Nissan 2005 Pathfinder Owners Manual MTC

mtc mtc

2015-10-23

: Nissan Nissan-2005-Nissan-Pathfinder-Owners-Manual-818310 nissan-2005-nissan-pathfinder-owners-manual-818310 nissan pdf

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J AIR CONDITIONER

SECTION

MTC

MANUAL AIR CONDITIONER

CONTENTS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
Contaminated Refrigerant ........................................ 4
General Refrigerant Precautions .............................. 5
Precautions for Leak Detection Dye ......................... 5
A/C Identification Label ............................................ 6
Precautions for Refrigerant Connection ................... 6
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 6
O-RING AND REFRIGERANT CONNECTION ..... 7
Precautions for Servicing Compressor ..................... 9
Precautions for Service Equipment .......................... 9
RECOVERY/RECYCLING EQUIPMENT .............. 9
ELECTRONIC LEAK DETECTOR ........................ 9
VACUUM PUMP ................................................. 10
MANIFOLD GAUGE SET .................................... 10
SERVICE HOSES ............................................... 10
SERVICE COUPLERS .........................................11
REFRIGERANT WEIGHT SCALE .......................11
CHARGING CYLINDER .......................................11
Wiring Diagrams and Trouble Diagnosis .................11
PREPARATION ......................................................... 12
Special Service Tools ............................................. 12
HFC-134a (R-134a) Service Tools and Equipment... 12
Commercial Service Tools ...................................... 15
REFRIGERATION SYSTEM ..................................... 16
Components ........................................................... 16
REFRIGERATION SYSTEM ............................... 16
Refrigerant Cycle ................................................... 17
REFRIGERANT FLOW ....................................... 17
FREEZE PROTECTION ..................................... 17
Refrigerant System Protection ............................... 17
REFRIGERANT PRESSURE SENSOR ............. 17
PRESSURE RELIEF VALVE ............................... 18

Revision: November 2005

LUBRICANT .............................................................. 19
Maintenance of Lubricant Quantity in Compressor... 19
LUBRICANT ........................................................ 19
CHECKING AND ADJUSTING ............................ 19
AIR CONDITIONER CONTROL ............................... 21
Description .............................................................. 21
Operation ................................................................ 21
AIR MIX DOOR CONTROL ................................. 21
BLOWER SPEED CONTROL ............................. 21
INTAKE DOORS CONTROL ............................... 21
MODE DOOR CONTROL ................................... 21
DEFROSTER DOOR CONTROL ........................ 21
MAGNET CLUTCH CONTROL ........................... 21
Description of Control System ................................ 23
Control Operation ................................................... 24
TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL) ............................................... 24
RECIRCULATION () SWITCH ............................. 24
DEFROSTER () SWITCH .................................... 24
REAR WINDOW DEFOGGER SWITCH ............. 24
OFF SWITCH (BLOWER SPEED SET TO 0) ..... 24
A/C SWITCH ....................................................... 24
MODE DIAL ......................................................... 24
FRONT BLOWER CONTROL DIAL .................... 24
Discharge Air Flow ................................................. 25
FRONT ................................................................ 25
System Description ................................................. 26
SWITCHES AND THEIR CONTROL FUNCTION... 26
CAN Communication System Description .............. 27
TROUBLE DIAGNOSIS ............................................ 28
CONSULT-II Function (BCM) ................................. 28
CONSULT-II BASIC OPERATION ....................... 28
DATA MONITOR ................................................. 29
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 30
WORK FLOW ...................................................... 30
SYMPTOM TABLE .............................................. 30
Component Parts and Harness Connector Location... 31
ENGINE COMPARTMENT .................................. 31
FRONT PASSENGER COMPARTMENT ............ 32

MTC-1

2005 Pathfinder

MTC

Schematic ............................................................... 33
Wiring Diagram — A/C,M — ................................... 34
Front Air Control Terminals and Reference Value... 38
PIN CONNECTOR TERMINAL LAYOUT ............ 38
TERMINALS AND REFERENCE VALUE FOR
FRONT AIR CONTROL ....................................... 38
Operational Check .................................................. 40
CHECKING BLOWER ......................................... 40
CHECKING DISCHARGE AIR ............................ 40
DISCHARGE AIR FLOW ..................................... 40
CHECKING RECIRCULATION ............................ 41
CHECKING TEMPERATURE DECREASE ......... 41
CHECKING TEMPERATURE INCREASE .......... 41
CHECK A/C SWITCH .......................................... 41
Power Supply and Ground Circuit for Front Air Control ........................................................................... 42
INSPECTION FLOW ........................................... 42
COMPONENT DESCRIPTION ............................ 43
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 43
Mode Door Motor Circuit ........................................ 45
INSPECTION FLOW ........................................... 45
SYSTEM DESCRIPTION .................................... 46
COMPONENT DESCRIPTION ............................ 46
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 47
Air Mix Door Motor Circuit ...................................... 49
INSPECTION FLOW ........................................... 49
SYSTEM DESCRIPTION .................................... 50
COMPONENT DESCRIPTION ............................ 50
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR (FRONT) .................................... 51
Intake Door Motor Circuit ........................................ 53
INSPECTION FLOW ........................................... 53
SYSTEM DESCRIPTION .................................... 54
COMPONENT DESCRIPTION ............................ 54
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR ................................................... 55
Front Blower Motor Circuit ...................................... 57
INSPECTION FLOW ........................................... 57
SYSTEM DESCRIPTION .................................... 58
COMPONENT DESCRIPTION ............................ 58
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ............................................................... 59
COMPONENT INSPECTION .............................. 63
Magnet Clutch Circuit ............................................. 65
INSPECTION FLOW ........................................... 65
SYSTEM DESCRIPTION .................................... 66
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 66
Insufficient Cooling ................................................. 70
INSPECTION FLOW ........................................... 70
PERFORMANCE TEST DIAGNOSES ................ 71
PERFORMANCE CHART ................................... 73
TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE ................................................................... 74

Revision: November 2005

Insufficient Heating .................................................77
INSPECTION FLOW ............................................77
Noise .......................................................................78
INSPECTION FLOW ............................................78
Intake Sensor Circuit ...............................................80
COMPONENT DESCRIPTION ............................80
DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR .....................................................................80
COMPONENT INSPECTION ...............................81
CONTROL UNIT ........................................................82
Removal and Installation .........................................82
FRONT AIR CONTROL .......................................82
INTAKE SENSOR ......................................................83
Removal and Installation .........................................83
REMOVAL ............................................................83
INSTALLATION ....................................................83
BLOWER MOTOR .....................................................84
Components ............................................................84
Removal and Installation .........................................84
REMOVAL ............................................................84
INSTALLATION ....................................................84
IN-CABIN MICROFILTER ..........................................85
Removal and Installation .........................................85
FUNCTION ..........................................................85
REPLACEMENT TIMING ....................................85
REPLACEMENT PROCEDURE ..........................85
HEATER & COOLING UNIT ASSEMBLY .................87
Components ............................................................87
Removal and Installation .........................................87
REMOVAL ............................................................87
INSTALLATION ....................................................88
HEATER CORE .........................................................89
Components ............................................................89
Removal and Installation .........................................89
REMOVAL ............................................................89
INSTALLATION ....................................................89
INTAKE DOOR MOTOR ............................................90
Removal and Installation .........................................90
REMOVAL ............................................................90
INSTALLATION ....................................................90
MODE DOOR MOTOR ..............................................91
Removal and Installation .........................................91
REMOVAL ............................................................91
INSTALLATION ....................................................91
AIR MIX DOOR MOTOR ...........................................92
Components ............................................................92
Removal and Installation .........................................92
REMOVAL ............................................................92
INSTALLATION ....................................................92
FRONT BLOWER MOTOR RESISTOR ....................93
Removal and Installation .........................................93
REMOVAL ............................................................93
INSTALLATION ....................................................93
DUCTS AND GRILLES .............................................94

MTC-2

2005 Pathfinder

Components ........................................................... 94
Removal and Installation ........................................ 95
CONSOLE DUCTS AND CONSOLE GRILLE ... 95
DEFROSTER NOZZLE ....................................... 96
RH AND LH SIDE DEMISTER DUCTS .............. 96
RH AND LH VENTILATOR DUCTS .................... 96
CENTER VENTILATOR DUCT ........................... 96
FLOOR CONNECTOR DUCT ............................. 96
FRONT AND REAR FLOOR DUCTS ................. 96
GRILLES ............................................................. 97
REFRIGERANT LINES ............................................. 98
HFC-134a (R-134a) Service Procedure ................. 98
SETTING OF SERVICE TOOLS AND EQUIPMENT .................................................................. 98
Components ......................................................... 100
Removal and Installation for Compressor ............ 101
COMPONENTS ................................................ 101
REMOVAL ......................................................... 101
INSTALLATION ................................................. 101
Removal and Installation for Compressor Clutch . 102
REMOVAL ......................................................... 102
INSPECTION .................................................... 103
INSTALLATION ................................................. 103
BREAK-IN OPERATION ................................... 105
Removal and Installation for High-pressure Flexible
A/C Hose .............................................................. 105
REMOVAL ......................................................... 105
INSTALLATION ................................................. 105
Removal and Installation for High-pressure A/C
Pipe ...................................................................... 105
REMOVAL ......................................................... 105
INSTALLATION ................................................. 105
Removal and Installation for Low-pressure Flexible
A/C Hose .............................................................. 105

REMOVAL ......................................................... 105
INSTALLATION ................................................. 105
Removal and Installation for Low-pressure A/C Pipe. 106
REMOVAL ......................................................... 106
INSTALLATION ................................................. 106
Removal and Installation for Refrigerant Pressure
Sensor .................................................................. 106
REMOVAL ......................................................... 106
INSTALLATION ................................................. 106
Removal and Installation for Condenser .............. 106
REMOVAL ......................................................... 106
INSTALLATION ................................................. 107
Removal and Installation for Evaporator .............. 108
REMOVAL ......................................................... 109
INSTALLATION ................................................. 109
Removal and Installation for Expansion Valve ...... 109
REMOVAL ......................................................... 109
INSTALLATION ................................................. 109
Checking for Refrigerant Leaks ............................ 109
Checking System for Leaks Using the Fluorescent
Dye Leak Detector ................................................ 109
Dye Injection ......................................................... 110
Electronic Refrigerant Leak Detector .................... 110
PRECAUTIONS FOR HANDLING LEAK
DETECTOR ....................................................... 110
CHECKING PROCEDURE ................................111
SERVICE DATA AND SPECIFICATIONS (SDS) .... 113
Service Data and Specifications (SDS) ................ 113
COMPRESSOR ................................................ 113
LUBRICANT ...................................................... 113
REFRIGERANT ................................................. 113
ENGINE IDLING SPEED .................................. 113
BELT TENSION ................................................. 113

MTC

Revision: November 2005

MTC-3

2005 Pathfinder

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

EJS003UK

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 Manual.
WARNING:
●
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 performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
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)

EJS003UL

WARNING:
●
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.
●
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor failure is likely to occur.
●
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:
–
When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.
–
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from the A/C system using certified service equipment meeting
requirements of SAE J2210 [HFC-134a (R-134a) recycling equipment], or SAE J2209 [HFC-134a (R134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refrigerant and
lubricant manufacturers.
–
Do not allow lubricant, Genuine NISSAN A/C System Lubricant Type S (DH-PS), part number
KLH00-PAGS0 or equivalent, to come in contact with styrofoam parts. Damage may result.

Contaminated Refrigerant

EJS003UM

If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are:
●
Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant
into the atmosphere.
●
Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply.
●
Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
Revision: November 2005

MTC-4

2005 Pathfinder

PRECAUTIONS
●

●

If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility
does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In
addition, replacement of all refrigerant system components on the vehicle is recommended.
If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NISSAN
Customer Affairs for further assistance.

General Refrigerant Precautions

EJS003UN

WARNING:
●
Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
●
Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
●
Do not store or heat refrigerant containers above 52°C (125°F).
●
Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
●
Do not intentionally drop, puncture, or incinerate refrigerant containers.
●
Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
●
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
●
Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Precautions for Leak Detection Dye
●
●
●

●
●
●
●

●
●
●

●

EJS003UO

The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
MTC
Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J- K
41995).
For your safety and the customer's satisfaction, read and follow all manufacturer's operating instructions
L
and precautions prior to performing work.
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis M
during a future service.
Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed .
Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.
Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C systems or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C systems or A/C system damage may result.
The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.

Revision: November 2005

MTC-5

2005 Pathfinder

PRECAUTIONS
A/C Identification Label

EJS003UP

Vehicles with factory installed fluorescent dye have this identification
label on the underside of hood.

LJIA0152E

Precautions for Refrigerant Connection

EJS003UQ

A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.
●
Expansion valve to cooling unit
●
Evaporator pipes to evaporator (inside cooling unit)
●
Refrigerant pressure sensor

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
●

●

The O-ring has been relocated. It has also been provided with a groove for proper installation. This
reduces the possibility of the O-ring being caught in, or damaged by, the mating part. The sealing direction
of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

SHA815E

Revision: November 2005

MTC-6

2005 Pathfinder

PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
A

A/C Compressor and Condenser

MTC

WJIA1253E

Revision: November 2005

MTC-7

2005 Pathfinder

PRECAUTIONS
1.

High-pressure service valve

Refrigerant pressure sensor

High-pressure flexible A/C hose

10. Low-pressure A/C pipe

Clip

High-pressure A/C pipe

Condenser

Compressor shaft seal

Low-pressure flexible A/C hose

Low-pressure service valve

11. Expansion valve

12. A/C drain hose

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at or
around the connection.

