belt NISSAN NAVARA 2005 Repair Workshop Manual

HARNESS CONNECTOR
PG-77
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PG
HARNESS CONNECTOR (DIRECT-CONNECT SRS COMPONENT TYPE)
lSRS direct-connect type harness connectors are used on certain SRS components such as air bag mod-
ules and seat belt pre-tensioners.
lAlways pull up to release black locking tab prior to removing connector from SRS component.
lAlways push down to lock black locking tab after installing connector to SRS component. When locked,
the black locking tab is level with the connector housing.
CAUTION:
lDo not pull the harness or wires when removing connectors
from SRS components.
WHIA0103E

PS-1
POWER STEERING SYSTEM
G STEERING
CONTENTS
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SECTIONPS
A
B
PS
POWER STEERING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions for Steering System .............................. 2
PREPARATION ........................................................... 3
Special Service Tools [SST] ..................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
POWER STEERING FLUID ........................................ 6
Checking Fluid Level ................................................ 6
Checking Fluid Leakage ........................................... 6
Air Bleeding Hydraulic System ................................. 6
STEERING WHEEL .................................................... 8
On-Vehicle Inspection and Service .......................... 8
CHECKING CONDITION OF INSTALLATION ...... 8
CHECKING STEERING WHEEL PLAY ................ 8
CHECKING NEUTRAL POSITION STEERING
WHEEL ................................................................. 8
CHECKING STEERING WHEEL TURNING
FORCE .................................................................. 8
CHECKING FRONT WHEEL TURNING ANGLE..... 9
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
STEERING COLUMN ................................................11
Removal and Installation ......................................... 11
COMPONENT ...................................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
POWER STEERING GEAR AND LINKAGE ............ 14Removal and Installation ........................................ 14
COMPONENT ..................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Disassembly and Assembly .................................... 16
COMPONENT ..................................................... 16
DISASSEMBLY ................................................... 17
INSPECTION AFTER DISASSEMBLY ................ 18
ASSEMBLY ......................................................... 20
POWER STEERING OIL PUMP ............................... 25
On-Vehicle Inspection and Service ......................... 25
CHECKING RELIEF OIL PRESSURE ................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 26
Disassembly and Assembly .................................... 26
COMPONENT ..................................................... 26
INSPECTION BEFORE DISASSEMBLY ............. 26
DISASSEMBLY ................................................... 27
INSPECTION AFTER DISASSEMBLY ................ 27
ASSEMBLY ......................................................... 28
HYDRAULIC LINE .................................................... 30
Component (RHD Models) ..................................... 30
Component (LHD Models) ...................................... 32
Removal and Installation ........................................ 33
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
Steering Wheel ....................................................... 34
Steering Angle ........................................................ 34
Steering Column ..................................................... 34
Steering Outer Socket and Inner Socket ................ 34
Steering Gear ......................................................... 35
Oil Pump ................................................................. 35
Steering Fluid .......................................................... 35

PS-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EGS001M0
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Steering SystemEGS001L9
lIn case of removing steering gear assembly, make the final tightening with grounded and unloaded vehi-
cle condition, and then check wheel alignment.
lObserve the following precautions when disassembling.
–Before disassembly, thoroughly clean the outside of the unit.
–Disassembly should be done in a clean work area. It is important to prevent the internal parts from becom-
ing contaminated by dirt or other foreign matter.
–For easier and proper assembly, place disassembled parts in order on a parts rack.
–Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere
with their operation.
–Do not reuse non-reusable parts.
–Before assembling, apply the specified grease to the directed parts.

