NISSAN NAVARA 2005 Repair Workshop Manual

IDENTIFICATION INFORMATION
GI-59
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GI
MANUAL TRANSMISSION NUMBER
PCIB1490E

GI-60
IDENTIFICATION INFORMATION
Dimensions
EAS001DO
KING CAB
Unit: mm (in)
DOUBLE CAB
Unit: mm (in)
Wheels & TyresEAS001DP
Drive Type 2WD 4WD
Tyre size 235/70R16 255/70R16 235/70R16 255/70R16 265/70R16 255/65R17
Overall length 5220 (205.5)
Overall width 1850 (72.8)
Overall height 1743 (68.6) 1756 (69.1) 1751 (68.9) 1766 (69.5) 1777 (70.0) 1771 (69.7)
Front tread width
1570 (61.8)
Rear tread width
Wheelbase 3200 (126.0)
Drive Type 2WD 4WD
Tyre size 255/70R16 255/65R17 235/70R16 255/70R16 265/70R16 255/65R17
Overall length 5220 (205.5)
Overall width 1850 (72.8)
Overall height
(with Roof Rack)1881 (74.1) 1885 (74.2) 1873 (73.7) 1888 (74.3) 1899 (74.8) 1893 (74.5)
Overall height
(without Roof Rack)1771 (69.7) 1775 (69.9) 1764 (69.4) 1779 (70.0) 1789 (70.4) 1784 (70.2)
Front tread width
1570 (61.8)
Rear tread width
Wheelbase 3200 (126.0)
Drive Type Road wheel Tyre Spare tyre size
All16 X 7J Steel 235/70R16 235/70R16
16 X 7J Aluminum Alloy235/70R16 235/70R16
255/70R16 255/70R16
17 X 7J Aluminum Alloy 255/65R17 255/65R17

TERMINOLOGY
GI-61
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TERMINOLOGYPFP:00011
ISO 15031-2 Terminology ListEAS001H9
All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve

GI-62
TERMINOLOGY
Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

TERMINOLOGY
GI-63
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Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnosis
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
Park/neutral position switch PNP switchPark/neutral switch
Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system ***
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control sole-
noid valvePAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
Simultaneous multiport fuel injection sys-
tem*** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter
systemTWC + OC system ***
Throttle body TBThrottle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valveLock-up cancel solenoid
Lock-up solenoid NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

GI-64
TERMINOLOGY
***: Not applicableTransmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
temWU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter sys-
temWU-TWC system ***
Wide open throttle position switch WOTP switch Full switchNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

GW-1
GLASSES, WINDOW SYSTEM & MIRRORS
IBODY
CONTENTS
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SECTIONGW
A
B
GW
GLASSES, WINDOW SYSTEM & MIRRORS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for Procedures without Cowl Top Cover..... 3
Handling for Adhesive and Primer ........................... 3
Trouble Diagnosis Precaution .................................. 3
PREPARATION ........................................................... 4
Commercial Service Tool ......................................... 4
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS ........... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REPAIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS ................................................................. 7
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
SEATS ................................................................... 8
UNDERHOOD ....................................................... 8
Diagnostic Worksheet .............................................. 9
WINDSHIELD GLASS ...............................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
POWER WINDOW SYSTEM .................................... 15
Component Parts and Harness Connector Location... 15
System Description ................................................ 15
MANUAL OPERATION ....................................... 16
AUTO OPERATION ............................................ 18
POWER WINDOW LOCK ................................... 18
DRIVER WINDOW ANTI-PINCH FUNCTION ..... 18
Schematic .............................................................. 19Wiring Diagram – WINDOW – ................................ 20
Terminal and Reference Value for Power Window
Main Switch ............................................................ 24
Terminal and Reference Value for Each Door's
Power Window Switch ............................................ 24
Terminal and Reference Value for BCM ................. 25
Work Flow ............................................................... 25
Trouble Diagnosis Symptom Chart ......................... 25
BCM Power Supply and Ground Circuit Check ...... 26
Power Window Main Switch Power Supply and
Ground Circuit Check ............................................. 27
Driver Side Power Window Motor Check ............... 28
Passenger Side Power Window Motor Circuit
Check ..................................................................... 29
Rear LH Power Window Motor Circuit Check ......... 30
Rear RH Power Window Motor Circuit Check ........ 31
Passenger Side Power Window Circuit Check ....... 31
Rear LH Power Window Circuit Check ................... 32
Rear RH Power Window Circuit Check .................. 33
Power Window Switch Check 1 .............................. 33
Power Window Switch Check 2 .............................. 34
FRONT DOOR GLASS AND REGULATOR ............. 35
Removal and Installation ........................................ 35
DOOR GLASS ..................................................... 35
REGULATOR ASSEMBLY .................................. 36
Disassembly and Assembly .................................... 37
REGULATOR ASSEMBLY .................................. 37
Inspection after Installation ..................................... 37
FITTING INSPECTION ....................................... 37
RESET OPERATION ........................................... 37
REAR DOOR GLASS AND REGULATOR ............... 38
Removal and Installation ........................................ 38
DOOR GLASS ..................................................... 38
REGULATOR ASSEMBLY .................................. 39
Disassembly and Assembly .................................... 40
REGULATOR ASSEMBLY .................................. 40
Inspection after Installation ..................................... 40
FITTING INSPECTION ....................................... 40

