heating NISSAN NAVARA 2005 Repair Workshop Manual

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

TROUBLE DIAGNOSIS
ATC-35
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AT C
How to Perform Trouble Diagnosis for Quick and Accurate RepairEJS006B9
WORK FLOW
SYMPTOM TABLE
*1AT C - 5 7 , "Operational Check".
SHA900E
Symptom Reference Page
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System.ATC-60, "
Power
Supply and
Ground Circuit for
Front Air Control"
A/C system display is malfunctioning. Go to "Navigation System".AV-61, "Navigation
System"
A/C system cannot be controlled. Go to Self-diagnosis Function.AT C - 5 5 , "
A/C Sys-
tem Self-diagno-
sis Function"
Air outlet does not change.
Go to Trouble Diagnosis Procedure for Mode Door Motor.AT C - 6 3 , "Mode
Door Motor Cir-
cuit"Mode door motor is malfunctioning.
Discharge air temperature does not change.
Go to Trouble Diagnosis Procedure for Air Mix Door Motor.ATC-68, "
Air Mix
Door Motor Cir-
cuit"Air mix door motor is malfunctioning.
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor.AT C - 7 7 , "
Intake
Door Motor Cir-
cuit"Intake door motor is malfunctioning.
Defroster door motor is malfunctioning. Go to Trouble Diagnosis Procedure for Defroster Door Motor.
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor.ATC-80, "
Blower
Motor Circuit"
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch.AT C - 8 7 , "Magnet
Clutch Circuit"
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.AT C - 9 3 , "Insuffi-
cient Cooling"
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating.ATC-100, "Insuffi-
cient Heating"
Noise Go to Trouble Diagnosis Procedure for Noise.ATC-101, "Noise"
Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis.ATC-103, "Self-
diagnosis"
Memory function does not operate. Go to Trouble Diagnosis Procedure for Memory Function.ATC-104, "Mem-
ory Function"

TROUBLE DIAGNOSIS
ATC-59
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AT C
CHECKING TEMPERATURE INCREASE
1. Rotate temperature control dial clockwise (driver side) until 32°C
(90°F) is displayed.
2. Check for hot air at appropriate discharge air outlets.
If NG, listen for sound of air mix door motor operation. If OK, go to
trouble diagnosis procedure forATC-100, "
Insufficient Heating".If
air mix door motor appears to be malfunctioning, go toAT C - 7 1 ,
"DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR
(DRIVER)".
If OK, continue with next check.
CHECK A/C SWITCH
1. Press A/C switch when AUTO switch is ON, or in manual mode.
2. A/C switch indicator will turn ON.
lConfirm that the compressor clutch engages (sound or visual
inspection).
If NG, go to trouble diagnosis procedure forAT C - 8 7 , "
Magnet Clutch
Circuit".
If OK, continue with next check.
CHECKING AUTO MODE
1. Press AUTO switch.
2. Display should indicate AUTO.
lIf ambient temperature is warm, and selected temperature is
cool, confirm that the compressor clutch engages (sound or
visual inspection). (Discharge air and blower speed will
depend on ambient, in-vehicle, and set temperatures.)
If NG, go to trouble diagnosis procedure forAT C - 6 0 , "
Power Supply
and Ground Circuit for Front Air Control", then if necessary, trouble
diagnosis procedure forAT C - 8 7 , "
Magnet Clutch Circuit".
If all operational checks are OK (symptom cannot be duplicated), go
to malfunction simulation tests inAT C - 3 5 , "
How to Perform Trouble
Diagnosis for Quick and Accurate Repair"and perform tests as out-
lined to simulate driving conditions environment. If symptom appears, refer toAT C - 3 5 , "
How to Perform Trou-
ble Diagnosis for Quick and Accurate Repair",AT C - 3 5 , "SYMPTOM TABLE"and perform applicable trouble
diagnosis procedures.
MJIB0341E
MJIB0342E
MJIB0336E

