light NISSAN NAVARA 2005 Repair Workshop Manual

TROUBLE DIAGNOSIS
MTC-53
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MTC
Operational CheckEJS005GB
The purpose of the operational check is to confirm that the system operates properly.
CHECKING BLOWER
1. Turn blower control switch clockwise. Blower should operate on
low speed. The blower symbol should have one blade lit (on dis-
play).
2. Turn the blower control switch again, and continue checking
blower speed and blower symbol until all speeds are checked.
3. Leave blower on MAX speed.
If NG, go to trouble diagnosis procedure for
If OK, continue with next check.
CHECKING DISCHARGE AIR
1. Turn the mode switch.
2. Each position indicator should change shape (on display, if
equipped).
3. Confirm that discharge air comes out according to the air distri-
bution table.
Mode door position is checked in the next step.
If NG, go to trouble diagnosis procedure forMTC-58, "
Mode Door
Motor Circuit".
If OK, continue with next check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at fresh when the DEF or D/F
is selected.
CHECKING RECIRCULATION
1. Press recirculation ( ) switch one time. Recirculation indica-
tor should illuminate.
2. Press recirculation ( ) switch one more time. Recirculation
indicator should go off.
3. Listen for intake door position change (blower sound should
change slightly).
If NG, go to trouble diagnosis procedure forMTC-68, "
Intake Door
Motor Circuit".
If OK, continue with next check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at fresh when the DEF or D/F is selected.Conditions : Engine running and at normal operating temperature
MJIB0223E
MJIB0224E
MJIB0284E
MJIB0225E

TROUBLE DIAGNOSIS
MTC-91
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MTC
High-pressure Side is Too Low and Low-pressure Side is Too High
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low and
low-pressure side is too high.High- and low-pressure sides
become equal soon after com-
pressor operation stops.Compressor pressure opera-
tion is improper.
¯
Damaged inside compressor
packings.Replace compressor.
No temperature difference
between high- and low-pres-
sure sides.Compressor pressure opera-
tion is improper.
¯
Damaged inside compressor
packings.Replace compressor.
AC356A
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure sides
are too low.
lThere is a big temperature
difference between receiver
drier outlet and inlet. Outlet
temperature is extremely
low.
lLiquid tank inlet and expan-
sion valve are frosted.Liquid tank inside is slightly
clogged.
lReplace liquid tank.
lCheck lubricant for contami-
nation.
lTemperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank.
lExpansion valve inlet may
be frosted.
lTemperature difference
occurs somewhere in high-
pressure side.High-pressure pipe located
between receiver drier and
expansion valve is clogged.
lCheck and repair malfunc-
tioning parts.
lCheck lubricant for contami-
nation.
Expansion valve and liquid
tank are warm or only cool
when touched.Low refrigerant charge.
¯
Leaking fittings or compo-
nents.Check refrigerant system for
leaks. Refer toMTC-131,
"Checking for Refrigerant
Leaks"
There is a big temperature dif-
ference between expansion
valve inlet and outlet while the
valve itself is frosted.Expansion valve closes a little
compared with the specifica-
tion.
¯
1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.
3. Outlet and inlet may be
clogged.lRemove foreign particles by
using compressed air.
lCheck lubricant for contami-
nation.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.Low-pressure pipe is clogged
or crushed.
lCheck and repair malfunc-
tioning parts.
lCheck lubricant for contami-
nation.
Air flow volume is too low. Evaporator is frozen.
lCheck intake sensor circuit.
Refer toMTC-95, "
Intake
Sensor Circuit".
lReplace compressor.
AC353A

REFRIGERANT LINES
MTC-131
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MTC
Checking for Refrigerant LeaksEJS0062F
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS0062G
1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future mis-
diagnosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionEJS0062H
(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.

