NISSAN NAVARA 2005 Repair Workshop Manual

SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS00G3O
*1: Refer toMA-14, "RECOMMENDED FLUIDS AND LUBRICANTS".
Stall SpeedECS00G3R
Line PressureECS00G3S
Applied modelYD25DDTi engine
2WD 4WD
Automatic transmission model RE5R05A
Transmission model code number 95X09 95X0C, 95X11
Stall torque ratio2.0 : 1
Transmission gear ratio1st 3.827
2nd 2.368
3rd 1.519
4th 1.000
5th 0.834
Reverse 2.613
Recommended fluid Genuine NISSAN ATF Matic Fluid J*1
Fluid capacity 10.3 liter (9-1/8 Imp qt)
CAUTION:
lUse only Genuine NISSAN ATF Matic Fluid J. Do not mix with other fluid.
lUsing A/T fluid other than Genuine NISSAN ATF Matic Fluid J will cause deterioration in driveability and A/T durability, and
may damage the A/T, which is not covered by the NISSAN new vehicle warranty.
Stall speed2,700 - 3,100 rpm
Engine speedLine pressure [kPa (bar, kg/cm2,psi)]
“R” position “D” position
At idle speed 425 - 465 (4.3 - 4.6, 4.3 - 4.7, 62 - 67) 379 - 428 (3.8 - 4.3, 3.9 - 4.4, 55 - 62)
At stall speed 1,605 - 1,950 (16.0 - 19.5, 16.4 - 19.9, 233 - 283) 1,310 - 1,500 (13.1 - 15.0, 13.4 - 15.3, 190 - 218)

AT-324
SERVICE DATA AND SPECIFICATIONS (SDS)
Vehicle Speed at Which Gear Shifting Occurs
ECS00H8W
2WD MODELS
lAt half throttle, the accelerator opening is 4/8 of the full opening.
4WD MODELS
lAt half throttle, the accelerator opening is 4/8 of the full opening.
Vehicle Speed at Which Lock-Up Occurs/ReleasesECS00H8X
2WD MODELS
lAt closed throttle, the accelerator opening is less than 1/8 condition. (Closed throttle position signal: OFF)
lAt half throttle, the accelerator opening is 4/8 of the full opening.
4WD MODELS
lAt closed throttle, the accelerator opening is less than 1/8 condition. (Closed throttle position signal: OFF)
lAt half throttle, the accelerator opening is 4/8 of the full opening.
A/T Fluid Temperature SensorECS00G3T
Tire sizeThrottle
