charging NISSAN NAVARA 2005 Repair Owner's Guide

PREPARATION
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Recovery/Recycling/
Recharging equipment (ACR4)Function: Refrigerant recovery and
recycling and recharging
Electrical leak detectorPower supply:
DC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
(J-42220)
UV lamp and UV safety gogglesPower supply:
DC 12V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PA G o i l
Container: 1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.) Tool number
Tool nameDescription
RJIA0195E
SHA705EB
ZHA200H
SHA438F
SHA439F

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

HEATER & COOLING UNIT ASSEMBLY
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Removal and InstallationEJS005GY
REMOVAL
1. Discharge the refrigerant from the A/C system. Refer toMTC-118, "Discharging Refrigerant".
2. Drain the coolant from the engine cooling system. Refer toCO-8, "
DRAINING ENGINE COOLANT".
3. Remove the cowl top extension. Refer toEI-20, "
Removal and Installation".
4. Remove the exhaust system. Refer toEX-3, "
Removal and Installation".
5. Disconnect the heater hoses from the heater core.
6. Disconnect the high/low pressure pipes from the expansion valve.
7. Move the two front seats to the rearmost position on the seat track.
8. Remove the instrument panel and console panel. Refer toIP-10, "
Removal and Installation".
9. Remove the steering column. Refer toPS-11, "
Removal and Installation".
10. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (J/B) electrical connectors. Refer toPG-38, "
Harness Layout".
11. Disconnect the steering member from each side of the vehicle body.
12. Remove the heater and cooling unit assembly with it attached to the steering member, from the vehicle.
CAUTION:
Use care not to damage the seats and interior trim panels when removing the heater and cooling
unit assembly with it attached to the steering member.
13. Remove the heater and cooling unit assembly from the steering member.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply
compressor oil to it when installing it.
lAfter charging the refrigerant, check for leaks.
NOTE:
lFill the engine cooling system with the specified coolant mixture. Refer toCO-8, "REFILLING ENGINE
COOLANT".
lRecharge the A/C system. Refer toMTC-118, "Evacuating System and Charging Refrigerant".

MTC-118
REFRIGERANT LINES
REFRIGERANT LINES
PFP:92600
HFC-134a (R-134a) Service ProcedureEJS005HA
SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant
WARNING:
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) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
Evacuating System and Charging Refrigerant
1. Shut-off valve 2. A/C service valve 3. Recovery/Recycling equipment ACR 2000
(J-43600) with refrigerant identifier
WJIA0579E
1. Shut-off valve 2. A/C service valve 3. Recovery/Recycling equipment ACR
2000 (J-43600) with refrigerant identifier
4. Refrigerant container (HFC-134a) 5. Weight scale (J-39650) 6. Evacuating vacuum pump (J-39699)
7. Manifold gauge set (J-39183)
WJIA0580E

MTC-122
REFRIGERANT LINES
Removal and Installation for Compressor
EJS005HC
A/C Compressor Mounting
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the front right wheel and tire assembly. Refer toWT-5, "
Rotation".
3. Remove the engine under cover and the splash shield using power tool.
4. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
5. Remove the drive belt. Refer toEM-12, "
DRIVE BELTS".
6. Disconnect the compressor electrical connector.
7. Disconnect the high-pressure flexible hose and low-pressure flexible hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
8. Remove the compressor bolts and nut using power tools.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new
one, apply compressor oil to the O-rings before installation.
lAfter recharging the A/C system with refrigerant, check for leaks.
MJIB0179E
1. Compressor 2. Alternator and A/C compressor
bracket3. Timing chain case
4. Cylinder block

MTC-126
REFRIGERANT LINES
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".

REFRIGERANT LINES
MTC-127
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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.
LJIA0145E

MTC-128
REFRIGERANT LINES
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.
LJIA0145E

MTC-130
REFRIGERANT LINES
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"
.

REFRIGERANT LINES
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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.