cooling NISSAN NAVARA 2005 Repair Owners Manual

MA-22
ENGINE MAINTENANCE
lPull negative-pressure valve to open it, and make sure that it is
completely closed when released.
–Makesurethatthereisnodirtordamageonthevalveseatof
radiator cap negative-pressure valve.
–Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
lCheck reservoir tank cap relief pressure.
–When connecting reservoir tank cap to the radiator cap tester
adapter (SST) and the radiator cap tester (Commercial service
tool), apply engine coolant to the cap seal surface.
lReplace reservoir tank cap if there is an unusualness in negative pressure value, or if the relief pressure
falls below the limit.
CAUTION:
When installing a radiator cap and reservoir tank cap, thoroughly wipe out the radiator and reservoir
tank filler neck to remove any waxy residue or foreign material.
CHECKING RADIATOR SYSTEM FOR LEAKS
lTo check for leaks of cooling system, apply pressure to the res-
ervoir tank (1) with the radiator cap tester (commercial service
tool) (A) and the radiator cap tester adapter (B) [SST:
EG17650301].
WARNING:
Do not remove reservoir tank cap and/or radiator cap when
engine is hot. Serious burns could occur from high pres-
sure engine coolant escaping from reservoir tank and/or
radiator.
CAUTION:
Higher test pressure than specified may cause cooling system damage.
NOTE:
In a case that engine coolant decreases, replenish radiator and reservoir tank with engine coolant.
lIf anything is found, repair or replace damaged parts.
SMA967B
Standard : 98.2 - 117.8 kPa (0.98 - 1.18 bar, 1.0 -
1.2 kg/cm
2,14-17psi)
Limit : 59 kPa (0.59 bar, 0.6 kg/cm
2,9psi)
SLC755AC
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2,23psi)
PBIC3501E

MA-30
CHASSIS AND BODY MAINTENANCE
NOTE:
A/T fluid level will be greatly affected by temperature as shown in figure. Therefore, be certain to
perform operation while checking data with CONSULT-II.
a. Connect CONSULT-II to data link connector. Refer toAT-79, "
CONSULT-II SETTING PROCEDURE".
b. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
c. Readthevalueof“ATFTEMP1”.
7. Recheck A/T fluid level at A/T fluid temperatures of approximately 65°C(149°F)using“HOT”rangeonA/
T fluid level gauge.
CAUTION:
lWhen wiping away A/T fluid level gauge, always use lint-free paper, not a cloth one.
lTo check A/T fluid level, insert A/T fluid level gauge until
the cap contacts the end of A/T fluid charging pipe, with
A/T fluid level gauge reversed from the normal attach-
ment conditions as shown.
8. Check A/T fluid condition.
lIf ATF is very dark or smells burned, check operation of A/T.
Flush cooling system after repair of A/T.
lIf 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 toCO-11,
"RADIATOR".
9. Install the removed A/T fluid level gauge into A/T fluid charging
pipe.
10. Tighten level gauge bolt to the specified torque. Refer toAT-247,
"COMPONENTS".
SLIA0016E
SCIA2899E
SCIA4896E

