cooling NISSAN NAVARA 2005 Repair Owner's Guide

VARIABLE BLOWER CONTROL
ATC-133
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VARIABLE BLOWER CONTROLPFP:27200
ComponentsEJS006CH
Variable Blower Control - Heater and Cooling Unit Assembly
NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.
Removal and InstallationEJS006DF
REMOVAL
1. Disconnect the variable blower control electrical connector.
2. Remove the two screws and remove the variable blower control.
INSTALLATION
Installation is in the reverse order of removal.
1. Heater and cooling unit assembly 2. Intake door motor 3. Air mix door motor (driver)
4. Variable blower control 5. Air mix door motor (passenger) 6. Mode door motor
LBIA0415E

ATC-134
DUCTS AND GRILLES
DUCTS AND GRILLES
PFP:27860
ComponentsEJS006CJ
Ducts - Heater and Cooling Unit Assembly
MJIB0212E
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 connector duct grilles 9. Floor connector duct

ATC-136
DUCTS AND GRILLES
Removal and Installation
EJS006CK
CONSOLE DUCTS AND CONSOLE GRILLE
Removal
The center console must be removed and disassembled to remove the console ducts and the console grille.
Refer toIP-16, "
CENTER CONSOLE".
Installation
Installation is in the reverse order of removal.
DEFROSTER NOZZLE
Removal
1. Remove the instrument panel trim. Refer toIP-10, "Removal and Installation".
2. Remove the defroster nozzle.
Installation
Installation is in the reverse order of removal.
RH AND LH SIDE DEMISTER DUCT
Removal
1. Remove the instrument panel trim. Refer toIP-10, "Removal and Installation".
2. Remove the center console. Refer toIP-16, "
CENTER CONSOLE".
3. Remove the RH or LH side demister duct.
Installation
Installation is in the reverse order of removal.
RH AND LH VENTILATOR DUCT
Removal
1. Remove the instrument panel trim. Refer toIP-10, "Removal and Installation".
2. Remove the center console. Refer toIP-16, "
CENTER CONSOLE".
3. Remove the RH or LH ventilator duct.
Installation
Installation is in the reverse order of removal.
CENTER VENTILATOR DUCT
Removal
1. Remove the heater and cooling unit assembly. Refer toATC-126, "REMOVAL".
2. Remove the center console. Refer toIP-16, "
CENTER CONSOLE".
3. Remove the defroster nozzle.
4. Remove the RH and LH ventilator ducts.
5. Remove the RH and LH side demister ducts.
6. Remove the center ventilator duct.
Installation
Installation is in the reverse order of removal.
FLOOR CONNECTOR DUCT
Removal
1. Remove the heater and cooling unit assembly. Refer toATC-126, "REMOVAL".
2. Remove the center console. Refer toIP-16, "
CENTER CONSOLE".
3. Remove the floor connector duct.
Installation
Installation is in the reverse order of removal.

REFRIGERANT LINES
ATC-149
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Removal and Installation for EvaporatorEJS006CX
Heater and Cooling Unit Assembly
REMOVAL
1. Remove the heater core. Refer toATC-127, "REMOVAL".
2. Separate the heater and cooling unit case.
3. Remove the evaporator.
INSTALLATION
Installation is in the reverse order of removal.
MJIB0214E
1. Center ventilator connector duct 2. Heater core cover 3. Intake air case
4. Heater core and evaporator pipes
bracket5. Heater core and evaporator pipes
grommet6. Heater core
7. Upper heater and cooling unit case 8. Expansion valve 9. Evaporator
10. Lower heater and cooling unit case 11. Variable blower control 12. Blower motor

ATC-150
REFRIGERANT LINES
CAUTION:
Replace the O-rings on the A/C low-pressure flexible A/C hose and the high-pressure A/C pipe with
new ones. Apply compressor oil to the O-rings for installation.
Removal and Installation for Expansion ValveEJS006CZ
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Remove the heater and cooling unit assembly. Refer toATC-126, "
REMOVAL".
3. Remove the heater core and evaporator pipes grommet.
4. Remove the expansion valve.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-rings on then expansion valve and the A/C refrigerant pipes with new ones, then
apply compressor oil to them for installation.
lAfter charging refrigerant, check for leaks.
Checking for Refrigerant LeaksEJS006D1
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 DetectorEJS006D2
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.
Cleanwithadryclothorblowoffwithshopair.
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.Expansion valve bolts : 4 N·m (0.41 kg-m, 35 in-lb)
A/C refrigerant pipe to expansion valve bolt : Refer toATC-140, "
Components"
.

ATC-152
REFRIGERANT LINES
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set (SST) to the A/C service valves.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50psi)above16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refriger-
ant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2,50psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal l). Refer toATC-140, "
Components". Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. MODE control dial: VENT (Ventilation)
c. Intake door position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
SHA708EA

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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ENGINE COOLING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions For Liquid Gasket ................................. 2
LIQUID GASKET APPLICATION PROCEDURE..... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
OVERHEATING CAUSE ANALYSIS .......................... 4
Troubleshooting Chart .............................................. 4
COOLING SYSTEM .................................................... 6
Cooling Circuit .......................................................... 6
ENGINE COOLANT .................................................... 7
Inspection ................................................................. 7
LEVEL CHECK ..................................................... 7
CHECKING RADIATOR SYSTEM FOR LEAKS..... 7
Changing Engine Coolant ........................................ 7
DRAINING ENGINE COOLANT ........................... 8
REFILLING ENGINE COOLANT .......................... 8
FLUSHING COOLING SYSTEM ........................... 9
RADIATOR .................................................................11
Components ............................................................ 11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 13
INSTALLATION ................................................... 14
INSPECTION AFTER INSTALLATION ............... 14
RADIATOR (ALUMINUM TYPE) .............................. 15
Components ........................................................... 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18COOLING FAN .......................................................... 19
Components (Crankshaft Driven Type) .................. 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
Removal and Installation (Motor Driven Type) (Mod-
els with A/C) ........................................................... 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 20
WATER PUMP .......................................................... 21
Components ........................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
THERMOSTAT AND WATER PIPING ...................... 23
Components ........................................................... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
ENGINE COOLANT CAPACITY .......................... 26
THERMOSTAT .................................................... 26
RESERVOIR TANK ............................................. 26

CO-4
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS
PFP:00012
Troubleshooting ChartEBS01E6M
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ateRefer toEC-132, "
DTC
P0217 ENGINE OVER
TEMPERATURE"
—
Highresistancetofanrota-
tion
Fan assembly
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

CO-6
COOLING SYSTEM
COOLING SYSTEM
PFP:21020
Cooling CircuitEBS01E6N
PBIC4099E

ENGINE COOLANT
CO-7
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ENGINE COOLANTPFP:KQ100
InspectionEBS01E6P
LEVEL CHECK
lCheck if the reservoir tank engine coolant level within MIN to
MAX when engine is cool.
lAdjust engine coolant level as necessary.
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.
Changing Engine CoolantEBS01E6Q
WARNING:
lTo avoid being scalded, do not change engine coolant when engine is hot.
lWrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to
release built-up pressure. Then turn cap all the way.
lBe careful not to allow engine coolant to contact drive belts.
SMA412B
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2,23psi)
PBIC3501E