Heater Core NISSAN NAVARA 2005 Repair Workshop Manual

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-124
HEATER & COOLING UNIT ASSEMBLY
HEATER & COOLING UNIT ASSEMBLY
PFP:27110
ComponentsEJS006C8
Heater and Cooling Unit Assembly —LHD Models—
MJIB0278E
1. High-pressure A/C pipe 2. Low-pressure A/C pipe 3. Expansion valve
4. Heater core and evaporator pipes
grommet5. A/C drain hose grommet 6. A/C drain hose
7. Heater core pipes 8. Coolant reservoir hose 9. Heater and cooling unit assembly

HEATER & COOLING UNIT ASSEMBLY
ATC-125
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AT C
Heater and Cooling Unit Assembly —RHD Models—
MJIB0279E
1. High-pressure A/C pipe A 2. High-pressure A/C pipe B 3. Low-pressure A/C pipe
4. Expansion valve 5. Heater core and evaporator pipes
grommet6. A/C drain hose grommet
7. A/C drain hose 8. Heater core pipe mounts 9. Heater core pipes
10. Heater and cooling unit assembly

ATC-126
HEATER & COOLING UNIT ASSEMBLY
Removal and Installation
EJS006C9
REMOVAL
1. Discharge the refrigerant from the A/C system. Refer toATC-138, "Discharging Refrigerant".
2. Drain the coolant from the engine cooling system. Refer toCO-8, "
DRAINING ENGINE COOLANT".
3. Remove the heater core pipes RH nut.
4. Disconnect the heater core hoses from the heater core.
5. Disconnect the high- and low-pressure A/C pipes from the
expansion valve.
6. Move the two front seats to the rearmost position on the seat
track.
7. Remove the instrument panel and console panel. Refer toIP-10,
"Removal and Installation".
8. Remove the two front floor ducts.
9. Remove the steering column. Refer toPS-10, "
Removal and
Installation".
10. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (SMJ) electrical connectors. Refer toPG-38, "
Harness Layout".
11. Remove the covers then remove the three steering member bolts from each side to disconnect the steer-
ing member from the vehicle body.
12. Remove the heater and cooling unit assembly with it attached to the steering member, from the vehicle.
CAUTION:
lUse 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.
lUse suitable plugs on the heater core pipes to prevent coolant leakage.
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 A/C pipe and high-pressure A/C pipe with a new one, and
apply compressor oil to the O-ring for installation.
lAfter charging the refrigerant, check for leaks. Refer toATC-150, "Checking for Refrigerant Leaks"
.
NOTE:
lFill the engine cooling system with the specified coolant mixture. Refer toCO-8, "REFILLING ENGINE
COOLANT".
lRecharge the A/C system. Refer toATC-138, "Evacuating System and Charging Refrigerant".
LJIA0165E

HEATER CORE
ATC-127
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AT C
HEATER COREPFP:27140
ComponentsEJS006CA
Removal and InstallationEJS006CB
REMOVAL
1. Remove the heater and cooling unit assembly. Refer toATC-126, "REMOVAL".
2. Remove the three screws and remove the heater core cover.
3. Remove the heater core and evaporator pipe bracket.
4. Remove the heater core.
NOTE:
If the air conditioner filters are contaminated from coolant leak-
ing from the heater core, replace the air conditioner filters with
new ones before installing the new heater core.
INSTALLATION
Installation is in the reverse order of removal.
1. Heater core and evaporator pipe bracket 2. Heater core 3. Heater and cooling unit assembly
4. Heater core cover
MJIB0211E
MJIB0216E

REFRIGERANT LINES
ATC-147
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CAUTION:
lReplace the O-ring of the low-pressure flexible A/C hose with a new one, then apply compressor
oil to it for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Low-pressure A/C PipeEJS006CS
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the heater pump connector.
3. Remove the heater pump from the bracket and reposition out of the way. Do not disconnect the heater
hoses from the heater pump.
4. Remove the low-pressure A/C pipe. Refer toATC-140, "
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 toATC-140, "
Components".
CAUTION:
lReplace the O-ring of the low-pressure A/C pipe with a new one, then apply compressor oil to it for
installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Refrigerant Pressure SensorEJS006CV
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the refrigerant pressure sensor harness 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 toATC-140, "
Components".
CAUTION:
lBe careful not to damage the condenser fins.
lApply compressor oil to the O-ring of the refrigerant pressure sensor for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for CondenserEJS006CW
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "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 A/C hose and the high-pressure A/C pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
LJIA0177E

REFRIGERANT LINES
ATC-149
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AT C
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"
.