MTC-2
Schematic —LHD MODELS— ............................... 38
Wiring Diagram —A/C— —LHD MODELS— ......... 39
Schematic —RHD MODELS— ............................... 44
Wiring Diagram —A/C— —RHD MODELS— ......... 45
Front Air Control Terminals and Reference Value... 49
PIN CONNECTOR TERMINAL LAYOUT ............ 49
TERMINALS AND REFERENCE VALUE FOR
FRONT AIR CONTROL ....................................... 49
A/C System Self-diagnosis Function ...................... 51
DESCRIPTION .................................................... 51
Operational Check .................................................. 53
CHECKING BLOWER ......................................... 53
CHECKING DISCHARGE AIR ............................ 53
CHECKING RECIRCULATION ............................ 53
CHECKING TEMPERATURE DECREASE ......... 54
CHECKING TEMPERATURE INCREASE .......... 54
CHECK A/C SWITCH .......................................... 54
Power Supply and Ground Circuit for Front Air Con-
trol ........................................................................... 55
INSPECTION FLOW ........................................... 55
COMPONENT DESCRIPTION ............................ 56
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 56
Mode Door Motor Circuit ........................................ 58
INSPECTION FLOW ........................................... 58
SYSTEM DESCRIPTION .................................... 59
COMPONENT DESCRIPTION ............................ 59
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 59
Air Mix Door Motor Circuit ...................................... 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 64
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (FRONT) .................................... 64
Intake Door Motor Circuit ........................................ 68
INSPECTION FLOW ........................................... 68
SYSTEM DESCRIPTION .................................... 69
COMPONENT DESCRIPTION ............................ 69
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 69
Blower Motor Circuit ............................................... 71
INSPECTION FLOW ........................................... 71
SYSTEM DESCRIPTION .................................... 72
COMPONENT DESCRIPTION ............................ 72
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ............................................................... 73
COMPONENT INSPECTION .............................. 77
Magnet Clutch Circuit ............................................. 79
INSPECTION FLOW ........................................... 79
SYSTEM DESCRIPTION .................................... 80
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 80
COMPONENT INSPECTION .............................. 85
Insufficient Cooling ................................................. 86
INSPECTION FLOW ........................................... 86
PERFORMANCE TEST DIAGNOSES ................ 87
PERFORMANCE CHART ................................... 89
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ................................................................... 90Insufficient Heating ................................................. 93
INSPECTION FLOW ............................................ 93
Noise ....................................................................... 94
INSPECTION FLOW ............................................ 94
Self-diagnosis ......................................................... 95
INSPECTION FLOW ............................................ 95
Intake Sensor Circuit ............................................... 95
COMPONENT DESCRIPTION ............................ 95
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ..................................................................... 96
COMPONENT INSPECTION ............................... 97
CONTROL UNIT ........................................................ 98
Removal and Installation ......................................... 98
REMOVAL ............................................................ 98
INSTALLATION .................................................... 98
INTAKE SENSOR ...................................................... 99
Removal and Installation ......................................... 99
REMOVAL ............................................................ 99
INSTALLATION .................................................... 99
BLOWER MOTOR ...................................................100
Components ..........................................................100
Removal and Installation .......................................100
REMOVAL ..........................................................100
INSTALLATION ..................................................100
AIR CONDITIONER FILTER ...................................101
Removal and Installation .......................................101
FUNCTION ........................................................101
REPLACEMENT TIMING ..................................101
REPLACEMENT PROCEDURE ........................101
HEATER & COOLING UNIT ASSEMBLY ...............103
Components ..........................................................103
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105
HEATER CORE .......................................................106
Components ..........................................................106
Removal and Installation .......................................107
REMOVAL ..........................................................107
INSTALLATION ..................................................107
DEFROSTER DOOR MOTOR .................................108
Components ..........................................................108
Removal and Installation .......................................108
REMOVAL ..........................................................108
INSTALLATION ..................................................108
INTAKE DOOR MOTOR ..........................................109
Components ..........................................................109
Removal and Installation .......................................109
REMOVAL ..........................................................109
INSTALLATION ..................................................109
MODE DOOR MOTOR ............................................110
Components ..........................................................110
Removal and Installation .......................................110
REMOVAL ..........................................................110
INSTALLATION ..................................................110
AIR MIX DOOR MOTOR ......................................... 111
Components .......................................................... 111
Removal and Installation ....................................... 111
REMOVAL .......................................................... 111
INSTALLATION .................................................. 111

