engine control NISSAN NAVARA 2005 Repair Workshop Manual

TROUBLE DIAGNOSIS FOR SYMPTOMS
RFD-73
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
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RFD
DIFF LOCK Indicator Lamp Does Not ChangeEDS003BA
SYMPTOM:
DIFF LOCK indicator lamp does not change when turning differential lock mode switch to “ON” after
engine start.
DIAGNOSTIC PROCEDURE
1.CHECK DIFF LOCK INDICATOR LAMP
Confirm DIFF LOCK indicator lamp when ignition switch is turned to ON.
Does DIFF LOCK indicator lamp turn on?
YES >> GO TO 2.
NO >> Go toRFD-70, "
DIFF LOCK Indicator Lamp Does Not Turn ON".
2.CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer toRFD-51, "
SELF-DIAG RESULTS MODE".
Is any malfunction detected by self-diagnosis?
YES >> Check the malfunctioning system.
NO >> GO TO 3.
3.CHECK SYSTEM FOR DIFFERENTIAL LOCK MODE SWITCH
Perform trouble diagnosis for differential lock mode switch system. Refer toRFD-56, "
Differential Lock Mode
Switch".
OK or NG
OK >> GO TO 4.
NG >> Repair or replace damaged parts.
4.CHECK SYMPTOM
Check again.
OK or NG
OK >>INSPECTION END
NG >> GO TO 5.
5.CHECK DIFFERENTIAL LOCK CONTROL UNIT
Check differential lock control unit input/output signal. Refer toRFD-48, "
Differential Lock Control Unit Input/
Output Signal Reference Values".
OK or NG
OK >>INSPECTION END
NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.

SC-14
CHARGING SYSTEM
CHARGING SYSTEM
PFP:00011
System DescriptionEKS00MZA
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 4 through:
l15A fuse (No. 30, located in the fuse and fusible link box).
Terminal 1 supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is
controlled by the IC regulator at terminal 4 detecting the input voltage. The charging circuit is protected by the
140A fusible link (letter "A", located in the fuse and fusible link box) .
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
l10A fuse [No. 14, located in the fuse block (J/B)]
lto combination meter terminal 16 for the charge warning lamp.
Ground is supplied With power and ground supplied
lto terminal 2 of the combination meter
lthrough terminal 3 of the alternator.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.