ATC-100
TROUBLE DIAGNOSIS
Insufficient Heating
EJS006BS
SYMPTOM: Insufficient heating
INSPECTION FLOW
*1ATC-57, "Operational Check".*2AT C - 6 8 , "Air Mix Door Motor Circuit".*3ATC-55, "A/C System Self-diagno-
sis Function".
*4ATC-55, "
A/C System Self-diagnosis
Function".*5AT C - 8 0 , "
Blower Motor Circuit".*6EC-103, "DTC P0117, P0118 ECT
SENSOR".
*7CO-7, "
Changing Engine Coolant".*8CO-13, "Checking Reservoir Tank
Cap".
MJIB0350E

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTIONCO
A
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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-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions For Liquid GasketEBS01E6J
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
lRemove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser [SST].
Use Genuine Liquid Gasket or equivalent.
lWithin five minutes of liquid gasket application, install the mat-
ing component.
lIf liquid gasket protrudes, wipe it off immediately.
lDo not retighten mounting bolts or nuts after the installation.
lAfter 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
PBIC2160E

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

OVERHEATING CAUSE ANALYSIS
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Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items

CO-24
THERMOSTAT AND WATER PIPING
Removal and Installation
EBS01E6X
WARNING:
Do not remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL
1. Remove front engine undercover and middle engine undercover. Refer toEI-15, "FRONT BUMPER".
2. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the
side of cylinder block. Refer toCO-7, "
Changing Engine Coolant"andEM-110, "CYLINDER BLOCK".
CAUTION:
Perform this step when engine is cold.
3. Remove engine cover. Refer toEM-20, "
INTAKE MANIFOLD".
4. Disconnect radiator hoses (upper and lower) from engine side. Refer toCO-11, "
RADIATOR".
5. Remove air inlet pipe and air duct between air cleaner case and turbocharger. Refer toEM-15, "
AIR
CLEANER AND AIR DUCT"andEM-28, "TURBO CHARGER".
6. Remove water outlet, water inlet and thermostat.
7. Remove thermostat housing.
8. Disconnect heater return hose and water hoses at heater return pipe side, and remove heater return pipe.
9. Remove oil level gauge guide mounting bolt, vacuum hoses (to turbocharger boost control solenoid valve)
and spill hose. Refer toEM-36, "
OIL PAN AND OIL STRAINER",EM-20, "INTAKE MANIFOLD"andEM-
44, "INJECTION TUBE AND FUEL INJECTOR".
10. Disconnect water hoses (to EGR cooler) (A/T models), vacuum hoses and heater feed hose at heater
feed pipe side, and remove heater feed pipe. Refer toEM-20, "
INTAKE MANIFOLD".
INSPECTION AFTER REMOVAL
Thermostat
lPlace a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
lThe valve opening temperature is the temperature at which the
valve opens and falls from the thread.
lContinue heating. Check the full-open lift amount.
lAfter checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
lIf out of the standard, replace thermostat.
INSTALLATION
Note the following, and install in the reverse order of removal.
lSecurely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
lWhen inserting heater feed pipe end into cylinder head, apply a neutral detergent to O-ring. Then insert it
immediately.
SLC252B
Item Thermostat
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Full-open lift amount More than 9 mm/ 95°C (0.35 in/ 203°F)
Valve closing temperature More than 77°C(171°F)