positionVehicle speed [km/h (MPH)]
D1®D2D2®D3D3®D4D4®D5D5®D4D4®D3D3®D2D2®D1
255/65 R17
255/70 R16Full
throttle41 - 45
(25 - 28)66 - 72
(41 - 45)103 - 113
(64 - 70)148 - 164
(92 - 102)144 - 160
(89 - 99)92 - 102
(57 - 63)53 - 59
(33 - 37)23 - 24
(14 - 15)
Half
throttle34 - 38
(21 - 24)55 - 61
(34 - 38)86 - 96
(53 - 60)118 - 130
(73 - 81)88 - 98
(55 - 61)60 - 66
(37 - 41)39 - 43
(24 - 27)10 - 11
(6 - 7)
Tire sizeThrottle
positionVehiclespeed [km/h(MPH)]
D1®D2D2®D3D3®D4D4®D5D5®D4D4®D3D3®D2D2®D1
255/65 R17
255/70 R16Full
throttle38 - 42
(24 - 26)62 - 68
(39 - 42)97 - 107
(60 - 66)141 - 155
(88 - 96)137 - 151
(85 - 94)87 - 97
(54 - 60)50 - 56
(31 - 35)22 - 24
(14 - 15)
Half
throttle32 - 36
(20 - 22)52 - 58
(32 - 36)82 - 90
(51 - 56)117 - 129
(73 - 80)83 - 91
(52 - 57)57 - 63
(35 - 39)37 - 41
(23 - 25)10 - 11
(6 - 7)
265/70 R16LTFull
throttle40 - 44
(25 - 27)65 - 71
(40 - 44)101 - 111
(63 - 69)145 - 161
(90 - 100)142 - 156
(88 - 97)90 - 100
(56 - 62)52 - 58
(32 - 36)23 - 25
(14 - 16)
Half
throttle33 - 37
(21 - 23)54 - 60
(34 - 37)85 - 93
(53 - 58)121 - 133
(75 - 83)85 - 95
(53 - 59)59 - 65
(37 - 40)38 - 42
(24 - 26)10 - 11
(6 - 7)
Tire size Throttle positionVehicle speed [km/h (MPH)]
Lock-up ON Lock-up OFF
255/65 R17
255/70 R16Closed throttle 73 - 81 (45 - 50) 70 - 78 (44 - 48)
Half throttle 141 - 155 (88 - 96) 130 - 144 (81 - 89)
Tire size Throttle positionVehicle speed [km/h (MPH)]
Lock-up ON Lock-up OFF
255/65 R17
255/70 R16Closed throttle 69 - 77 (43 - 48) 66 - 74 (41 - 46)
Half throttle 134 - 148 (83 - 92) 123 - 137 (76 - 85)
265/70 R16LTClosed throttle 72 - 80 (45 - 50) 69 - 77 (43 - 48)
Half throttle 139 - 153 (86 - 95) 128 - 142 (80 - 88)
Name Condition CONSULT-II “DATA MONITOR” (Approx.) Resistance (Approx.)
ATFTEMPSE10°C(32°F) 3.3 V 15 kW
20°C(68°F) 2.7 V 6.5 kW
80°C(176°F) 0.9 V 0.9 kW
ATFTEMPSE20°C(32°F) 3.3 V 10 kW
20°C(68°F) 2.5V 4kW
80°C(176°F) 0.7 V 0.5 kW