O-Ring Part Numbers and Specifications
Connection type

O-ring
size

Part number*

New

92471 N8210

6.8 (0.268)

1.85 (0.0728)

Former

J2476 89956

9.25 (0.3642)

1.78 (0.0701)

92472 N8210

10.9 (0.429)

2.43 (0.0957)

New
Former
New
Former
New
SHA814E

Former
New

19
24

mm (in)

W mm (in)

92475 71L00

11.0 (0.433)

2.4 (0.094)

92473 N8210

13.6 (0.535)

2.43 (0.0957)

92475 72L00

14.3 (0.563)

2.3 (0.091)

92474 N8210

16.5 (0.650)

2.43 (0.0957)

92477 N8200

17.12 (0.6740)

1.78 (0.0701)

92195 AH300

21.8 (0.858)

2.4 (0.094)

*: Always check with the Parts Department for the latest parts information.

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
●
When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
●
When connecting tubes, always use a torque wrench and a back-up wrench.
●
After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
●
When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for
connection.
●
Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
●
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
●
Always replace used O-rings.
●
When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Genuine NISSAN A/C System Lubricant Type S (DH-PS) or equivalent
Part number: KLH00-PAGS0
●
O-ring must be closely attached to dented portion of tube.
●
When replacing the O-ring, be careful not to damage O-ring and tube.
●
Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.

Revision: November 2005

MTC-8

2005 Pathfinder

PRECAUTIONS
●

After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.

G
RHA861F

Precautions for Servicing Compressor
●
●
●
●
●

●

EJS003UR

H
Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in CompresI
sor” exactly. Refer to MTC-19, "Maintenance of Lubricant Quantity in Compressor" .
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
MTC
After compressor service operation, turn the compressor shaft by hand more than 5 turns in both
directions. This will equally distribute lubricant inside the compressor. After the compressor is
installed, let the engine idle and operate the compressor for 1 hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for normal K
operation. Refer to MTC-102, "Removal and Installation for Compressor Clutch" .

Precautions for Service Equipment

EJS003US

RECOVERY/RECYCLING EQUIPMENT
Follow the manufacturer's instructions for machine operation and machine maintenance. Never introduce any
refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR
Follow the manufacturer's instructions for tester operation and tester maintenance.

Revision: November 2005

MTC-9

2005 Pathfinder

PRECAUTIONS
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pressure so the vacuum pump lubricant may migrate out of the pump into
the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
●
Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.
●
For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
●
If the hose has an automatic shut off valve, disconnect the hose
from the pump: as long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
RHA270D

MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a (R-134a). Make
sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant.

SHA533D

SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.

RHA272D

Revision: November 2005

MTC-10

2005 Pathfinder

PRECAUTIONS
SERVICE COUPLERS
A

Never attempt to connect HFC-134a (R-134a) service couplers to a
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. If an improper
connection is attempted, discharging and contamination may occur.
Shut-off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

RHA273D

REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC134a (R-134a) and specified
lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2”-16 ACME.

RHA274D

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.

Wiring Diagrams and Trouble Diagnosis

EJS003UT

When you read wiring diagrams, refer to the following:
●
GI-15, "How to Read Wiring Diagrams"
●
PG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble diagnosis, refer to the following:
●
GI-10, "How to Follow Trouble Diagnoses"
●
GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident"

MTC

Revision: November 2005

MTC-11

2005 Pathfinder

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
EJS003UU

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name

Description

—
(J-38873-A)
Pulley installer

Installing pulley

LHA171

KV99233130
(J-29884)
Pulley puller

Removing pulley

LHA172

HFC-134a (R-134a) Service Tools and Equipment

EJS003UV

Never mix HFC-134a (R-134a) refrigerant and/or the specified lubricant with CFC-12 (R-12) refrigerant and/or
the lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used refrigerant/lubricant contamination will
occur and compressor failure will result.
Tool number
(Kent-Moore No.)
Tool name

Description

HFC-134a (R-134a)
( — )
Refrigerant

Container color: Light blue
Container marking: HFC-134a (R134a)
Fitting size: Thread size
●

large container 1/2”-16 ACME

S-NT196

Type: Poly alkylene glycol oil (PAG),
type S (DH-PS)
Application: HFC-134a (R-134a)
swash plate compressors (NISSAN
only)
Lubricity: 40 m (1.4 US fl oz, 1.4 Imp
fl oz)

KLH00-PAGS0
( — )
NISSAN A/C System Lubricant
Type S (DH-PS)

S-NT197

KV991J0130
(ACR2005-NI)
ACR A/C Service Center

Refrigerant Recovery and Recycling
and Recharging

WJIA0293E

Revision: November 2005

MTC-12

2005 Pathfinder

PREPARATION
Tool number
(Kent-Moore No.)
Tool name

Description

—
(J-41995)
Electronic refrigerant leak detector

Power supply:

●

DC 12V (battery terminal)

D
AHA281A

—
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
Refrigerant dye injector
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye (box of 24, 1/4
ounce bottles)
(J-43872)
Refrigerant dye cleaner

Power supply:
●

DC 12V (battery terminal)

H
ZHA200H

—
(J-42220)
Fluorescent dye leak detector

Power supply:
●

DC 12V (battery terminal)

For checking refrigerant leak when fluorescent dye is installed in A/C system.
Includes: UV lamp and UV safety goggles

MTC

SHA438F

Application: For HFC-134a (R-134a)
PAG oil
Container: 1/4 ounce (7.4cc) bottle
(Includes self-adhesive dye identification labels for affixing to vehicle after
charging system with dye.)

—
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(box of 24, 1/4 ounce bottles)

M
SHA439F

For injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.

—
(J-41459)
HFC-134a (R-134a) Refrigerant
dye injector
Use with J-41447, 1/4 ounce bottle

SHA440F

For cleaning dye spills.

—
(J-43872)
Refrigerant dye cleaner

SHA441F

Revision: November 2005

MTC-13

2005 Pathfinder

PREPARATION
Tool number
(Kent-Moore No.)
Tool name

Description

—
(J-39183-C)
Manifold gauge set (with hoses
and couplers)

Identification:
●

The gauge face indicates R-134a.
Fitting size-Thread size

●

1/2”-16 ACME

RJIA0196E

Hose color:

Service hoses:
●

High side hose
(J-39500-72B)

●

Low side hose
(J-39500-72R)

●

Utility hose
(J-39500-72Y)

S-NT201

High side coupler
(J-39500-20A)

●

Low side coupler
(J-39500-24A)

Low side hose: Blue with black stripe

●

High side hose: Red with black stripe

●

Utility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:

●

1/2”-16 ACME

Hose fitting to service hose:

Service couplers
●

●

M14 x 1.5 fitting is optional or permanently attached.

S-NT202

For measuring of refrigerant
Fitting size-Thread size

—
(J-39699)
Refrigerant weight scale

●

1/2”-16 ACME

S-NT200

Capacity:

—
(J-39649)
Vacuum pump
(Including the isolator valve)

●

Air displacement: 4 CFM

●

Micron rating: 20 microns

●

Oil capacity: 482 g (17 oz)
Fitting size-Thread size

●

1/2”-16 ACME

S-NT203

Revision: November 2005

MTC-14

2005 Pathfinder

PREPARATION
Commercial Service Tools

EJS003UW

A
Tool name

Description

(J-41810-NI)
Refrigerant identifier equipment (R134a)

For checking refrigerant purity and
system contamination

D
RJIA0197E

Power tool

Loosening bolts and nuts

PBIC0190E

(J-44614)
Clutch disc holding tool

G
Clutch disc holding tool

WHA230

MTC

Revision: November 2005

MTC-15

2005 Pathfinder

REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Components

PFP:KA990
EJS003UX

REFRIGERATION SYSTEM

LJIA0155E

Revision: November 2005

MTC-16

2005 Pathfinder

REFRIGERATION SYSTEM
1.

Defroster nozzle

LH side demister duct

LH ventilator duct

RH side demister duct

RH ventilator duct

Center ventilator duct

Front heater and cooling unit assembly

Floor connector duct grilles

Floor connector duct

10. Front ducts

11. Floor ducts

13. Center console duct

14. Front console duct

Refrigerant Cycle

12. Rear console duct

B
EJS003UY

MTC

RJIA1552E

REFRIGERANT FLOW
The refrigerant flows in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank,
expansion valve, evaporator, and back to the compressor. The refrigerant evaporation through the evaporator
coil is controlled by an externally equalized expansion valve, located inside the evaporator case.

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
evaporator coil temperature falls below a specified point, the intake sensor interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the intake sensor allows compressor
operation.

Refrigerant System Protection

EJS003UZ

REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends a voltage signal to the ECM.
The ECM de-energizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high
pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm2 , 398 psi), or below
about 120 kPa (1.22 kg/cm2 , 17.4 psi).

Revision: November 2005

MTC-17

2005 Pathfinder

REFRIGERATION SYSTEM
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an abnormal level [more than 2,990 kPa (30.5 kg/
cm2 , 433.6 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant
into the atmosphere.

Revision: November 2005

MTC-18

2005 Pathfinder

LUBRICANT
LUBRICANT
Maintenance of Lubricant Quantity in Compressor

PFP:KLG00

A
EJS003V0

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage has occurred. It is important to maintain
the specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
●
Lack of lubricant: May lead to a seized compressor
●
Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT
D

Name: NISSAN A/C System Lubricant Type S (DH-PS) or equivalent.
Part number: KLH00-PAGS0.

CHECKING AND ADJUSTING
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
Start the engine and set the following conditions:
Test Condition
●
Engine speed: Idling to 1,200 rpm
●
A/C switch: On
●
Blower speed: Max. position
●
Temperature control: Optional [Set so that intake air temperature is 25° to 30° C (77° to 86°F)]
●
Intake position: Recirculation (
)
●
Perform lubricant return operation for about ten minutes
Adjust the lubricant quantity according to the following table.

Lubricant Adjusting Procedure for Components Replacement Except Compressor

After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of Lubricant to be Added

MTC
Lubricant to be added to system

Part replaced

Amount of lubricant
m (US fl oz, Imp fl oz)

Remarks

Evaporator

75 (2.5, 2.6)

—

Condenser

75 (2.5, 2.6)

—

Liquid tank

5 (0.2, 0.2)

Add if compressor is not replaced.

30 (1.0, 1.1)

Large leak

—

Small leak *1

In case of refrigerant leak

*1: If refrigerant leak is small, no addition of lubricant is needed.

Lubricant Adjustment Procedure for Compressor Replacement
1.
2.
3.
4.
5.
6.
7.

Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
Connect recovery/recycling equipment to vehicle. Confirm refrigerant purity in supply tank using recovery/
recycling equipment and refrigerant identifier. If NG, refer to MTC-4, "Contaminated Refrigerant" .
Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identifier. If NG, refer to MTC-4, "Contaminated Refrigerant" .
Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
Drain the lubricant from the “old” (removed) compressor into a graduated container and recover the
amount of lubricant drained.
Drain the lubricant from the “new” compressor into a separate, clean container.
Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this
lubricant to “new” compressor through the suction port opening.

Revision: November 2005

MTC-19

2005 Pathfinder

LUBRICANT
8.
9.

Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to “new” compressor through the suction port opening.
If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant
at this time.
Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.

RHA065DD

Revision: November 2005

MTC-20

2005 Pathfinder

AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL
Description

PFP:27500

A
EJS003V1

The front air control provides regulation of the vehicle's interior temperature. The system is based on the position of the front air controls temperature switch selected by the driver. This is done by utilizing a microcomputer, also referred to as the front air control, which receives input signals from the following two sensors:
●
Intake sensor
●
PBR (position balanced resistor)
The front air control uses these signals (including the set position of the temperature switch) to control:
●
Outlet air volume
●
Air temperature
●
Air distribution

Operation

EJS003V2

AIR MIX DOOR CONTROL
The air mix door is controlled so that in-vehicle temperature changed based on the position of the temperature
switch.

BLOWER SPEED CONTROL
Blower speed is controlled based on front blower switch settings.
When blower switch is turned, the blower motor starts and increases air flow volume each time the blower
switch is turned counterclockwise, and decreases air flow volume each time the blower switch is turned counterclockwise.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

INTAKE DOORS CONTROL
The intake doors are controlled by the recirculation switch setting, and the mode (defroster) switch setting.

MODE DOOR CONTROL
The mode door is controlled by the position of the mode dial.

MTC

DEFROSTER DOOR CONTROL
The defroster door is controlled by the defroster dial set to defroster.

MAGNET CLUTCH CONTROL

WJIA1293E

When the A/C switch is pressed, or the mode dial is turned to the defroster position, the front air control outputs a compressor ON signal to BCM.
The BCM then sends a compressor ON signal to ECM, via CAN communication line.
Revision: November 2005

MTC-21

2005 Pathfinder

AIR CONDITIONER CONTROL
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle sensor, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line.
Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.

Revision: November 2005

MTC-22

2005 Pathfinder

AIR CONDITIONER CONTROL
Description of Control System

EJS003V3

The control system consists of input sensors, switches, the front air control (microcomputer) and outputs.
The relationship of these components is shown in the figure below:

MTC

WJIA1294E

Revision: November 2005

MTC-23

2005 Pathfinder

AIR CONDITIONER CONTROL
Control Operation

EJS003V4

Front air control

WJIA1510E

Temperature control dial

Blower control dial

A/C switch

Rear window defogger switch

Recirculation switch

Mode dial

TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL)
Increases or decreases the set temperature.

