engine control NISSAN NAVARA 2005 Repair Workshop Manual

PERIODIC MAINTENANCE
MA-11
C
D
E
F
G
H
I
J
K
MA
B
MA
ENGINE AND EMISSION CONTROL MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, D = Check filter and drain water
NOTE:
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
l(1) If valve noise increases, check valve clearance.
l(2)NeveruseCG-4oil.
l(3) Oil filter element assembly and O-ring seal are replacement parts.
l(4) First replace at 100,000 Km (60,000 miles), then every 60,000Km (36,000 miles). After first replacement, perform "I"
(checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
l(5) If engine power decreases, black exhaust smoke is emitted or engine noise increases, perform this maintenance item.
CHASSIS AND BODY MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x 1,000)30
(18)60
(36)90
(54)120
(72)
Engine compartment and under vehicle
Intake & exhaust valve clearanceSee
NOTE (1)EM-66
Drive beltsIIIIMA-17
Engine oil (Use recommended oil.)See
NOTE (2)RRRRMA-25
Engine oil filter (Use NISSAN genuine part or equivalent)See
NOTE (3)RRRRMA-26
Engine anti-freeze coolant (Use Genuine NISSAN Anti-freeze
Coolant (L250) or equivalent)See
NOTE (4)IIIIMA-19
Cooling system I I I IMA-21
Fuel linesIIMA-23
Air cleaner filter (Dry paper type)RRMA-25
Fuel filterDRDRMA-23
Fuel injectorSee
NOTE (5)EM-44
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x
1,000)30
(18)60
(36)90
(54)120
(72)
Underhood and under vehicle
Headlamp aiming I I I ILT- 2 8
Brake & clutch, systems and fluid (For level & leaks) I I I IMA-35,
MA-28
Brake fluidRRMA-35
Brake booster vacuum hoses, connections & check valve I IBR-22
Power steering fluid & lines (For level & leaks) I I I IMA-37
Manual transmission gear oil (For leaks) I I I IMA-28
Automatic transmission fluid (For level & leeaks)IIIIMA-29
Transfer fluid (For level & leaks) I I I IMA-31
Differential gear oil (For level & leaks or replace)IIIIMA-32,
MA-33

MA-20
ENGINE MAINTENANCE
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.
lIf water drain plug on cylinder block is removed, close and tighten it. Refer toEM-110, "CYLIN-
DER BLOCK".
2. Make sure that each hose clamp has been firmly tightened.
3. Fill radiator and reservoir tank to the specified level.
lPour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
lUse Genuine NISSAN Anti-freeze Coolant (L250) or equiv-
alent in its quality. Refer toMA-14, "
RECOMMENDED
FLUIDS AND LUBRICANTS"
lWhen engine coolant overflows air relief hole, install air relief
plug.
4. Warm up engine to normal operating temperature without radiator cap and reservoir tank cap installed.
lIf engine coolant overflows radiator filler hole and reservoir tank filler hole, install radiator cap
and reservoir tank cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed.
lRepeat two or three times.
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
6. Stop engine and cool down to less than approximately 50°C(122°F).
lCool down using a fan to reduce the time.
lIf necessary, refill radiator up to filler neck with engine coolant.
7. Refill reservoir tank to MAX level line with engine coolant.
8. Repeat steps 3 through 6 two or more times with radiator cap installed until engine coolant level no longer
drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between COOL and WARM.
lSound may be noticeable at heater unit.Radiator drain plug:
: 1.2 N·m (0.12 kg-m, 11 in-lb)
Engine coolant capacity
(with reservoir tank at “MAX” level)
LHD models
: Approx. 9.9 (8 - 3/4 lmp qt)
RHD models
: Approx. 10.2 (9 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.8 (3/4 lmp qt)
SMA412B

TRANSMISSION ASSEMBLY
MT-17
D
E
F
G
H
I
J
K
L
MA
B
MT
4WD models
REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Drain gear oil, if remove transfer assembly. Refer toMT-9, "
Changing M/T Oil".
3. Remove control lever assembly. Refer toMT-13, "
Removal and Installation".
4. Remove engine under cover middle and engine under cover rear.
5. Remove main muffler and tail tube. Refer toEX-3, "
Removal and Installation".
6. Remove front propeller shaft (for 4WD models) and rear propeller shaft. Refer toPR-4, "
Removal and
Installation"(front) andPR-8, "Removal and Installation"(rear).
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal of transfer, when removing propeller
shaft.
NOTE:
Insert a suitable plug into rear oil seal of transfer after removing propeller shaft.
7. Remove clutch operating cylinder. Refer toCL-11, "
Removal and Installation".
CAUTION:
Do not depress clutch pedal during removal procedure.
PCIB1609E
1. Transmission assembly 2. Transmission cross member 3. Insulator