SERVICE DATA AND SPECIFICATIONS (SDS)
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Vehicle Speed Sensor A/T (Revolution Sensor)ECS00G3V
Turbine Revolution SensorECS00G3U
Reverse BrakeECS00G3W
*: Always check with the Parts Department for the latest parts information.
To ta l E n d P l a yECS00G3X
Name Condition Data (Approx.)
Revolution sensor When moving at 20 km/h (12 MPH). 185 Hz
Name ConditionData
(Approx.)
Turbine revolution
sensor 1When running at 50 km/h (31 MPH) in 4th gear with the closed throttle position signal “OFF”.
1.3 kHz
Turbine revolution
sensor 2When running at 20 km/h (12 MPH) in 1st gear with the closed throttle position signal “OFF”.
Number of drive plates7
Number of driven plates7
Clearance mm (in) Standard 0.7 - 1.1 (0.028 - 0.043)
Total end play [mm (in)] 0.25 - 0.55 (0.0098 - 0.0217)

AT-326
SERVICE DATA AND SPECIFICATIONS (SDS)

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
Contaminated Refrigerant ........................................ 4
General Refrigerant Precautions .............................. 5
Precautions for Refrigerant Connection ................... 5
ABOUT ONE-TOUCH JOINT ................................ 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 7
O-RING AND REFRIGERANT CONNECTION..... 9
Precautions for Servicing Compressor ................... 12
Precautions for Service Equipment ........................ 12
RECOVERY/RECYCLING EQUIPMENT ............ 12
ELECTRONIC LEAK DETECTOR ...................... 12
VACUUM PUMP ................................................. 13
MANIFOLD GAUGE SET .................................... 13
SERVICE HOSES ............................................... 13
SERVICE COUPLERS ........................................ 14
REFRIGERANT WEIGHT SCALE ...................... 14
CALIBRATING ACR4 WEIGHT SCALE .............. 14
CHARGING CYLINDER ...................................... 14
Precautions for Leak Detection Dye ....................... 14
IDENTIFICATION ................................................ 15
IDENTIFICATION LABEL FOR VEHICLE ........... 15
Wiring Diagrams and Trouble Diagnosis ................ 15
PREPARATION ......................................................... 16
Special Service Tools ............................................. 16
HFC-134a (R-134a) Service Tools and Equipment... 16
Commercial Service Tools ...................................... 19
REFRIGERATION SYSTEM ..................................... 20
Refrigerant Cycle ................................................... 20
REFRIGERANT FLOW ....................................... 20
FREEZE PROTECTION ..................................... 20
Refrigerant System Protection ............................... 20
REFRIGERANT PRESSURE SENSOR ............. 20
PRESSURE RELIEF VALVE ............................... 21
Components ........................................................... 22
REFRIGERATION SYSTEM ............................... 22LUBRICANT .............................................................. 24
Maintenance of Lubricant Quantity in Compressor... 24
LUBRICANT ........................................................ 24
CHECKING AND ADJUSTING ............................ 24
AIR CONDITIONER CONTROL ............................... 26
Description .............................................................. 26
Operation ................................................................ 26
AIR MIX DOORS CONTROL .............................. 26
BLOWER SPEED CONTROL ............................. 26
INTAKE DOOR CONTROL ................................. 26
MODE DOOR CONTROL ................................... 26
DEFROSTER DOOR CONTROL ........................ 26
MAGNET CLUTCH CONTROL ........................... 27
SELF-DIAGNOSTIC SYSTEM ............................ 27
Description of Control System ................................ 28
Control Operation ................................................... 28
DISPLAY SCREEN .............................................. 29
AUTO SWITCH ................................................... 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE CONTROL) (DRIVER SIDE) ..................... 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE CONTROL) (PASSENGER SIDE) ............ 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE AND MODE CONTROL) (REAR) ............. 29
RECIRCULATION (REC) SWITCH ..................... 29
DEFROSTER (DEF) SWITCH ............................. 29
REAR WINDOW DEFOGGER SWITCH ............. 29
OFF SWITCH ...................................................... 29
A/C SWITCH ....................................................... 29
MODE SWITCH (FRONT) ................................... 29
FRONT BLOWER CONTROL DIAL .................... 29
MODE SWITCH (REAR) ..................................... 29
Discharge Air Flow ................................................. 30
FRONT ................................................................ 30
System Description ................................................. 31
SWITCHES AND THEIR CONTROL FUNCTION... 31
CAN Communication System Description .............. 32
TROUBLE DIAGNOSIS ............................................ 33
CONSULT-II Function (BCM) ................................. 33
CONSULT-II BASIC OPERATION ....................... 33

