seats NISSAN NAVARA 2005 Repair Workshop Manual

PRECAUTIONS
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INSTALLATION
1. Clean piping connection points, and insert male-side piping into female-side piping.
2. Push inserted male-side piping harder so that female-side piping flare stretches garter spring.
3. If inside diameter of garter spring becomes larger than outside diameter of female-side piping flare, garter
spring seats on flare. Then, it fits in between male-side piping cage and female-side piping flare to anchor
piping connection point.
NOTICE:
When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare,
it clicks.
CAUTION:
lFemale-side piping connection point is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert it in axial direction.
lInsert piping securely until a click is heard.
lAfter piping connection is completed, pull male-side piping by hand to make sure connection
does not come loose.
NOTE:
One-touch joint connection is used in points below.
lLow-pressure flexible hose to evaporator (O-ring size: 16)
lHigh-pressure flexible hose to condenser (O-ring size: 12)
lHigh-pressure pipe 1 to high-pressure pipe 2 (O-ring size: 8)
lHigh-pressure pipe 1 to condenser (O-ring size: 8)
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
lThe O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance 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.
SJIA0107E

ATC-126
HEATER & COOLING UNIT ASSEMBLY
Removal and Installation
EJS006C9
REMOVAL
1. Discharge the refrigerant from the A/C system. Refer toATC-138, "Discharging Refrigerant".
2. Drain the coolant from the engine cooling system. Refer toCO-8, "
DRAINING ENGINE COOLANT".
3. Remove the heater core pipes RH nut.
4. Disconnect the heater core hoses from the heater core.
5. Disconnect the high- and low-pressure A/C pipes from the
expansion valve.
6. Move the two front seats to the rearmost position on the seat
track.
7. Remove the instrument panel and console panel. Refer toIP-10,
"Removal and Installation".
8. Remove the two front floor ducts.
9. Remove the steering column. Refer toPS-10, "
Removal and
Installation".
10. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (SMJ) electrical connectors. Refer toPG-38, "
Harness Layout".
11. Remove the covers then remove the three steering member bolts from each side to disconnect the steer-
ing member from the vehicle body.
12. Remove the heater and cooling unit assembly with it attached to the steering member, from the vehicle.
CAUTION:
lUse 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.
lUse suitable plugs on the heater core pipes to prevent coolant leakage.
13. Remove the heater and cooling unit assembly from the steering member.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace 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.
lAfter charging the refrigerant, check for leaks. Refer toATC-150, "Checking for Refrigerant Leaks"
.
NOTE:
lFill the engine cooling system with the specified coolant mixture. Refer toCO-8, "REFILLING ENGINE
COOLANT".
lRecharge the A/C system. Refer toATC-138, "Evacuating System and Charging Refrigerant".
LJIA0165E

BL-1
BODY, LOCK & SECURITY SYSTEM
IBODY
CONTENTS
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SECTIONBL
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BODY, LOCK & SECURITY SYSTEM
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for procedures with out cowl top cover..... 4
Precautions for Work ................................................ 4
Wiring Diagrams and Trouble Diagnosis .................. 4
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 6
Work Flow ................................................................ 6
CUSTOMER INTERVIEW ..................................... 6
DUPLICATE THE NOISE AND TEST DRIVE ....... 7
CHECK RELATED SERVICE BULLETINS ........... 7
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 7
REPAIR THE CAUSE ........................................... 7
CONFIRM THE REPAIR ....................................... 8
Generic Squeak and Rattle Troubleshooting ........... 8
INSTRUMENT PANEL .......................................... 8
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 9
SUNROOF/HEADLINING ..................................... 9
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
HOOD ....................................................................... 12
Fitting Adjustment .................................................. 12
LONGITUDINAL AND LATERAL CLEARANCE
ADJUSTMENT .................................................... 13
FRONT END HEIGHT ADJUSTMENT ............... 13
SURFACE HEIGHT ADJUSTMENT ................... 13
Removal and Installation of Hood Assembly .......... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Removal and Installation of Hood Hinge ................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Removal and Installation of Hood Lock Control ..... 15REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Hood Lock Control Inspection ................................ 17
RADIATOR CORE SUPPORT .................................. 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
FRONT FENDER ...................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
POWER DOOR LOCK SYSTEM .............................. 21
Component Parts and Harness Connector Location... 21
KING CAB ........................................................... 21
DOUBLE CAB ..................................................... 22
System Description ................................................. 23
OUTLINE ............................................................. 24
CAN Communication System Description .............. 25
CAN Communication Unit ....................................... 25
Schematic ............................................................... 26
Wiring Diagram —D/LOCK— ................................. 27
Terminals and Reference Value for BCM ............... 34
CONSULT-II Function (BCM) ................................. 35
CONSULT-II BASIC OPERATION PROCEDURE
... 35
CONSULT-II APPLICATION ITEMS .................... 36
Work Flow ............................................................... 37
Trouble Diagnoses Chart by Symptom ................... 37
Check Power Supply and Ground Circuit ............... 37
Check Door Switch ................................................. 39
CHECK DOOR SWITCH (DOUBLE CAB) .......... 39
CHECK DOOR SWITCH (KING CAB) ................ 41
Check Key Switch ................................................... 43
Check Door Key Cylinder Switch (LHD Model Only)... 45
Check Front Door Lock Actuator (Driver Side) ....... 48
Check Front Door Lock Actuator (Passenger Side)... 49
Check Front Door Lock Actuator Switch ................. 50
Check Rear Door Lock Actuator LH (Double Cab
Model) ..................................................................... 50
Check Rear Door Lock Actuator RH (Double Cab