RECIRCULATION () SWITCH
●
●
●

When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF. REC mode can be re-entered by pressing REC switch again.
REC switch is not operated when DEF switch is turned ON, or at the D/F position.

DEFROSTER () SWITCH
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.

REAR WINDOW DEFOGGER SWITCH
When switch is ON, rear window is defogged.

OFF SWITCH (BLOWER SPEED SET TO 0)
The compressor and blower are OFF.

A/C SWITCH
The compressor is ON or OFF.
(Pressing the A/C switch when the AUTO switch is ON will turn off the A/C switch and compressor.)

MODE DIAL
Controls the air discharge outlets.

FRONT BLOWER CONTROL DIAL
Manually controls the four blower speeds.

Revision: November 2005

MTC-24

2005 Pathfinder

AIR CONDITIONER CONTROL
Discharge Air Flow

EJS004O3

FRONT

D
WJIA1296E

Air outlet/distribution

Mode door position
Vent

Foot

Defroster

95%

—

60%

40%

—

20%

55%

25%

15%

50%

35%

15%

78%

Airflow always present at driver and passenger side demisters

MTC

Revision: November 2005

MTC-25

2005 Pathfinder

AIR CONDITIONER CONTROL
System Description

EJS003V6

SWITCHES AND THEIR CONTROL FUNCTION

WJIA1496E

WJIA1497E

Revision: November 2005

MTC-26

2005 Pathfinder

AIR CONDITIONER CONTROL
CAN Communication System Description

EJS003V7

Refer to LAN-24, "CAN COMMUNICATION" .

MTC

Revision: November 2005

MTC-27

2005 Pathfinder

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
CONSULT-II Function (BCM)

PFP:00004
EJS003V8

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
BCM diagnostic
test item

Diagnostic mode

WORK SUPPORT
DATA MONITOR
Inspection by part

ACTIVE TEST
SELF-DIAG RESULTS
CAN DIAG SUPPORT MNTR
ECU PART NUMBER
CONFIGURATION

Description
Supports inspections and adjustments. Commands are transmitted to the BCM
for setting the status suitable for required operation, input/output signals are
received from the BCM and received data is displayed.
Displays BCM input/output data in real time.
Operation of electrical loads can be checked by sending drive signal to them.
Displays BCM self-diagnosis results.
The result of transmit/receive diagnosis of CAN communication can be read.
BCM part number can be read.
Performs BCM configuration read/write functions.

CONSULT-II BASIC OPERATION
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, and turn the
ignition switch ON.

WJIA1078E

Touch “START (NISSAN BASED VHCL)”.

BCIA0029E

Touch “BCM” on “SELECT SYSTEM” screen.
If “BCM” is not indicated, go to GI-39, "CONSULT-II Data Link
Connector (DLC) Circuit" .

BCIA0030E

Revision: November 2005

MTC-28

2005 Pathfinder

TROUBLE DIAGNOSIS
DATA MONITOR
Operation Procedure
1.

Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen.
B

D
WJIA0468E

Touch “DATA MONITOR” on “SELECT DIAG MODE” screen.

H
BCIA0031E

Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on
“DATA MONITOR” screen.

All signals

Monitors all the items.

Selection from menu

Selects and monitors the individual item selected.

5.
6.

MTC

When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the items
will be monitored.
Touch “START”.
Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”.

WJIA0469E

Display Item List
Monitor item name
“OPERATION OR UNIT”

Contents

IGN ON SW

“ON/OFF”

Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal.

COMP ON SIG

“ON/OFF”

Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal.

FAN ON SIG

“ON/OFF”

Displays “FAN (ON)/FAN (OFF)” status as judged from blower motor switch signal.

Revision: November 2005

MTC-29

2005 Pathfinder

TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis for Quick and Accurate Repair

EJS003V9

WORK FLOW

SHA900E

ATC-52, "Operational Check
(Front)".

SYMPTOM TABLE
Symptom
A/C system does not come on.

Reference Page
Go to Trouble Diagnosis Procedure for A/C System.

MTC-42

Go to Trouble Diagnosis Procedure for Mode Door Motor.

MTC-45

Go to Trouble Diagnosis Procedure for Air Mix Door Motor.

MTC-49

Go to Trouble Diagnosis Procedure for Intake Door Motor.

MTC-53

Front blower motor operation is malfunctioning.

Go to Trouble Diagnosis Procedure for Front Blower Motor.

MTC-57

Magnet clutch does not engage.

Go to Trouble Diagnosis Procedure for Magnet Clutch.

MTC-65

Insufficient cooling

Go to Trouble Diagnosis Procedure for Insufficient Cooling.

MTC-70

Insufficient heating

Go to Trouble Diagnosis Procedure for Insufficient Heating.

MTC-77

Noise

Go to Trouble Diagnosis Procedure for Noise.

MTC-78

Air outlet does not change.
Mode door motor is malfunctioning.
Discharge air temperature does not change.
Air mix door motor is malfunctioning.
Intake door does not change.
Intake door motor is malfunctioning.

Revision: November 2005

MTC-30

2005 Pathfinder

TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location

EJS003VA

ENGINE COMPARTMENT

MTC

WJIA1489E

Revision: November 2005

MTC-31

2005 Pathfinder

TROUBLE DIAGNOSIS
FRONT PASSENGER COMPARTMENT

WJIA1301E

Revision: November 2005

MTC-32

2005 Pathfinder

TROUBLE DIAGNOSIS
Schematic

EJS003VB

MTC

WJWA0197E

Revision: November 2005

MTC-33

2005 Pathfinder

TROUBLE DIAGNOSIS
Wiring Diagram — A/C,M —

EJS003VC

WJWA0279E

Revision: November 2005

MTC-34

2005 Pathfinder

TROUBLE DIAGNOSIS
A

MTC

WJWA0280E

Revision: November 2005

MTC-35

2005 Pathfinder

TROUBLE DIAGNOSIS

WJWA0281E

Revision: November 2005

MTC-36

2005 Pathfinder

TROUBLE DIAGNOSIS
A

MTC

WJWA0199E

Revision: November 2005

MTC-37

2005 Pathfinder

TROUBLE DIAGNOSIS
Front Air Control Terminals and Reference Value

EJS003VD

Measure voltage between each terminal and ground by following
Terminals and Reference Value for front air control.

WJIA1302E

PIN CONNECTOR TERMINAL LAYOUT

WJIA1303E

TERMINALS AND REFERENCE VALUE FOR FRONT AIR CONTROL
Ignition
switch

Voltage (V)
(Approx.)

Terminal No.

Wire
color

Mode door motor CW

Clockwise rotation

Battery voltage

Air mix door motor (Driver) CW

Clockwise rotation

Battery voltage

G/R

Air mix door motor (Driver) CCW

Counterclockwise rotation

Battery voltage

Intake door motor CW

Clockwise rotation

Battery voltage

Intake door motor CCW

Counterclockwise rotation

Battery voltage

W/G

Power supply for IGN

Battery voltage

Illumination +

Park lamps ON

Illumination -

Park lamps ON

Item

Condition

Battery voltage

PIIA2344E

A/C switch OFF

A/C switch ON

Compressor ON signal

Rear defrost request

Battery voltage

Intake sensor

0 - 5V

Sensor ground

0 - 5V

Mode door motor CCW

Counterclockwise rotation

Battery voltage

Front blower monitor

Front blower motor OFF

Battery voltage

Front blower motor ON

R/Y

Power supply for BAT

Battery voltage

Ground

Revision: November 2005

MTC-38

2005 Pathfinder

TROUBLE DIAGNOSIS
Terminal No.

Wire
color

Item

Ignition
switch

Condition

Voltage (V)
(Approx.)

Mode door motor feedback

0 - 5V

Air mix door motor (Front) feedback

0 - 5V

Power supply for mode door motor
and air mix door motor (Front) PBR

Rear defroster request

Battery voltage

Ground for mode door motor and air
mix door motor (Front) PBR

MTC

Revision: November 2005

MTC-39

2005 Pathfinder

TROUBLE DIAGNOSIS
Operational Check

EJS003VE

The purpose of the operational check is to confirm that the system operates properly.
Conditions

: Engine running and at normal operating temperature

CHECKING BLOWER
1.

Turn blower control dial clockwise. Blower should operate on
low speed.
2. Turn the blower control dial again, and continue checking each
blower speed until all speeds are checked.
3. Leave blower on speed 4.
If NG, go to trouble diagnosis procedure for MTC-57, "Front Blower
Motor Circuit" .
If OK, continue with next check.
WJIA1488E

CHECKING DISCHARGE AIR
1.

Turn the mode switch to each position.

WJIA1305E

2. Confirm that discharge air comes out according to the air distribution table.
Mode door position is checked in the next step.
If NG, go to trouble diagnosis procedure for MTC-45, "Mode Door Motor Circuit" .
If OK, continue with next check.
NOTE:
Confirm that the A/C compressor clutch is engaged (sound or visual inspection) and intake door position is at
fresh when the DEF (
) or D/F (
) is selected.

DISCHARGE AIR FLOW
Air outlet/distribution

Mode door position
Vent

Foot

Defroster

95%

—

60%

40%

—

20%

55%

25%

15%

50%

35%

15%

78%

Airflow always present at side demisters

Revision: November 2005

MTC-40

2005 Pathfinder

TROUBLE DIAGNOSIS
CHECKING RECIRCULATION
Press recirculation (
) switch one time. Recirculation indicator should illuminate.
2. Press recirculation (
) switch one more time. Recirculation
indicator should go off.
3. Listen for intake door position change (blower sound should
change slightly).
If NG, go to trouble diagnosis procedure for MTC-53, "Intake Door
Motor Circuit" .
If OK, continue with next check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at fresh when the DEF or D/F is selected.

WJIA1306E

CHECKING TEMPERATURE DECREASE

1. Rotate temperature control dial counterclockwise.
2. Check for cold air at appropriate discharge air outlets.
If NG, listen for sound of air mix door motor operation if OK, go to
trouble diagnosis procedure for MTC-70, "Insufficient Cooling" . If air
mix door motor appears to be malfunctioning, go to MTC-51, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (FRONT)" .
If OK, continue with next check.

H
WJIA1307E

CHECKING TEMPERATURE INCREASE

1. Rotate temperature control dial clockwise.
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 for MTC-77, "Insufficient Heating" . If air
mix door motor (front) appears to be malfunctioning, go to MTC-51,
"DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR
(FRONT)" .
If OK, continue with next check.

MTC

L
WJIA1308E

CHECK A/C SWITCH
1.
2.

Press A/C switch with the blower switch ON.
A/C switch indicator will turn ON.
● Confirm that the compressor clutch engages (sound or visual
inspection).
If NG, go to trouble diagnosis procedure for MTC-65, "Magnet Clutch
Circuit" .
If OK, continue with next check.

WJIA1309E

Revision: November 2005

MTC-41

2005 Pathfinder

TROUBLE DIAGNOSIS
Power Supply and Ground Circuit for Front Air Control

EJS003VF

SYMPTOM: A/C system does not come on.

INSPECTION FLOW

WJIA1498E

ATC-56, "Power Supply and Ground
Circuit for Front Air Control".

Revision: November 2005

ATC-52, "Operational Check (Front)" *3

MTC-42

MTC-82, "FRONT AIR CONTROL"

2005 Pathfinder

TROUBLE DIAGNOSIS
COMPONENT DESCRIPTION
Front Air Control

The front air control has a built-in microcomputer which processes
information sent from various sensors needed for air conditioner
operation. The air mix door motor, mode door motor, intake door
motor, defroster door motor, blower motor and compressor are then
controlled.
The front air control is unitized with control mechanisms. When the
various switches and temperature dials are operated, data is input to
the front air control.

D
WJIA1302E

Potentio Temperature Control (PTC)

The PTC is built into the front air control. It can be set from cold to
hot or any intermediate position by rotating the temperature dial.
F

H
WJIA1311E

DIAGNOSTIC PROCEDURE FOR A/C SYSTEM
I

SYMPTOM: A/C system does not come on.

MTC

L
WJIA1461E

Revision: November 2005

MTC-43

2005 Pathfinder

TROUBLE DIAGNOSIS

1. CHECK POWER SUPPLY CIRCUITS FOR FRONT AIR CONTROL
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect front air control connector.
Turn ignition switch ON.
Check voltage between front air control harness connector M49
terminals 6 and 19, and ground.
Terminals

Ignition switch position

(+)
Front air
control
connector

Terminal No.

(-)

OFF

ACC

ON
WJIA1082E

M49

Ground

Approx. 0V

Battery
voltage

OK or NG
OK
>> GO TO 2.
NG
>> Check 10A fuses [Nos. 8 and 19, located in the fuse block (J/B)]. Refer to PG-81 .
● If fuses are OK, check harness for open circuit. Repair or replace as necessary.
● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace as necessary.

2. CHECK GROUND CIRCUIT FOR FRONT AIR CONTROL
1.
2.

Turn ignition switch OFF.
Check continuity between front air control harness connector
M49 terminal 20 and ground.
20 - Ground

: Continuity should exist.

OK or NG
OK
>> Replace front air control. Refer to ATC-127, "FRONT
AIR CONTROL" .
NG
>> Repair harness or connector.

WJIA1239E

Revision: November 2005

MTC-44

2005 Pathfinder

TROUBLE DIAGNOSIS
Mode Door Motor Circuit

EJS003VG

SYMPTOM:
●
Air outlet does not change.
●
Mode door motor does not operate normally.

INSPECTION FLOW
C

MTC

WJIA1630E

ATC-29, "Discharge Air Flow".