TF-2
DIAGNOSTIC PROCEDURE .............................. 53
COMPONENT INSPECTION .............................. 54
Transfer Control Unit .............................................. 54
DIAGNOSTIC PROCEDURE .............................. 54
Output Shaft Revolution Signal (TCM) ................... 55
DIAGNOSTIC PROCEDURE .............................. 55
Vehicle Speed Sensor (ABS) .................................. 55
DIAGNOSTIC PROCEDURE .............................. 55
4LO Switch ............................................................. 56
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 56
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 56
DIAGNOSTIC PROCEDURE .............................. 57
COMPONENT INSPECTION .............................. 59
4WD Shift Switch .................................................... 59
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 59
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 59
DIAGNOSTIC PROCEDURE .............................. 60
COMPONENT INSPECTION .............................. 62
Wait Detection Switch ............................................. 63
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 63
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 63
DIAGNOSTIC PROCEDURE .............................. 64
COMPONENT INSPECTION .............................. 66
PNP Switch Signal (TCM) ...................................... 66
DIAGNOSTIC PROCEDURE .............................. 66
Actuator Motor ........................................................ 67
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 67
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 67
DIAGNOSTIC PROCEDURE .............................. 68
COMPONENT INSPECTION .............................. 74
Actuator Position Switch ......................................... 75
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 75
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 75
DIAGNOSTIC PROCEDURE .............................. 76
Transfer Control Device .......................................... 78
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 78
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 78
DIAGNOSTIC PROCEDURE .............................. 79
Engine Speed Signal (ECM) ................................... 81
DIAGNOSTIC PROCEDURE .............................. 81
CAN Communication Line ...................................... 82
DIAGNOSTIC PROCEDURE .............................. 82
ATP Switch ............................................................. 82
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 82
TRANSFER CONTROL UNIT TERMINALS ANDREFERENCE VALUE .......................................... 82
DIAGNOSTIC PROCEDURE ............................... 83
COMPONENT INSPECTION ............................... 85
Park/Neutral Position Switch ................................... 85
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 85
DIAGNOSTIC PROCEDURE ............................... 85
COMPONENT INSPECTION ............................... 87
TROUBLE DIAGNOSIS FOR SYMPTOMS .............. 88
4WD Shift Indicator Lamp and 4LO Indicator Lamp
Do Not Turn ON ...................................................... 88
SYMPTOM: .......................................................... 88
DIAGNOSTIC PROCEDURE ............................... 89
4WD Warning Lamp Does Not Turn ON ................. 91
SYMPTOM: .......................................................... 91
DIAGNOSTIC PROCEDURE ............................... 92
4WD Shift Indicator Lamp or 4LO Indicator Lamp
Does Not Change ................................................... 94
SYMPTOM: .......................................................... 94
DIAGNOSTIC PROCEDURE ............................... 95
ATP Warning Lamp Does Not Turn ON .................. 96
SYMPTOM: .......................................................... 96
DIAGNOSTIC PROCEDURE ............................... 96
4WD Shift Indicator Lamp Repeats Flashing .......... 98
SYMPTOM: .......................................................... 98
DIAGNOSTIC PROCEDURE ............................... 98
4WD Warning Lamp Flashes Slowly ....................... 99
SYMPTOM: .......................................................... 99
DIAGNOSTIC PROCEDURE ............................... 99
TRANSFER CONTROL UNIT .................................100
Removal and Installation .......................................100
REMOVAL ..........................................................100
INSTALLATION ..................................................100
FRONT OIL SEAL ...................................................101
Removal and Installation .......................................101
REMOVAL ..........................................................101
INSTALLATION ..................................................102
REAR OIL SEAL .....................................................103
Removal and Installation .......................................103
REMOVAL ..........................................................103
INSTALLATION ..................................................103
TRANSFER CONTROL DEVICE ............................105
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105
AIR BREATHER HOSE ...........................................107
Removal and Installation .......................................107
A/T MODELS .....................................................107
M/T MODELS .....................................................109
TRANSFER ASSEMBLY ......................................... 111
Removal and Installation ....................................... 111
REMOVAL .......................................................... 111
INSTALLATION ..................................................112
Disassembly and Assembly ..................................112
COMPONENTS .................................................112
DISASSEMBLY ..................................................114
INSPECTION AFTER DISASSEMBLY ..............119
ASSEMBLY ........................................................120

TF-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003ID
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 Transfer Assembly and Transfer Control Unit ReplacementEDS0031A
lWhen replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and
adjustment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf OK, the position between transfer assembly and transfer control unit is correct.
lIf NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Transfer position adjustment pattern
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.
SDIA3289E
4WD shift switch condition Refer procedure
4WD shift switch is under “2WD” condition when engine is being stopped.TF-5, "
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“2WD”"
4WD shift switch is under “4H” or “4LO” condition when engine is being stopped.TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“4H”OR“4LO”"

4WD SYSTEM
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4WD WARNING LAMP
Turns ON or flashes when there is a malfunction in 4WD system.
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ond after the engine starts if system is normal.
4WD Warning Lamp Indication
NOTE:
4WD warning lamp is turned on when the following one or more parts are malfunctioning.
lVehicle speed signal
[from ABS actuator and electric unit (control unit)]
lCAN communication line
lAD converter
lEngine speed signal
l4WD shift switch
lWait detection switch
lActuator motor
lTransfer control device
lTransfer shut off relay
lTransfer shift relay
lPNP switch signal
ATP WARNING LAMP (A/T MODELS)
When A/T selector lever is in “P” position, vehicle may move because A/T parking mechanism does not oper-
ate when transfer is under neutral condition. ATP warning lamp is turned on to indicate this condition to the
driver.
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.
4WD system malfunctionON
(For indicated malfunction items, see the “NOTE”)
During self-diagnosis Flashes at malfunction mode.
Large difference in diameter of front/
rear tiresSlow flashing: 1 time/2 seconds
(Continues to flash until ignition switch is turned OFF)
Other than above (system normal) OFF

