NISSAN NAVARA 2005 Repair Workshop Manual

MTC-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS005QE
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Working with HFC-134a (R-134a)EJS00627
WARNING:
lCFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed and compressor
malfunction is likely occur.
lUse only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor malfunction is likely to occur.
lThe specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
–When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refriger-
ant. If accidental system discharge occurs, ventilate work area before resuming service. Addi-
tional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
–Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
Contaminated RefrigerantEJS0063C
If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are:
lExplain to the customer that environmental regulations prohibit the release of contaminated refrigerant
into the atmosphere.
lExplain that recovery of the contaminated refrigerant could damage your service equipment and refriger-
ant supply.
lSuggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
lIf you choose to perform the repair, recover the refrigerant using onlydedicated equipment and contain-
ers. Do not recover contaminated refrigerant into your existing service equipment.If your facility
does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for avail-
able service. This refrigerant must be disposed of in accordance with all federal and local regulations. In
addition, replacement of all refrigerant system components on the vehicle is recommended.

PRECAUTIONS
MTC-5
C
D
E
F
G
H
I
K
L
MA
B
MTC
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

MTC-6
PRECAUTIONS
FUNCTIONS OF COMPONENT PARTS
NOTE:
lGarter spring cannot be removed from cage of male-side piping.
lIndicator ring remains near piping connection point, however, this is not a malfunction. (This is to check
piping connection during factory assembly.)
REMOVAL
1. Clean piping connection point, and set a disconnector.
2. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector.
3. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter of
female-side piping flare. Then male-side piping can be disconnected.
Pipe (Male side)lRetains O-rings.
lRetains garter spring in cage.
Garter spring Anchors female side piping.
Indicator ringWhen connection is made properly, this is ejected from male-side piping. (This part is no longer neces-
sary after connection.)
O-ring Seals connection point. (Not reusable)
Pipe (Female side)
lSeals connection by compressing O-rings.
lAnchors piping connection using flare and garter spring.
SJIA0106E

PRECAUTIONS
MTC-7
C
D
E
F
G
H
I
K
L
MA
B
MTC
INSTALLATION
1. Clean piping connection points, and insert male-side piping into female-side piping.
2. Push inserted male-side piping harder so that female-side piping flare stretches garter spring.
3. If inside diameter of garter spring becomes larger than outside diameter of female-side piping flare, garter
spring seats on flare. Then, it fits in between male-side piping cage and female-side piping flare to anchor
piping connection point.
NOTICE:
When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare,
it clicks.
CAUTION:
lFemale-side piping connection point is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert it in axial direction.
lInsert piping securely until a click is heard.
lAfter piping connection is completed, pull male-side piping by hand to make sure connection
does not come loose.
NOTE:
One-touch joint connection is used in points below.
lLow-pressure flexible hose to evaporator (O-ring size: 16)
lHigh-pressure flexible hose to condenser (O-ring size: 12)
lHigh-pressure pipe 1 to high-pressure pipe 2 (O-ring size: 8)
lHigh-pressure pipe 1 to condenser (O-ring size: 8)
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
lThe O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
SJIA0107E

MTC-8
PRECAUTIONS
lThe reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-
itating piping connections.
SHA815E

PRECAUTIONS
MTC-9
C
D
E
F
G
H
I
K
L
MA
B
MTC
O-RING AND REFRIGERANT CONNECTION
A/C Compressor and Condenser —LHD Models—
MJIB0276E
1. High-pressure service valve 2. Clip 3. High-pressure A/C pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible A/C hose 8. Low-pressure flexible A/C hose 9. Low-pressure service valve
10. Low-pressure A/C pipe 11. Expansion valve 12. A/C drain hose

MTC-10
PRECAUTIONS
A/C Compressor and Condenser —RHD Models—
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at or
around the connection.
MJIB0277E
1. High-pressure service valve 2. Clip 3. High-pressure A/C pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible A/C hose 8. Low-pressure flexible A/C hose 9. Low-pressure service valve
10. Low-pressure A/C pipe 11. Expansion valve 12. A/C drain hose

PRECAUTIONS
MTC-11
C
D
E
F
G
H
I
K
L
MA
B
MTC
O-Ring Part Numbers and Specifications
*: Always check with the Parts Department for the latest parts information.
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
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 Lubricant Type S (DH-PS) or equivalent
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.
Connec-
tion typeO-ring
sizePart number* D mm (in) W mm (in)
New 8 92471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New
1292472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
1692473 N8210 13.6 (0.535) 2.43 (0.0957)
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
1992474 N8210 16.5 (0.650) 2.43 (0.0957)
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)
SHA814E

MTC-12
PRECAUTIONS
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 CompressorEJS00629
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 toMTC-24, "
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.
lAfter replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.
Precautions for Service EquipmentEJS0062A
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
RHA861F

PRECAUTIONS
MTC-13
C
D
E
F
G
H
I
K
L
MA
B
MTC
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.
lUsually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.
lFor pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
lIf the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2²-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shut-
off devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.
RHA270DA
SHA533D
RHA272D