IDX-4
ALPHABETICAL INDEX
Engine control system diagram and chart .........EC-15
Engine coolant ....................................................CO-7
Engine coolant temperature sensor (ECTS) ....EC-103
Engine oil .............................................................LU-5
Engine oil filter replacement .............................MA-26
Engine oil precautions ..........................................GI-7
Engine removal ...............................................EM-106
Engine room cover ............................................EM-20
Engine serial number ..........................................GI-58
Evaporator ....................................ATC-149,MTC-129
Exhaust manifold ..............................................EM-34
Exhaust system ...................................................EX-2
Exhaust system inspection ..................................EX-2
Expansion valve ............................ATC-150,MTC-130
F
F/FOG - Wiring diagram .....................................LT-74
F/PUMP - Wiring diagram ..EC-248,EC-254,EC-260,
EC-266
Final drive pre-inspection .................................FFD-18
Final drive removal and installation ..RFD-14,RFD-81
Flow charts .........................................................GI-24
Fluid temperature sensor (A/T) ........................AT-118
Fluids ................................................................MA-14
Fluorescent leak detector .............ATC-150,MTC-131
Flywheel (clutch) ................................................CL-17
Flywheel runout ..............................................EM-134
Fog lamp, front ....................................................LT-71
Foot lamp ..........................................................LT-145
Fork rod (M/T) ....................................................MT-23
Freeze frame data .............................................EC-28
Front brake solenoid valve .................AT-137,AT-139
Front bumper ......................................................EI-15
Front case (Transfer) ..........................TF-114,TF-120
Front combination lamp removal and installationLT-30
Front door ................BL-118,BL-120,BL-126,GW-35
Front Door Trim ..................................................EI-30
Front drive shaft (Transfer) ...TF-114,TF-120,TF-133
Front final drive removal and installation (4WD) ...........
FFD-15
Front fog lamp .....................................................LT-71
Front passenger air bag ..................................SRS-40
Front seat ...........................................................SE-20
Front seat belt ............................................SB-3,SB-5
Front seat belt pre-tensioner ...............SRS-3,SRS-47
Front side air bag ............................................SRS-43
Front washer ......................................................WW-4
Front wiper .........................................................WW-4
FRPS - Wiring diagram ....................................EC-120
FTS - Wiring diagram .......................................EC-115
Fuel cut control (at no load high engine speed) .EC-20
Fuel filler lid ......................................................BL-136
Fuel filter ............................................................EC-23
Fuel filter replacement ..........................................FL-4
Fuel gauge ............................................................DI-4
Fuel injection control system .............................EC-18
Fuel injector ............EC-25,EC-123,EC-125,EC-237
Fuel injector and fuel tube ................................EM-44
Fuel leak ............................................................EC-88
Fuel line inspection ..............................................FL-3
Fuel pumpEC-86,EC-217,EC-245,EC-251,EC-258,
EC-263
Fuel pump(Learning Value Clearing) .................EC-24
Fuel rail pressure sensor .................................EC-118
Fuel system .........................................................FL-3
Fuel tank ..............................................................FL-9
Fuel temperature sensor ..................................EC-113
Fuse ......................................................PG-74,PG-84
Fuse and fusible link box ..................................PG-84
Fusible link ............................................PG-74,PG-84
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Garage jack and safety stand .............................GI-52
Gauges .................................................................DI-4
Gear components (M/T) ....................................MT-21
Generator ...........................................................SC-14
Generator - See Alternator ................................SC-14
Glass ........................GW-11,GW-35,GW-38,GW-43
Glove box lamp ................................................LT-162
GLOW - Wiring diagram ..................................EC-296
Glow plug ............................................EM-41,EC-295
Glow relay ........................................................EC-295
Grease ..............................................................MA-14
Ground distribution ...........................................PG-27
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H/AIM - Wiring diagram .....................................LT-66
Harness connector ............................................PG-75
Harness layout ..................................................PG-38
Hazard warning lamp .........................................LT-97
Headlamp aiming control ...................................LT-66
Headlamp leveler - See Headlamp aiming control ........
LT-66
Headlamp removal and installation ....................LT-30
Heat up switch .................................................EC-319
Heated seat .......................................................SE-12
Heater and cooling unit (Heater core) ..........ATC-124,
ATC-127
,MTC-103,MTC-106
Heater unit (heater core) ..............ATC-124,ATC-127,
MTC-103
,MTC-106
HEATUP - Wiring diagram ...............................EC-320
Height (Dimensions) ...........................................GI-60
HFC134a (R134a) system precaution .ATC-4,MTC-4
HFC134a (R134a) system service procedureATC-138,
MTC-118
HFC134a (R134a) system service tools ........ATC-16,
MTC-16
HFC134a system service equipment precaution ..........
ATC-12
,MTC-12
High and low reverse clutch solenoid valve ....AT-147,
AT-149
HLC - Wiring diagram ......................................WW-41
Horn .................................................................WW-59
HORN - Wiring diagram ...................................WW-59
How to erase DTC .............................................EC-27