MTC-1
MANUAL AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
C
D
E
F
G
H
I
K
L
M
SECTIONMTC
A
B
MTC
MANUAL AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
Contaminated Refrigerant ........................................ 4
General Refrigerant Precautions .............................. 5
Precautions for Refrigerant Connection ................... 5
ABOUT ONE-TOUCH JOINT ................................ 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 7
O-RING AND REFRIGERANT CONNECTION..... 9
Precautions for Servicing Compressor ................... 12
Precautions for Service Equipment ........................ 12
RECOVERY/RECYCLING EQUIPMENT ............ 12
ELECTRONIC LEAK DETECTOR ...................... 12
VACUUM PUMP ................................................. 13
MANIFOLD GAUGE SET .................................... 13
SERVICE HOSES ............................................... 13
SERVICE COUPLERS ........................................ 14
REFRIGERANT WEIGHT SCALE ...................... 14
CALIBRATING ACR4 WEIGHT SCALE .............. 14
CHARGING CYLINDER ...................................... 14
Precautions for Leak Detection Dye ....................... 14
IDENTIFICATION ................................................ 15
IDENTIFICATION LABEL FOR VEHICLE ........... 15
Wiring Diagrams and Trouble Diagnosis ................ 15
PREPARATION ......................................................... 16
Special Service Tools ............................................. 16
HFC-134a (R-134a) Service Tools and Equipment... 16
Commercial Service Tools ...................................... 19
REFRIGERATION SYSTEM ..................................... 20
Refrigerant Cycle ................................................... 20
REFRIGERANT FLOW ....................................... 20
FREEZE PROTECTION ..................................... 20
Refrigerant System Protection ............................... 20
REFRIGERANT PRESSURE SENSOR ............. 20
PRESSURE RELIEF VALVE ............................... 21
Component Layout ................................................. 22
REFRIGERATION SYSTEM ............................... 22LUBRICANT .............................................................. 24
Maintenance of Lubricant Quantity in Compressor... 24
LUBRICANT ........................................................ 24
CHECKING AND ADJUSTING ............................ 24
AIR CONDITIONER CONTROL ............................... 26
Description .............................................................. 26
Operation ................................................................ 26
AIR MIX DOOR CONTROL ................................. 26
BLOWER SPEED CONTROL ............................. 26
INTAKE DOORS CONTROL ............................... 26
MODE DOOR CONTROL ................................... 26
DEFROSTER DOOR CONTROL ........................ 26
MAGNET CLUTCH CONTROL ........................... 27
SELF-DIAGNOSTIC SYSTEM ............................ 27
Description of Control System ................................ 28
Control Operation ................................................... 28
DISPLAY SCREEN .............................................. 29
TEMPERATURE SWITCH (TEMPERATURE
CONTROL) (FRONT) .......................................... 29
RECIRCULATION () SWITCH ............................. 29
REAR WINDOW DEFOGGER SWITCH ............. 29
OFF SWITCH (BLOWER SPEED SET TO 0) ..... 29
A/C SWITCH ....................................................... 29
MODE SWITCH .................................................. 29
Discharge Air Flow ................................................. 30
FRONT ................................................................ 30
System Description ................................................. 31
SWITCHES AND THEIR CONTROL FUNCTION... 31
CAN Communication System Description .............. 32
TROUBLE DIAGNOSIS ............................................ 33
CONSULT-II ............................................................ 33
CONSULT-II BASIC OPERATION ....................... 33
DATA MONITOR ................................................. 34
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 35
WORK FLOW ...................................................... 35
SYMPTOM TABLE .............................................. 35
Component Parts and Harness Connector Location... 36
ENGINE COMPARTMENT .................................. 36
FRONT PASSENGER COMPARTMENT ............ 37

MTC-24
LUBRICANT
LUBRICANT
PFP:KLG00
Maintenance of Lubricant Quantity in CompressorEJS005FV
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large refrigerant leakage has occurred. It is important to maintain
the specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
lLack of lubricant: May lead to a seized compressor
lExcessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name: NISSAN A/C System Lubricant Type S (DH-PS)
Part number: KLH00-PAGS0
CHECKING AND ADJUSTING
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
Start the engine and set the following conditions:
test condition
lEngine speed: Idling to 1,200 rpm
lA/C switch: On
lBlower speed: Max. position
lTemp. control: Optional [Set so that intake air temperature is 25°to 30°C(77°to 86°F).]
lIntake position: Recirculation ( )
lPerform lubricant return operation for about ten minutes
Adjust the lubricant quantity according to the following table.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
l*1: If refrigerant leak is small, no addition of lubricant is needed.
Lubricant Adjustment Procedure for Compressor Replacement
1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
3. Drain the lubricant from the “old” (removed) compressor into a graduated container and recover the
amount of lubricant drained.
4. Drain the lubricant from the “new” compressor into a separate, clean container.
5. Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this
lubricant to “new” compressor through the suction port opening.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to “new” compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz) of lubricant if only replacing the compressor.
Part replacedLubricant to be added to system
Remarks
Amount of lubricant
m(Impfloz)
Evaporator 75 (2.6) —
Condenser 75 (2.6) —
Liquid tank 5 (0.2) Add if compressor is not replaced.
In case of refrigerant leak30 (1.1) Large leak
— Small leak *1