ATC-52, "Operational Check
(Front)".

MTC-30, "SYMPTOM TABLE".

MTC-82, "FRONT AIR CONTROL"

Revision: November 2005

MTC-45

ATC-61, "DIAGNOSTIC PROCEDURE FOR MODE DOOR
MOTOR".

2005 Pathfinder

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Mode door control system components are:
●
Front air control
●
Mode door motor
●
PBR (built into mode door motor)
●
Intake sensor

System Operation
The mode door position (vent, B/L, foot, D/F, and defrost) is set by the front air control by means of the mode
door motor. When a mode door position is selected on the front air control, voltage is applied to one circuit of
the mode door motor while ground is applied to the other circuit, causing the mode door motor to rotate. The
direction of rotation is determined by which circuit has voltage applied to it, and which one has ground applied
to it. The front air control monitors the mode door position by measuring the voltage signal on the PBR circuit.

WJIA1314E

COMPONENT DESCRIPTION
Mode Door Motor
The mode door motor is attached to the heater & cooling unit. It
rotates so that air is discharged from the outlet as indicated by the
front air control. Motor rotation is conveyed to a link which activates
the mode door.

WJIA1484E

Revision: November 2005

MTC-46

2005 Pathfinder

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR
A

1. CHECK POWER SUPPLY AND GROUND CIRCUITS FOR MODE DOOR MOTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector and mode door motor
connector.
Check continuity between front air control harness connector
M49 terminal 1 and mode door motor harness connector M142
terminal 1 and between front air control harness connector M49
terminal 14 and mode door motor harness connector M142 terminal 6.
1-1

: Continuity should exist.

14 - 6

: Continuity should exist.

WJIA1241E

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace harness as necessary.

2. CHECK PBR REFERENCE SIGNAL VOLTAGE
1.
2.
3.

Reconnect the front air control connector.
Turn ignition switch ON.
Check voltage between mode door motor harness connector
M142 terminal 3 and ground.
3 - Ground

: Approx. 5V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

WJIA1242E

MTC

3. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN MODE DOOR AND FRONT AIR CONTROL
1.
2.
3.

Turn ignition switch OFF.
Disconnect the front air control connector.
Check continuity between mode door motor harness connector
M142 terminal 3 and front air control harness connector M49 terminal 23.
3 - 23

: Continuity should exist.

OK or NG
OK
>> Replace front air control. Refer to ATC-127, "FRONT
AIR CONTROL" .
NG
>> Repair or replace harness as necessary.

Revision: November 2005

MTC-47

WJIA1085E

2005 Pathfinder

TROUBLE DIAGNOSIS

4. CHECK PBR GROUND REFERENCE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect the front air control connector.
Check continuity between mode door motor harness connector
M142 terminal 2 and front air control harness connector M49 terminal 26.
2 - 26

: Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness as necessary.
WJIA1087E

5. CHECK PBR FEEDBACK SIGNAL
1.
2.
3.
4.

Reconnect the front air control connector and mode door motor
connector.
Turn ignition switch ON.
Check voltage between front air control harness connector M49
terminal 21 and ground.
Press mode switch through all modes.
21 - Ground

: Approx. 0 - 5V

OK or NG
OK
>> Replace front air control. Refer to ATC-127, "FRONT
AIR CONTROL" .
NG
>> GO TO 6.

WJIA1088E

6. CHECK PBR FEEDBACK CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect the mode door motor connector and front air control
harness connector.
Check continuity between mode door motor harness connector
M142 terminal 4 and front air control harness connector M49 terminal 21.
4 - 21

: Continuity should exist.

OK or NG
OK
>> Replace mode door motor. Refer to ATC-144, "MODE
DOOR MOTOR" .
NG
>> Repair or replace harness as necessary.

Revision: November 2005

MTC-48

WJIA1089E

2005 Pathfinder

TROUBLE DIAGNOSIS
Air Mix Door Motor Circuit

EJS003VH

SYMPTOM:
●
Discharge air temperature does not change.
●
Air mix door motor does not operate.

INSPECTION FLOW
C

MTC

WJIA1500E

MTC-40, "Operational Check"

Revision: November 2005

MTC-51, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR
MOTOR (FRONT)".

MTC-49

MTC-82, "FRONT AIR CONTROL"

2005 Pathfinder

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Air mix door control system components are:
●
Front air control
●
Air mix door motor
●
PBR (built into air mix door motor)
●
Intake sensor

System Operation
The front air control receives data from the temperature selected by the driver. The front air control then
applies a voltage to one circuit of the air mix door motor, while ground is applied to the other circuit, causing
the air mix door motor to rotate. The direction of rotation is determined by which circuit has voltage applied to
it, and which one has ground applied to it. The front air control monitors the air mix door positions by measuring the voltage signal on the PBR circuits of each door.

WJIA1316E

Air Mix Door Control Specification
COMPONENT DESCRIPTION
Air Mix Door Motors

WJIA0435E

The air mix door motor is attached to the front heater & cooling unit.
This motor rotates so that the air mix door is opened or closed to a
position set by the front air control. Motor rotation is then conveyed
through a shaft and the air mix door position is then fed back to the
front air control by the PBR built into the air mix door motor.

WJIA1485E

Revision: November 2005

MTC-50

2005 Pathfinder

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (FRONT)
A

1. CHECK POWER SUPPLY CIRCUITS FOR AIR MIX DOOR MOTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector and air mix door motor
(front) connector.
Check continuity between front air control harness connector
M49 terminal 2 and 3 and air mix door motor (front) harness
connector M147 terminal 6 and 5.
2-6

: Continuity should exist.

3-5

: Continuity should exist.

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace harness as necessary.

WJIA1318E

2. CHECK PBR REFERENCE SIGNAL VOLTAGE
1.
2.
3.

Reconnect the front air control connector.
Turn ignition switch ON.
Check voltage between air mix door motor (front) harness connector M147 terminal 1 and ground.
1 - Ground

: Approx. 5V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

I
WJIA1319E

3. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN AIR MIX DOOR MOTOR (FRONT) AND

MTC

FRONT AIR CONTROL
1.
2.
3.

Turn ignition switch OFF.
Disconnect the front air control connector.
Check continuity between air mix door motor (front) harness
connector M147 terminal 1 and front air control harness connector M49 terminal 23.
A

Connector

Terminal

Connector

Terminal

Continuity

Front air control:
M49

Air mix door motor
(front): M143

Yes

WJIA1656E

OK or NG
OK
>> Replace front air control. Refer to ATC-127, "FRONT AIR CONTROL" .
NG
>> Repair or replace harness as necessary.

Revision: November 2005

MTC-51

2005 Pathfinder

TROUBLE DIAGNOSIS

4. CHECK PBR GROUND REFERENCE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect the front air control connector.
Check continuity between air mix door motor (front) harness
connector M147 terminal 3 and front air control harness connector M49 terminal 26.
3 - 26

: Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness as necessary.
WJIA1320E

5. CHECK PBR FEEDBACK SIGNAL
1.
2.
3.
4.

Reconnect the front air control connector and air mix door motor
(front) connector.
Turn ignition switch ON.
Check voltage between front air control harness connector M49
terminal 22 and ground.
Rotate temperature control dial through complete range.
22 - Ground

: Approx. 0V - 5V

OK or NG
OK
>> Replace front air control. Refer to ATC-127, "FRONT
AIR CONTROL" .
NG
>> GO TO 6.

WJIA1096E

6. CHECK PBR FEEDBACK CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect the air mix door motor (front) connector and front air
control connector.
Check continuity between air mix door motor (front) harness
connector M147 terminal 2 and front air control harness connector M49 terminal 22.
2 - 22

: Continuity should exist.

OK or NG
OK
>> Replace air mix door motor (front). Refer to MTC-92,
"AIR MIX DOOR MOTOR" .
NG
>> Repair or replace harness as necessary.

Revision: November 2005

MTC-52

WJIA1321E

2005 Pathfinder

TROUBLE DIAGNOSIS
Intake Door Motor Circuit

EJS003VI

SYMPTOM:
●
Intake door does not change.
●
Intake door motor does not operate normally.

INSPECTION FLOW
C

MTC

WJIA1477E

ATC-52, "Operational Check
(Front)".

Revision: November 2005

MTC-82, "FRONT AIR CONTROL".

MTC-53

2005 Pathfinder

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Intake door control system components are:
●
Front air control
●
Intake door motor
●
Intake sensor

System Operation
The intake door control determines the intake door position based on the position of the recirculation switch.
When the recirculation switch is depressed the intake door motor rotates closing off the fresh air inlet and
recirculating the cabin air. If the recirculation switch is depressed again, the intake door motor rotates in the
opposite direction, again allowing fresh air into the cabin.

WJIA1478E

COMPONENT DESCRIPTION
Intake door motor
The intake door motor is attached to the intake unit. It rotates so that
air is drawn from inlets set by the front air control. Motor rotation is
conveyed to a lever which activates the intake door.

WJIA1486E

Revision: November 2005

MTC-54

2005 Pathfinder

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR
A

1. CHECK INTAKE DOOR MOTOR CIRCUIT VOLTAGE
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Disconnect intake door motor connector.
Turn ignition switch ON.
Rotate the temperature control dial counterclockwise.
Check voltage between intake door motor harness connector
M58 terminal 6 and ground.
6 - Ground

: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

WJIA1324E

2. CHECK INTAKE DOOR MOTOR CIRCUIT FOR OPEN
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector.
Check continuity between front air control harness connector
M49 terminal 5 and intake door motor harness connector M58
terminal 6.
5-6

: Continuity should exist.

OK or NG
OK
>> Replace front air control connector. Refer to MTC-82,
"CONTROL UNIT" .
NG
>> Repair or replace harness as necessary.

I
WJIA1468E

3. CHECK INTAKE DOOR MOTOR CIRCUIT VOLTAGE
1.
2.

MTC

Rotate the temperature control dial clockwise.
Check voltage between intake door motor harness connector
M58 terminal 1 and ground.
1 - Ground

:Battery voltage
L

OK or NG
OK
>> Replace intake door motor. Refer to ATC-143, "INTAKE
DOOR MOTOR" .
NG
>> GO TO 4.

M
WJIA1326E

Revision: November 2005

MTC-55

2005 Pathfinder

TROUBLE DIAGNOSIS

4. CHECK INTAKE DOOR MOTOR CIRCUIT FOR OPEN
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector.
Check continuity between front air control harness connector
M49 terminal 4 and intake door motor harness connector M58
terminal 1.
A

Connector

Terminal

Connector

Terminal

Continuity

Front air control:
M49

Intake door motor:
M58

Yes
WJIA1684E

OK or NG
OK
>> Replace front air control connector. Refer to MTC-82, "CONTROL UNIT" .
NG
>> Repair or replace harness as necessary.

Revision: November 2005

MTC-56

2005 Pathfinder

TROUBLE DIAGNOSIS
Front Blower Motor Circuit

EJS003VJ

SYMPTOM:
●
Blower motor operation is malfunctioning.

INSPECTION FLOW

MTC

WJIA1501E

MTC-40, "Operational Check"

MTC-59, "DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR"

MTC-30, "SYMPTOM TABLE".

MTC-82, "FRONT AIR CONTROL"

Revision: November 2005

MTC-57

EC-204, "DTC P0117, P0118 ECT
SENSOR"

2005 Pathfinder

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Blower speed control system components are:
●
Front air control
●
Front blower motor resistor
●
Front blower motor
●
Front blower relay
●
Intake sensor

System Operation

WJIA1502E

COMPONENT DESCRIPTION
Blower Motor Resistor
The front blower motor resistor is located on the cooling unit. The
front blower motor resistor grounds the front blower motor through a
series of 1, 2, or 3 resistors, depending upon speed selected. For
high speed operation the front blower motor resistor is circumvented
and the front blower motor grounds directly.

WJIA1487E

Revision: November 2005

MTC-58

2005 Pathfinder

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR
A

SYMPTOM: Blower motor operation is malfunctioning under starting
blower speed control.

G
WJIA1503E

1. DIAGNOSTIC PROCEDURE

1.
2.

Turn ignition switch ON.
Turn the front blower switch to each of its four speeds.
Does blower motor rotate normally at each speed?
YES or NO
YES >> Inspection End.
NO
>> 1. Does not rotate at any speed, GO TO 2.
2. Does not rotate at 1 - 3 speed, GO TO 13.
3. Does not rotate at 4 speed, GO TO 16.

MTC

2. CHECK FUSES
Check 15A fuses (Nos. 24 and 27, located in the fuse and fusible link box). Refer to PG-82, "FUSE AND
FUSIBLE LINK BOX" .
2. Check 10A fuse [No. 8, located in the fuse block (JB)]. Refer to PG-81, "FUSE BLOCK-JUNCTION
BOX(J/B)" .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 8.

Revision: November 2005

MTC-59

2005 Pathfinder

TROUBLE DIAGNOSIS

3. CHECK FRONT BLOWER MOTOR POWER SUPPLY
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Disconnect front blower motor harness connector.
Turn ignition switch ON.
Select any front blower speed except OFF.
Check voltage between front blower motor harness connector
M62 terminal 2 and ground.
2 - Ground

: Battery voltage

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 4.

WJIA1331E

4. CHECK FRONT BLOWER MOTOR RELAY
1. Turn Ignition switch OFF.
2. Check front blower motor relay. Refer to MTC-63, "Front Blower Motor Relay" .
OK or NG
OK
>> GO TO 5.
NG
>> Replace front blower motor relay.

