check engine NISSAN NAVARA 2005 Repair Owners Manual

REFRIGERANT LINES
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AT C
2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
4. Install the clutch disc on the compressor shaft, together with the
original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc
from turning and tighten the bolt to specification. Refer toAT C -
140, "Components".
CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as
shown.
7. If the specified clearance is not obtained, replace the adjusting
spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer toEM-12, "
DRIVE BELTS".
10. Install the engine under cover and the splash shield.Tool number : KV99106200
MJIB0290E
WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
WHA194

REFRIGERANT LINES
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AT C
Dye InjectionEJS006D3
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak DetectorEJS006D4
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
SHA705EB
SHA707EA
SHA706E

ATC-152
REFRIGERANT LINES
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
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 calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set (SST) to the A/C service valves.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50psi)above16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refriger-
ant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2,50psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal l). Refer toATC-140, "
Components". Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
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.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. MODE control dial: VENT (Ventilation)
c. Intake door position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
SHA708EA

REFRIGERANT LINES
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10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
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 pressure is high.
11. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
12. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
13. Perform A/C performance test to ensure system works properly.
SHA839E

BL-3
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BL INSTALLATION ................................................. 136
Removal and Installation of Fuel Lid Lock Striker. 137
REMOVAL ......................................................... 137
INSTALLATION ................................................. 137
THEFT WARNING SYSTEM .................................. 138
Component Parts and Harness Connector Location. 138
KING CAB ......................................................... 138
DOUBLE CAB ................................................... 139
System Description .............................................. 140
DESCRIPTION .................................................. 140
POWER SUPPLY AND GROUND CIRCUIT .... 141
INITIAL CONDITION TO ACTIVATE THE SYS-
TEM ................................................................... 141
THEFT WARNING SYSTEM ALARM OPERA-
TION .................................................................. 141
THEFT WARNING SYSTEM DEACTIVATION . 141
CAN Communication System Description ............ 141
Schematic ............................................................ 142
Wiring Diagram — VEHSEC — for LHD Models . 143
Wiring Diagram — VEHSEC — for RHD Models . 149
Terminals and Reference Value for BCM ............. 155
Terminals and Reference Value for IPDM E/R ..... 156
CONSULT-II Function (BCM) ............................... 156
CONSULT-II INSPECTION PROCEDURE ....... 156
CONSULT-II APPLICATION ITEM .................... 157
Trouble Diagnosis ................................................ 159
WORK FLOW .................................................... 159
Preliminary Check ................................................ 160
Symptom Chart .................................................... 161
Diagnostic Procedure 1 ........................................ 162
CHECK DOOR SWITCH (DOUBLE CAB) ........ 162
CHECK DOOR SWITCH (KING CAB) .............. 164
CHECK HOOD SWITCH ................................... 166
Diagnostic Procedure 2 ........................................ 168
Diagnostic Procedure 3 ........................................ 169
Diagnostic Procedure 4 ........................................ 169
NATS(NISSAN ANTI-THEFT SYSTEM) ................. 170Component Parts and Harness Connector Location.170
System Description ...............................................171
System Composition .............................................172
ECM Re-communicating Function ........................172
Wiring Diagram — NATS — .................................173
Terminals and Reference Value for BCM .............174
CONSULT-II Function ...........................................174
CONSULT-II INSPECTION PROCEDURE ........174
CONSULT-II DIAGNOSTIC TEST MODE FUNC-
TION ..................................................................175
HOW TO READ SELF-DIAGNOSTIC RESULTS.176
NATS SELF-DIAGNOSTIC RESULTS ITEM
CHART ..............................................................176
Trouble Diagnosis Procedure ...............................177
WORK FLOW ....................................................177
Trouble Diagnoses ...............................................178
SYMPTOM MATRIX CHART 1 ..........................178
SYMPTOM MATRIX CHART 2 ..........................178
Diagnostic Procedure 1 ........................................179
Diagnostic Procedure 2 ........................................181
Diagnostic Procedure 3 ........................................181
Diagnostic Procedure 4 ........................................184
Diagnostic Procedure 5 ........................................185
Diagnostic Procedure 6 ........................................187
Removal and Installation of NATS Antenna Amp . 188
REMOVAL .........................................................188
INSTALLATION .................................................188
CAB AND REAR BODY .........................................189
Body Mounting (King Cab) ...................................189
Body Mounting (Double Cab) ...............................190
BODY REPAIR ........................................................191
Body Alignment ....................................................191
DESCRIPTION ..................................................191
ENGINE COMPARTMENT ................................192
UNDERBODY ...................................................194
PASSENGER COMPARTMENT .......................196
REAR BODY .....................................................201