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PS-5
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PS
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEGS001LC
Use chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
PS-6PS-6PS-18PS-18PS-18PS-6PS-8PS-8EM-12PS-8—
PS-18PS-12PS-11PS-16
NVHinPRsection
NVH in RFD section
NVH in FAX, RAX, FSU, RSU section
NVH in WT section
NVH in WT section
NVHinBRsection
NVHinBRsection
Possible cause and SUSPECTED PARTS
Fluid level
Air in hydraulic system
Outer socket ball joint swinging force
Outer socket ball joint rotating torque
Outer socket ball joint end play
Steering fluid leakage
Steering wheel play
Steering gear rack sliding force
Drive belt looseness
Improper steering wheel
Improper installation or looseness of tilt lock lever
Mounting rubber deterioration
Steering column deformation or damage
Improper installation or looseness of steering column
Steering linkage looseness
PROPELLER SHAFT
DIFFERENTIAL
AXLE and SUSPENSION
TYRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
Symptom SteeringNoise´ ´ ´´´´´ ´ ´ ´´´´´´ ´
Shake´´´ ´ ´´´´ ´
Vibration´´´´´ ´ ´´ ´
Shimmy´´´ ´ ´´´ ´
Shudder´ ´ ´´´ ´

POWER STEERING OIL PUMP
PS-25
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PS
POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceEGS001LL
CHECKING RELIEF OIL PRESSURE
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer toPS-6, "
Air
Bleeding Hydraulic System".
2. Start engine. Run engine until oil temperature reaches 50 to
80°C(122to176°F).
CAUTION:
lLeave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
lBe sure to keep hose clear or belts and other parts when
engineisstarted.
3. Fully close the hydraulic pressure gauge [SST] valve with
engine at idle and measure the relief oil pressure.
CAUTION:
Never keep valve closed for 10 seconds or longer.
4. Open the valve slowly after measuring. Repair oil pump is the
relief oil pressure is outside the standard. Refer toPS-26, "
Dis-
assembly and Assembly".
5. After inspection, disconnect the hydraulic pressure gauge [SST] from hydraulic circuit, then add fluid and
bleed air. Refer toPS-6, "
Air Bleeding Hydraulic System".
Removal and InstallationEGS001LM
REMOVAL
1. Drain power steering fluid from reservoir tank.
2. Remove radiator shroud. Refer toCO-11, "
Components".
3. Loosen drive belt. Refer toEM-12, "
DRIVE BELTS".
4. Remove drive belt from oil pump pulley.
5. Disconnect the pressure sensor electrical connector.
6. Remove piping of high pressure and low pressure (drain fluid from their pipings). Refer toPS-30,
"HYDRAULIC LINE".
7. Remove oil pump mounting bolts, and then remove power steering pump. Refer toPS-30, "
HYDRAULIC
LINE". Relief oil pressure:
8,500 - 9,300 kpa (86.7 - 94.9 kg/cm
2, 1,233 - 1,349 psi)
SGIA1225E

PS-26
POWER STEERING OIL PUMP
INSTALLATION
Installation is the reverse order of removal. For tightening torque, refer toPS-30, "HYDRAULIC LINE".
lPerform the following procedure after installing.
–Adjust belt tension. Refer toEM-12, "DRIVE BELTS".
–Bleed air. Refer toPS-6, "Air Bleeding Hydraulic System".
Disassembly and AssemblyEGS001LN
COMPONENT
INSPECTION BEFORE DISASSEMBLY
Disassemble oil pump only when the following malfunctions occur.
lIf oil leakage is found on oil pump.
lOil pump pulley is damaged or deformed.
lPerformance of oil pump is low.
1. Pulley 2. Front bracket 3. Snap ring
4. Oil seal 5. Drive shaft 6. Body assembly
7. Suction pipe 8. O-ring A 9. Spring
10. Flow control valve 11. Copper washer 12. Joint
13. O-ring B 14. Side plate 15. Rotor
16. Cartridge 17. Vane 18. Cam ring
19. Dowel pin 20. Gasket 21. Rear cover
22. Rear bracket
Referr toGI-10, "
Components"and the followings for the symbols in the figure.
:
Apply Type DEXRON
TMIII or equivalent.
:Apply multi-purpose grease.
SGIA1318E