PG-68
HARNESS
Wiring Diagram Codes (Cell Codes)
EKS00LJ9
Use the chart below to find out what each wiring diagram code stands for.
Refer to the wiring diagram code in the alphabetical index to find the location (page number) of each wiring
diagram.
Code Section Wiring Diagram Name
A/C,A ATC Auto Air Conditioner
A/C,M MTC Manual Air Conditioner
ABS BRC Anti-lock Brake System
APP1PW EC Accelerator Pedal Position Sensor 1 Power
APP2PW EC Accelerator Pedal Position Sensor 2 Power
APPS1 EC Accelerator Pedal Position Sensor 1
APPS2 EC Accelerator Pedal Position Sensor 2
APPS3 EC Accelerator Pedal Position Sensor
ASC/BS EC ASCD Brake Switch
ASC/SW EC ASCD Steering Switch
ASCBOF EC ASCD Brake Switch
ASCIND EC ASCD Indicator
AT/IND DI A/T Indicator Lamp
AUDIO AV Audio
AUTO/L LT Auto Lignt System
BACK/L LT Back-up Lamp
BOOST EC Turbocharger Boost Sensor
CAN AT CAN Communication Line
CAN EC CAN Communication Line
CAN LAN CAN System
CHARGE SC Charging System
CHIME DI Warning Chime
CIGER WW Cigarette Lighter
CKPS EC Crankshaft Position Sensor
CMPS EC Camshaft Position Sensor
COMBSW LT Combination Switch
COMM AV Audio Visual Communication Line
COMPAS DI Compass
COOL/F EC Cooling Fan Control
D/LOCK BL Power Door Lock
DIFLOC RFD Rear Final Drive
DEF GW Rear Window Defogger
DTRL LT Headlamp — With Daytime Running Light System
ECMRLY EC ECM Relay
ECTS EC Engine Coolant Temperature Sensor
EGRVLV EC EGR Volume Control System
EMNT EC Electronic Controlled Engine Mount Control Solenoid Valve
F/FOG LT Front Fog Lamp
F/PUMP EC Fuel Pump
FRPS EC Fuel Rail Pressure Sensor
FTS AT A/T Fluid Temperature Sensor

FRONT PROPELLER SHAFT
PR-5
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PR
lWhile holding the flange yoke on one side, check axial play of
the joint as shown. If the journal axial play exceeds the specifi-
cation, repair or replace the journal parts.
lCheck the propeller shaft tube surface for dents or cracks. If
damage is detected, replace the propeller shaft assembly.
INSTALLATION
Installation is in the reverse order of removal.
lAfter installation, check for vibration by driving the vehicle. Refer toPR-2, "NVH Troubleshooting Chart".
CAUTION:
Do not reuse the bolts and nuts. Always install new ones.
Disassembly and AssemblyEDS002WQ
DISASSEMBLY
1. Put matching marks on the front propeller shaft and flange yoke
as shown.
CAUTION:
For matching marks, use paint. Never damage the front pro-
peller shaft or flange yoke.
2. Remove the snap rings.
3. Push out and remove the journal bearings by lightly tapping the
flange yoke with a hammer, taking care not to damage the jour-
nal or flange yoke hole.
NOTE:
Put marks on the disassembled parts so that they can be rein-
stalled in their original positions from which they were removed.Journal axial play : 0.02 mm (0.0008 in) or less
LDIA0117E
SPD128
PDIA0957E
SPD732

PR-6
FRONT PROPELLER SHAFT
4. Push out and remove the remaining journal bearings at the
opposite side by lightly tapping the flange yoke with a hammer,
taking care not to damage the journal or flange yoke hole.
NOTE:
Put marks on the disassembled parts so that they can be rein-
stalled in their original positions from which they were removed.
ASSEMBLY
1. Assemble the journal bearings. Apply multipurpose grease on
the bearing inner surface.
NOTE:
During assembly, use caution so that the needle bearings do not
fall down.
2. Select snap rings that will provide the specified play in an axial
direction of the journal, and install them. Refer toPR-12, "
Snap
Ring".
NOTE:
Select snap rings with a difference in thickness at both sides
within 0.02 mm (0.0008 in).
3. Adjust the thrust clearance between the bearing and snap ring
to zero by tapping the yoke.
4. Make sure that the journal moves smoothly and is below the
joint flex effort specification.
SPD131
WPD019
SPD732
Joint flex effort : 1.96 N·m (0.20 kg-m, 17 in-lb) or less
LDIA0119E

PR-10
REAR PROPELLER SHAFT
INSTALLATION
Installation is in the reverse order of removal.
lAfter installation, check for vibration by driving the vehicle. Refer toPR-2, "NVH Troubleshooting Chart".
CAUTION:
Do not reuse the bolts and nuts. Always install new ones.
Disassembly and AssemblyEDS002WT
DISASSEMBLY
1. Put matching marks on the rear propeller shaft and flange yoke
as shown.
CAUTION:
For matching marks use paint. Never damage the rear pro-
peller shaft or flange yoke.
2. Remove the snap rings.
l2WD
l4WD
3. Push out and remove the journal bearings by lightly tapping the
flange yoke with a hammer, taking care not to damage the jour-
nal or flange yoke hole.
NOTE:
Put marks on the disassembled parts so that they can be rein-
stalled in their original positions from which they were removed.
SPD128
PDIA0957E
PDIA1021E
SPD732

