Nissan Primastar X83 (2002-2006) Service Manual #15

HEATING 161
General information 61
AIR DISTRIBUTION: description of the air distributors in the passenger compartment.
1 Left-hand side air vent

2 Left-hand side window demisting
3 Windscreen demisting
4 Central air vents
5 Control panel
6 Right-hand side window demisting
7 Right-hand side air vent
8 Footwell heater outlets for front passengers
61-1
HEATING
1 Air distribution unit

2 Heater radiator
3 Heater hoses
1 Fan assembly
2 Recirculation motor
3 Power module
4 Ventilation motor
61-2
HEATING
Operating principle 61
CONTROL PANEL
A Air temperature adjustment,

B Air recirculation operation,
B1 Passenger compartment air recirculation operating indicator light (on
some vehicles),
C Adjustment of the amount of air delivered to the passenger
compartment,
D Distribution of air in the passenger compartment.
Recirculation can:
– isolate the passenger compartment from the external atmosphere (e.g.
when driving in polluted areas, etc.),
– reach the desired passenger compartment temperature quickly.
Prolonged use of the air recirculation mode may cause the windows to mist
up or lead to odours, as the air is not renewed.
We therefore recommend that you return to normal mode (external air)

as soon as you have passed through the polluted areas, by pressing
button (B).
61-3
HEATING
Air temperature adjustment

Move the control (A).
To the right: Maximum possible temperature.
To the left: Minimum possible temperature.
Adjustment of the amount of air delivered to the passenger

compartment.
Move control (C).
The passenger compartment is ventilated by blown air. The ventilation fan

determines the amount of air supplied, but vehicle speed does affect it
slightly.
The further the control is moved to the right, the greater the quantity of air
blown.
NOTE:
To fully close the air inlet and turn off this function, turn control (C) to 0.
61-4
HEATING
Air recirculation control

Press control (B); the operation indicator light (B1) lights up.
When this function is switched on, the air from the passenger compartment is
recirculated and no external air is admitted.
61-5
HEATING
Passenger compartment filter 61
REMOVAL
Open the bonnet.
Remove the filter.
REFITTING
Proceed in the reverse order to removal.
61-6
HEATING
Control panel 61
REMOVAL Remove the control panel and its support - bolt (D).
Disconnect the battery.
Unclip:
– gear lever gaiter (A) and unscrew the four bolts (B)
on the console,
– the central console to access the hazard warning

lights switch connector (C).
61-7
HEATING
Control panel 61
REMOVAL – the two mounting bolts (F) securing the control panel
to its support.
Disconnect connectors (A), (B) and (C).
Remove:
– air temperature control wire (D),
– air distribution control wire (E),
Remove lower mounting (I) and remove the control

panel.
REFITTING
Carry out the removal procedure in reverse.
61-8
HEATING
Control cables 61
TEMPERATURE ADJUSTMENT DIAL CONTROL Remove wire (B).
WIRE
REMOVAL
Temperature adjustment dial control wire on the

control unit side.
Remove the control panel (see the Control panel

section).
REFITTING

Temperature adjustment dial control wire on the
distribution unit side.
Remove:
– the right-hand side covers,
– the two clips (A).
61-9
HEATING
Control cables 61
AIR MIXING FLAP CONTROL WIRE
REMOVAL
Air mixing flap control wire on the control unit

side.
Remove the control panel (see the Control panel

section).
Air mixing flap control wire on the distribution unit

side.
Remove:
– the two clips (A),
– the right-hand side cover.
Remove wire (C).
REFITTING
61-10
HEATING
Air distribution unit 61
REMOVAL - REFITTING
Air distribution unit (A) can be accessed after removing the dashboard and
the passenger compartment reinforcement beam.
Follow the removal - refitting instructions in Section 62: Removal - refitting

the evaporator unit.
IMPORTANT:
Before reconnecting the driver's and passenger front airbag modules, the
procedure for checking the correct operation of the system must be
performed:
● Switch on the ignition and check that the indicator light comes on for three
seconds and then goes out permanently.
● Refer to Section 88 if the light fails to operate in this way.
61-11
HEATING
Air distribution unit 61
ADJUSTMENT AND DISTRIBUTION OF THE
HEATING POWER
There are two ways of varying the heating power:

– air flow,
– the air temperature.
The driver can adjust the air flow by using the control
panel instruments.
The air temperature is adjusted using the various

settings of the mixing flap. In the air distribution unit,
the air is diverted depending on the position of the
mixing flap, passes through to the heating radiator and
is then mixed with cold air to obtain the air temperature
requested by the user.
Air is supplied and distributed to the passenger

compartment through:
– a five-mode air distributor,
– four vents,
– two front footwell ducts,
– a windscreen demisting/de-icing vent,
– two front side window demisting/de-icing vents.
61-12
HEATING
Radiator 61
REMOVAL Place a container underneath the radiator and drain it.
Engine compartment side Unscrew the two clips (A) on the radiator coolant
circuit hoses.
Place hose clamps over each coolant hose in front of
the heater matrix bleed screws. Remove the two coolant hoses.
Passenger compartment side Unscrew the two radiator mounting bolts (B) and then
remove the radiator.
The dashboard does not need to be removed
before removing the radiator.
Remove the central console (see the Control panel

section).
Disconnect the hazard lights switch.
Unclip the three clips (A) on the left-hand side cover