PRECAUTIONS
MTC-5
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lIf the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NISSAN
Customer Affairs for further assistance.
General Refrigerant PrecautionsEJS00628
WARNING:
lDo not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
lAlways wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
lDo not store or heat refrigerant containers above 52°C.
lDo not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
lDo not intentionally drop, puncture, or incinerate refrigerant containers.
lKeep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
lRefrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
lDo not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refriger-
ant manufacturers.
Precautions for Refrigerant ConnectionEJS005FL
A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.
lExpansion valve to cooling unit
lEvaporator pipes to evaporator (inside cooling unit)
lRefrigerant pressure sensor
ABOUT ONE-TOUCH JOINT
Description
lOne-touch joints are pipe joints which do not require tools during piping connection.
lUnlike conventional connection methods using union nuts and flanges, controlling tightening torque at
connection point is not necessary.
lWhen removing a pipe joint, use a disconnector.
COMPONENT PARTS
RJIA0970E

REFRIGERATION SYSTEM
MTC-23
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1. Defroster nozzle 2. LH side demister duct 3. LH ventilator duct
4. RH side demister duct 5. RH ventilator duct 6. Center ventilator duct
7. Heater and cooling unit assembly 8. Floor duct 9. Clips
10. Heat duct

MTC-24
LUBRICANT
LUBRICANT
PFP:KLG00
Maintenance of Lubricant Quantity in CompressorEJS005FV
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 has occurred. It is important to maintain
the specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
lLack of lubricant: May lead to a seized compressor
lExcessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name: NISSAN A/C System Lubricant Type S (DH-PS)
Part number: KLH00-PAGS0
CHECKING AND ADJUSTING
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
Start the engine and set the following conditions:
test condition
lEngine speed: Idling to 1,200 rpm
lA/C switch: On
lBlower speed: Max. position
lTemp. control: Optional [Set so that intake air temperature is 25°to 30°C(77°to 86°F).]
lIntake position: Recirculation ( )
lPerform lubricant return operation for about ten minutes
Adjust the lubricant quantity according to the following table.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
l*1: If refrigerant leak is small, no addition of lubricant is needed.
Lubricant Adjustment Procedure for Compressor Replacement
1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
3. Drain the lubricant from the “old” (removed) compressor into a graduated container and recover the
amount of lubricant drained.
4. Drain the lubricant from the “new” compressor into a separate, clean container.
5. Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this
lubricant to “new” compressor through the suction port opening.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to “new” compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz) of lubricant if only replacing the compressor.
Part replacedLubricant to be added to system
Remarks
Amount of lubricant
m(Impfloz)
Evaporator 75 (2.6) —
Condenser 75 (2.6) —
Liquid tank 5 (0.2) Add if compressor is not replaced.
In case of refrigerant leak30 (1.1) Large leak
— Small leak *1

TROUBLE DIAGNOSIS
MTC-35
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How to Perform Trouble Diagnosis for Quick and Accurate RepairEJS005G5
WORK FLOW
SYMPTOM TABLE
*1: Self-diagnosis not available on vehicles not equipped with navigation system display screen.*1MTC-53, "
Operational Check"
SHA900E
Symptom Reference Page
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System.MTC-55
A/C system cannot be controlled. Go to Self-diagnosis Function.MTC-51
Air outlet does not change.
Go to Trouble Diagnosis Procedure for Mode Door Motor.MTC-58
Mode door motor is malfunctioning.
Discharge air temperature does not change.
Go to Trouble Diagnosis Procedure for Air Mix Door Motor.MTC-63
Air mix door motor is malfunctioning.
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor.MTC-68
Intake door motor is malfunctioning.
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor.MTC-71
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch.MTC-79
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.MTC-86
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating.MTC-93
Noise Go to Trouble Diagnosis Procedure for Noise.MTC-94
Self-diagnosis cannot be performed *1. Go to Trouble Diagnosis Procedure for Self-diagnosis.MTC-95