ATC-2
DATA MONITOR .................................................. 34
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 35
WORK FLOW ...................................................... 35
SYMPTOM TABLE .............................................. 35
Component Parts and Harness Connector Location... 36
ENGINE COMPARTMENT .................................. 36
FRONT PASSENGER COMPARTMENT ............ 37
Schematic —LHD MODELS— ............................... 38
Wiring Diagram —A/C— —LHD MODELS— ......... 39
Schematic —RHD MODELS— ............................... 46
Wiring Diadram —A/C— —RHD MODELS— ......... 47
Front Air Control Terminals and Reference Value... 53
PIN CONNECTOR TERMINAL LAYOUT ............ 53
TERMINALS AND REFERENCE VALUE FOR
FRONT AIR CONTROL ....................................... 53
A/C System Self-diagnosis Function ...................... 55
DESCRIPTION .................................................... 55
Operational Check .................................................. 57
CHECKING MEMORY FUNCTION ..................... 57
CHECKING BLOWER ......................................... 57
CHECKING DISCHARGE AIR ............................ 58
CHECKING RECIRCULATION ............................ 58
CHECKING TEMPERATURE DECREASE ......... 58
CHECKING TEMPERATURE INCREASE .......... 59
CHECK A/C SWITCH .......................................... 59
CHECKING AUTO MODE ................................... 59
Power Supply and Ground Circuit for Front Air Con-
trol ........................................................................... 60
INSPECTION FLOW ........................................... 60
COMPONENT DESCRIPTION ............................ 61
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 61
Mode Door Motor Circuit ........................................ 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 65
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 65
Air Mix Door Motor Circuit ...................................... 68
INSPECTION FLOW ........................................... 68
SYSTEM DESCRIPTION .................................... 69
COMPONENT DESCRIPTION ............................ 70
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (DRIVER) ................................... 71
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (PASSENGER) .......................... 73
Intake Door Motor Circuit ........................................ 77
INSPECTION FLOW ........................................... 77
SYSTEM DESCRIPTION .................................... 78
COMPONENT DESCRIPTION ............................ 79
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 79
Blower Motor Circuit ............................................... 80
INSPECTION FLOW ........................................... 80
SYSTEM DESCRIPTION .................................... 81
COMPONENT DESCRIPTION ............................ 82
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ............................................................... 82
COMPONENT INSPECTION .............................. 86Magnet Clutch Circuit .............................................. 87
INSPECTION FLOW ............................................ 87
SYSTEM DESCRIPTION ..................................... 88
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 88
COMPONENT INSPECTION ............................... 92
Insufficient Cooling .................................................. 93
INSPECTION FLOW ............................................ 93
PERFORMANCE TEST DIAGNOSES ................ 94
PERFORMANCE CHART .................................... 96
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ................................................................... 97
Insufficient Heating ...............................................100
INSPECTION FLOW ..........................................100
Noise .....................................................................101
INSPECTION FLOW ..........................................101
Self-diagnosis .......................................................103
INSPECTION FLOW ..........................................103
Memory Function ..................................................104
INSPECTION FLOW ..........................................104
Ambient Sensor Circuit .........................................105
COMPONENT DESCRIPTION ..........................105
AMBIENT TEMPERATURE INPUT PROCESS.105
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ............................................................105
COMPONENT INSPECTION .............................107
In-vehicle Sensor Circuit .......................................108
COMPONENT DESCRIPTION ..........................108
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR ............................................................109
COMPONENT INSPECTION ............................. 111
Optical Sensor Circuit ...........................................112
COMPONENT DESCRIPTION ..........................112
OPTICAL INPUT PROCESS .............................112
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR ............................................................112
Intake Sensor Circuit .............................................114
COMPONENT DESCRIPTION ..........................114
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ...................................................................114
COMPONENT INSPECTION .............................115
CONTROL UNIT ......................................................116
Removal and Installation .......................................116
REMOVAL ..........................................................116
INSTALLATION ..................................................116
AMBIENT SENSOR ................................................117
Removal and Installation .......................................117
REMOVAL ..........................................................117
INSTALLATION ..................................................117
IN-VEHICLE SENSOR ............................................118
Removal and Installation .......................................118
REMOVAL ..........................................................118
INSTALLATION ..................................................118
OPTICAL SENSOR .................................................119
Removal and Installation .......................................119
INTAKE SENSOR ....................................................120
Removal and Installation .......................................120
REMOVAL ..........................................................120
INSTALLATION ..................................................120

