexible hose and the high-pressure pipe with new ones.
Apply compressor oil to the O-rings before installing them.
Removal and Installation for Expansion ValveEJS005HM
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the heater and cooling unit assembly. Refer toMTC-103, "
HEATER&COOLING UNIT ASSEM-
BLY".
3. Remove the cooler grommet.
4. Remove the expansion valve.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-rings on the A/C refrigerant pipes with new ones, then apply compressor oil to them
when installing them.
lAfter charging refrigerant, check for leaks.
WJIA0582E
Expansion valve bolts : 4 N·m (0.41 kg-m, 35 in-lb)
A/C refrigerant pipe to expansion valve bolt : Refer toMTC-120, "
Components"
.

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Checking for Refrigerant LeaksEJS0062F
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 DetectorEJS0062G
1. Check A/C system for leaks using the UV lamp and safety goggles [SST: 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 open-
ing indicates 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 [SST: J-43872] to prevent future mis-
diagnosis.
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 InjectionEJS0062H
(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 [SST: 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
connection 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 Detector
EJS0062I
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly 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.
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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 (SST) to the A/C service valves.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50 psi) above 16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refriger-
ant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2,50psi).
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 l). Refer toMTC-120, "
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 flexible hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
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 door 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
pressure 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.
SHA839E