MTC-54
TROUBLE DIAGNOSIS
CHECKING TEMPERATURE DECREASE
1. Rotate temperature dial counterclockwise.
2. Check for cold air at appropriate discharge air outlets.
If NG, listen for sound of air mix door motor operation if OK, go to
trouble diagnosis procedure forMTC-86, "
Insufficient Cooling".Ifair
mix door motor appears to be malfunctioning, go toMTC-63, "
Air Mix
Door Motor Circuit".
If OK, continue with next check.
CHECKING TEMPERATURE INCREASE
1. Rotate temperature dial clockwise.
2. Check for hot air at appropriate discharge air outlets.
If NG, listen for sound of air mix door motor operation. If OK, go to
trouble diagnosis procedure forMTC-93, "
Insufficient Heating".Ifair
mix door motor appears to be malfunctioning, go toMTC-63, "
Air Mix
Door Motor Circuit".
If OK, continue with next check.
CHECK A/C SWITCH
1. Press A/C switch with the blower switch ON.
2. A/C switch indicator will turn ON.
lConfirm that the compressor clutch engages (sound or visual
inspection).
If NG, go to trouble diagnosis procedure forMTC-79, "
Magnet Clutch
Circuit".
If OK, continue with next check.
MJIB0226E
MJIB0227E
MJIB0228E

TROUBLE DIAGNOSIS
MTC-59
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SYSTEM DESCRIPTION
Component Parts
Mode door control system components are:
lFront air control
lMode door motor
lPBR (built into mode door motor)
System Operation
The mode door position (vent, B/L, foot, and defrost) is set by the front air control by means of the mode door
motor. When a mode door position is selected on the front air control, voltage is applied to one circuit of the
mode door motor while ground is applied to the other circuit, causing the mode door motor to rotate. The direc-
tion of rotation is determined by which circuit has voltage applied to it, and which one has ground applied to it.
The front air control monitors the mode door position by measuring the voltage signal on the PBR circuit.
Mode Door Control Specification
COMPONENT DESCRIPTION
Mode Door Motor
The mode door motor is attached to the heater & cooling unit. It
rotates so that air is discharged from the outlet as indicated by the
front air control. Motor rotation is conveyed to a link which activates
themodedoor.
NOTE:
This illustration is for LHD models.
The layout for RHD models is symmetrically opposite.
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR
1.CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS OR PROCEED FROM SYMPTOM
TABLE
Is vehicle equipped with NAVI?
YES or NO
YES >> GO TO 2.
NO >> GO TO 4.
2.CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS
Self-diagnosis code 92 is present. Refer toMTC-51, "
A/C System Self-diagnosis Function".
YES or NO
YES >> GO TO 3.
NO >> GO TO 4.
WJIA0434E
MJIB0191E

MTC-64
TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Air mix door control system components are:
lFront air control
lAir mix door motors (Front and rear)
lPBR (built-into air mix motors)
System Operation
The front air control receives data from the temperature selected by the driver and rear passenger. The front
air control then applies a voltage to one circuit of the appropriate air mix door motor, while ground is applied to
the other circuit, causing the appropriate air mix door motor to rotate. The direction of rotation is determined by
which circuit has voltage applied to it, and which one has ground applied to it. The front air control monitors the
air mix door positions by measuring the voltage signal on the PBR circuits of each door.
Air Mix Door Control Specification
COMPONENT DESCRIPTION
Air Mix Door Motors
The air mix door motor is attached to the heater & cooling unit. This
motor rotates so that the air mix door is opened or closed to a posi-
tion set by the front air control. Motor rotation is then conveyed
through a shaft and the air mix door position is then fed back to the
front air control by the PBR built into the air mix door motor.
NOTE:
This illustration is for LHD models.
The layout for RHD models is symmetrically opposite.
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (FRONT)
1.CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS OR PROCEED FROM SYMPTOM
TABLE
Is vehicle equipped with NAVI?.
YESorNO
YES >> GO TO 2.
NO >> GO TO 4.
2.CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS
Self-diagnosis code 22 is present. Refer toMTC-51, "
A/C System Self-diagnosis Function".
YESorNO
YES >> GO TO 3.
NO >> GO TO 4.
WJIA0435E
MJIB0192E