Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 MTC
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J AIR CONDITIONER
A
SECTION
MANUAL AIR CONDITIONER
MTC B
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 4
. AIR CONDITIONER CONTROL .............................. 21 . F
Precautions for Supplemental Restraint System Description ............................................................. 21
.
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Operation ............................................................... 21
.
SIONER" ................................................................. 4
. AIR MIX DOOR CONTROL ................................ 21 . G
Precautions for Working with HFC-134a (R-134a) 4 ..... BLOWER SPEED CONTROL ............................ 21 .
Contaminated Refrigerant ....................................... 4 . INTAKE DOORS CONTROL .............................. 21 .
General Refrigerant Precautions ............................. 5 . MODE DOOR CONTROL .................................. 21 .
H
Precautions for Leak Detection Dye ........................ 5 . DEFROSTER DOOR CONTROL ....................... 21 .
A/C Identification Label ........................................... 6
. MAGNET CLUTCH CONTROL .......................... 21 .
Precautions for Refrigerant Connection .................. 6 . Description of Control System ............................... 23 .
FEATURES OF NEW TYPE REFRIGERANT Control Operation .................................................. 24 . I
CONNECTION ..................................................... 6. TEMPERATURE CONTROL DIAL (TEMPERA-
O-RING AND REFRIGERANT CONNECTION ..... 7 TURE CONTROL) .............................................. 24 .
Precautions for Servicing Compressor .................... 9 . RECIRCULATION () SWITCH ............................ 24 . MTC
Precautions for Service Equipment ......................... 9 . DEFROSTER SWITCH ...................................... 24 .
RECOVERY/RECYCLING EQUIPMENT ............. 9 . REAR WINDOW DEFOGGER SWITCH (IF
ELECTRONIC LEAK DETECTOR ....................... 9 . EQUIPPED) ........................................................ 24 .
K
VACUUM PUMP ................................................ 10 . OFF SWITCH (BLOWER SPEED SET TO 0) .... 24 .
MANIFOLD GAUGE SET ................................... 10 . A/C SWITCH (IF EQUIPPED) ............................ 24 .
SERVICE HOSES .............................................. 10 . MODE DIAL ........................................................ 24 .
SERVICE COUPLERS ........................................11 . BLOWER CONTROL DIAL ................................ 24 . L
REFRIGERANT WEIGHT SCALE ......................11 . Discharge Air Flow ................................................ 25 .
CHARGING CYLINDER ......................................11 . ........................................................................... 25
.
Wiring Diagrams and Trouble Diagnosis ................11 . DISCHARGE AIR FLOW .................................... 25 . M
PREPARATION ........................................................ 12
. System Description ................................................ 26 .
Special Service Tools ............................................ 12
. SWITCHES AND THEIR CONTROL FUNCTION 26 ...
HFC-134a (R-134a) Service Tools and Equipment 12 ... TROUBLE DIAGNOSIS ........................................... 27 .
Commercial Service Tools ..................................... 15 . CONSULT-II Function (BCM) ................................ 27 .
REFRIGERATION SYSTEM .................................... 16 . CONSULT-II BASIC OPERATION ...................... 27 .
Refrigerant Cycle .................................................. 16
. DATA MONITOR ................................................ 28 .
REFRIGERANT FLOW ...................................... 16 . How to Perform Trouble Diagnosis for Quick and
FREEZE PROTECTION .................................... 16 . Accurate Repair ..................................................... 29 .
Refrigerant System Protection .............................. 16 . WORK FLOW ..................................................... 29 .
REFRIGERANT PRESSURE SENSOR ............ 16 . SYMPTOM TABLE ............................................. 29 .
PRESSURE RELIEF VALVE .............................. 16 . Component Parts and Harness Connector Location 30 ...
Component Layout ................................................ 17. ENGINE COMPARTMENT ................................. 30 .
LUBRICANT ............................................................ 19
. PASSENGER COMPARTMENT ........................ 31 .
Maintenance of Lubricant Quantity in Compressor 19 ... Schematic .............................................................. 32.
LUBRICANT ....................................................... 19
. Wiring Diagram -- HEATER -- ............................. 33 .
CHECKING AND ADJUSTING .......................... 19 . Wiring Diagram -- A/C,M -- .................................. 35 .
Revision: November 2005 MTC-1 2005 Frontier
Front Air Control Terminals and Reference Value... 39 Insufficient Heating ................................................78 .