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

EI-1
EXTERIOR & INTERIOR
IBODY
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SECTIONEI
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EXTERIOR & INTERIOR
PRECAUTIONS .......................................................... 3
Service Notice .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for SRS “AIR BAG” and “SEAT BELT
PRE-TENSIONER” Service ..................................... 3
Precautions for Procedures without Cowl Top Cover..... 4
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 6
Work Flow ................................................................ 6
CUSTOMER INTERVIEW ..................................... 6
DUPLICATE THE NOISE AND TEST DRIVE ....... 7
CHECK RELATED SERVICE BULLETINS ........... 7
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 7
REPAIR THE CAUSE ........................................... 7
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
OVERHEAD CONSOLE (FRONT AND REAR)..... 8
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
CLIP AND FASTENER ............................................. 12
Clip and Fastener ................................................... 12
FRONT BUMPER ..................................................... 15
Removal and Installation ........................................ 15
FRONT BUMPER ............................................... 15
REAR BUMPER ....................................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18FRONT GRILLE ........................................................ 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 19
COWL TOP ............................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
FENDER PROTECTOR ............................................ 21
Components ........................................................... 21
Removal and Installation of Front Fender Protector... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
Removal and Installation of Rear Fender Protector... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
MUDGUARD ............................................................. 23
Removal and Installation ........................................ 23
RUNNING BOARDS ................................................. 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
ROOF RACK ............................................................. 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
DOOR OUTSIDE MOLDING ..................................... 27
Removal and Installation ........................................ 27
FRONT DOOR OUTSIDE MOLDING .................. 27
SIDE GUARD MOLDING .......................................... 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
DOOR FINISHER ...................................................... 30
Removal and Installation ........................................ 30
FRONT DOOR .................................................... 30
REAR DOOR - DOUBLE CAB ............................ 31
REAR DOOR - KING CAB .................................. 32
BODY SIDE TRIM ..................................................... 33
Components ........................................................... 33

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

EI-36
BODY SIDE TRIM
REAR
CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from finishers.
Removal
1. Remove rear seats. Refer toSE-29, "Removal and Installation".
2. Remove storage boxes (if equipped). Refer toEI-38, "
FLOOR TRIM".
3. Remove rear kick plates RH/LH and seat belt anchor bolts.
4. Remove seatback latch strikers (Double cab models).
5. Remove jack storage cover, then remove jack.
1. Rear upper finisher (King cab) 2. Rear lower finisher (King cab) 3. Rear upper finisher (Double cab)
4. Rear lower finisher (Double cab) 5. Pushpin 6. Rear panel lower (Double cab)
7. Rear panel upper (Double cab) 8. Drafter duct (Double cab) 9. Jack storage cover
10. Child seat anchor cover 11. Rear panel (King cab) 12. Drafter ducts (King cab)
MIIB9133E

FLOOR TRIM
EI-39
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Storage Box
REMOVAL
1. Remove front seats. Refer toSE-20, "FRONT SEAT".
2. Remove rear seats. Refer toSE-29, "
Removal and Installation".
3. Remove storage boxes (if equipped).
4. Remove lower seat belt anchors (double cab only). Refer toSB-3, "
SEAT BELTS".
5. Remove lower body side trim panels. Refer toEI-33, "
BODY SIDE TRIM".
6. Remove center console. Refer toIP-16, "
CENTER CONSOLE".
7. Remove front lower duct grille, LH and RH side.
8. Remove floor mat hooks.
9. Remove carpet.
INSTALLATION
Installation is in the reverse order of removal.
MIIB9145E
1. Net 2. Tray (King Cab) 3. Locking clip
4. Storage box (King Cab) 5. Storage box RH (Double Cab) 6. Storage box LH (Double Cab)

CYLINDER HEAD
EM-93
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Compression pressure
Unit: kPa (bar, kg/cm2, psi)/rpm
lWhen engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
lIf engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
lIf compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
lIf compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
9. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuse [EGI (20A)].
e. Connect the battery cable to the negative terminal.
f. Using CONSULT-II make sure no DTC is indicated for items of self-diagnosis.
ComponentsEBS01EKC
Standard Minimum Difference limit between cylinders
3,100 (31, 31.6, 450)/200 2,500 (25, 25.5, 363)/200 490 (4.9, 5.0, 71)/200
PBIC3477E

EM-100
CYLINDER HEAD
NOTE:
Refer to the figure for intake and exhaust valve positions.
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.
5. Remove valve oil seals using the valve oil seal puller [SST].
6. Remove valve spring seats.
7. Before removing valve seats, perform valve seat contact check.
Refer toEM-103, "
Va l v e S e a t C o n t a c t".
8. Before removing valve guides, perform valve guide clearance
check. Refer toEM-101, "
Valve Guide Clearance".
ASSEMBLY
1. Install valve guides. Refer toEM-102, "Valve Guide Replacement".
2. Install valve seats. Refer toEM-103, "
Valve Seat Replacement".
3. Using the valve oil seal drift [SST], install valve oil seals referring
to the dimension shown in the figure.
4. Install valve spring seats.
5. Install valves.
lInstall the valves with bigger outer diameter to intake valve
side.
lNote that valve layout here is different from that of conven-
tional engine.
6. Install valve spring.
7. Install valve spring retainers.
SBIA0196E
JEM153G
JEM165G
SBIA0196E