MTC-26
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL
PFP:27500
DescriptionEJS005FW
The front air control provides regulation of the vehicle's interior temperature. The system is based on the posi-
tion of the front air controls temperature switch selected by the driver. This is done by utilizing a microcom-
puter, also referred to as the front air control, which receives input signals from the following three sensors:
lIntake sensor
lPBR (Position Balanced Resistor).
The front air control uses these signals (including the set position of the temperature switch) to control:
lOutlet air volume
lAir temperature
lAir distribution
The front air control is used to select:
lOutlet air volume
lAir temperature/distribution
OperationEJS005FX
AIR MIX DOOR CONTROL
The air mix door is controlled so that in-vehicle temperature changed based on the position of the temperature
switch.
BLOWER SPEED CONTROL
Blower speed is controlled based on front blower switch settings.
When blower switch is turned, the blower motor starts and increases air flow volume each time the blower
switch is turned counterclockwise, and decreases air flow volume each time the blower switch is turned coun-
terclockwise.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing.
INTAKE DOORS CONTROL
The intake doors are controlled by the recirculation switch setting, and the mode (defroster) switch setting.
MODE DOOR CONTROL
The mode door is controlled by the position of the mode switch.
DEFROSTER DOOR CONTROL
The defroster door is controlled by: Turning the defroster dial to front defroster.

TROUBLE DIAGNOSIS
MTC-53
C
D
E
F
G
H
I
K
L
MA
B
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-83
C
D
E
F
G
H
I
K
L
MA
B
MTC
8.CHECK REFRIGERANT PRESSURE SENSOR
WITH CONSULT-II
1. Start engine.
2. Check voltage of refrigerant pressure sensor. Refer toBCS-14, "
CONSULT-II Function (BCM)".
WITHOUT CONSULT-II
1. Start engine.
2. Check voltage between ECM harness connector F1 terminal 53
and ground.
OK or NG
OK >>lWITH CONSULT-II
GO TO 9.
lWITHOUT CONSULT-II
GO TO 10.
NG >> Refer toEC-325, "
REFRIGERANT PRESSURE SENSOR".
9.CHECK BCM INPUT (FAN ON) SIGNAL
Check FAN ON/OFF signal. Refer toBCS-14, "
CONSULT-II Func-
tion (BCM)".
OK or NG
OK >> GO TO 12.
NG >> GO TO 10.
Terminals
Condition Voltage (+)
(-)
ECM
connectorTerminal No.
F1 53 Ground A/C switch: ON Approx. 0.36 - 3.88V
MJIB0071E
BLOWER CONTROL
SWITCH ON: FAN ON SIG ON
BLOWER CONTROL
SWITCH OFF:FANONSIGOFF
WJIA0469E

REFRIGERANT LINES
MTC-133
C
D
E
F
G
H
I
K
L
MA
B
MTC
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, 50 psi) above 16°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 toMTC-120, "
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.
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.
SHA839E

SERVICE DATA AND SPECIFICATIONS (SDS)
MTC-135
C
D
E
F
G
H
I
K
L
MA
B
MTC
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Service Data and Specifications (SDS)EJS005HS
COMPRESSOR
LUBRICANT
REFRIGERANT
ENGINE IDLING SPEED
Refer toEC-357, "General Specifications".
BELT TENSION
Refer toEM-13, "Deflection Adjustment".
MakeZEXEL VALEO CLIMATE CONTROL
ModelDKS-17D
Ty p eSwash plate
Displacement
175.5 cm
3(10.7 in3)/rev
Cylinder bore´stroke 30.5 mm (1.20 in) x 24.0 mm (0.94 in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V
MakeZEXEL VALEO CLIMATE CONTROL
ModelDKS-17D
NameNISSAN A/C System Lubricant Type S (DH-PS)
Part number KLH00-PAGS0
Capacity Total in system
290m (10.2lmpfloz)
Ty p eHFC-134a (R-134a)
Capacity 1080±50g(38.09±1.76 oz)