PIN CONNECTOR TERMINAL LAYOUT ........... 39 . INSPECTION FLOW ...........................................78 .
TERMINALS AND REFERENCE VALUE FOR Noise ......................................................................79
.
FRONT AIR CONTROL ...................................... 39 . INSPECTION FLOW ...........................................79 .
Operational Check ................................................. 41 . Intake Sensor Circuit ..............................................81 .
CHECKING BLOWER ........................................ 41 . COMPONENT DESCRIPTION ...........................81 .
CHECKING DISCHARGE AIR ........................... 41 . DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
DISCHARGE AIR FLOW .................................... 41 . SOR ....................................................................81
.
CHECKING TEMPERATURE DECREASE ........ 42 . COMPONENT INSPECTION ..............................82 .
CHECKING TEMPERATURE INCREASE ......... 42 . CONTROL UNIT .......................................................83 .
CHECK A/C SWITCH (IF EQUIPPED) ............... 42 . Removal and Installation ........................................83 .
Power Supply and Ground Circuit for Front Air Con- FRONT AIR CONTROL ......................................83 .
trol .......................................................................... 43
. INTAKE SENSOR .....................................................84 .
INSPECTION FLOW .......................................... 43 . Removal and Installation ........................................84 .
COMPONENT DESCRIPTION ........................... 44 . REMOVAL ...........................................................84 .
COMPONENT DESCRIPTION ........................... 44 . INSTALLATION ...................................................84 .
DIAGNOSTIC PROCEDURE FOR HEATER/A/C BLOWER MOTOR ....................................................85 .
SYSTEM (IF EQUIPPED) ................................... 44 . Components ...........................................................85 .
Mode Door Motor Circuit ....................................... 46 . Removal and Installation ........................................85 .
INSPECTION FLOW .......................................... 46 . REMOVAL ...........................................................85 .
SYSTEM DESCRIPTION ................................... 46 . INSTALLATION ...................................................85 .
COMPONENT DESCRIPTION ........................... 47 . IN-CABIN MICROFILTER .........................................86 .
DIAGNOSTIC PROCEDURE FOR MODE Removal and Installation ........................................86 .
DOOR MOTOR .................................................. 48 . FUNCTION .........................................................86 .
Air Mix Door Motor Circuit ..................................... 50 . REPLACEMENT TIMING ...................................86 .
INSPECTION FLOW .......................................... 50 . REPLACEMENT PROCEDURE .........................86 .
SYSTEM DESCRIPTION ................................... 51 . HEATER & COOLING UNIT ASSEMBLY ................88 .
COMPONENT DESCRIPTION ........................... 51 . Components ...........................................................88 .
DIAGNOSTIC PROCEDURE FOR AIR MIX Removal and Installation ........................................88 .
DOOR MOTOR .................................................. 52 . REMOVAL ...........................................................88 .
Intake Door Motor Circuit ....................................... 54 . INSTALLATION ...................................................89 .
INSPECTION FLOW .......................................... 54 . HEATER CORE ........................................................90 .
SYSTEM DESCRIPTION ................................... 55 . Components ...........................................................90 .
COMPONENT DESCRIPTION ........................... 55 . Removal and Installation ........................................90 .
DIAGNOSTIC PROCEDURE FOR INTAKE REMOVAL ...........................................................90 .
DOOR MOTOR .................................................. 56 . INSTALLATION ...................................................90 .
Front Blower Motor Circuit ..................................... 58 . INTAKE DOOR MOTOR ...........................................91 .
INSPECTION FLOW .......................................... 58 . Removal and Installation ........................................91 .
SYSTEM DESCRIPTION ................................... 59 . REMOVAL ...........................................................91 .
COMPONENT DESCRIPTION ........................... 59 . INSTALLATION ...................................................91 .
DIAGNOSTIC PROCEDURE FOR BLOWER MODE DOOR MOTOR .............................................92 .
MOTOR .............................................................. 60 . Removal and Installation ........................................92 .
COMPONENT INSPECTION ............................. 64 . REMOVAL ...........................................................92 .
Magnet Clutch Circuit ............................................ 66 . INSTALLATION ...................................................92 .
INSPECTION FLOW .......................................... 66 . AIR MIX DOOR MOTOR ..........................................93 .