with the air duct.
REFITTING
Replace the two radiator hose seals and replace the

two clamps correctly.
61-13
HEATING
Air inlet unit 61
REMOVAL
Disconnect:
– the battery,
– the air inlet unit connector.
Remove the four air inlet unit mountings.
Remove the coolant recovery hose.
Remove the air inlet unit.
REFITTING
61-14
HEATING
Fan assembly 61
REMOVAL
Open the bonnet.
Unscrew bolts (A) and remove the heating ventilation

motor from its housing.
Remove the unit and turn it gently. This will enable you
to disconnect supply connector (B).
REFITTING
61-15
AIR CONDITIONING
Power module 61
REFITTING
The power module controls the speed of the fan

assembly depending on the requirements determined
by the automatic control.
It can be accessed without removing the fan assembly.
REMOVAL
Disconnect connectors, (A) and (B).
Unscrew the fan assembly trim bolt.
Remove:
– the wiring harness,
– the power module mounting bolt,
– the power module.
61-16
HEATING
Independent heater unit 61
Disconnect connector (C) from the metering pump.
TIGHTENING TORQUE (in daNm)
Heater unit mounting bolts 0.8
The heater unit is located under the vehicle on the

right-hand side.
REMOVAL
Put the vehicle on a 2-post lift (5 tonnes minimum).
Place a hose clamp on each pipe (A) of the coolant

circuit, on the boiler side.
Remove the two clamps (B) on the coolant hoses

(heater inlet/outlet connections).
Disconnect heater connections (D).
Remove:
– supply hose (1) from the metering pump,
– boiler mounting bolt (E).
61-17
HEATING
Independent heating duct 61
Remove the two other mounting bolts (F) while
supporting it.
Removal of the heater from its bracket
Unscrew bolt (1) then turn the unit over.
61-18
HEATING
Unscrew bolt (2) and remove the heater from its mounting by releasing
lugs (3).
61-19
HEATING
Metering pump 61
REMOVAL
Place the vehicle on a lift.
Disconnect connectors (A) on the metering pump.
Remove:
– fuel supply pipes (B) and (C),
– the metering pump with or without its mounting.
REFITTING
IMPORTANT:
When refitting, fix the metering pump in the same
position.
61-20
HEATING
F9Q engine
Fuel supply pipe 61
REMOVAL
To remove the fuel supply pipe from the heater, you must first drain and remove the fuel tank (see the procedure in
Section 13 of the Workshop Repair Manual).
Unclip the supply quick-release union on the metering pump.
Drain the fuel tank and remove it.
Unclip supply quick-release union (1) on the pump-gauge assembly.
REFITTING
Refit in the reverse order to removal.
61-21
HEATING
Coolant supply pipe 61
REMOVAL
To remove the coolant supply pipes from the heater

unit, you must:
– disconnect the battery.
– fit a hose clamp on each side of the coolant supply
pipe.
– pierce rivet (A) on the vehicles concerned.
– unscrew the two coolant supply pipe mounting bolts
(B).
– loosen clamps (B) and remove the supply pipe
housing.
REFITTING
Top up the coolant and bleed the main circuit.
61-22
HEATING
– the two front seat anchoring points (C), then remove
IMPORTANT:
the trim as shown above (1).
It is not permitted to handle the pyrotechnic systems
(airbags and pretensioners) near a source of heat or
flame as there is a risk of triggering.
IMPORTANT:
Before removing a seat, lock the computer using the
diagnostic tool. When this function is activated, all
the trigger lines are disabled and the airbag indicator
light on the instrument panel comes on.
REMOVAL
Remove the front bench seat (see Section 75:

Complete seat).
NOTE:
This operation does not require the removal of the Remove mounting (D), then pull back the trim (2).
driver's seat.
The procedure for removing the bench seat is identical

to the procedure for removing a single seat.
Remove the central console (see Section 61: Control

panel).
Right-hand side
Remove:
– bench seat (A),
– mounting bolts (B), then release the step,
61-23
HEATING
Partially release the door seal on the door on the right- REFITTING
hand side.
Remove the two clips (3) then partially remove the

carpet and fold it back. When refitting the seat and the front bench seat,
Unclip the electrical wiring harness clip. ensure that seat and front bench seat height
Remove the air duct. adjustment spacers (C) are replaced.
IMPORTANT:
Before refitting the seat, check visually the condition
of the connectors on the seat frame and on the body.
TIGHTENING TORQUES (in Nm)
Front seat mounting nuts 44
Seat belt mounting 37
61-24
162
AIR CONDITIONING
62-1
AIR CONDITIONING
A Passenger compartment
B Engine compartment
C External air
D To air mixing unit
E Bulkhead
F External or recirculated air
1 Compressor
2 Condenser
3 Dehydration canister
4 Pressure sensor
5 Pressure relief valve
6 Evaporator
7 Climate control fan
8 Engine cooling fan
9 Engine radiator
10 High pressure fluid
11 Low pressure vapour
12 High pressure vapour
62-2
AIR CONDITIONING
Consumables 62
F9Q ENGINE
– Compressor:
DELPHI HARRISON V5
– Oil for DELPHI HARRISON compressor:

PLANETELF PAG 488 220 cm3 + 15
– Refrigerant:
R134a: 700 + 25
62-3
AIR CONDITIONING
CONTROL PANEL
A Air temperature adjustment,