5. CHECK FRONT BLOWER MOTOR RELAY POWER SUPPLY (SWITCH SIDE)
Check voltage between front blower motor relay harness connector
E54 terminals 7 and 5 and ground.
A
(+)
Front air control
connector

Terminal

M54

Voltage
(Approx.)

Condition

(-)

Ground

Blower motor
relay power
supply

Ground

Blower motor
relay power
supply

Battery voltage
WJIA1634E

Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> Repair harness or connector.

Revision: November 2005

MTC-60

2005 Pathfinder

TROUBLE DIAGNOSIS

6. CHECK FRONT BLOWER MOTOR RELAY POWER SUPPLY (COIL SIDE)
1.
2.

Turn ignition switch ON.
Check voltage between front blower motor relay harness connector E54 terminal 1 and ground.
A
(+)

Front air control
connector

M54

Condition
Terminal

Voltage
(Approx.)

(-)

Ground

Blower motor
relay power
supply (coil
side)

D
Battery voltage

WJIA0504E

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace harness as necessary.

7. CHECK FRONT BLOWER MOTOR POWER FROM RELAY TO FRONT BLOWER MOTOR
1.
2.

Turn Ignition switch OFF.
Check continuity between front blower motor relay harness connector E54 terminals 6 and 3 and front blower motor harness
connector M62 terminal 2.
3, 6 - 2

: Continuity should exist.

OK or NG
OK
>> Repair or replace harness as necessary.
NG
>> Repair harness or connector between the front blower
motor relay and the front blower motor.

WJIA1333E

MTC

8. REPLACE FUSE
K

Refer to PG-82, "FUSE AND FUSIBLE LINK BOX" .
Does fuse No. 24 or 27 open when the front blower motor is turned on?
YES or NO
YES >> GO TO 10.
NO
>> GO TO 9.

9. REPLACE FUSE

Refer to PG-81, "FUSE BLOCK-JUNCTION BOX(J/B)" .
Does fuse No. 8 open when the ignition switch is turned ON?
YES or NO
YES >> Repair or replace harness as necessary.
NO
>> Inspection End.

Revision: November 2005

MTC-61

2005 Pathfinder

TROUBLE DIAGNOSIS

10. CHECK FRONT BLOWER MOTOR POWER SUPPLY CIRCUIT FOR SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect front blower motor connector.
Check continuity between front blower motor harness connector
M62 terminal 2 and ground.
2 - Ground

: Continuity should not exist.

OK or NG
OK
>> GO TO 11.
NG
>> Repair or replace harness as necessary.

WJIA0649E

11. CHECK FRONT BLOWER MOTOR RELAY (SWITCH SIDE) POWER SUPPLY CIRCUIT FOR SHORT
1.
2.

Disconnect front blower motor relay connector.
Check continuity between the front blower motor relay harness
connector E54 terminal 7 and terminal 5 and ground.
7, 5 - Ground

: Continuity should not exist.

OK or NG
OK
>> Check front blower motor. Refer to MTC-64, "Front
Blower Motor" .
NG
>> Repair harness or connector.
WJIA1334E

12. CHECK FRONT BLOWER MOTOR
1. Turn ignition switch OFF.
2. Check front blower motor. Refer to MTC-64, "Front Blower Motor" .
OK or NG
OK
>> GO TO 13.
NG
>> Replace front blower motor. Refer to MTC-84, "BLOWER MOTOR" .

13. CHECK FRONT BLOWER MOTOR RESISTOR
Check front blower motor resistor. Refer to MTC-58, "Blower Motor Resistor" .
OK or NG
OK
>> GO TO 14.
NG
>> Replace front blower motor resistor. Refer to MTC-93, "Removal and Installation" .

14. CHECK FRONT BLOWER SWITCH
Check front blower switch. Refer to MTC-64, "Front Blower Switch" .
OK or NG
OK
>> GO TO 15.
NG
>> Replace front blower switch. Refer to MTC-82, "FRONT AIR CONTROL" .

Revision: November 2005

MTC-62

2005 Pathfinder

TROUBLE DIAGNOSIS

15. CHECK FRONT BLOWER MOTOR GROUND CIRCUIT TO FRONT BLOWER MOTOR RESISTOR
1.
2.

Disconnect front blower motor resistor harness connector.
Check continuity between front blower motor connector M62 terminal 1 and front blower motor resistor harness connector M122
terminal 3.
A

Connector

Terminal

Connector

Terminal

Continuity

Front blower motor:
M62

Front blower
motor resistor:
M122

Yes

D
WJIA1676E

OK or NG
OK
>> Repair harness or connector between front blower switch connector M51 terminal 4 and ground.
NG
>> Repair harness or connector between front blower motor resistor and front blower motor.

16. CHECK FRONT BLOWER SWITCH

Check front blower switch. Refer to MTC-64, "Front Blower Switch" .
OK or NG
OK
>> Repair harness or connector between front blower motor switch connector M51 terminal 8 and
front blower motor resistor connector M122 terminal 3.
NG
>> Replace front blower switch. Refer to MTC-82, "FRONT AIR CONTROL" .

COMPONENT INSPECTION
Front Blower Motor Relay
I

Check continuity between terminals by supplying 12 volts and
ground to coil side terminals of relay.

MTC

LJIA0068E

Revision: November 2005

MTC-63

2005 Pathfinder

TROUBLE DIAGNOSIS
Front Blower Motor
Confirm smooth rotation of the blower motor.
●
Ensure that there are no foreign particles inside the blower unit.
●
Apply 12 volts to terminal 2 and ground to terminal 1 and verify
that the motor operates freely and quietly.

WJIA1508E

Front Blower Switch
Check continuity between terminals at each switch position.

WJIA0508E

Revision: November 2005

MTC-64

2005 Pathfinder

TROUBLE DIAGNOSIS
Magnet Clutch Circuit

EJS003VK

SYMPTOM: Magnet clutch does not engage.

INSPECTION FLOW
B

MTC

WJIA1677E

.ATC-52, "Operational Check
(Front)" .

Revision: November 2005

ATC-125, "Intake Sensor Circuit".

MTC-65

MTC-82, "FRONT AIR CONTROL".

2005 Pathfinder

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
The front air control controls compressor operation based on ambient and intake temperature and a signal
from ECM.

Low Temperature Protection Control
The front air control will turn the compressor ON or OFF as determined by a signal detected by the intake sensor and the ambient sensor.
When intake air temperature is higher than 3.5° C (38.3° F), the compressor turns ON. The compressor turns
OFF when intake air temperature is lower than 2.5° C (36.5° F).

DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH
SYMPTOM: Magnet clutch does not engage when A/C switch is ON.

WJIA1490E

1. PERFORM AUTO ACTIVE TEST
Refer to PG-22, "Auto Active Test" .
Does magnet clutch operate?
YES or NO
YES >> ●
WITH CONSULT-II
GO TO 2.
WITHOUT CONSULT-II
GO TO 8.
>> Check 10A fuse (No. 42, located in IPDM E/R), and GO TO 12.
●

2. CHECK BCM INPUT (A/C COMPRESSOR ON) SIGNAL
Check A/C compressor ON/OFF signal. Refer to MTC-28, "CONSULT-II Function (BCM)" .
A/C SW ON

: COMP ON SIG ON

A/C SW OFF

: COMP ON SIG OFF

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 8.

WJIA0469E

Revision: November 2005

MTC-66

2005 Pathfinder

TROUBLE DIAGNOSIS

3. CHECK REFRIGERANT PRESSURE SENSOR

Check refrigerant pressure sensor. Refer to EC-691, "REFRIGERANT PRESSURE SENSOR"
OK or NG
OK
>> GO TO 4.
NG
>> Replace refrigerant pressure sensor. Refer to MTC-106, "Removal and Installation for Refrigerant
Pressure Sensor" .

4. CHECK BCM INPUT (FAN ON) SIGNAL
Check FAN ON/OFF signal. Refer to MTC-28, "CONSULT-II Function (BCM)" .
BLOWER CONTROL DIAL
ON

: FAN ON SIG ON

BLOWER CONTROL DIAL
OFF

: FAN ON SIG OFF

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

WJIA0469E

5. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND FRONT AIR CONTROL
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and front air control connector.
Check continuity between BCM harness connector M18 terminal
28 and front air control harness connector M49 terminal 18.
A
Connector
BCM: M18

B
Terminal

Connector

Terminal

Continuity

Front air control:
M49

Yes

OK or NG
OK
>> GO TO 6.
NG
>> Repair harness or connector.

MTC

WJIA1627E

Revision: November 2005

MTC-67

2005 Pathfinder

TROUBLE DIAGNOSIS

6. CHECK VOLTAGE FOR FRONT AIR CONTROL (FAN ON SIGNAL)
1.
2.
3.
4.

Reconnect BCM connector and front air control connector.
Turn ignition switch ON.
Turn A/C switch ON.
Check voltage between front air control harness connector M49
terminal 18 and ground.
Terminals
(+)

Front air control connector

(-)

Voltage
(Approx.)

Condition

Terminal No.
WJIA1628E

M49

Ground

A/C switch: ON
Blower motor
operates

A/C switch: OFF

OK or NG
OK
>> Replace BCM. Refer to BCS-20, "Removal and Installation of BCM" .
NG-1 >> If the voltage is approx. 5V when blower motor is ON, replace front air control. Refer to MTC-82,
"CONTROL UNIT" .
NG-2 >> If the voltage is approx. 0V when blower motor is OFF, replace BCM. Refer to BCS-20, "Removal
and Installation of BCM" .

7. CHECK CAN COMMUNICATION
Check CAN communication. Refer to LAN-24, "CAN COMMUNICATION" .
OK or NG
OK
>> Inspection End.
NG
>> Repair or replace malfunctioning part(s).

8. CHECK VOLTAGE FOR FRONT AIR CONTROL (A/C COMPRESSOR ON SIGNAL)
1.
2.
3.

Reconnect BCM connector and front air control connector.
Turn ignition switch ON.
Check voltage between front air control harness connector M49
terminal 10 and ground.
Terminals
(+)

Front air
control connector
M49

(-)
Condition

Voltage
(Approx.)

A/C switch: ON

A/C switch:
OFF

Battery voltage

Terminal No.
WJIA1137E

Ground

OK or NG
OK
>> GO TO 9.
NG-1 >> If the voltage is approx. 5V when A/C switch is ON, replace front air control. Refer to MTC-82,
"CONTROL UNIT" .
NG-2 >> If the voltage is approx. 0V when A/C switch is OFF, replace BCM. Refer to BCS-20, "Removal
and Installation of BCM" .

Revision: November 2005

MTC-68

2005 Pathfinder

TROUBLE DIAGNOSIS

9. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND FRONT AIR CONTROL
1.
2.

Disconnect BCM connector and front air control connector.
Check continuity between BCM harness connector M18 terminal
27 and front air control harness connector M49 terminal 10.
27 - 10

: Continuity should exist.

OK or NG
OK
>> GO TO 10.
NG
>> Repair harness or connector.

D
WJIA1136E

10. CHECK INTAKE SENSOR CIRCUITS

Check intake sensor. Refer to MTC-80, "Intake Sensor Circuit" .
OK or NG
OK
>> GO TO 11.
NG
>> Replace intake sensor. Refer to MTC-83, "INTAKE SENSOR" .

11. CHECK CAN COMMUNICATION

Check CAN communication. Refer to LAN-24, "CAN COMMUNICATION" .
OK or NG
OK
>> Replace BCM. Refer to BCS-20, "Removal and Installation of BCM" .
NG
>> Repair or replace malfunctioning part(s).

12. CHECK MAGNET CLUTCH CIRCUIT
Check for operation sound when applying battery voltage to terminal.
OK or NG
OK
>> GO TO 13.
NG
>> Replace magnet clutch. Refer to MTC-102, "Removal
and Installation for Compressor Clutch" .

MTC

WJIA1472E

13. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND A/C COMPRESSOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector and A/C compressor (magnet
clutch) connector.
Check continuity between IPDM E/R harness connector E119
terminal 11 and A/C compressor harness connector F3 terminal
1.
11 – 1

: Continuity should exist.

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-29, "Removal and
Installation of IPDM E/R" .
NG
>> Repair harness or connector.

Revision: November 2005

MTC-69

WJIA1470E

2005 Pathfinder

TROUBLE DIAGNOSIS
Insufficient Cooling

EJS003VL

SYMPTOM: Insufficient cooling

INSPECTION FLOW

WJIA1340E

.ATC-52, "Operational Check
(Front)" .

EC-463, "SYSTEM DESCRIPTION". *3

ATC-5, "Contaminated Refrigerant".

ATC-103, "PERFORMANCE TEST
DIAGNOSES".

ATC-105, "Test Reading"
.

MA-13, "Checking Drive Belts"

Revision: November 2005

MTC-70

2005 Pathfinder

TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSES
A

MTC

RJIA1601E

ATC-105, "PERFORMANCE
CHART".

ATC-63, "Air Mix Door Motor Circuit".

Revision: November 2005

ATC-105, "PERFORMANCE
CHART".

MTC-71

ATC-106, "Trouble Diagnoses for
Unusual Pressure".

2005 Pathfinder

TROUBLE DIAGNOSIS

RJIA3107E

ATC-159, "Removal and Installation
for Compressor Clutch".

Revision: November 2005

ATC-75, "Front Blower Motor Circuit".

MTC-72

MA-13, "Checking Drive Belts".

2005 Pathfinder

TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition

Testing must be performed as follows:
Vehicle location

Indoors or in the shade (in a well-ventilated place)

Doors

Closed

Door window

Open

Hood

Open

TEMP.