SYSTEM DESCRIPTION ................................... 67 . Components ...........................................................93 .
DIAGNOSTIC PROCEDURE FOR MAGNET Removal and Installation ........................................93 .
CLUTCH ............................................................. 67 . REMOVAL ...........................................................93 .
Insufficient Cooling ................................................ 71 . INSTALLATION ...................................................93 .
INSPECTION FLOW .......................................... 71 . FRONT BLOWER MOTOR RESISTOR ...................94 .
PERFORMANCE TEST DIAGNOSES ............... 72 . Removal and Installation ........................................94 .
PERFORMANCE CHART .................................. 74 . REMOVAL ...........................................................94 .
TROUBLE DIAGNOSES FOR UNUSUAL PRES- INSTALLATION ...................................................94 .
SURE .................................................................. 75. DUCTS AND GRILLES ............................................95 .
Revision: November 2005 MTC-2 2005 Frontier
Components .......................................................... 95 . REMOVAL ........................................................ 106 .
Removal and Installation ....................................... 96 . INSTALLATION ................................................ 106 . A
DEFROSTER NOZZLE ...................................... 96 . Removal and Installation for Low-pressure A/C Pipe 107 .
RH AND LH SIDE DEMISTER DUCTS ............. 97 . REMOVAL ........................................................ 107 .
RH AND LH VENTILATOR DUCTS ................... 97 . INSTALLATION ................................................ 107 . B
CENTER VENTILATOR DUCT .......................... 97 . Removal and Installation for Refrigerant Pressure
FLOOR CONNECTOR DUCT ............................ 97 . Sensor ................................................................. 107
.
FRONT AND REAR FLOOR DUCTS ................ 97 . REMOVAL ........................................................ 107 .
GRILLES ............................................................ 97. INSTALLATION ................................................ 107 . C
REFRIGERANT LINES ............................................ 98 . Removal and Installation for Condenser ............. 107 .
HFC-134a (R-134a) Service Procedure ................ 98 . REMOVAL ........................................................ 107 .
SETTING OF SERVICE TOOLS AND EQUIP- INSTALLATION ................................................ 108 . D
MENT ................................................................. 98
. Removal and Installation for Evaporator ............. 109 .
Components ........................................................ 100 . REMOVAL ........................................................ 110 .
Removal and Installation for Compressor ........... 101 . INSTALLATION ................................................ 110 . E
COMPONENTS ............................................... 101 . Removal and Installation for Expansion Valve ..... 110 .
REMOVAL ........................................................ 102 . REMOVAL ........................................................ 110 .
INSTALLATION ................................................ 102 . INSTALLATION ................................................ 110 .
Removal and Installation for Compressor Clutch . 103 Checking for Refrigerant Leaks ........................... 110 . F
REMOVAL ........................................................ 103 . Checking System for Leaks Using the Fluorescent
INSPECTION ................................................... 104 . Dye Leak Detector ............................................... 110 .
INSTALLATION ................................................ 104 . Dye Injection .........................................................111
. G
BREAK-IN OPERATION .................................. 106 . Electronic Refrigerant Leak Detector ....................111 .
Removal and Installation for High-pressure Flexible PRECAUTIONS FOR HANDLING LEAK
A/C Hose ............................................................. 106
. DETECTOR .......................................................111 . H
REMOVAL ........................................................ 106 . CHECKING PROCEDURE .............................. 112 .
INSTALLATION ................................................ 106 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 114 .
Removal and Installation for High-pressure A/C Service Data and Specifications (SDS) ............... 114 .
I
Pipe ..................................................................... 106
. COMPRESSOR ............................................... 114 .
REMOVAL ........................................................ 106 . LUBRICANT ..................................................... 114 .
INSTALLATION ................................................ 106 . REFRIGERANT ................................................ 114 .
Removal and Installation for Low-pressure Flexible ENGINE IDLING SPEED ................................. 114 . MTC
A/C Hose ............................................................. 106
. BELT TENSION ................................................ 114 .
K
L
M
Revision: November 2005 MTC-3 2005 Frontier
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EJS003OA
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Working with HFC-134a (R-134a) EJS003OB
WARNING:
G CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed compressor failure is likely to occur. Refer MTC-4, "Contaminated Refrigerant" . To
determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant
Recovery/Recycling Recharging equipment and Refrigerant Identifier.
G Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
G The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
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