B Air recirculation selection,
B1 Passenger compartment air recirculation operating indicator light (on
some vehicles),
C Adjustment of the amount of air delivered to the passenger
compartment,
D Air conditioning selection,
D1 Air conditioning operation indicator light
(the air is taken from outside the vehicle and is recirculated
continuously),
E Distribution of air in the passenger compartment.
Recirculation can:
– isolate the passenger compartment from the external atmosphere
(e.g. when driving in polluted areas, etc.),
– reach the desired passenger compartment temperature quickly.
Prolonged use of the air recirculation mode may cause the windows to mist
up or lead to odours, as the air is not renewed.
We therefore recommend that you return to normal mode (external air) as

soon as you have passed through the polluted areas, by pressing
button (B).
62-4
AIR CONDITIONING
AIR CONDITIONING
Air conditioning controls.
Control (D) switches the air conditioning system on and off.
Use the air conditioning to:

● lower the temperature inside the passenger compartment, especially on hot
days when driving or after parking the vehicle in direct sunlight,
● reduce the volume of air blown into the passenger compartment
(for demisting).
NOTE: the air conditioning can be used in any conditions, but it does not
operate when the external temperature is low.
Indicator light D1 off

The air conditioning is not operating.
The heating and ventilation system is identical to a vehicle without air
conditioning.
Indicator light D1 on
The air conditioning is operating normally.
The air is taken from outside the vehicle and is recirculated continuously.
62-5
AIR CONDITIONING
In very hot weather, or when the vehicle has been parked in direct sunlight,
open the doors for a few minutes to let the hot air out before driving off.
Use the isolating the passenger compartment function to lower the

temperature to the desired level more quickly. Switch the recirculation mode
off once the desired temperature level has been reached.
Keep the windows closed when using the air conditioning to ensure that the
function works efficiently.
No cool air production

Check that the controls are working correctly and that the fuses are in good
condition. If not, turn off the heating and ventilation function (indicator light
D1 goes out).
Do not open the circuit as the refrigerant can harm the eyes and skin.
62-6
AIR CONDITIONING
Particle filter 62
REMOVAL
Open the bonnet.
Remove the filter.
REFITTING
62-7
AIR CONDITIONING
Condenser 62
REMOVAL REFITTING
Disconnect the battery. Check that the condenser is correctly secured.
Drain the refrigerant circuit using the filling equipment. Carry out the removal procedure in reverse.
Remove: Refit the bumper (two-man job).

– the radiator grille,
– the lens units, Fill up the refrigerant circuit using the filling equipment.
– the engine undertray,
– the mudflap mountings on the bumper, When replacing the condenser, add 30 ml of
– the inner protection bolts on the wing fixed to the recommended oil to the compressor.
bumper only,
– front bumper (two-man job) NOTE: remember to reconnect the pressure sensor.
(see the information on the exterior protection in
section 55).
Disconnect the pressure sensor.
Remove the hose unions on the condenser.
Unclip the condenser from the radiator at (A) and (B)

then gently raise the condenser upwards.
Take the condenser out from underneath.
62-8
AIR CONDITIONING
Dehydration canister 62
REMOVAL
Drain the refrigerant circuit using the filling equipment.
Remove:
– the right-hand side lens unit,
– the mounting bolt (A) on the hose retaining bracket,
– the mounting bolt (B) on the low pressure hose on the
body,
– the mounting bolts (C) on the two hoses on the
dehydration canister,
– the canister with the seal.
REFITTING
Oil the hose seals with the recommended oil.
Fill up the refrigerant circuit using the filling equipment.
When changing the dehydration canister, add 15 ml of

recommended oil to the compressor.
62-9
AIR CONDITIONING
Compressor 62
REMOVAL Remove the three mountings (B) on the compressor.
Drain the refrigerant circuit using the filling equipment.
Remove the accessories belt (see Section 07 for

information on the accessories belt tension).
NOTE: all removed belts must be replaced.
Remove:
– the engine undertray,
– the air conditioning hoses.
Disconnect the compressor connector (A).
REFITTING
If you need to fit a new compressor, remember that

they come pre-filled with oil.
IMPORTANT: Please follow carefully all the

instructions relating to adding oil when working on air
conditioning circuit components.
Proceed in the reverse order to removal (see

Section 07 Accessories belt tension).
Tighten the refrigerant hose mounting bolts on the

compressor to 3 daNm.
Fill up the refrigerant circuit using the filling equipment.
62-10
AIR CONDITIONING
Pressure relief valve 62
SPECIAL FEATURE: Loosen nut (A).
Trafic is fitted with a calibrated choke pressure relief Unscrew bolt (B).
valve.
Take out the high pressure hose and finish unscrewing
the nut.
Remove the pressure relief valve with a pair of long

flat-nose pliers.
A evaporator side
B driver's side
REMOVAL
Disconnect the battery. REFITTING
Drain the refrigerant circuit using the filling equipment. Oil the hose seals with the recommended oil.
Remove the air inlet unit (see Section 61 Heating for Carry out the removal procedure in reverse.
information on the air inlet unit and the fan
assembly). Fill up the refrigerant circuit using the filling equipment.
When changing the condenser, add 10 ml of

recommended oil to the compressor.
62-11
AIR CONDITIONING
Evaporator unit 62
REMOVING THE DASHBOARD
IMPORTANT: it is forbidden to handle the pyrotechnic systems

(air bags and pretensioners) near a source of heat or flame as there is
a risk of triggering.
62-12
AIR CONDITIONING
Evaporator unit 62
REMOVAL Unclip the steering wheel air bag cushion.
Disconnect the air bag connector.
IMPORTANT: you must mark the position of the

rotary switch with the wheels straight at the
removal stage. This will ensure that the strip
length can be correctly positioned in the centre.
Remove:
– the steering wheel bolt,
– the steering wheel.
Unclip the cover under the steering wheel.
IMPORTANT: use the diagnostic tool to lock the

computer before removing the air bags (see
Section 88 for instructions).
– the windscreen pillar trims.
62-13
AIR CONDITIONING
Evaporator unit 62
Disconnect the antenna connector. Remove the two mounting bolts (A).
Unlock the steering wheel height adjustment control.
Undo the lower half cowling (1) then (2).
Unclip the instrument panel visor.
62-14
AIR CONDITIONING
Evaporator unit 62
Disconnect the connectors. Remove:

