2005 NISSAN NAVARA service

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
MTC-131
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MTC
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.

REFRIGERANT LINES
MTC-133
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MTC
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, 50 psi) above 16°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 toMTC-120, "
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.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
SHA839E

SERVICE DATA AND SPECIFICATIONS (SDS)
MTC-135
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MTC
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Service Data and Specifications (SDS)EJS005HS
COMPRESSOR
LUBRICANT
REFRIGERANT
ENGINE IDLING SPEED
Refer toEC-357, "General Specifications".
BELT TENSION
Refer toEM-13, "Deflection Adjustment".
MakeZEXEL VALEO CLIMATE CONTROL
ModelDKS-17D
Ty p eSwash plate
Displacement
175.5 cm
3(10.7 in3)/rev
Cylinder bore´stroke 30.5 mm (1.20 in) x 24.0 mm (0.94 in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V
MakeZEXEL VALEO CLIMATE CONTROL
ModelDKS-17D
NameNISSAN A/C System Lubricant Type S (DH-PS)
Part number KLH00-PAGS0
Capacity Total in system
290m (10.2lmpfloz)
Ty p eHFC-134a (R-134a)
Capacity 1080±50g(38.09±1.76 oz)

MTC-136
SERVICE DATA AND SPECIFICATIONS (SDS)

PB-1
PARKING BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTIONPB
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B
PB
PARKING BRAKE SYSTEM
PARKING BRAKE CONTROL ................................... 2
On-Vehicle Service ................................................... 2
INSPECTION ........................................................ 2
COMPONENTS INSPECTION ............................. 2
ADJUSTMENT ...................................................... 2Components ............................................................. 3
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 5
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 6
Parking Brake Control .............................................. 6

PB-2
PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
PFP:36010
On-Vehicle ServiceEFS006AJ
INSPECTION
When parking brake lever is operated with a force of 196 N (20 kg,
44 lb), make sure parking brake lever stroke is within the specified
number of notches. (Check it by listening and counting ratchet
clicks.)
COMPONENTS INSPECTION
lMake sure that the mounting conditions (looseness, backlash, etc.) of each component are normal.
lCheck the following:
–Device assembly for bend, damage and cracks. Replace if there are.
–Cables and equalizer for wear and damage. Replace if there are.
–Parking brake switch. Replace if it does not work correctly.
ADJUSTMENT
1. Remove center console. Refer toIP-16, "CENTER CONSOLE".
2. Pull parking brake lever until a deep socket wrench can be
inserted.
3. Insert a deep socket wrench onto adjusting nut. Rotate adjusting
nut to fully loosen cable, and then release parking brake lever.
4. Depress the foot brake about 10 times and adjust the rear shoe
clearance.
CAUTION:
Be sure to securely depress the foot brake.
5. Rotate drum to make sure that there is no drag.
6. Adjust parking brake cable with the following procedure.
lWhen replacing parking brake cable, operate parking brake
leverwithaforceof490N(50kg,110lb)about10timesMIN.
lPull parking brake lever until a deep socket wrench can be inserted.
lRotate adjusting nut to adjust parking brake lever stroke using a deep socket wrench.
CAUTION:
Do not reuse adjusting nut after removing it.
lOperate parking brake lever with a force of 196 N (20 kg, 44lb), make sure the parking brake lever
stroke is within the specified number of notches. (Check it by listening and counting ratchet clicks.)
lMake sure that there is no drag on rear brake with parking brake lever completely released.
7. Install center console. Refer toIP-16, "
CENTER CONSOLE". Lever stroke :9-10 notches
SBR073D
SFIA2989E

PB-6
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Parking Brake ControlEFS005SA
Control typeCenter lever
Number of notches [under a force of 196 N (20 kg, 44 lb)] 9 -10 notches
Number of notches when warning lamp switch comes on. 1 notch