NISSAN NAVARA 2005 Repair Workshop Manual

PRECAUTIONS
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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

ATC-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
ATC-9
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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

ATC-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
ATC-11
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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: Genuine 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

ATC-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 CompressorEJS006AP
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 toATC-154, "
Service Data and Specifications (SDS)".
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 EquipmentEJS006AQ
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
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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

ATC-14
PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2²-16
ACME.
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset”and“Enter”at the same time.
2. Press “8787”.“A1” will be displayed.
3. Remove all weight from the scale.
4. Press “0”, then press “Enter”.“0.00” will be displayed and change to “A2”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb.) on the center
of the weight scale.
6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50)
7. Press “Enter”— the display returns to the vacuum mode.
8. Press“Shift/Reset”and“Enter”at the same time.
9. Press “6” — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00” will be displayed.
11. Press“Shift/Reset” to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.
Precautions for Leak Detection DyeEJS006AR
lThe A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
lAlways wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
lThe fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo-
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-
41995) to pin-point refrigerant leaks.
lFor your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions
and precautions prior to performing the work.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D
RHA274D

PRECAUTIONS
ATC-15
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lA compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
lAlways remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis
during a future service.
lDo not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
lDo not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
lDo not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.
lLeak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result.
lThe fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
Wiring Diagrams and Trouble DiagnosisEJS006AS
When you read wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams"
lPG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble diagnosis, refer to the following:
lGI-11, "How to Follow Trouble Diagnoses"
lGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident"
SHA749F

ATC-16
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEJS006AT
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
HFC-134a (R-134a) Service Tools and EquipmentEJS006AU
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor malfunction will result.
Tool number
Tool nameDescription
KV99106200
Pulley installerInstalling pulley
KV99233130
Pulley pullerRemoving pulley
S-NT235
LHA172
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color: Light blue
Container marking: HFC-134a (R-
134a)
Fitting size: Thread size
lLarge container 1/2²-16 ACME
KLH00-PAGS0
Nissan A/C System Oil Type S
(DH-PS)Type: Polyalkylene glycol oil (PAG),
type S (DH-PS)
Application: HFC-134a (R-134a)
wobble (swash) plate compressors
(Nissan only)
Lubricity: 40 m (1.4 Imp fl oz.)
S-NT196
S-NT197