RF-1
ROOF
IBODY
CONTENTS
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SECTIONRF
A
B
RF
ROOF
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Commercial Service Tool ......................................... 3
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 4
Work Flow ................................................................ 4
CUSTOMER INTERVIEW ..................................... 4
DUPLICATE THE NOISE AND TEST DRIVE ....... 5
CHECK RELATED SERVICE BULLETINS ........... 5
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 5
REPAIR THE CAUSE ........................................... 5
CONFIRM THE REPAIR ....................................... 6
Generic Squeak and Rattle Troubleshooting ........... 6
INSTRUMENT PANEL .......................................... 6
CENTER CONSOLE ............................................. 6
DOORS ................................................................. 6
TRUNK .................................................................. 7
SUNROOF/HEADLINING ..................................... 7
SEATS ................................................................... 7
UNDERHOOD ....................................................... 7
Diagnostic Worksheet .............................................. 8
SUNROOF ................................................................ 10
Component Parts and Harness Connector Location... 10
System Description ................................................. 11
TILT UP / SLIDE CLOSE OPERATION ................ 11
TILT DOWN / SLIDE OPEN OPERATION ........... 11AUTO OPERATION ............................................. 11
ANTI-PINCH FUNCTION .................................... 11
MEMORY RESET PROCEDURE ....................... 12
INITIALIZATION PROCEDURE .......................... 12
CAN Communication System Description .............. 13
CAN Communication Unit ....................................... 13
Wiring Diagram — SROOF — ................................ 14
Terminals and Reference Value for BCM ............... 15
Terminals and Reference Value for Sunroof Motor
Assembly ................................................................ 15
Work Flow ............................................................... 16
Trouble Diagnosis Symptom Chart ......................... 16
BCM Power Supply and Ground Circuit Check ...... 16
Sunroof Motor Assembly Power Supply and Ground
Circuit Check .......................................................... 17
Sunroof Switch System Check ............................... 18
Fitting Adjustment ................................................... 20
GAP ADJUSTMENT ............................................ 20
HEIGHT DIFFERENCE ADJUSTMENT .............. 20
Removal and Installation ........................................ 21
SUNROOF UNIT ................................................. 22
GLASS LID .......................................................... 22
WIND DEFLECTOR ............................................ 23
SUNSHADE ........................................................ 23
SUNROOF MOTOR ............................................ 23
DRAIN HOSES .................................................... 25
WEATHERSTRIP ................................................ 25
REAR DRAIN ASSEMBLY .................................. 25
LINK AND WIRE ASSEMBLY ............................. 26

RF-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EIS00CE9
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
PrecautionsEIS00B92
lDisconnect both battery cables in advance.
lNever tamper with or force air bag lid open, as this may adversely affect air bag performance.
lBe careful not to scratch pad and other parts.
lWhen removing or disassembling any part, be careful not to damage or deform it. Protect parts which may
get in the way with cloth.
lWhen removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
lKeep removed parts protected with cloth.
lIf a clip is deformed or damaged, replace it.
lIf an unreusable part is removed, replace it with a new one.
lTighten bolts and nuts firmly to the specified torque.
lAfter re-assembly has been completed, make sure each part functions correctly.
lRemove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Thenwipetheareawithasoftdrycloth.
lDo not use any organic solvent, such as thinner or benzine.