EC-2
DTC Confirmation Procedure ................................. 88
Diagnostic Procedure ............................................. 89
Component Inspection ............................................ 90
Removal and Installation ........................................ 91
DTC P0102, P0103 MAF SENSOR ........................... 92
Component Description .......................................... 92
CONSULT-II Reference Value in Data Monitor Mode
... 92
ECM Terminals and Reference Value ..................... 92
On Board Diagnosis Logic ...................................... 93
DTC Confirmation Procedure ................................. 93
Wiring Diagram ....................................................... 94
Diagnostic Procedure ............................................. 95
Component Inspection ............................................ 96
Removal and Installation ........................................ 97
DTC P0112, P0113 IAT SENSOR ............................. 98
Component Description .......................................... 98
On Board Diagnosis Logic ...................................... 98
DTC Confirmation Procedure ................................. 98
Wiring Diagram .....................................................100
Diagnostic Procedure ...........................................101
Component Inspection ..........................................102
Removal and Installation ......................................102
DTC P0117, P0118 ECT SENSOR ..........................103
Description ............................................................103
On Board Diagnosis Logic ....................................103
DTC Confirmation Procedure ...............................103
Wiring Diagram .....................................................105
Diagnostic Procedure ...........................................106
Component Inspection ..........................................107
Removal and Installation ......................................107
DTC P0122, P0123 APP SENSOR .........................108
Description ............................................................108
CONSULT-II Reference Value in Data Monitor Mode
.108
ECM Terminals and Reference Value ...................108
On Board Diagnosis Logic ....................................109
DTC Confirmation Procedure ...............................109
Wiring Diagram .....................................................110
Diagnostic Procedure ............................................111
Component Inspection ..........................................112
Removal and Installation ......................................112
DTC P0182, P0183 FUEL PUMP TEMPERATURE
SENSOR ..................................................................113
Description ............................................................113
CONSULT-II Reference Value in Data Monitor Mode
.113
ECM Terminals and Reference Value ...................113
On Board Diagnosis Logic ....................................113
DTC Confirmation Procedure ...............................114
Wiring Diagram .....................................................115
Diagnostic Procedure ...........................................116
Removal and Installation ......................................117
DTC P0192, P0193 FRP SENSOR .........................118
Description ............................................................118
CONSULT-II Reference Value in Data Monitor Mode
.118
ECM Terminals and Reference Value ...................118
On Board Diagnosis Logic ....................................118DTC Confirmation Procedure ................................119
Wiring Diagram .....................................................120
Diagnostic Procedure ............................................121
Component Inspection ..........................................122
Removal and Installation .......................................122
DTC P0200 FUEL INJECTOR .................................123
On Board Diagnosis Logic ....................................123
DTC Confirmation Procedure ................................123
Diagnostic Procedure ............................................123
DTC P0201 - P0204 FUEL INJECTOR ...................125
Component Description ........................................125
CONSULT-II Reference Value in Data Monitor Mode
.125
ECM Terminals and Reference Value ...................125
On Board Diagnosis Logic ....................................126
DTC Confirmation Procedure ................................127
Wiring Diagram .....................................................128
Diagnostic Procedure ............................................129
Component Inspection ..........................................130
Removal and Installation .......................................131
DTC P0217 ENGINE OVER TEMPERATURE ........132
Description ............................................................132
CONSULT-II Reference Value in Data Monitor Mode
.133
On Board Diagnosis Logic ....................................133
Overall Function Check .........................................133
Wiring Diagram .....................................................135
Diagnostic Procedure ............................................137
Main 12 Causes of Overheating ...........................140
Component Inspection ..........................................141
DTC P0222, P0223 APP SENSOR .........................142
Description ............................................................142
CONSULT-II Reference Value in Data Monitor Mode
.142
ECM Terminals and Reference Value ...................142
On Board Diagnosis Logic ....................................143
DTC Confirmation Procedure ................................143
Wiring Diagram .....................................................144
Diagnostic Procedure ............................................145
Component Inspection ..........................................146
Removal and Installation .......................................146
DTC P0234 TC SYSTEM .........................................147
Description ............................................................147
ECM Terminals and Reference Value ...................147
On Board Diagnosis Logic ....................................148
Overall Function Check .........................................148
Wiring Diagram .....................................................149
Diagnostic Procedure ............................................150
Component Inspection ..........................................152
Removal and Installation .......................................152
DTC P0237, P0238 TC BOOST SENSOR ..............153
Component Description ........................................153
CONSULT-II Reference Value in Data Monitor Mode
.153
ECM Terminals and Reference Value ...................153
On Board Diagnosis Logic ....................................154
DTC Confirmation Procedure ................................154
Wiring Diagram .....................................................155
Diagnostic Procedure ............................................156