ATC-3
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AT C BLOWER MOTOR .................................................. 121
Components ......................................................... 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 121
AIR CONDITIONER FILTER ................................... 122
Removal and Installation ...................................... 122
FUNCTION ........................................................ 122
REPLACEMENT TIMING .................................. 122
REPLACEMENT PROCEDURE ....................... 122
HEATER & COOLING UNIT ASSEMBLY .............. 124
Components ......................................................... 124
Removal and Installation ...................................... 126
REMOVAL ......................................................... 126
INSTALLATION ................................................. 126
HEATER CORE ...................................................... 127
Components ......................................................... 127
Removal and Installation ...................................... 127
REMOVAL ......................................................... 127
INSTALLATION ................................................. 127
HEATER PUMP ...................................................... 128
Components ......................................................... 128
Removal and Installation ...................................... 128
REMOVAL ......................................................... 128
INSTALLATION ................................................. 128
INTAKE DOOR MOTOR ......................................... 129
Components ......................................................... 129
Removal and Installation ...................................... 129
REMOVAL ......................................................... 129
INSTALLATION ................................................. 129
MODE DOOR MOTOR ........................................... 130
Components ......................................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130
AIR MIX DOOR MOTOR ......................................... 131
Components ......................................................... 131
Removal and Installation ...................................... 131
AIR MIX DOOR MOTOR (DRIVER) .................. 131
AIR MIX DOOR MOTOR (PASSENGER) ......... 131
VARIABLE BLOWER CONTROL .......................... 133
Components ......................................................... 133
Removal and Installation ...................................... 133
REMOVAL ......................................................... 133
INSTALLATION ................................................. 133
DUCTS AND GRILLES .......................................... 134
Components ......................................................... 134
Removal and Installation ...................................... 136
CONSOLE DUCTS AND CONSOLE GRILLE .. 136
DEFROSTER NOZZLE ..................................... 136
RH AND LH SIDE DEMISTER DUCT ............... 136
RH AND LH VENTILATOR DUCT ..................... 136
CENTER VENTILATOR DUCT ......................... 136
FLOOR CONNECTOR DUCT ........................... 136
FRONT AND REAR FLOOR DUCTS ............... 137
REAR OVERHEAD DUCTS .............................. 137
SIDE REAR FLOOR DUCT .............................. 137
GRILLES ........................................................... 137REFRIGERANT LINES ...........................................138
HFC-134a (R-134a) Service Procedure ...............138
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................138
Components .........................................................140
Removal and Installation for Compressor ............142
REMOVAL .........................................................142
INSTALLATION .................................................142
Removal and Installation for Compressor Clutch . 143
REMOVAL .........................................................143
INSPECTION ....................................................144
INSTALLATION .................................................144
BREAK-IN OPERATION ....................................146
Removal and Installation for High-pressure Flexible
A/C Hose ..............................................................146
REMOVAL .........................................................146
INSTALLATION .................................................146
Removal and Installation for High-pressure A/C
Pipe ......................................................................146
REMOVAL .........................................................146
INSTALLATION .................................................146
Removal and Installation for Low-pressure Flexible
A/C Hose ..............................................................146
REMOVAL .........................................................146
INSTALLATION .................................................146
Removal and Installation for Low-pressure A/C Pipe.147
REMOVAL .........................................................147
INSTALLATION .................................................147
Removal and Installation for Refrigerant Pressure
Sensor ..................................................................147
REMOVAL .........................................................147
INSTALLATION .................................................147
Removal and Installation for Condenser ..............147
REMOVAL .........................................................147
INSTALLATION .................................................148
Removal and Installation for Evaporator ..............149
REMOVAL .........................................................149
INSTALLATION .................................................149
Removal and Installation for Expansion Valve ......150
REMOVAL .........................................................150
INSTALLATION .................................................150
Checking for Refrigerant Leaks ............................150
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................150
Dye Injection .........................................................151
Electronic Refrigerant Leak Detector ....................151
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................151
CHECKING PROCEDURE ...............................152
SERVICE DATA AND SPECIFICATIONS (SDS) ....154
Service Data and Specifications (SDS) ................154
COMPRESSOR ................................................154
LUBRICANT ......................................................154
REFRIGERANT .................................................154
ENGINE IDLING SPEED ..................................154
BELT TENSION .................................................154

ATC-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS006AK
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)EJS006AL
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 RefrigerantEJS006AM
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
ATC-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 PrecautionsEJS006AN
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 ConnectionEJS006AO
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

ATC-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