4WD SYSTEM
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CAN CommunicationEDS0031N
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
For details, refer toLAN-23, "
CAN COMMUNICATION".
TCM
(A/T models)Transmits the following signal via CAN communication to Transfer control unit.lOutput shaft revolution signal
lA/T position indicator signal (PNP switch signal)
ECMTransmits engine speed signal via CAN communication to Transfer control unit.
lEngine speed signal Component parts Function

TF-38
TROUBLE DIAGNOSIS
Trouble Diagnosis Chart for Symptoms
EDS0031U
If 4WD warning lamp turns ON, perform self-diagnosis. Refer toTF-49, "Self-Diagnostic Procedure".
Transfer Control Unit Input/Output Signal Reference ValuesEDS0031V
TRANSFER CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II
Symptom Condition Check item Reference page
4WD shift indicator lamp and 4LO indicator
lamp do not turn ON
(4WD shift indicator lamp and 4LO indicator
lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-88
Transfer shut off relay
Combination meter
4WD warning lamp does not turn ON
(4WD warning lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-91
Transfer shut off relay
Combination meter
4WD shift indicator lamp or 4LO indicator
lamp does not changeEngine running4WD shift switch
TF-94
Wait detection switch
4LO switch
AT P s w i t c h
Transfer inner parts
ATP warning lamp does not turn ON Engine runningCAN communication line
TF-96
4WD shift switch
PNP switch signal
AT P s w i t c h
Combination meter
Transfer inner parts
4WD shift indicator lamp repeats flashing Engine runningWait detection switch
TF-98
4LO switch
Transfer inner parts
4WD warning lamp flashes slowly
Slow flashing: 1 time/2 secondsWhile drivingTire size is different between front and
rear of vehicle.TF-99
Monitored item [Unit] Content Condition Display value
VHCL/S SEN·FR [km/h]
or [mph]Wheel speed (Front wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
VHCL/S SEN·RR [km/h]
or [mph]Wheel speed (Rear wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
ENGINE SPEED [rpm] Engine speedEngine stopped
(Engine speed: Less than 400 rpm)0rpm
Engine running
(Engine speed: 400 rpm or more)Approximately
equal to the indica-
tion on tachometer
BATTERY VOLT [V]Power supply voltage for
transfer control unitIgnition switch: ON Battery voltage

TROUBLE DIAGNOSIS
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2WDSWITCH[ON/
OFF]Input condition from 4WD
shift switch4WD shift switch: 2WD ON
4WD shift switch: 4H and 4LO OFF
4H SWITCH [ON/OFF]Input condition from 4WD
shift switch4WD shift switch: 4H ON
4WD shift switch: 2WD and 4LO OFF
4L SWITCH [ON/OFF]Input condition from 4WD
shift switch4WD shift switch: 4LO ON
4WD shift switch: 2WD and 4H OFF
4L POSI SW [ON/OFF] Condition of 4LO switch
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch: 4LO ON
Except the above OFF
ATP SWITCH [ON/OFF] Condition of ATP switch
lVehicle stopped
lEngine running
lA/T selector lever “N”
position with brake
pedal depressed.4WD shift switch:
4H to 4LO or 4LO to 4H
(While actuator motor is
operating.)ON
Except the above OFF
WAIT DETCT SW [ON/
OFF]Condition of wait detection
switch
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
4H and 4LOON
4WD shift switch: 2WD OFF
4WD MODE [2H/4H/4L]Control status of 4WD
(Output condition of 4WD
shift indicator lamp and
4LO indicator lamp)4WD shift switch
(Engine running)2WD 2H
4H 4H
4LO 4L
VHCL/S COMP [km/h]
or [mph]Vehicle speedVehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tires under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
SHIFT ACT 1 [ON/OFF]Output condition to actua-
tor motor (clockwise)
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
2WDto4Hor4Hto4LO
or 2WD to 4LOON
Except the above OFF Monitored item [Unit] Content Condition Display value

