boot NISSAN NAVARA 2005 Repair Owner's Manual

IP-1
INSTRUMENT PANEL
IBODY
CONTENTS
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SECTIONIP
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IP
INSTRUMENT PANEL
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions for SRS “AIR BAG” and “SEAT BELT
PRE-TENSIONER” Service ..................................... 2
PREPARATION ........................................................... 3
Commercial Service Tools ........................................ 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 ....................................... 5
Generic Squeak and Rattle Troubleshooting ........... 6
INSTRUMENT PANEL .......................................... 6
CENTER CONSOLE ............................................. 6
DOORS ................................................................. 6TRUNK .................................................................. 6
SUNROOF/HEADLINING ..................................... 7
OVERHEAD CONSOLE (FRONT AND REAR)..... 7
SEATS ................................................................... 7
UNDERHOOD ....................................................... 7
Diagnostic Worksheet ............................................... 8
INSTRUMENT PANEL ASSEMBLY ......................... 10
Removal and Installation ........................................ 10
INSTRUMENT PANEL ........................................ 10
CLUSTER LID C ................................................. 11
CLUSTER LID D ................................................. 12
LOWER INSTRUMENT PANEL LH ..................... 13
COMBINATION METER ...................................... 13
A/T CONTROL FINISHER (A/T) .......................... 14
CONSOLE BOOT M/T ........................................ 14
LOWER INSTRUMENT PANEL RH AND GLOVE
BOX ..................................................................... 15
CENTER CONSOLE ........................................... 16
Disassembly and Assembly .................................... 17
CENTER CONSOLE ........................................... 17

IP-12
INSTRUMENT PANEL ASSEMBLY
Removal - with NAVI
1. Remove A/T control finisher, or console boot M/T. Refer toIP-14, "A/T CONTROL FINISHER (A/T)",or
Refer toIP-14, "
CONSOLE BOOT M/T".
2. Pull cluster lid C rearward to release clips.
3. Disconnect electrical connectors and remove cluster lid C.
Installation - with NAVI
Installation is in the reverse order of removal.
CLUSTER LID D
Removal
1. Remove center console. Refer toIP-16, "CENTER CONSOLE".
2. Remove lower instrument panel LH. Refer toIP-13, "
LOWER INSTRUMENT PANEL LH".
3. Remove glove box lower. Refer toIP-15, "
LOWER INSTRUMENT PANEL RH AND GLOVE BOX".
4. Disconnect the electrical connectors and remove cluster lid D.
Installation
Installation is in the reverse order of removal.
1. Instrument panel 2. Cluster lid C
MIIB9079E
WIIA0564E
1. Cluster lid D 2. Screws

IP-14
INSTRUMENT PANEL ASSEMBLY
A/T CONTROL FINISHER (A/T)
1. Remove cup holder finisher.
2. Remove finisher, from A/T control finisher.
3. Pull up to release clips and remove the A/T finisher.
Installation
Installation is in the reverse order of removal.
CONSOLE BOOT M/T
1. Remove cup holder finisher.
2. Remove M/T finisher bezel.
3. Pull up to release clips and remove the M/T finisher.
Installation
Installation is in the reverse order of removal.
LIIA1941E
LIIA1942E

MA-38
CHASSIS AND BODY MAINTENANCE
Checking Axle and Suspension Parts
ELS001J5
FRONT AND REAR AXLE AND SUSPENSION PARTS
Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage.
lShake each wheel to check for excessive play.
lRotate each wheel to check for abnormal noise.
lCheck axle and suspension nuts and bolts for looseness.
lCheck the strut and shock absorber for oil leakage or other damage.
lCheck suspension ball joints for grease leakage and ball joint dust cover for cracks or other damage.
FRONT DRIVE SHAFT
Check the boots and drive shaft for cracks, wear, damage, and
grease leakage.
SMA525A
SFA901

SHIFT CONTROL
MT-13
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SHIFT CONTROLPFP:34103
Removal and InstallationECS00ID7
COMPONENTS
REMOVAL
1. Remove console boot. Refer toIP-14, "CONSOLE BOOT M/T".
2. Remove shift knob.
3. Remove cover mounting bolts and then remove cover, control lever boot and insulator.
4. Remove clip (B) and then separate boot from control housing.
5. Remove guide plate mounting bolts and then separate guide plate.
6. Remove control lever assembly and spring from the transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
1. Cover 2. Control lever boot 3. Insulator
4. Shift knob 5. Control lever assembly 6. Clip (A)
7. Boot 8. Guide plate 9. Socket
10. Bushing 11. Clip (B) 12. Spring
PCIB1634E