MTC-2
Schematic —LHD MODELS— ............................... 38
Wiring Diagram —A/C— —LHD MODELS— ......... 39
Schematic —RHD MODELS— ............................... 44
Wiring Diagram —A/C— —RHD MODELS— ......... 45
Front Air Control Terminals and Reference Value... 49
PIN CONNECTOR TERMINAL LAYOUT ............ 49
TERMINALS AND REFERENCE VALUE FOR
FRONT AIR CONTROL ....................................... 49
A/C System Self-diagnosis Function ...................... 51
DESCRIPTION .................................................... 51
Operational Check .................................................. 53
CHECKING BLOWER ......................................... 53
CHECKING DISCHARGE AIR ............................ 53
CHECKING RECIRCULATION ............................ 53
CHECKING TEMPERATURE DECREASE ......... 54
CHECKING TEMPERATURE INCREASE .......... 54
CHECK A/C SWITCH .......................................... 54
Power Supply and Ground Circuit for Front Air Con-
trol ........................................................................... 55
INSPECTION FLOW ........................................... 55
COMPONENT DESCRIPTION ............................ 56
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 56
Mode Door Motor Circuit ........................................ 58
INSPECTION FLOW ........................................... 58
SYSTEM DESCRIPTION .................................... 59
COMPONENT DESCRIPTION ............................ 59
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 59
Air Mix Door Motor Circuit ...................................... 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 64
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (FRONT) .................................... 64
Intake Door Motor Circuit ........................................ 68
INSPECTION FLOW ........................................... 68
SYSTEM DESCRIPTION .................................... 69
COMPONENT DESCRIPTION ............................ 69
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 69
Blower Motor Circuit ............................................... 71
INSPECTION FLOW ........................................... 71
SYSTEM DESCRIPTION .................................... 72
COMPONENT DESCRIPTION ............................ 72
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ............................................................... 73
COMPONENT INSPECTION .............................. 77
Magnet Clutch Circuit ............................................. 79
INSPECTION FLOW ........................................... 79
SYSTEM DESCRIPTION .................................... 80
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 80
COMPONENT INSPECTION .............................. 85
Insufficient Cooling ................................................. 86
INSPECTION FLOW ........................................... 86
PERFORMANCE TEST DIAGNOSES ................ 87
PERFORMANCE CHART ................................... 89
TROUBLE DIAGNOSES FOR UNUSUAL PRES-
SURE ................................................................... 90Insufficient Heating ................................................. 93
INSPECTION FLOW ............................................ 93
Noise ....................................................................... 94
INSPECTION FLOW ............................................ 94
Self-diagnosis ......................................................... 95
INSPECTION FLOW ............................................ 95
Intake Sensor Circuit ............................................... 95
COMPONENT DESCRIPTION ............................ 95
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ..................................................................... 96
COMPONENT INSPECTION ............................... 97
CONTROL UNIT ........................................................ 98
Removal and Installation ......................................... 98
REMOVAL ............................................................ 98
INSTALLATION .................................................... 98
INTAKE SENSOR ...................................................... 99
Removal and Installation ......................................... 99
REMOVAL ............................................................ 99
INSTALLATION .................................................... 99
BLOWER MOTOR ...................................................100
Components ..........................................................100
Removal and Installation .......................................100
REMOVAL ..........................................................100
INSTALLATION ..................................................100
AIR CONDITIONER FILTER ...................................101
Removal and Installation .......................................101
FUNCTION ........................................................101
REPLACEMENT TIMING ..................................101
REPLACEMENT PROCEDURE ........................101
HEATER & COOLING UNIT ASSEMBLY ...............103
Components ..........................................................103
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105
HEATER CORE .......................................................106
Components ..........................................................106
Removal and Installation .......................................107
REMOVAL ..........................................................107
INSTALLATION ..................................................107
DEFROSTER DOOR MOTOR .................................108
Components ..........................................................108
Removal and Installation .......................................108
REMOVAL ..........................................................108
INSTALLATION ..................................................108
INTAKE DOOR MOTOR ..........................................109
Components ..........................................................109
Removal and Installation .......................................109
REMOVAL ..........................................................109
INSTALLATION ..................................................109
MODE DOOR MOTOR ............................................110
Components ..........................................................110
Removal and Installation .......................................110
REMOVAL ..........................................................110
INSTALLATION ..................................................110
AIR MIX DOOR MOTOR ......................................... 111
Components .......................................................... 111
Removal and Installation ....................................... 111
REMOVAL .......................................................... 111
INSTALLATION .................................................. 111