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models).
6) Raisethevehicleonahoistandhitatirewitharubberhammer.
lDrive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
lIf it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Engine Ear or mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
lremoving the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
or lost during the repair, resulting in the creation of new noise.
ltapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.
lfeeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
lplacing a piece of paper between components that you suspect are causing the noise.
llooking for loose components and contact marks.
Refer toBL-8, "
Generic Squeak and Rattle Troubleshooting".
REPAIR THE CAUSE
lIf the cause is a loose component, tighten the component securely.
lIf the cause is insufficient clearance between components:
–separate components by repositioning or loosening and retightening the component, if possible.
–insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape are available through your authorized Nissan Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
NOTE:
Always check with the Parts Department for the latest parts information.
Each item can be ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100´135 mm (3.94´5.31 in)/76884-71L01: 60´85 mm (2.36´3.35 in)/76884-71L02: 15´
25 mm (0.59´0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
73982-9E000: 45 mm (1.77 in) thick, 50´50 mm (1.97´1.97 in)/73982-50Y00: 10 mm (0.39 in) thick, 50
´50 mm (1.97´1.97 in)
INSULATOR (Light foam block)
80845-71L00: 30 mm (1.18 in) thick, 30´50 mm (1.18´1.97 in)

BL-16
HOOD
3. Remove the hood lock assembly.
4. Disconnect the hood lock cable from the hood lock, and clip it from the radiator core support upper and
hood ledge.
5. Remove the hood lock opener mounting bolts, and remove the
hood lock opener.
6. Separate the grommet from the lower dash panel. Pull the hood
lock cable out through the passenger compartment.
CAUTION:
While pulling, be careful not to damage (peeling) the out-
side of the hood lock cable.
INSTALLATION
1. Pull the hood lock cable through the panel hole to the engine
room.
CAUTION:
Be careful not to bend the cable too much, keeping the
radius 100 mm (3.94 in) or more.
2. Make sure the cable is not offset from the positioning grommet,
and push the grommet into the panel hole securely.
3. Apply the sealant to the grommet (at * mark) properly.
4. Install the cable securely to the lock in order of (1) and (2).
5. After installing, check the hood lock adjustment and hood
opener operation.
6. After installing, perform hood fitting adjustment. Refer toBL-12,
"Fitting Adjustment". : 23.0 N·m (2.3 kg-m, 17.0 ft-lb)
MIIB0629E
MIIB0657E
PIIB2909J
MIIB0638E

BL-156
THEFT WARNING SYSTEM
TerminalsandReferenceValueforIPDME/R
EIS00DC3
*: When horn reminder is ON.
CONSULT-II Function (BCM)EIS00DC4
CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
CONSULT-II INSPECTION PROCEDURE
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 carry out CAN communication.
1. Turn ignition switch OFF.
2. Connect CONSULT-II and CONSULT-II CONVERTER to the
data link connector.
3. Turn ignition switch ON.
4. Touch “START (NISSAN BASED VHCL)”.
TerminalWire
ColorItem ConditionVoltage (V)
(Approx.)
38 B Ground — 0
39 L CAN-H — —
40 P CAN-L — —
41 G Engine hood switchON (hood open) 0
OFF (hood close) Battery voltage
45 BR Horn relayWhen doors locks are operated using
keyfob (OFF®ON) *Battery voltage®0
59 B Ground — 0
BCM diagnosis
partDiagnostic mode Description
THEFT ALMWORK SUPPORTSupports 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.
DATA MONITOR Displays BCM input/output data in real time.
ACTIVE TEST Operation of electrical loads can be checked by sending drive signal to them.
BBIA0538E
BCIA0029E

