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Old 10-12-2018, 02:32 AM   #11
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I got an entire O-ring kit at Autozone, said it would fit my 2004 Frontier: MT2571, set of 30 green O-rings, like about 5 or 6 different sizes (still did not locate my stash of new refrigeration O-rings, sure it will turn up someday).

I was able to remove the old compressor through the top of the engine compartment, so I didn't have to remove the compressor brackets from the engine block itself.

I drained only about 2 oz. oil from my old compressor, maybe that's why it locked up (my Mazda B2200 compressor that seized a few years ago had only a few drops).

The new UAC CO10607C compressor from Rock Auto stated that it contained PAG 45 oil, so I drained that out. I added 2 oz. PAG-100 contain UV dye to the condenser and 4 oz. to the new compressor, added the rubber plugs and bolted those in. I used the new green O-rings for the high pressure connections to the condenser, one for the pressure switch that I swapped to the new condenser, and 2 different size ones for the compressor connections.

New condenser installed, photo #1

New compressor installed, photo #2; I flushed out the high pressure line with solvent and blew out the solvent.

I pulled good vacuum for 90 minutes, and vacuum held after disconnecting the pump, good, photo #3

Adding refrigerant, just over 25 oz.

Pressures at idle; forgot to measure at 1800 rpm. Photo #4

Good thing I had some photos of Mrs. Cusser to look at (photo #5), as this took most of the day. Just have to add the front plastic trim tomorrow. AC works, and is quiet too - good !!!
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Old 10-17-2018, 12:54 AM   #12
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I had the front grille off on my 2004 Frontier to replace the AC condenser last week, and I decided maybe that I should add some mesh to its grille openings.
Before, sorry didn't take head on picture (photo 1)

I used "hardware cloth" which is a steel mesh screen, 1/4 inch openings. I cut to fit, spray painted with black engine enamel, and used my Harbor Freight pneumatic staple gun to attach. This should provide some protection from flying stones without impeding air flow. (Photos 2 and 3)
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Old 10-17-2018, 01:10 PM   #13
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Note that there is an aftermarket grille available for the 2004 Frontier, for all pieces maybe about $75 plus shipping. But to me looks like it might affect air flow over the condenser and radiator, not something that one would want in Arizona heat.
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Old 12-12-2018, 03:28 PM   #14
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Well, shouldn't be surprised, but owner's manual pages 8-23 through 8-24 do NOT apply to MY 2004 Frontier King Cab. My glove box does not have removable pivot pins as stated on p. 8-23 diagram WD10315, my entire glove box assembly comes off as a unit with 6 Phillips head screws. There also is NO clip securing the filter as shone in diagram WD10317 on p. 8-24, just a plastic strip with an arrow pointing up.


After removing that, there was a rectangular opening but no cabin filter, just empty space


Inside that opening, the evaporator fins looked super clean, so I decided not to try to install a filter. So it looks like on mine that a cabin filter could be installed with zero cutting.


I didn't measure, but maybe one of these would fit
https://www.autozone.com/filters-and...ter/108656_0_0

https://www.oreillyauto.com/shop/b/f...bin+Air+Filter
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Old 12-31-2018, 07:36 AM   #15
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Quote:
Originally Posted by Cusser View Post
Note that there is an aftermarket grille available for the 2004 Frontier, for all pieces maybe about $75 plus shipping. But to me looks like it might affect air flow over the condenser and radiator, not something that one would want in Arizona heat.
I have those installed on my fronty. Both top and bottom pieces. The supplied bolt heads were too big and required them to be sanded down to fit between the slots. They do not seem to affect airflow on my truck. Also they're cheaply made, a few of the corner pieces have bent by themselves.
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Old 07-04-2019, 05:42 PM   #16
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I got and installed new NGK PFR5G 11 spark plugs. I also checked the ignition timing as per service manual, even the thing with unplugging the throttle position sender harness, and it was right at 20* BTDC as it should be.


I did this because my 2004 King Cab (105K) seems to have less power than my same-equipped 1998 regular cab with 240K (both 4-cylinder, 5-speed, 2WD). I realize that the King Cab weighs like 300 lbs more, and I also typically have a passenger along, but the difference seems more than that weight difference could explain. Maybe the difference is due to different electronics over the 6 years. Does anyone have have any ideas what I could do to the 2004 to attain equivalent power (other than shoving Mrs. Cusser out) ??? Or any explanations?? Thanks.
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Old 07-26-2019, 01:03 AM   #17
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D'oh !!! Noticed the water pump seeping a little out of its weep hole. Looks like a task for tomorrow, lifetime warranty pump in stock in small town, good, because this will be a warranty part (100 miles away from Phoenix).
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Old 06-10-2020, 11:45 AM   #18
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Sept. 2018 the AC compressor on my 2004 Frontier seized up about 100 miles into our vacation.

Oct. 2018 I replaced the compressor, condenser, receiver-drier, flushed the high pressure lines, all detailed in post #28. I used brand-new parts from RockAuto, new UAC CO10607C compressor.

Vent temperatures have been fine. Only concern was that on first use of AC each day (first time I pressed the AC on-off switch each day), there was a metallic grind-type noise the first half-second. When cycling, or turning on the AC switch on subsequent trips that day, no noise at all, silent operation. I even tried with engine cold first thing in the morning to turn the ac compressor drive plate by hand, turned readily, and smoothly; then I started up and when I pressed in the AC switch, got the same noise for the half second. Ambient temperature a first start of the day did not seem to affect this at all.

Jump to May 2020. On this Frontier I was still on the factory AC idler pulley at 105K miles, so I bought a new idler for $42 to swap that in (I'd had to replace same part on my 1998 Frontier previously when its idler seized up). So I installed the idler, and the factory one had just a twinkling of vibration when I spun it by hand. Anyway, after that, and with AC belt a little looser, I started it up; and when I pushed in the AC button, the noise appeared again for its usual half-second.

So next day, I decided that I wanted to hear the noise while being under the hood. Since my AC compressor won't engage unless the engine is running (or I jump its wire), I pulled the "AC compressor" fuse just rearward of the battery. I started the engine, turned AC on (switch "in"), and went up to the front. I inserted the AC compressor fuse and the compressor engaged BUT WITHOUT THE NOISE. So I pulled the fuse again and cleaned up its contact arms/blades, even though they looked OK, and re-inserted the fuse.

I fully realize that I'll jinx myself my writing this, but in two subsequent "first AC switch on of the day" situations, the noise has not occurred.

I'm open to any explanations, as to why somewhat-intermittent contact of the fuse blades would cause such a noise, and only on the first start up of the day.

A couple of weeks later, still operating silently. My theory is that oxidation on the AC compressor fuse blades prevented full amps from getting to the compressor clutch, and cleaning off the fuse blades with some steel wool enabled full amps.

Someone suggested maybe it's just because it's getting the 12 volts cleanly now instead of struggling. Maybe the flow of current improved after heating up the contacts points on the fuse legs after the 1st start of the day.
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Old 06-10-2020, 11:36 PM   #19
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It’s a odd one, but no sort of electrical problem really seems too off the wall. I’ve seen some weird stuff at work that made no sense.
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Old 09-30-2020, 06:54 PM   #20
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My electric blue 2004 has been spared the sun-induced paint peeling much more than its brothers; my main area of peel has been by the passenger window.



Knowing that more paint would peel off during touch up attempts (I know that from my white '98 Frontier), I took the coward's way out and ordered 3/4 inch striping tape through Amazon. I used that to cover up the paint peel area.
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