– the diagnostic socket (F),
Undo the screw (B) then release the rotary switch. – the ignition switch connector (G).
Remove: Disconnect the UCH (H) (it is located close to the

– the transponder ring (C), steering column).
– the two dashboard mounting bolts (D),
– the instrument panel.
– the plate (E) and disconnect the connectors
(according to the version).
62-15
AIR CONDITIONING
Evaporator unit 62
Remove the mounting bolts (I). Remove the mounting bolts (J).
Lock the steering wheel height adjustment control. Disconnect the glove compartment light connector.
Remove the six mounting bolts from the passenger air Unclip the central upper cover.
bag.
Remove the audio equipment.
Disconnect the connector, then release the air bag.
62-16
AIR CONDITIONING
Evaporator unit 62
Remove: Unclip the gaiter from the gear control lever.

– the central display,
Remove the four mounting screws (L).
Disconnect the hazard warning lights connector.
Release the central console.
– the mounting bolts (K).
Remove the mounting bolt (M).
Disconnect the connectors, then release the heater

control panel.
62-17
AIR CONDITIONING
Evaporator unit 62
Remove: Unclip the ashtray supports.

– the mounting bolts (N),
– the earth wire (O),
Remove the four side mounting bolts (P).
– the connector. The remaining operations require two people.
Partially release the dash board.
Disconnect the connectors from the speakers.
Remove the dashboard.
62-18
AIR CONDITIONING
Evaporator unit 62
In the engine compartment Passenger compartment side
Drain the refrigerant circuit using the filling equipment. Remove the two side covers with their heating duct.
Remove the air inlet unit (see Section 61 for Place a container underneath the radiator and drain it.
information on fan assembly heating) to enable you
to remove the two air conditioning hoses where they Unscrew the two clamps (A) on the refrigerant hoses
meet the bulkhead (remember to plug the holes). and then remove the hoses.
Fit a hose clamp on each refrigerant hose on the

radiator in front of the heater matrix bleed screws.
62-19
AIR CONDITIONING
Evaporator unit 62
Remove the electric wiring harness and the relay plate (mountings linked to
the reinforcer beam).
Disconnect the evaporator sensor.
Remove:
– the two mounting bolts (B) on the steering column,
– the bolts (D) and (E) on the air distribution unit,
– the mounting bolts (F) and (G) on the reinforcer beam,
Tip the reinforcer beam to remove the air distribution unit.
NOTE: check that the coolant channel of the evaporator is sound.
62-20
AIR CONDITIONING
Evaporator unit 62
EVAPORATOR UNIT REMOVAL
Remove the seals (A) and (B).
Open the unit (C) and (D).
EVAPORATOR UNIT REFITTING
IMPORTANT: It is essential to fit the electrical wiring

harness correctly to avoid any possible damage.
62-21
AIR CONDITIONING
Evaporator unit 62
DASHBOARD REFITTING Special notes on the driver's air bag
Special notes on the rotary switch
Ensure that the wheels are straight.
Tighten the rotary switch mounting bolt.
Connect the connectors.
Connect the connector, the lock it.
Place the cushion on the steering wheel and slide it

Special notes on the steering wheel downwards until it clicks.
IMPORTANT: the splines on the steering wheel have

foolproofing devices. The steering wheel must fit
back into the splines easily. Be careful not to
damage them.
It is essential to replace the steering wheel bolt each

time it is removed and to tighten it to a torque of
4.4 daNm.
62-22
AIR CONDITIONING
Evaporator unit 62
Special notes on the passenger air bag
IMPORTANT:
– Check for foreign bodies (bolts, clips, etc.) when

fitting the air bag module.
– On the module side, make sure that the connector

is properly clipped (powerful clip) and position the
safety lock.
It is essential to check the tightening torque of the

mounting bolts:
– four bolts (O) = 2 daNm,
– two bolts (P) = 8 daNm.
Check the module using the diagnostic tool. If

everything is correct, unlock the computer or see the
"Fault finding" section.
Special features for vehicles fitted with a

tachograph
Refer to the user's manual for vehicles fitted with a

tachograph for a description of how to reboot the
system.
Fill up with refrigerant using the filling equipment.
62-23
AIR CONDITIONING
Connecting pipes 62
HIGH PRESSURE HOSE BETWEEN THE
COMPRESSOR AND THE CONDENSER
REMOVAL
Drain refrigerant circuit R134a using the filling

equipment.
Remove:
– the assembly,
– the lens units,
– the bumper,
– the hose.
Fit the plugs into the ports.
REFITTING
When changing a hose, add 10 ml of oil or when a