Max. COLD

Mode switch

(Ventilation) set

Recirculation (REC) switch

(Recirculation) set
Max. speed set

Blower speed
Engine speed

Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading

Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Relative humidity
%

Discharge air temperature at center ventilator
°C (°F)

Air temperature
°C (°F)
20 (68)

5.3 - 6.5 (42 - 44)

25 (77)

9.7 - 11.5 (49 - 53)

30 (86)

13.8 - 16.3 (57 - 61)

35 (95)

18.0 - 21.2 (64 - 70)

40 (104)

22.2 - 25.7 (72 - 78)

50 - 60

20 (68)

6.5 - 7.7 (44 - 46)

25 (77)

11.5 - 13.3 (53 - 56)

30 (86)

16.3 - 18.8 (61 - 66)

35 (95)

21.2 - 24.0 (70 - 75)

40 (104)

25.7 - 29.2 (78 - 85)

60 - 70

MTC

Ambient Air Temperature-to-operating Pressure Table
Ambient air
Relative humidity
%

50 - 70

Revision: November 2005

High-pressure (Discharge side)

Low-pressure (Suction side)

Air temperature
°C (°F)

kPa (kg/cm2 , psi)

20 (68)

680 - 840
(6.94 - 8.57, 98.6 - 121.8)

160 - 198
(1.63 - 2.02, 23.2 - 28.7)

25 (77)

800 - 985
(8.16 - 10.05, 116.0 - 142.8)

198 - 245
(2.02 - 2.50, 28.7 - 35.5)

30 (86)

940 - 1,150
(9.59 - 11.73, 136.3 - 166.8)

225 - 278
(2.30 - 2.84, 32.6 - 40.3)

35 (95)

1,160 - 1,410
(11.83 - 14.38, 168.2 - 204.5)

273 - 335
(2.78 - 3.42, 39.6 - 48.6)

40 (104)

1,325 - 1,620
(13.52 - 16.52, 192.1 - 234.9)

325 - 398
(3.32 - 4.06, 47.1 - 57.7)

MTC-73

2005 Pathfinder

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE
Whenever system′s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker
above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperatureto-operating pressure table).

Both High- and Low-pressure Sides are Too High
Gauge indication

Refrigerant cycle
Pressure is reduced soon
after water is splashed on
condenser.

Air suction by cooling fan is
insufficient.

Probable cause
Excessive refrigerant charge
in refrigeration cycle
Insufficient condenser cooling
performance
↓
1. Condenser fins are clogged.

Corrective action
Reduce refrigerant until specified pressure is obtained.

●

Clean condenser.

●

Check and repair cooling fan
if necessary.

2. Improper fan rotation of
cooling fan
Both high- and low-pressure sides
are too high.

●

Low-pressure pipe is not
cold.

●

When compressor is
stopped high-pressure
value quickly drops by
approximately 196 kPa (2
kg/cm2 , 28 psi). It then
decreases gradually thereafter.

AC359A

Engine tends to overheat.

●

An area of the low-pressure pipe is colder than
areas near the evaporator
outlet.
Plates are sometimes covered with frost.

Poor heat exchange in condenser
(After compressor operation
stops, high-pressure
decreases too slowly.)
↓
Air in refrigeration cycle

Evacuate and recharge system.

Engine cooling systems malfunction.

Check and repair engine cooling system.

●

Excessive liquid refrigerant
on low-pressure side

●

Excessive refrigerant discharge flow

●

Expansion valve is open a
little compared with the
specification.

Replace expansion valve.

↓
Improper expansion valve
adjustment

High-pressure Side is Too High and Low-pressure Side is Too Low
Gauge indication

Refrigerant cycle

Probable cause

Corrective action

High-pressure side is too high and
low-pressure side is too low.
Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.

High-pressure tube or parts
located between compressor
and condenser are clogged or
crushed.

●

Check and repair or replace
malfunctioning parts.

●

Check lubricant for contamination.

AC360A

Revision: November 2005

MTC-74

2005 Pathfinder

TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High
Gauge indication
High-pressure side is too low and
low-pressure side is too high.

Refrigerant cycle

Probable cause

High- and low-pressure sides
become equal soon after compressor operation stops.

Compressor pressure operation is improper.
↓
Damaged inside compressor
packings.

No temperature difference
between high- and low-pressure sides.

Compressor pressure operation is improper.
↓
Damaged inside compressor
packings.

AC356A

Corrective action

Replace compressor.

C
Replace compressor.

Both High- and Low-pressure Sides are Too Low
Gauge indication

Refrigerant cycle
●

●

Both high- and low-pressure sides
are too low.

AC353A

There is a big temperature
difference between liquit
tand outlet and inlet. Outlet
temperature is extremely
low.

Probable cause

Liquid tank inside is slightly
clogged.

Corrective action

●

Replace liquid tank.

●

Check lubricant for contamination.

Liquid tank inlet and expansion valve are frosted.
Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank.

●

Expansion valve inlet may
be frosted.

●

Temperature difference
occurs somewhere in highpressure side.

Expansion valve and liquid
tank are warm or only cool
when touched.

There is a big temperature difference between expansion
valve inlet and outlet while the
valve itself is frosted.

Air flow volume is too low.

Revision: November 2005

High-pressure pipe located
between liquit tank and expansion valve is clogged.

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

Low refrigerant charge.
↓
Leaking fittings or components.

Check refrigerant system for
leaks. Refer to ATC-170,
"Checking for Refrigerant
Leaks" .

Expansion valve closes a little
compared with the specification.
↓

●

Remove foreign particles by
using compressed air.

●

Check lubricant for contamination.

1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.
3. Outlet and inlet may be
clogged.

An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.

Low-pressure pipe is clogged
or crushed.

Evaporator is frozen.

MTC-75

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

●

Check intake sensor circuit.
Refer to ATC-125, "Intake
Sensor Circuit" .

●

Replace compressor.

●

Repair evaporator fins.

●

Replace evaporator.

●

Refer to ATC-75, "Front
Blower Motor Circuit" .

2005 Pathfinder

MTC

TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative
Gauge indication
Low-pressure side sometimes
becomes negative.

Refrigerant cycle
●

●

Air conditioning system
does not function and does
not cyclically cool the compartment air.
The system constantly functions for a certain period of
time after compressor is
stopped and restarted.

Probable cause
Refrigerant does not discharge cyclically.
↓
Moisture is frozen at expansion valve outlet and inlet.
↓
Water is mixed with refrigerant.

Corrective action

●

Drain water from refrigerant
or replace refrigerant.

●

Replace liquid tank.

AC354A

Low-pressure Side Becomes Negative
Gauge indication

Refrigerant cycle

Probable cause

Corrective action
Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
●

If water is the cause, initially
cooling is okay. Then the
water freezes causing a
blockage. Drain water from
refrigerant or replace refrigerant.

●

If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed air
(not shop air).

●

If either of the above methods cannot correct the malfunction, replace expansion
valve.

●

Replace liquid tank.

●

Check lubricant for contamination.

Low-pressure side becomes negative.
Liquid tank or front/rear side of
expansion valve′s pipe is
frosted or dewed.

High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted.

AC362A

Revision: November 2005

MTC-76

2005 Pathfinder

TROUBLE DIAGNOSIS
Insufficient Heating

EJS003VM

SYMPTOM: Insufficient heating

INSPECTION FLOW
B

MTC

WJIA1678E

.ATC-52, "Operational Check
(Front)"

ATC-63, "Air Mix Door Motor Circuit". *3

MA-13, "Changing Engine Coolant".

CO-10, "CHECKING RESERVOIR
CAP".

Revision: November 2005

MTC-77

EC-204, "DTC P0117, P0118 ECT
SENSOR".

2005 Pathfinder

TROUBLE DIAGNOSIS
Noise

EJS003VN

SYMPTOM: Noise

INSPECTION FLOW

WJIA0473E

Revision: November 2005

MTC-78

2005 Pathfinder

TROUBLE DIAGNOSIS
*1

ATC-159, "REMOVAL".

ATC-52, "Operational Check (Front)" *5

ATC-160, "INSTALLATION".

ATC-22, "Maintenance of Lubricant
Quantity in Compressor".

MA-13, "Checking Drive Belts".

MTC

Revision: November 2005

MTC-79

2005 Pathfinder

TROUBLE DIAGNOSIS
Intake Sensor Circuit

EJS003VO

COMPONENT DESCRIPTION
Intake Sensor
The intake sensor is located on top of the heater and cooling unit
assembly next to the A/C evaporator cover. It converts temperature
of air after it passes through the evaporator into a resistance value
which is then input to the front air control.

WJIA1155E

DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR
SYMPTOM: Intake sensor circuit is open or shorted.

WJIA1156E

1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND
1.
2.
3.

Disconnect intake sensor connector.
Turn ignition switch ON.
Check voltage between intake sensor harness connector M146
terminal 2 and ground.
2 - Ground

: Approx. 5V

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.
WJIA1278E

2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND FRONT AIR CONTROL
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector.
Check continuity between intake sensor harness connector
M146 terminal 1 and front air control harness connector M49 terminal 13.
1 - 13

: Continuity should exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

Revision: November 2005

WJIA1157E

MTC-80

2005 Pathfinder

TROUBLE DIAGNOSIS

3. CHECK INTAKE SENSOR

Refer to ATC-126, "Intake Sensor" .
OK or NG
OK
>> Replace front air control. Refer to MTC-82, "FRONT AIR CONTROL" .
NG
>> Replace intake sensor. Refer to MTC-83, "INTAKE SENSOR" .

4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND FRONT AIR CONTROL
1.
2.
3.

Turn ignition switch OFF.
Disconnect front air control connector.
Check continuity between intake sensor harness connector
M146 terminal 2 and front air control harness connector M49 terminal 12.
2 - 12

: Continuity should exist.

Check continuity between intake sensor harness connector
M146 terminal 2 and ground.
2 - Ground

: Continuity should not exist.

F
WJIA1158E

OK or NG
OK
>> Replace front air control. Refer to MTC-82, "FRONT AIR CONTROL" .
NG
>> Repair harness or connector.

COMPONENT INSPECTION
Intake Sensor

After disconnecting intake sensor connector, measure resistance
between terminals 1 and 2 at sensor harness side, using the table
below.
Temperature °C (°F)

Resistance kΩ

−15 (5)

209.0

−10 (14)

160.0

−5 (23)

123.0

0 (32)

95.8

5 (41)

74.9

10 (50)

58.9

15 (59)

46.7

20 (68)

37.3

25 (77)

30.0

30 (86)

24.2

35 (95)

19.7

40 (104)

16.1

45 (113)

13.2

MTC

WJIA1159E

If NG, replace intake sensor.

Revision: November 2005

MTC-81

2005 Pathfinder

CONTROL UNIT
CONTROL UNIT
Removal and Installation

PFP:27500
EJS003VP

FRONT AIR CONTROL
Removal
1.
2.
3.

Remove cluster lid C. Refer to IP-11, "CLUSTER LID C" .
Remove the four screws securing the front air control to cluster
lid C.
Remove the front air control.

LBIA0416E

Installation
Installation is in the reverse order of removal.

Revision: November 2005

MTC-82

2005 Pathfinder

INTAKE SENSOR
INTAKE SENSOR
Removal and Installation

PFP:27723

A
EJS003VQ

REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.

Remove the front kick plate. Refer to EI-28, "KICK PLATES" .
Remove the lower dash side finisher. Refer to EI-28, "LOWER DASH SIDE FINISHER" .
Remove the front pillar lower finisher. Refer to EI-28, "FRONT PILLAR LOWER FINISHER" .
Remove the assist grip handle
Remove the front pillar upper finisher. Refer to EI-28, "FRONT PILLAR UPPER FINISHER" .
Remove the lower glove box. Refer to IP-14, "LOWER INSTRUMENT PANEL RH AND GLOVE BOX" .
Remove the upper glove box (cluster lid E). Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Disconnect the intake sensor electrical connector.
NOTE:
The intake sensor is located on the top of the heater and cooling
unit assembly next to the A/C evaporator cover.
Twist the intake sensor to remove the intake sensor from the
heater and cooling unit assembly.

G
WJIA1415E

INSTALLATION
Installation is in the reverse order of removal.

MTC

Revision: November 2005

MTC-83

2005 Pathfinder

BLOWER MOTOR
BLOWER MOTOR
Components

PFP:27226
EJS003VR

Blower Motor

LJIA0136E

Heater and cooling unit assembly

Blower motor

Removal and Installation

Blower motor resistor
EJS003VS

REMOVAL
1.
2.
3.

Remove the lower glove box assembly. Refer to IP-14, "LOWER INSTRUMENT PANEL RH AND GLOVE
BOX" .
Disconnect the blower motor electrical connector.
Remove the three screws and remove the blower motor.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2005

MTC-84

2005 Pathfinder

IN-CABIN MICROFILTER
IN-CABIN MICROFILTER
Removal and Installation

PFP:27277

A
EJS003VT

FUNCTION
The air inside the passenger compartment is filtered by the in-cabin
microfilters when the heater or A/C controls are set on either the
recirculation or fresh mode. The two in-cabin microfilters are located
in the heater and cooling unit assembly.

LJIA0012E

REPLACEMENT TIMING
Replacement of the two in-cabin microfilters is recommended on a regular interval depending on the driving
conditions. Refer to MA-7, "PERIODIC MAINTENANCE" . It may also be necessary to replace the two in-cabin
microfilters as part of a component replacement if the in-cabin microfilters are damaged.