BL-176
NATS(NISSAN ANTI-THEFT SYSTEM)
HOW TO READ SELF-DIAGNOSTIC RESULTS
NATS SELF-DIAGNOSTIC RESULTS ITEM CHART
PIIA1124E
Detected items
[NATS program card screen terms]P No. Code
(Self-diagnostic
result of
“ENGINE”)Malfunction is detected when.....Reference
page
CHAIN OF ECM-IMMU
[P1612]NATS MAL-
FUNCTION
P1612Communication impossible between ECM and BCM
In rare case, “CHAIN OF ECM-IMMU” might be stored
during key registration procedure, even if the system is
not malfunctioning.BL-179
DIFFERENCE OF KEY
[P1615]NATS MAL-
FUNCTION
P1615BCM can receive the key ID signal but the result of ID
verification between key ID and BCM is NG.BL-181
CHAIN OF IMMU-KEY
[P1614]NATS MAL-
FUNCTION
P1614BCM cannot receive the key ID signal.BL-181
ID DISCORD, IMM-ECM
[P1611]NATS MAL-
FUNCTION
P1611The result of ID verification between BCM and ECM is
NG. System initialization is required.BL-184
LOCK MODE
[P1610]NATS MAL-
FUNCTION
P1610When the starting operation is carried out five or more
times consecutively under the following conditions, NATS
will shift the mode to one which prevents the engine from
being started.
lUnregistered ignition key is used.
lBCM or ECM’s malfunctioning.BL-187
ECM
[P1616]ECM
P1616ECM ROM is malfunctioning.EC-269
DON'T ERASE BEFORE CHECK-
ING ENG DIAG—All engine trouble codes except NATS trouble code has
been detected in ECM.BL-177

BL-178
NATS(NISSAN ANTI-THEFT SYSTEM)
Trouble Diagnoses
EIS00DB0
SYMPTOM MATRIX CHART 1
Self-diagnosis related item
*1: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position.
SYMPTOM MATRIX CHART 2
Non self-diagnosis related item
*: CONSULT-II self-diagnostic results display screen “no malfunction is detected”.SYMPTOMDisplayed “SELF-DIAG
RESULTS” on CON-
SULT-II screen.DIAGNOSTIC PROCE-
DURE
(Reference page)SYSTEM
(Malfunctioning part or mode)
lSecurity indicator
lighting up*1
lEngine cannot be
startedCHAIN OF ECM-IMMU
[P1612]PROCEDURE 1
(BL-179
)In rare case, “CHAIN OF ECM-IMMU” might be stored
during key registration procedure, even if the system is
not malfunctioning.
Open circuit in battery voltage line of BCM circuit
Open circuit in ignition line of BCM circuit
Open circuit in ground line of BCM circuit
Open or short circuit between BCM and ECM communi-
cation line
ECM
BCM
DIFFERENCE OF KEY
[P1615]PROCEDURE 2
(BL-181
)Unregistered key
BCM
CHAIN OF IMMU-KEY
[P1614]PROCEDURE 3
(BL-181
)Malfunction of key ID chip
Communication line between ANT/ AMP and BCM:
Open circuit or short circuit of battery voltage line or
ground line
Open circuit in power source line of ANT/ AMP circuit
Open circuit in ground line of ANT/ AMP circuit
NATS antenna amp.
BCM
ID DISCORD, IMM-
ECM
[P1611]PROCEDURE 4
(BL-184
)System initialization has not yet been completed.
ECM
ECM
[P1616]EC-269, "
DTC P1616
ECM"ECM
lSecurity indicator
lighting up*1
lEngine cannot be
startedLOCK MODE
[P1610]PROCEDURE 6
(BL-187)When the starting operation is carried out five or more
times consecutively under the following conditions, NATS
will shift the mode to one which prevents the engine from
being started.
lUnregistered ignition key is used.
lBCM or ECM’s malfunctioning.
Security indicator
lighting up*
1
DON'T ERASE
BEFORE CHECKING
ENG DIAGWORK FLOW
(BL-177
)Engine trouble data and NATS trouble data have been
detected in ECM
SYMPTOMDIAGNOSTIC PROCEDURE
(Reference page)SYSTEM
(Malfunctioning part or mode)
Security indicator does not light up*.PROCEDURE 5
(BL-185
)Security indictor.
Open circuit between Fuse and BCM
BCM