hose splits (rapid leak), add 100 ml.
62-24
AIR CONDITIONING
Connecting pipes 62
HIGH PRESSURE HOSE BETWEEN THE CONDENSER AND THE EVAPORATOR
REMOVAL
Drain refrigerant circuit R134a using the filling equipment.
Remove:
– the fan assembly,
– the mounting bolt on the evaporator where it meets the bulkhead,
– the lens units.
Unclip the central retaining clip on the connecting hose.
Remove:
– the engine undertray (front and centre sections),
– the mounting bolt on the condenser.
Unscrew the front section and tip it up.
Remove the connecting hose.
REFITTING
NOTE: divide the hose into two sections with the threaded union (A) to remove the pressure relief valve.
When changing a hose, add 10 ml of oil or when a hose splits (rapid leak), add 100 ml.
62-25
AIR CONDITIONING
Connecting pipes 62
LOW PRESSURE HOSE BETWEEN THE EVAPORATOR AND THE DEHYDRATION CANISTER
REMOVAL
Remove:
– the assembly,
– the lens units,
– the mounting bolt on the evaporator where it meets the bulkhead,
– the mounting bolt on the dehydration canister,
– the retaining bracket bolt on the bumper.
Unclip the retaining clip on the retaining bracket located by the shock absorber.
Remove the hose.
REFITTING
62-26
AIR CONDITIONING
Connecting pipes 62
LOW PRESSURE HOSE BETWEEN THE DEHYDRATION CANISTER AND THE COMPRESSOR
REMOVAL
Remove:
– the lens units,
– the mounting bolt on the dehydration canister,
– the engine undertray (front and centre sections),
– the mounting bolt on the compressor.
Unclip the retaining clip on the retaining bracket located by the shock absorber.
Remove the hose.
REFITTING
62-27
AIR CONDITIONING
Pressure sensor 62
PRESSURE SENSOR The injection computer controls the engine cooling
fans depending on the high pressure in the refrigerant
circuit and the vehicle speed.
You do not need to drain the refrigerant circuit to

remove the pressure sensor.
An automatic shut-off valve isolates the circuit from the

environment when the switch is removed.
The pressure sensor fitted at the condenser inlet

protects the refrigerant circuit.
– Low pressure cut-off: 3 bar
– High pressure cut-off: 30 bar
It keeps the injection computer informed of the

refrigerant circuit pressure.
62-28
AIR CONDITIONING
Power module 62
The power module controls the speed of the blower

depending on the requirements determined by the
automatic control.
It can be accessed without removing the fan assembly.
REMOVAL
Disconnect the connectors, (A) and (B).
Unscrew the fan assembly trim bolt (C).
Remove:
– the wiring harness,
– the power module mounting bolt,
– the power module.
REFITTING
62-29
AIR CONDITIONING
Recirculation motor 62
The recirculation motor positions the air inlet flap

accrording to the requirements determined by the
automatic control.
Remove the air inlet unit assembly before removing

the recirculation motor.
REMOVAL
Disconnect:
– the main supply connector (A),
– the connector located on the power module (B).
Remove:
– the lower trim on the fan assembly,
– the recirculation motor mounting bolts (C),
– the recirculation motor.
REFITTING
62-30
AIR CONDITIONING
Evaporator sensor 62
The evaporator sensor provides information about the

temperature at the evaporator outlet.
It is a negative temperature coefficient (NTC)

thermistor.
REMOVAL
Slide your hand under the dashboard on the

passenger side.
Disconnect the sensor connector.
Turn the sensor a quarter turn to remove it.
REFITTING
62-31
AIR CONDITIONING
External temperature sensor 62
The temperature sensor is located in the right-hand NOTE: the lower reflective glass is made of tough
side door mirror. plastic.
REMOVAL Unclip the temperature sensor and cut the wires (3) to
approximately four centimetres.
Use a mastic knife (1) to remove the inner reflective
glass in the door mirror, then use tool Car. 1363 (2), to
complete the operation.
REFITTING
Rejoin the two temperature sensor wires using heat-

shrink sleeves.
Fix the glass in place again with double sided tape.
NOTE: The external temperature sensor resistance

should be approximately 2500 Ω at 20 °C.
62-32
161
HEATING
Program No.: 0001
Vdiag No.: 04
Independent heater unit 61
FAULT FINDING - INTRODUCTION
This document presents the general fault finding procedure applicable to the auxiliary heating function on
PRIMASTAR vehicles with petrol and diesel combi engines and bus versions.
To perform fault finding on this system, it is essential to have the following items available:
– The Workshop Repair Manual for the vehicle concerned,

– The wiring diagram of the function for the vehicle concerned,
– The tools listed under Special tooling required.
GENERAL APPROACH TO FAULT FINDING:
– Use one of the diagnostic tools for identifying the system fitted on the vehicle (reading the computer type, program
number, Vdiag number, etc.).
– Look in the Fault finding documents corresponding to the system identified.
– Take note of information contained in the introductory sections.
– Read the faults stored in the computer memory and use the "Interpretation of faults" section of the documents.
REMINDER:
Each fault is interpreted for a particular type of storage (fault present, fault stored, fault present or stored). The
specified checks for dealing with each fault are therefore only to be performed if the fault declared by the
diagnostic tool can be identified in the document by its type. The way in which the fault is stored should be
considered when using the diagnostic tool after switching the ignition off and on again.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the notes box.
When these conditions are not satisfied, use the fault finding procedure to check the circuit of the faulty part, since
the fault is no longer present on the vehicle. Perform the same operation when a fault is declared as stored by the
diagnostic tool but is only interpreted in the documentation as a present fault.
– Carry out the conformity check (appearance of possible faults not yet identified by the system's self-diagnostic
procedure) and apply the associated fault finding procedure according to the results.
– Confirm the repair (customer complaint disappears).
– Use the fault finding procedure for each Customer complaint if the problem persists.
SPECIAL TOOLING REQUIRED:
– diagnostic tool,
– multimeter.
61-1
HEATING
61
Program No.: 0001
Vdiag No.: 04
Independent heater unit
FAULT FINDING - INTERPRETATION OF FAULTS
DF001 PRE-HEATER PLUG

PRESENT CC.0 : Short circuit to earth
OR CO : Open circuit
STORED
Application condition for a fault finding strategy for a stored fault only one fault
can be recalled at a time:
NOTES
The fault is declared present after:
– the spark plug has been ignited and with no other fault declared present.
Remove the blower cover and disconnect connector B2 from the control unit.
Check the condition of the connector and replace it if necessary.
Check the insulation, continuity and absence of interference resistance of the

connections:
Connector B2 track 9 + Heater plug
Connector B2 track 12 Earth spark plug
Repair if necessary.
If the fault persists, change the pre-heater plug.
Apply the procedures to confirm that the repair is successful.