REPLACEMENT PROCEDURE
1.

Open the lower glove box and press in on the sides so that it will
open completely allowing it to hang by the cord.

MTC
WLIA0023E

2.
3.

Remove the screw and remove the in-cabin microfilter cover.
Remove the in-cabin microfilters from the heater and cooling
unit housing.

M
LJIA0134E

Insert the first new in-cabin microfilter into the heater and cooling unit housing and slide it over to the right. Insert the second
new in-cabin microfilter into the heater and cooling unit housing.
NOTE:
The in-cabin microfilters are marked with air flow arrows. The
end of the microfilter with the arrow should face the rear of the
vehicle. The arrows should point downward.

LJIA0148E

Revision: November 2005

MTC-85

2005 Pathfinder

IN-CABIN MICROFILTER
5.

Install the in-cabin microfilter cover.

LJIA0134E

Close the lower glove box completely.

Revision: November 2005

MTC-86

2005 Pathfinder

HEATER & COOLING UNIT ASSEMBLY
HEATER & COOLING UNIT ASSEMBLY
Components

PFP:27110

A
EJS003VU

Heater and Cooling Unit Assembly
B

MTC

WJIA1416E

High-pressure A/C pipe

Low-pressure A/C pipe

Expansion valve

Heater core and evaporator pipes
grommet

A/C drain hose grommet

A/C drain hose

Heater core pipe mounts

Heater core pipes

Heater and cooling unit assembly

Removal and Installation

EJS003VV

REMOVAL
1.
2.
3.

Discharge the refrigerant from the A/C system. Refer to ATC-154, "Discharging Refrigerant" .
Drain the coolant from the engine cooling system. Refer to MA-13, "DRAINING ENGINE COOLANT" .
Disconnect the battery negative and positive terminals.

Revision: November 2005

MTC-87

2005 Pathfinder

HEATER & COOLING UNIT ASSEMBLY
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

14.

Remove the RH heater core pipes nut.
Disconnect the heater core hoses from the heater core.
Disconnect the high- and low-pressure A/C pipes from the
expansion valve.
Move the two front seats to the rearmost position on the seat
track.
Remove the instrument panel and console panel. Refer to IP-10,
"Removal and Installation" .
Remove the two front floor ducts.
WJIA1292E
Remove the steering column. Refer to PS-10, "Removal and
Installation" .
Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (SMJ) electrical connectors. Refer to PG-40, "Harness Layout" .
Remove the covers then remove the three steering member bolts from each side to disconnect the steering member from the vehicle body.
Remove the heater and cooling unit assembly with it attached to the steering member, from the vehicle.
CAUTION:
● Use 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.
● Use suitable plugs on the heater core pipes to prevent coolant leakage.
Remove the heater and cooling unit assembly from the steering member.

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
●
Replace 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. Refer to MTC-100, "Components" .
●
After charging the refrigerant, check for leaks. Refer to ATC-170, "Checking for Refrigerant Leaks"
.
NOTE:
●
Fill the engine cooling system with the specified coolant mixture. Refer to MA-14, "REFILLING ENGINE
COOLANT" .
●
Recharge the A/C system. Refer to ATC-154, "Evacuating System and Charging Refrigerant" .

Revision: November 2005

MTC-88

2005 Pathfinder

HEATER CORE
HEATER CORE
Components

PFP:27140

A
EJS003VW

Heater and Cooling Unit Assembly
B

LJIA0167E

Heater core and evaporator pipe bracket 2.

Heater core cover

Heater core

MTC

Heater and cooling unit assembly

Removal and Installation

EJS003VX

REMOVAL
1.
2.
3.
4.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the three screws and remove the heater core cover.
Remove the heater core and evaporator pipe bracket.
Remove the heater core.
NOTE:
If the in-cabin microfilters are contaminated from coolant leaking
from the heater core, replace the in-cabin microfilters with new
ones before installing the new heater core.

LJIA0134E

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2005

MTC-89

2005 Pathfinder

INTAKE DOOR MOTOR
INTAKE DOOR MOTOR
Removal and Installation

PFP:27730
EJS003VY

Intake Door Motor - Heater and Cooling Unit Assembly

WJIA1312E

Heater and cooling unit assembly

Intake door motor

Blower motor resistor

Mode door motor

Air mix door motor

REMOVAL
1.
2.
3.
4.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the steering member from the heater and cooling unit assembly.
Disconnect the intake door motor electrical connector.
Remove the three screws and remove the intake door motor.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2005

MTC-90

2005 Pathfinder

MODE DOOR MOTOR
MODE DOOR MOTOR
Removal and Installation

PFP:27731

A
EJS003VZ

Mode Door Motor - Heater and Cooling Unit Assembly
B

WJIA1312E

Heater and cooling unit assembly

Intake door motor

Blower motor resistor

Mode door motor

REMOVAL
1.
2.
3.

MTC

Air mix door motor

Remove the lower instrument panel LH. Refer to IP-13, "LOWER INSTRUMENT PANEL LH" .
Disconnect the mode door motor electrical connector.
Remove the three screws and remove the mode door motor.

INSTALLATION
M

Installation is in the reverse order of removal.

Revision: November 2005

MTC-91

2005 Pathfinder

AIR MIX DOOR MOTOR
AIR MIX DOOR MOTOR
Components

PFP:27732
EJS003W0

Air Mix Door Motor - Heater and Cooling Unit Assembly

WJIA1312E

Heater and cooling unit assembly

Intake door motor

Blower motor resistor

Mode door motor

Removal and Installation

Air mix door motor

EJS003W1

REMOVAL
1.
2.
3.
4.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the steering member from the heater and cooling unit assembly.
Disconnect the air mix door motor electrical connector.
Remove the three screws and remove the air mix door motor.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2005

MTC-92

2005 Pathfinder

FRONT BLOWER MOTOR RESISTOR
FRONT BLOWER MOTOR RESISTOR
Removal and Installation

PFP:27077

A
EJS003W2

Blower Motor Resistor - Heater and Cooling Unit Assembly
B

WJIA1312E

Heater and cooling unit assembly

Intake door motor

Blower motor resistor

Mode door motor

REMOVAL
1.
2.

MTC

Air mix door motor

Disconnect the blower motor resistor electrical connector.
Remove the two screws and remove the blower motor resistor.

INSTALLATION
Installation is in the reverse order of removal.
M

Revision: November 2005

MTC-93

2005 Pathfinder

DUCTS AND GRILLES
DUCTS AND GRILLES
Components

PFP:27860
EJS003W3

Ducts

LJIA0155E

Revision: November 2005

MTC-94

2005 Pathfinder

DUCTS AND GRILLES
1.

Defroster nozzle

LH side demister duct

LH ventilator duct

RH side demister duct

RH ventilator duct

Center ventilator duct

Front heater and cooling unit assembly

Floor connector duct grilles

Floor connector duct

10. Front floor ducts

11. Floor floor ducts

13. Center console duct

14. Front console duct

12. Rear console duct

Grilles
C

MTC

WJIA1424E

Instrument panel and pad assembly

LH side ventilator grille

LH ventilator grille

RH ventilator grille

RH side ventilator grille

Console assembly rear base

Rear finisher assembly

Console grille

RH side demister grille

10. Rear cup holder assembly

Removal and Installation

EJS003W4

CONSOLE DUCTS AND CONSOLE GRILLE
Removal
The center console must be removed and disassembled to remove the console ducts and the console grille.
Refer to IP-15, "CENTER CONSOLE" .

Installation
Installation is in the reverse order of removal.
Revision: November 2005

MTC-95

2005 Pathfinder

DUCTS AND GRILLES
DEFROSTER NOZZLE
Removal
1.
2.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the defroster nozzle.

Installation
Installation is in the reverse order of removal.

RH AND LH SIDE DEMISTER DUCTS
Removal
1.
2.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the RH or LH side demister duct.

Installation
Installation is in the reverse order of removal.

RH AND LH VENTILATOR DUCTS
Removal
1.
2.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the RH or LH ventilator duct.

Installation
Installation is in the reverse order of removal.

CENTER VENTILATOR DUCT
Removal
1.
2.
3.
4.
5.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the defroster nozzle.
Remove the RH and LH ventilator ducts.
Remove the RH and LH side demister ducts.
Remove the center ventilator duct.

Installation
Installation is in the reverse order of removal.

FLOOR CONNECTOR DUCT
Removal
1.
2.

Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the floor connector duct.

Installation
Installation is in the reverse order of removal.

FRONT AND REAR FLOOR DUCTS
Removal
1.
2.

Remove the floor carpet. Refer to EI-29, "FLOOR TRIM" .
Remove the clips and front and rear floor ducts.

Installation
Installation is in the reverse order of removal.

Revision: November 2005

MTC-96

2005 Pathfinder

DUCTS AND GRILLES
GRILLES
Removal
1.
2.

Remove the interior trim panel as necessary that contains the grille to be removed. Refer to IP-10,
"INSTRUMENT PANEL ASSEMBLY" and EI-27, "BODY SIDE TRIM" .
Remove the grille from the interior trim panel.

Installation
Installation is in the reverse order of removal.

MTC

Revision: November 2005

MTC-97

2005 Pathfinder

REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service Procedure

PFP:92600
EJS003W5

SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant

WJIA1160E

Shut-off valve

A/C service valve

Recovery/recycling equipment

WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) refrigerant from the A/C system using certified service equipment
meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment or SAE J2201 HFC-134a
(R-134a) recovery equipment. If an accidental system discharge occurs, ventilate the work area before
resuming service. Additional health and safety information may be obtained from the refrigerant and
lubricant manufacturers.

Evacuating System and Charging Refrigerant

WJIA1161E

Shut-off valve

A/C service valve

Recovery/recycling equipment

Refrigerant container (HFC-134a)

Refrigerant weight scale (J-39699)

Vacuum pump (J-39649)

Manifold gauge set with hoses and
couplers (J-39183-C)

Revision: November 2005

MTC-98

2005 Pathfinder

REFRIGERANT LINES
A

MTC

WJIA0530E

ATC-22, "CHECKING AND
ADJUSTING" .

ATC-170, "Checking for Refrigerant
Leaks".

ATC-103, "PERFORMANCE TEST
DIAGNOSES".

Revision: November 2005

MTC-99

ATC-5, "Contaminated Refrigerant".

2005 Pathfinder

REFRIGERANT LINES
Components

EJS003W6

A/C Compressor and Condenser

WJIA1253E

Revision: November 2005

MTC-100

2005 Pathfinder

REFRIGERANT LINES
1.

High-pressure service valve

Clip

High-pressure A/C pipe

Refrigerant pressure sensor

Condenser

Compressor shaft seal

High-pressure flexible A/C hose

Low-pressure flexible A/C hose

Low-pressure service valve

10. Low-pressure A/C pipe

11. Expansion valve

12. A/C drain hose

NOTE:
Refer to MTC-6, "Precautions for Refrigerant Connection" .

Removal and Installation for Compressor

EJS003W7

COMPONENTS
A/C Compressor Mounting

I
LJIA0176E

Compressor

Cylinder block

Front timing chain case

Rear timing chain case

REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.

Discharge the A/C refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the front left wheel and tire assembly. Refer to WT-6, "Rotation" .
Remove the front left mud guard.
Remove the front left splash shield.
Remove the engine air cleaner and air ducts. Refer to EM-15, "AIR CLEANER AND AIR DUCT" .
Remove the drive belt. Refer to EM-13, "DRIVE BELTS" .
Disconnect the compressor harness connector.
Disconnect both the high-pressure flexible A/C hose and low-pressure flexible A/C hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove the A/C compressor bolts using power tools.

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
●
Replace the O-ring of the low-pressure flexible A/C hose and high-pressure flexible A/C hose with
a new one, apply compressor oil to the O-rings before installation.
●
After recharging the A/C system with refrigerant, check for leaks. Refer to MTC-109, "Checking for
Refrigerant Leaks" .

Revision: November 2005

MTC-101

2005 Pathfinder

MTC

REFRIGERANT LINES
Removal and Installation for Compressor Clutch

EJS003W8

Magnet Clutch Assembly

WJIA1162E

Magnet clutch assembly

Magnet coil

Pulley

Clutch disc

Snap ring

Thermal protector (built in)

Compressor

REMOVAL
1.
2.

Remove the compressor. Refer to MTC-101, "Removal and Installation for Compressor" .
Remove the center bolt while holding the clutch disc stationary
using Tool as shown.
Tool number

: J-44614

Remove the clutch disc.

WHA228

Remove the snap ring using external snap ring pliers or suitable
tool.

RHA072C

Revision: November 2005

MTC-102

2005 Pathfinder

REFRIGERANT LINES
5.

Remove the pulley using Tool with a small adapter. Position the
small adapter on the end of the drive shaft and the center of the
puller on the small adapter.
Tool number

: KV99233130 (J-29884)
B

CAUTION:
To prevent deformation of the pulley groove, the puller
claws should be hooked under the pulley groove and not
into the pulley groove.

C
WJIA1017E

Remove the magnet coil harness clip using a screwdriver,
remove the three magnet coil fixing screws and remove the
magnet coil.

G
WHA212

INSPECTION
Clutch Disc

If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.

MTC

K
WHA183

Pulley
Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving,
replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable
solvent before reinstallation.

Coil
Check magnet coil for loose connections or any cracked insulation.

INSTALLATION
1.

Install the magnet coil.
CAUTION:
Be sure to align the magnet coil pin with the hole in the
compressor front head.