GW-2
SIDE WINDOW GLASS ............................................ 41
Removal and Installation ........................................ 41
REMOVAL ........................................................... 41
INSTALLATION .................................................... 42
REAR WINDOW GLASS AND MOLDING ................ 43
Removal and Installation ........................................ 43
REMOVAL ........................................................... 43
INSTALLATION .................................................... 44
INSIDE MIRROR ....................................................... 45
Wiring Diagram –I/MIRR– ...................................... 45
Removal and Installation ........................................ 46
REMOVAL ........................................................... 46
INSTALLAION ..................................................... 46
REAR WINDOW DEFOGGER .................................. 47
Component Parts and Harness Connector Location... 47
System Description ................................................. 47
CAN Communication System Description .............. 48
Schematic ............................................................... 49
Wiring Diagram –DEF– ........................................... 50
Terminal and Reference Value for BCM ................. 53
Terminal and Reference Value for IPDM E/R ......... 53
Work Flow ............................................................... 53
CONSULT-II Function (BCM) .................................. 54
CONSULT-II BASIC OPERATION PROCEDURE... 54
DATA MONITOR .................................................. 55
ACTIVE TEST ...................................................... 55
Trouble Diagnoses Symptom Chart ........................ 56
BCM Power Supply and Ground Circuit Check ...... 56
Rear Window Defogger Switch Circuit Check ......... 57
Rear Window Defogger Power Supply Circuit
Check ...................................................................... 59
Rear Window Defogger Circuit Check .................... 59
Rear Window Defogger Signal Check .................... 60
Filament Check ....................................................... 61
Filament Repair ....................................................... 61
REPAIR EQUIPMENT ......................................... 61
REPAIRING PROCEDURE ................................. 62
DOOR MIRROR ......................................................... 63
Wiring Diagram – MIRROR – / LHD Models .......... 63
Wiring Diagram – MIRROR – / RHD Models ......... 64
Door Mirror Assembly ............................................. 65
REMOVAL ............................................................ 65
INSTALLATION .................................................... 65
Disassembly and Assembly .................................... 65
DISASSEMBLY .................................................... 65
ASSEMBLY .......................................................... 66

PRECAUTIONS
GW-3
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GW
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EIS00CED
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 Procedures without Cowl Top CoverEIS00DGM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Handling for Adhesive and PrimerEIS00B7B
lDo not use an adhesive which is past its usable date. Shelf life of this product is limited to six months after
the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box.
lKeep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.
lOpen the seal of the primer and adhesive just before application. Discard the remainder.
lBefore application, be sure to shake the primer container to stir the contents. If any floating material is
found, do not use it.
lIf any primer or adhesive contacts the skin, wipe it off with gasoline or equivalent and wash the skin with
soap.
lWhen using primer and adhesive, always observe the precautions in the instruction manual.
Trouble Diagnosis PrecautionEIS00B7C
When you read wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams"
lPG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble diagnosis, refer to the following:
lGI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
lGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident"
Check for any service bulletins before servicing the vehicle.
PIIB3706J

GW-4
PREPARATION
PREPARATION
PFP:00002
Commercial Service ToolEIS00B7E
Tool name Description
Engine ear Locating the noise
Suction lifter Holding the door glass
SIIA0995E
PIIB1805J