AFTER REPAIR Deal with any other possible faults.
Clear the stored faults and check that no other fault appears.
61-2
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF002 FUEL METERING PUMP

STORED
NOTES
– the metering pump has been switched on and no other fault is declared present.
Check the condition of the 8-track connector and replace it if necessary.

connections:
8-track connector track 4 Track 2 connector ST2 of the
metering pump
8-track connector track 2 Track 1 connector ST2 of the
metering pump
Measure the resistance at the metering pump terminals, if it is not approximately

10 Ω replace the metering pump.
If the fault persists, replace the metering pump.

61-3
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF003 COOLANT TEMPERATURE SENSOR CIRCUIT

STORED
NOTES
– the boiler has been ignited and with no other fault has been declared present.

connections:
Connector B2 track 3 Temperature sensor
Measure the resistance at the sensor terminals. If it is not 12 KΩ ± 5% at 20°C,

replace the internal wiring of the boiler.
If the fault persists, replace the heater.

61-4
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF004 COMBUSTION AIR FAN

STORED DEF : Blocked
NOTES

connections:
Connector B2 track 14 Earth combustion air fan
Connector B2 track 13 + Combustion air fan
Using a multimeter, check that the winding of the ventilation fan is not cut.
Replace the heater if necessary.

61-5
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF005 OVERHEATING SWITCH

STORED
Application condition for a fault finding strategy for a stored fault: only one fault
NOTES

connections:
Connector B2 track 6 Overheating switch
Measure the resistance at the terminals of the switch. If it is not 12 KΩ ± 5% at 20°C,

replace the internal wiring of the boiler (the overheating switch is not separated from
the internal wiring).

61-6
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF006 FLAME DETECTOR

STORED
NOTES

connections:
Connector B2 track 1 Flame detector
Measure the resistance at the terminals of the flame detector. If it is not 1200 KΩ
± 5% at 50°C, replace the internal wiring of the boiler (the flame detector is not
separate from the internal wiring).

61-7
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF008 HEATER STOPS OPERATING

PRESENT 1.DEF : Excess voltage
OR 2.DEF : Not enough voltage
STORED
NOTES
Check the voltage between tracks 1 and 2 of the 8-track connector, it should be
between: 10.2 V < X < 16 V.

connections:
8-track connector track 1 + Battery
8-track connector track 2 Battery earth
If the fault persists, check the vehicle battery and charge circuit.

61-8
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF010 START UP TIME EXCEEDED

PRESENT 1.DEF
OR
STORED
NOTES The fault is declared present after:
– two unsucessful attempts have been made to ignite the heater in 180 seconds and
no other fault is declared present.
Check the air inlet and exhaust ducts.

Check the heater diesel fuel supply pipes and ensure that they contain no air
bubbles, and check the condition of the metering pump filter.
Measure the resistance at the metering pump terminals, if it is not approximately

10 Ω ± 5% replace the metering pump.
Check the condition of the spark plug.

Replace if necessary.
Replace the heater if the fault persists.

61-9
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF011 COLD BLOWER TIME EXCEEDED

PRESENT 1.DEF : If the flame detector > 70°C the fan is triggered for 4 minutes
OR
STORED
NOTES
Check the exhaust gas and combustion air pipes.


connections:
Measure the resistance at the terminals of the flame detector. If it is not

1200 KΩ ± 5% at 50°C, replace the internal wiring of the boiler (the flame detector is
not separate from the internal wiring).
Replace the heater if the fault persists.

61-10
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF012 CONTROL UNIT

PRESENT 1.DEF : Unidentified electrical fault
OR
STORED
NOTES
Replace the control unit.

61-11
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF013 MINIMUM FLAME EXTINGUISHER OUTPUT

DF014
AVERAGE FLAME EXTINCTION OUTPUT MAXIMUM
DF015
PRESENT FLAME EXTINGUISHER OUTPUT
OR DEF : Unidentified electrical fault
STORED
NOTES
Check the exhaust gas and combustion air pipes.

Check the diesel supply pipes to the heater for air bubbles.
Check the condition of connector B2 in the control unit and replace it if necessary.

connections:
Connector B2 track 9 + Heater plug
Connector B2 track 12 Earth spark plug
If the fault persists, replace the spark plug.

61-12
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF016 OVERHEATING DETECTION: LOW PROBABILITY

DF017
OVERHEATING DETECTION: LIKELY
DF018
PRESENT OVERHEATING DETECTION: CONFIRMED
OR DEF : Unidentified electrical fault
STORED
NOTES
Special features
likely: difference in temperature of 15°C between the sensor and the
overheating switch
confirmed: temperature at the sensor or switch > 125°C
low probability: material temperature threshold exceeded, sensor or
switch > 130°C.
Check the circulation of coolant through the system.