REAR PROPELLER SHAFT
PR-11
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PR
4. Push out and remove the remaining journal bearings at the
opposite side by lightly tapping the flange yoke with a hammer,
taking care not to damage the journal or flange yoke hole.
NOTE:
Put marks on the disassembled parts so that they can be rein-
stalled in their original positions from which they were removed.
ASSEMBLY
1. Assemble the journal bearings. Apply multipurpose grease on
the bearing inner surface.
NOTE:
During assembly, use caution so that the needle bearings do not
fall down.
2. Select snap rings that will provide the specified play in an axial
direction of the journal, and install them. Refer toPR-12, "
Snap
Ring".
NOTE:
Select snap rings with a difference in thickness at both sides
within 0.02 mm (0.0008 in).
3. Adjust the thrust clearance between the bearing and snap ring
to zero by tapping the yoke.
4. Make sure that the journal moves smoothly and is below the
joint flex effort specification.
SPD131
WPD019
SPD732
Joint flex effort
2WD : 1.96 N·m (0.20 kg-m, 17 in-lb) or less
4WD : 2.26 N·m (0.23 kg-m, 20 in-lb) or less
LDIA0119E

PS-8
STEERING WHEEL
STEERING WHEEL
PFP:48430
On-Vehicle Inspection and ServiceEGS001LG
CHECKING CONDITION OF INSTALLATION
lCheck installation conditions of steering gear assembly, front suspension assembly, axle and steering col-
umn assembly.
lCheck if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction.
lCheck steering gear assembly mounting bolts and nuts for looseness. Refer toPS-14, "COMPONENT".
CHECKING STEERING WHEEL PLAY
lTurn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn
steering wheel to the left and right until front wheels start to move. Measure steering wheel movement on
the outer circumference.
lWhen the measurement value is outside the standard value, check backlash for each joint of steering col-
umn assembly and installation condition of steering gear assembly.
CHECKING NEUTRAL POSITION STEERING WHEEL
lMake sure that steering gear assembly, steering column assembly and steering wheel are installed in the
correct position.
lPerform neutral position inspection after wheel alignment. Refer toFSU-7, "Front Wheel Alignment".
lSet vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
lLoosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustment if
steering wheel is not in the neutral position.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is
approximately 50 to 80°C(122to176°F).]
4. Check steering wheel turning force when steering wheel has
been turned 360°from neutral position.
NOTE:
Multiply the distance (L) from the hook of spring scale to the
center of steering wheel by the measurement value with a spring
scale.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump.
Regarding relief hydraulic pressure of oil pump, refer toPS-25,
"CHECKING RELIEF OIL PRESSURE".
a. Disconnect lower joint and steering knuckle from steering gear assembly. Refer toPS-11, "
COMPO-
NENT",FAX-5, "Removal and Installation".
b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature.Steering wheel axial end play : 0 mm (0 in)
Steering wheel play : 0 - 35 mm (0 - 1.38 in)
Steering wheel turn-
ing force: Less than 39 N (4.0 kg-m, 8.8 lb)
SGIA1136E

RF-4
SQUEAK AND RATTLE TROUBLE DIAGNOSES
SQUEAK AND RATTLE TROUBLE DIAGNOSES
PFP:00000
Work FlowEIS00CDY
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer toRF-8, "
Diagnostic Worksheet". This information is necessary to duplicate the
conditions that exist when the noise occurs.
lThe customer may not be able to provide a detailed description or the location of the noise. Attempt to
obtain all the facts and conditions that exist when the noise occurs (or does not occur).
lIf there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
is concerned about. This can be accomplished by test driving the vehicle with the customer.
lAfter identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
lSqueak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard sur-
faces=higher pitch noise/softer surfaces=lower pitch noises/edge to surface=chirping
lCreak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
dependent on materials/often brought on by activity.
lRattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
lKnock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
lTick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
lThump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
lBuzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
lOften the degree of acceptable noise level will vary depending upon the person. A noise that you may
judge as acceptable may be very irritating to the customer.
lWeather conditions, especially humidity and temperature, may have a great effect on noise level.
SBT842