TF-40
TROUBLE DIAGNOSIS
SHIFT AC MON1 [ON/
OFF]Check signal for transfer
control unit signal output
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
2WDto4Hor4Hto4LO
or 2WD to 4LOON
Except the above OFF
SHIFT ACT 2 [ON/OFF]Output condition to actua-
tor motor (counterclock-
wise)
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
4LOto4Hor4Hto2WD
or 4LO to 2WDON
Except the above OFF
SHIFT AC MON2 [ON/
OFF]Check signal for transfer
control unit signal output
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
4LOto4Hor4Hto2WD
or 4LO to 2WDON
Except the above OFF
SHIFT ACT/R MON
[ON/OFF]Operating condition of
actuator motor relay (inte-
grated in transfer control
unit)
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.When 4WD shift switch is
operatedON
When 4WD shift switch is
not operatedOFF
SHIFT POS SW1 [ON/
OFF]Condition of actuator posi-
tion switch 1
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
2WD and 4LOON
4WD shift switch: 4H OFF
SHIFT POS SW2 [ON/
OFF]Condition of actuator posi-
tion switch 24WD shift switch: 4LO ON
4WD shift switch:
2WD and 4HOFF
SHIFT POS SW3 [ON/
OFF]Condition of actuator posi-
tion switch 34WD shift switch:
2WD and 4HON
4WD shift switch: 4LO OFF
SHIFT POS SW4 [ON/
OFF]Condition of actuator posi-
tion switch 44WD shift switch:
4H and 4LOON
4WD shift switch: 2WD OFF
4WD FAIL LAMP [ON/
OFF]4WD warning lamp condi-
tion4WD warning lamp: ON ON
4WD warning lamp: OFF OFF Monitored item [Unit] Content Condition Display value

TROUBLE DIAGNOSIS
TF-41
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TFSpecifications Between Transfer Control Unit Terminals
TRANSFER CONTROL UNIT TERMINAL CONNECTOR LAYOUT
NOTE:
Data are reference value and are measured between each terminal and ground.
2WD IND [ON/OFF]Rear indicator of 4WD shift
indicator lamp conditionRear indicator of 4WD shift indicator lamp: ON ON
Rear indicator of 4WD shift indicator lamp: OFF OFF
4H IND [ON/OFF]Front and center indicator
of 4WD shift indicator lamp
conditionFront and center indicator of 4WD shift indicator lamp:
ONON
Front and center indicator of 4WD shift indicator lamp:
OFFOFF
4L IND [ON/OFF]4LO indicator lamp condi-
tion4LO indicator lamp: ON ON
4LO indicator lamp: OFF OFF Monitored item [Unit] Content Condition Display value
SDIA3402E
TerminalWire
colorItem Condition Data (Approx.)
1 L CAN-H – –
2 P CAN-L – –
3 SB K-LINE (CONSULT-II signal) – –
6 B Ground Always 0V
10 LG Actuator position switch 1
lVehicle stopped
lEngine running
lFor A/T models,
A/T selector
lever “N” position
with brake pedal
depressed.
lFor M/T models,
M/T shift lever
neutral position
with clutch and
brake pedal
depressed.4WD shift switch: 2WD and 4LO 0V
4WD shift switch: 4H Battery voltage
11 W Actuator position switch 24WD shift switch: 4LO 0V
4WD shift switch: 2WD and 4H Battery voltage
12 BR Actuator position switch 34WD shift switch: 2WD and 4H 0V
4WD shift switch: 4LO Battery voltage
13 V Actuator position switch 44WD shift switch: 4H and 4LO 0V
4WD shift switch: 2WD Battery voltage
14 G 4WD shift switch (2WD)
Ignition switch: ON4WD shift switch: 2WD Battery voltage
4WD shift switch: 4H and 4LO 0V
15 O 4WD shift switch (4H)4WD shift switch: 4H Battery voltage
4WD shift switch: 2WD and 4LO 0V
16 W 4WD shift switch (4LO)4WD shift switch: 4LO Battery voltage
4WD shift switch: 2WD and 4H 0V