Ensure that it is thoroughly degassed.

connections:
Measure the resistance at the sensor terminals. If it is not 12 KΩ ± 5% at 20°C,

Measure the resistance at the switch terminals. If it is not 12 KΩ ± 5% at 20°C,

61-13
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF019 BLOCK: TOO MANY SUCCESSIVE START UPS

PRESENT DEF : Unidentified electrical fault
OR
STORED
Priority in dealing with a number of faults:

If more than one of faults DF019 and DF001, DF002 are stored, deal with faults DF001
Pre-heater plug and DF002 Metering pump first.
NOTES Application condition for a fault finding strategy for a stored fault only one fault
– ten unsucessful attempts have been made to ignite the heater and no other fault is
declared present.
Clear incorrect start up counter using the delete command RZ002.

61-14
HEATING
61
Program No.: 0001
Vdiag No.: 04
DF020 BLOCK: SUCCESSIVE OVERHEATING

PRESENT DEF : Unidentified electrical fault
OR
STORED
NOTES
– the heater has overheated ten times and no other fault is declared present.
Delete overheating meter using the clear control RZ001.

61-15
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - CONFORMITY CHECK
Only check the conformity after a complete check with the diagnostic tool.
The values indicated in this conformity check are given as examples.
NOTES
Condition for performing check: engine temperature below 81°C and external
temperature below 5°C.
Parameter or state Display

Order Function Fault finding
Check or action and notes
If there is a fault, refer to

+ After ignition feed ET001: + After ignition
1 YES the fault finding procedure
present present
for state ET001
YES If there is a fault, refer to

2 Engine running ET007: Engine running NO if control AC002 is the fault finding procedure
active, light the heater for state ET007
ET002: Combustion air

LIT
fan In the event of a fault,
perform the fault finding
3 Heater ventilation
procedure for fault DF004
PR014: Heater fan Combustion air fan
0 at 7 V
voltage
In the event of a fault,

4 Flame detected ET003: Flame detected YES
procedure for fault DF006
Flame detector

procedure for faults
5 System blocked ET004: System blocked NO DF019 Block due to
successive starting, and
DF020 Block due to
successive overheating
MIN If there is a fault, refer to

6 Heater output ET005: Heater output OR the fault finding procedure
AVERAGE for state ET005
61-16
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - CONFORMITY CHECK
Only check the conformity after a complete check with the diagnostic tool.
The values indicated in this conformity check are given as examples.
NOTES
Condition for performing check: engine temperature below 81°C and external
temperature below 5°C
Parameter or state Display

Order Function Fault finding
Check or action and notes
If there is a fault, apply

Overheats if the
PR008: Overheating the fault finding
9 Overheating switch temperature is above
switch value measured procedure for fault DF005
125°C
Overheating switch

PR010: Coolant the fault finding
Coolant X = engine
10 temperature sensor value procedure for fault DF003
temperature sensor temperature ± 5 ºC
measured Coolant temperature
sensor circuit

PR013: Flame detector X = heater perform the fault finding
11 Flame detector
value measured temperature ± 20°C procedure for fault DF006
Flame detector
In the event of a problem,

Computer supply PR108: Computer supply refer to the fault finding
12 10.2 V < X < 16 V
voltage voltage procedure for parameter
PR108

Spark plug feed PR016: Pre-heater feed the fault finding
13 None
instruction instruction procedure for fault DF001
Pre-heating plug
If there is a fault apply the

Fuel pump control PR017: Fuel pump control X = frequency in Hz fault finding procedure
14
frequency frequency ± 5% for fault DF002 Fuel
metering pump
61-17
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - INTERPRETATION OF CONTROLS
HEATER CONTROL
AC002 AC002 : Ignite the heater
AC003 : Switch off the heater
AC003
Important : During boiler control phase, it is essential that the engine is running
NOTES
to avoid any overheating due to non-circulation of coolant.
The boiler can be activated or deactivated using the control menu on the fault finding
tool. If it is not activated, check the following:
– there is fuel in the tank,
– that the fuses are intact
– that the combustion air and exhaust pipes are not plugged.
Check the connection and the condition of the intermediary 5-track connector
between the vehicle wiring and the heater and replace if necessary.
Check the insulation, continuity and absence of interference resistance on the

connections between:
+ Battery Track A 5-track connector
Earth Track D 5 track connector
+12 V after ignition Track E 5-track connector
Diagnostic socket HK7 Track B 5-track connector
61-18
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - INTERPRETATION OF STATES
+ AFTER IGNITION PRESENT

ET001
NOTES None.
If the state is INACTIVE check that the battery charge is above 10.2 V, if not repair
the vehicle charge circuit.
Check the connection and condition of the intermediate 8-track connector

located on the heater mounting.

+ battery Track 1 8-track connector
Earth Track 2 8-track connector
+12 V after ignition Track 7 8 track connector
Replace the heater control unit if the fault persists.
61-19
HEATING
61
Program No.: 0001
Vdiag No.: 04
HEATER OUTPUT
ET005
NOTES None
OFF State normal if engine off.
The heater state is OFF if the external air temperature is above 5°C.
The heater state is also OFF if the engine temperature is above 82°C.
MIN The state of the heater is MINIMUM OUTPUT when the engine temperature is
between 77°C and 82°C (and is increasing) and the external air temperature is
below 5°C.
The state of the heater is MINIMUM OUTPUT when the engine temperature is
between 82°C and 73°C (and is decreasing) and the external air temperature is
below 5°C.
AVERAGE The heater state is MEDIUM OUTPUT when the outside temperature is below 5°C
and the coolant temperature is below 73°C, it operates at this level of output until the
coolant temperature reaches 77°C.
61-20
HEATING
61
Program No.: 0001
Vdiag No.: 04
ENGINE RUNNING
ET007
NOTES None.
PRIMASTAR Check the insulation, continuity and absence of interference resistance of the
connection between:
Inertia sensor Track 1 independent heating relay
With the engine running, check that there is a 12 V supply to track 1 and track 3
of the relay and an earth from the oil pressure switch on track 2 of the relay.
Repair if necessary (see the vehicle wiring diagram).