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTIONRFD
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RFD
REAR FINAL DRIVE
WITH LIMITED SLIP DIFFERENTIAL
PRECAUTIONS .......................................................... 3
Limited Slip Differential (LSD) Performance Judge-
ment ......................................................................... 3
METHOD FOR TROUBLESHOOTING ................. 3
Service Notice or Precautions .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 5
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DIFFERENTIAL GEAR OIL ........................................ 9
Changing Differential Gear Oil ................................. 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking Differential Gear Oil .................................. 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
FRONT OIL SEAL .................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION .................................................... 11
CARRIER COVER .................................................... 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Disassembly and Assembly ................................... 15
COMPONENTS .................................................. 15
ASSEMBLY INSPECTION AND ADJUSTMENT... 16
DISASSEMBLY ................................................... 19
INSPECTION AFTER DISASSEMBLY ............... 22
SELECTION ADJUSTING WASHERS ............... 23
ASSEMBLY ......................................................... 24SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Inspection and Adjustment ..................................... 31
PRELOAD TORQUE ........................................... 31
BACKLASH ......................................................... 31
COMPANION FLANGE RUNOUT ....................... 31
SELECTIVE PARTS ............................................ 32
WITH ELECTRONIC LOCKING DIFFEREN-
TIAL
PRECAUTIONS ........................................................ 33
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” ................................................................. 33
Precautions for Differential Case Assembly and Dif-
ferential Lock Control Unit Replacement ................ 33
CHECK DIFF LOCK INDICATOR LAMP ............. 33
METHOD FOR ADJUSTMENT ........................... 34
Precautions ............................................................. 34
Service Notice or Precaution .................................. 35
Wiring Diagrams and Trouble Diagnosis ................ 35
PREPARATION ......................................................... 36
Special Service Tools ............................................. 36
Commercial Service Tools ...................................... 37
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 39
NVH Troubleshooting Chart ................................... 39
DIFFERENTIAL GEAR OIL ...................................... 40
Changing Differential Gear Oil ................................ 40
DRAINING ........................................................... 40
FILLING ............................................................... 40
Checking Differential Gear Oil ................................ 40
OIL LEAKAGE AND OIL LEVEL ......................... 40
DIFFERENTIAL LOCK SYSTEM .............................. 41
Cross-sectional View .............................................. 41
Differential Lock Operation ..................................... 42
System Description ................................................. 42
DIFFERENTIAL LOCK SOLENOID .................... 42
DIFFERENTIAL LOCK POSITION SWITCH ....... 42

PRECAUTIONS
RFD-33
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
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RFD
[WITH ELECTRONIC LOCKING DIFFERENTIAL]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003IE
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Differential Case Assembly and Differential Lock Control Unit
Replacement
EDS003AG
lWhen replacing differential case assembly or differential lock control unit, check the DIFF LOCK indicator
pattern and adjustment of the position between differential case assembly and differential lock control unit
if necessary.
CHECK DIFF LOCK INDICATOR LAMP
1. Start engine. Run engine for at least 10 seconds.
2. Turn 4WD shift switch to “4LO” and confirm 4LO indicator lamp is turned on. Refer toTF-16, "
4WD SHIFT
SWITCH AND INDICATOR LAMP".
3. Stop vehicle and turn differential lock mode switch to “ON”.
4. Drive vehicle at 7 km/h (4 MPH) or less.
NOTE:
Differential case assembly must be given a rotation from rear left wheel and rear right wheel.
5. Check if DIFF LOCK indicator lamp flashes to turn on.
6. Check if DIFF LOCK indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf each indication and state is OK, rear final drive assembly and differential lock control unit is working cor-
rectly.
lIf each indication and state is NG, rear final drive assembly and differential lock control unit is not working
correctly. Refer toRFD-34, "
METHOD FOR ADJUSTMENT".
Differential lock mode
switch4LO indicator lamp Vehicle speed (VSS)Differential case assem-
bly stateDIFF LOCK indicator
lamp
ONOFF7 km/h (4 MPH) < VSS
Disengage Flash VSS£7km/h(4MPH)
ON7 km/h (4 MPH) < VSS
VSS£7 km/h (4 MPH) Disengage®Engage Flash®ON
OFFOFF7 km/h (4 MPH) < VSS
Disengage OFF VSS£7km/h(4MPH)
ON7 km/h (4 MPH) < VSS
VSS£7km/h(4MPH)