WHA213

Revision: November 2005

MTC-103

2005 Pathfinder

REFRIGERANT LINES
2.
3.

Install the magnet coil harness clip using a screwdriver.
Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
Tool number

—

(J-38873-A)

WJIA1016E

Install the clutch disc on the compressor shaft, together with the
original shim(s). Press the clutch disc down by hand.

WHA184

Install the clutch pulley bolt using Tool, to prevent the clutch disc
from turning and tighten the bolt to specification. Refer to MTC101, "COMPONENTS" .
Tool number

: J-44614

CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.

WHA229

Check the pulley clearance all the way around the clutch disc as
shown.
Clutch disc-to-pulley clearance

7.
8.

: 0.3 - 0.6 mm
(0.012 - 0.024 in)

If the specified clearance is not obtained, replace the adjusting
spacer to readjust.
Install the compressor. Refer to MTC-101, "Removal and Installation for Compressor" .

WHA194

Revision: November 2005

MTC-104

2005 Pathfinder

REFRIGERANT LINES
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.

Removal and Installation for High-pressure Flexible A/C Hose

EJS003W9

REMOVAL
1.
2.
3.
4.
5.

Remove the front left wheel and tire assembly. Refer to WT-6, "Rotation" .
Remove the front left mud guard.
Remove the front left splash shield.
Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the high-pressure flexible A/C hose. Refer to MTC-105, "Removal and Installation for High-pressure Flexible A/C Hose" .
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 to MTC-100, "Components" .
CAUTION:
●
Replace the O-ring of the high-pressure flexible A/C hose with a new one, then apply compressor
oil to it for installation.
●
After charging refrigerant, check for leaks.

Removal and Installation for High-pressure A/C Pipe

EJS003WA

REMOVAL
1.
2.
3.
4.
5.
6.

Remove the front right wheel and tire assembly. Refer to WT-6, "Rotation" .
Remove the front right mud guard.
I
Remove the front right splash shield.
Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the low pressure A/C pipe. Refer to MTC-106, "Removal and Installation for Low-pressure A/C MTC
Pipe" .
Remove the high-pressure A/C pipe. Refer to MTC-100, "Components" .
CAUTION:
K
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 to MTC-100, "Components" .
CAUTION:
●
Replace the O-ring of the high-pressure A/C pipe with a new one, then apply compressor oil to it
for installation.
●
After charging refrigerant, check for leaks.

Removal and Installation for Low-pressure Flexible A/C Hose

EJS003WB

REMOVAL
1.
2.
3.
4.

Remove the front right wheel and tire assembly. Refer to WT-6, "Rotation" .
Remove the front right mud guard.
Remove the front right splash shield.
Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove the low-pressure flexible A/C hose. Refer to MTC-105, "Removal and Installation for Low-pressure Flexible A/C Hose" .

INSTALLATION
Installation is in the reverse order of removal.
Revision: November 2005

MTC-105

2005 Pathfinder

REFRIGERANT LINES
Refer to MTC-100, "Components" .
CAUTION:
●
Replace the O-ring of the low-pressure flexible A/C hose with a new one, then apply compressor
oil to it for installation.
●
After charging refrigerant, check for leaks.

Removal and Installation for Low-pressure A/C Pipe

EJS003WC

REMOVAL
1.
2.

Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the low-pressure A/C pipe. Refer to MTC-100, "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 to MTC-100, "Components" .
CAUTION:
●
Replace the O-ring of the low-pressure A/C pipe with a new one, then apply compressor oil to it for
installation.
●
After charging refrigerant, check for leaks.

Removal and Installation for Refrigerant Pressure Sensor

EJS003WD

REMOVAL
1.
2.

Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
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.

LJIA0177E

INSTALLATION
Installation is in the reverse order of removal.
Refer to MTC-100, "Components" .
CAUTION:
●
Replace the O-ring of the refrigerant pressure sensor with a new one, then apply compressor oil to
it for installation.
●
Be careful not to damage the condenser fins.
●
After charging refrigerant, check for leaks.

Removal and Installation for Condenser

EJS003WE

REMOVAL
1.
2.

Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the radiator. Refer to CO-11, "RADIATOR" .
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
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.

Revision: November 2005

MTC-106

2005 Pathfinder

REFRIGERANT LINES
4.
5.
6.

Disconnect the refrigerant pressure sensor harness connector.
Remove the refrigerant pressure sensor from the condenser.
Lift the condenser out of the mounting grommets and remove
the condenser.

C
LJIA0177E

INSTALLATION
Installation is in the reverse order of removal.
Refer to MTC-100, "Components" .
CAUTION:
●
Replace the O-rings of the high-pressure A/C pipe, refrigerant pressure sensor, and high-pressure
flexible A/C hose with new ones, then apply compressor oil to them for installation.
●
After charging refrigerant, check for leaks.
●
Replace the mounting grommets as necessary.

MTC

Revision: November 2005

MTC-107

2005 Pathfinder

REFRIGERANT LINES
Removal and Installation for Evaporator

EJS003WF

Heater and Cooling Unit Assembly

LJIA0178E

Center ventilator connector duct

Heater core cover

Intake air case

Heater core and evaporator pipes
bracket

Heater core and evaporator pipes
grommet

Heater core

Upper heater and cooling unit case

Expansion valve

Evaporator

10. Lower heater and cooling unit case

Revision: November 2005

11. Blower motor resistor

MTC-108

12. Blower motor

2005 Pathfinder

REFRIGERANT LINES
REMOVAL
1.
2.
3.

Remove the heater core. Refer to MTC-89, "HEATER CORE" .
Separate the heater and cooling unit case.
Remove the evaporator.

INSTALLATION
Installation is in the reverse order of removal.
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 Valve

EJS003WG

REMOVAL
1.
2.
3.
4.

Discharge the refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
Remove the heater and cooling unit assembly. Refer to MTC-87, "HEATER & COOLING UNIT ASSEMBLY" .
Remove the heater core and evaporator pipes grommet.
Remove the expansion valve.

INSTALLATION
Installation is in the reverse order of removal.

Expansion valve bolts

: Refer to MTC-100, "Components"
.

A/C refrigerant pipe to expansion valve bolt

: Refer to MTC-100, "Components"
.

CAUTION:
●
Replace the O-rings on then expansion valve and the A/C refrigerant pipes with new ones, then
apply compressor oil to them for installation.
●
After charging refrigerant, check for leaks.

MTC

Checking for Refrigerant Leaks

EJS003WH

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage, and corrosion. Any 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 (J-41995) or fluorescent dye leak detector (J-42220).
If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic
refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that 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 refrigerant leak detector (J-41995), move the probe
along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the
component.
CAUTION:
Moving the electronic refrigerant 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 Dye Leak Detector
1.

2.
3.

EJS003WI

Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (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 opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent
future misdiagnosis.

Revision: November 2005

MTC-109

2005 Pathfinder

REFRIGERANT LINES
4.

Perform a system performance check and then verify the leak repair using a electronic refrigerant leak
detector (J-41995).
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 electronic refrigerant leak detector (J-41995) to contact with any substance. This can also cause false readings and may damage the detector.

Dye Injection

EJS003WJ

NOTE:
This procedure is only necessary when recharging the system or when the compressor has seized and must
be replaced.
1.
2.

3.
4.
5.

6.
7.

Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm 2 , 50 psi).
Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into
the HFC-134a (R-134a) refrigerant dye injector (J-41459).
CAUTION:
If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) directly into the open system connection and proceed with the service
procedures.
Connect the refrigerant dye injector (J-41459) to the low-pressure service valve.
Start the engine and switch the A/C system ON.
When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a
(R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC134a (R-134a) refrigerant dye injector (J-41459). Refer to the manufacturer's operating instructions.
With the engine still running, disconnect the HFC-134a (R-134a) refrigerant dye injector (J-41459) from
the low-pressure service valve.
Operate the A/C system for a minimum of 20 minutes to mix the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) with the A/C system oil. Depending on the leak size, operating conditions and
location of the leak, it may take from minutes to days for the HFC-134a (R-134a) fluorescent leak detection dye to penetrate an A/C system leak and become visible.

Electronic Refrigerant Leak Detector

EJS003WK

PRECAUTIONS FOR HANDLING LEAK DETECTOR
NOTE:
When performing a refrigerant leak check, use a electronic refrigerant leak detector (J-41995) or equivalent.
Ensure that the electronic refrigerant leak detector (J-41995) is calibrated and set properly according to the
manufacturer's operating instructions.
The electronic refrigerant leak detector (J-41995) is a delicate
device. To use the leak detector properly, read the manufacturer's
operating instructions and perform any specified maintenance.

AHA281A

Revision: November 2005

MTC-110

2005 Pathfinder

REFRIGERANT LINES
1.

Position the probe approximately 5 mm (3/16 in) away from the
point to be checked as shown.

C
SHA707EA

When checking for leaks, circle each fitting completely with the
probe as shown.
E

G
SHA706E

Move the probe along each component at a speed of approximately 25 - 50 mm (1 - 2 in)/second as shown.

MTC

K
SHA708EA

CHECKING PROCEDURE
NOTE:
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 a calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn the engine OFF.
2. Connect the manifold gauge set (J-39183-C) to the A/C service ports. Refer to MTC-9, "Precautions for
Service Equipment" .
3.

Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm2 , 50 psi) above a temperature of
16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified
amount of refrigerant. Refer to MTC-98, "HFC-134a (R-134a) Service Procedure" .
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa
(3.52 kg/cm2 , 50 psi) pressure.
Perform the leak test from the high-pressure side (A/C compressor discharge “a” to evaporator inlet “f”) to
the low-pressure side (A/C evaporator drain hose “g” to shaft seal “k”). Refer to MTC-100, "Components"
. Clean the component to be checked and carefully move the electronic refrigerant leak detector probe
completely around the following connections and components.
● Check the compressor shaft seal
● Check the high and low-pressure pipe and hose fittings, relief valve, and compressor shaft seal
● Check the liquid tank

Revision: November 2005

MTC-111

2005 Pathfinder

REFRIGERANT LINES
Check the refrigerant pressure sensor
● Check all around the service valves. Check that the service valve caps are screwed tightly on the service valves (to prevent leaks).
NOTE:
After removing manifold gauge set (J-39183-C) from the service valves, wipe any residue from the service valves to prevent any false readings by the electronic refrigerant leak detector (J-41995).
● Evaporator
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in
the heater and cooling unit assembly. Wait a minimum of 10 minutes accumulation time (refer to the
manufacturer's recommended procedure for actual wait time) before inserting the electronic refrigerant
leak detector probe into the heater and cooling unit assembly drain hose.
NOTE:
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.
If a leak is detected, verify at least once by blowing compressed air into the area of the suspected leak,
then repeat the leak check.
Do not stop when one leak is found. Continue to check for additional leaks at all system components and
connections.
If no leaks are found, perform steps 8 - 11.
Start the engine.
Set the heater A/C controls as follows:
NOTE:
For the automatic system, turn OFF the automatic controls and set the heater A/C controls manually.
A/C switch to ON
Air flow to VENT mode
Intake position to RECIRCULATION mode
Temperature to MAX cold
Blower speed to HIGH
●

5.
6.
7.
8.
9.

a.
b.
c.
d.
e.

10. Run the engine at 1,500 rpm for at least 2 minutes.
11. Turn the engine OFF and perform the leak check again following
steps 4 through 6 above.
Refrigerant leaks should be checked immediately after turning
the engine OFF. Begin with the leak detector at the compressor.
The pressure on the high pressure side will gradually drop after
the 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 the pressure is high.

SHA839E

12. Before connecting the recovery/recycling equipment to the vehicle, check the recovery/recycling equipment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover the refrigerant from the equipment lines and then check the refrigerant purity.
13. Confirm refrigerant purity in supply tank using recovery/recycling equipment and refrigerant identifier
equipment (J-41810-NI).
14. Confirm the refrigerant purity in the vehicle's A/C system using recovery/recycling equipment and refrigerant identifier equipment (J-41810-NI).
15. Discharge the A/C system using recovery/recycling equipment. Repair the leaking fitting or component as
necessary.
16. Evacuate and recharge the A/C system and perform the leak test to confirm that there are no refrigerant
leaks.
17. Conduct the Operational Check to ensure system works properly. Refer to ATC-52, "Operational Check
(Front)" .
Revision: November 2005

MTC-112

2005 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Service Data and Specifications (SDS)

PFP:00030

A
EJS003WL

COMPRESSOR
B

Make

CALSONIC KANSEI CO. LTD.

Model

DKS-17D

Type

Swash plate

Displacement

144 cm3 (8.79 in3 ) / revolution

Relief valve set pressure

3800 ± 300 kPa (38.76 ± 3.06 kg/cm2 , 551.0 ± 43.5 psi)

Direction of rotation

Clockwise (viewed from drive end)

Drive belt

Poly V ribbed

LUBRICANT

Description

Genuine NISSAN A/C System Lubricant Type S (DH-PS)

Part number

KLH00-PAGS0

Capacity

180 m

(6.1 US fl oz, 6.3 Imp fl oz)

REFRIGERANT

Type

HFC 134a (R-134a)

Capacity

0.70 ± 0.05 kg (1.54 ± 0.11 lb)

ENGINE IDLING SPEED
Refer to EC-76, "Idle Speed and Ignition Timing Check" .

BELT TENSION

Refer to MA-13, "DRIVE BELT TENSION" .
MTC

Revision: November 2005

MTC-113

2005 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: November 2005

MTC-114

2005 Pathfinder

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Nissan 2005 Pathfinder Owners Manual MTC

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