Track 5 independent heating relay Track C ST1 5-track
connector
Track C ST1 5-track connector Track 1 ST3 bimetallic strip
connector
Track 2 ST3 bimetallic strip connector Track 6 8-track connector
If the continuity is poor between tracks 1 and 2 of the ST3 connector, replace the
bimetallic strip with a shunt and test the continuity between tracks 1 and 2.
Replace the bimetal strip if necessary.
61-21
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - INTERPRETATION OF PARAMETERS
COMPUTER SUPPLY VOLTAGE

PR108
NOTES None.

+ Battery Track A 5-track connector
Earth Track D 5-track connector
+12 V after ignition Track E 5-track connector

Track A 5-track connector Track 1 8-track connector
Track D 5-track connector Track 2 8-track connector
Track E 5-track connector Track 7 8-track connector
61-22
HEATING
61
Program No.: 0001
Vdiag No.: 04
DIAGNOSTICS - CUSTOMER COMPLAINTS
NO DIALOGUE WITH THE COMPUTER CHART 1
NO HEATING OR INADEQUATE HEATING CHART 2
61-23
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - FAULT FINDING CHARTS
CHART 1 No dialogue with the computer
NOTES None.
Try the diagnostic tool on another vehicle.
Check:
– the connection between the diagnostic tool and the diagnostic socket (wiring in
good condition),
– the engine fuses.
Check for the presence of + 12 V before ignition on track 16, for + 12 V after
ignition on track 1 and for an earth on tracks 4 and 5 of the diagnostic socket.

Connector ST1 track A V battery (fuse box)
Connector ST1 track E + After ignition (fuse box)
Connector ST1 track D Earth
Connector ST1 track B Track 7 of the diagnostic socket
(line K)
61-24
HEATING
61
Program No.: 0001
Vdiag No.: 04
FAULT FINDING - FAULT FINDING CHARTS
CHART 2 No heating or inadequate heating
NOTES Only refer to this customer complaint after a complete check with the diagnostic tool.
Is the air flow correct? NO Carry out the fault finding procedure for
climate control.
YES
Is the air distribution correct? NO Carry out the fault finding procedure for
climate control.
YES
With the engine warm, turn the heating on NO Are the heater matrix pipes on the
full. bulkhead hot?
Is the air supplied hot?

YES NO
YES
Check that the heater works properly with
the AC002 engine running command.
Check that the Does the heater heat up correctly (see
YES heater matrix is not parameter PR010: Coolant temperature
blocked, clean or sensor)?
replace it if
necessary.
NO
Replace the heater.
End of fault finding.
AFTER REPAIR Check that the system is operating correctly.
61-25

Nissan Primastar X83 (2002-2006) Service Manual #15

Uploaded by

Copyright:

Available Formats

Nissan Primastar X83 (2002-2006) Service Manual #15

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Nissan Primastar X83 (2002-2006) Service Manual #15

Uploaded by

Copyright:

Available Formats

HEATING 161

1 Left-hand side air vent

1 Air distribution unit

A Air temperature adjustment,

We therefore recommend that you return to normal mode (external air)

Air temperature adjustment

Adjustment of the amount of air delivered to the passenger

The passenger compartment is ventilated by blown air. The ventilation fan

Air recirculation control

Open the bonnet.

Remove the filter.

Proceed in the reverse order to removal.

Disconnect the battery.

– the central console to access the hazard warning

Remove lower mounting (I) and remove the control

Carry out the removal procedure in reverse.

Temperature adjustment dial control wire on the

Remove the control panel (see the Control panel

Carry out the removal procedure in reverse.

Air mixing flap control wire on the control unit

Remove the control panel (see the Control panel

Air mixing flap control wire on the distribution unit

Remove wire (C).

Carry out the removal procedure in reverse.

Follow the removal - refitting instructions in Section 62: Removal - refitting

● Refer to Section 88 if the light fails to operate in this way.

There are two ways of varying the heating power:

The air temperature is adjusted using the various

Air is supplied and distributed to the passenger

Remove the central console (see the Control panel

Disconnect the hazard lights switch.

Unclip the three clips (A) on the left-hand side cover

Proceed in the reverse order to removal.

Replace the two radiator hose seals and replace the

Remove the four air inlet unit mountings.

Remove the coolant recovery hose.

Remove the air inlet unit.

Proceed in the reverse order to removal.

Open the bonnet.

Disconnect the battery.

Unscrew bolts (A) and remove the heating ventilation

Proceed in the reverse order to removal.

Carry out the removal procedure in reverse.

The power module controls the speed of the fan

It can be accessed without removing the fan assembly.

Disconnect connectors, (A) and (B).

Unscrew the fan assembly trim bolt.

Heater unit mounting bolts 0.8

The heater unit is located under the vehicle on the

Disconnect the battery.

Put the vehicle on a 2-post lift (5 tonnes minimum).

Place a hose clamp on each pipe (A) of the coolant

Remove the two clamps (B) on the coolant hoses

Disconnect heater connections (D).

Removal of the heater from its bracket

Unscrew bolt (1) then turn the unit over.

Place the vehicle on a lift.

Disconnect the battery.

Disconnect connectors (A) on the metering pump.