MT-14
SHIFT CONTROL
lInstall shift knob according to the following.
–Apply cement to threads of control lever assembly.
–Tightening shift knob until reacting. Then align shift knob to the
position as shown in the figure within one turn.
CAUTION:
Do not adjust shift knob with loosing.
CAUTION:
lInsert bushing of control lever assembly to the hole of striking arm as far as bushing goes.
lApply multi-purpose grease to socket and bushing.
lBe careful with the orientation guide plate and boot.
lTighten guide plate mounting bolts to the specified torque.
lBe careful with the orientation clip.
lDo not reuse clip.
lBe careful with the orientation control lever boot and insu-
lator.
INSPECTION AFTER INSTALLATION
After installing, confirm the following items:
lWhen control lever assembly is shifted to each position, make sure there is no binding or disconnection in
each boot.
lWhen shifted to each position, make sure there is no noise, catching, and backlash. Especially when con-
trol lever assembly is shifted to 5th, 6th without pressing downward, check for catching.
lWhen control lever assembly is shifted to 1st, 2nd side and 5th, 6th side, confirm control lever assembly
returns to neutral position smoothly.
lIn any position other than reverse, confirm that control lever assembly can be pressed downward.
lWith control lever assembly pressed downward, confirm that it can be shifted to reverse.
lWhen shifted from reverse to neutral position, confirm control lever assembly returns to neutral position
smoothly with spring power.
lWithout control lever assembly pressed downward, confirm that it cannot be shifted to reverse.
PCIB1435E
PCIB1434E

PS-6
POWER STEERING FLUID
POWER STEERING FLUID
PFP:KLF20
Checking Fluid LevelEGS001LD
lCheck fluid level with engine stopped.
lMake sure that fluid level is between MIN and MAX.
lFluid levels at HOT and COLD are different. Do not confuse
them.
CAUTION:
lThe fluid level should not exceed the MAX line. Excessive
fluid will cause fluid leakage from the cap.
lDo not reuse drained power steering fluid.
lRecommended fluid is Type DEXRONTMIII or equivalent.
Checking Fluid LeakageEGS001LE
Check hydraulic connections for fluid leakage, cracks, damage,
looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80°C(122
to 176°F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right
stop.
3. Hold steering wheel at each lock position for five seconds and
carefully, check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 10 seconds. (There is the possibility that oil pump may
be damaged.)
4. If fluid leakage at connections is noticed, then loosen flare nut and then retighten. Do not over-tighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer toPS-25, "
POWER STEERING OIL
PUMP".
6. Check steering gear boots for accumulation of fluid, indicating from steering gear.
Air Bleeding Hydraulic SystemEGS001LF
If air bleeding is not complete, the following symptoms can be observed.
lBubbles are created in reservoir tank.
lClicking noise can be heard from oil pump.
lExcessive buzzing in the oil pump
NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of
the system.
1. Turn steering wheel several times from full left to full right stop with engine off.
CAUTION:
Turn steering wheel while filling reservoir tank with fluid so as not to lower fluid level below the
MIN line.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
3. Repeat step 2 above several times at approximately 3 second intervals.
CAUTION:
Do not hold the steering wheel in a locked position for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and while contamination.HOT : Fluid temperature 50 - 80°C (122 - 176°F)
COLD : Fluid temperature 0 - 30°C(32-86°F)
SGIA0232J
SGIA0506E

STEERING COLUMN
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STEERING COLUMNPFP:48810
Removal and InstallationEGS001LI
COMPONENT
CAUTION:
lDo not give axial impact to steering column assembly during removal and installation.
lDo not move steering gear assembly when removing steering column assembly.
REMOVAL
1. Set vehicle to the straight ahead-position.
2. Remove driver air bag module. Refer toSRS-36, "
DRIVER AIR BAG MODULE".
3. Remove steering wheel. Refer toPS-10, "
Removal and Installation".
4. Remove steering column cover (upper and lower). Refer toIP-10, "
INSTRUMENT PANEL ASSEMBLY".
5. Remove combination switch & spiral cable. Refer toSRS-38, "
SPIRAL CABLE".
6. Remove lower instrument panel LH. Refer toIP-10, "
INSTRUMENT PANEL ASSEMBLY".
7. Disconnect each switch connectors installed to steering column assembly, and then disconnect harness
from steering column assembly.
8. Remove fixing bolt of upper joint (steering column assembly side), and then remove upper joint from
steering column assembly.
1. Steering wheel 2. Combination switch & spiral cable 3. Steering column assembly
4. Upper joint 5. Collar 6. Hole cover seal
7. Clamp 8. Hole cover mounting plate 9. Hole cover
10. Upper shaft 11. Boot clamp 12. Lower shaft
13. Boot 14. Clips (plastic) 15. Spring
Refer toGI-10, "
Components"for the symbols in the figure.
SGIA1221E

PS-14
POWER STEERING GEAR AND LINKAGE
POWER STEERING GEAR AND LINKAGE
PFP:49001
Removal and InstallationEGS001LJ
COMPONENT
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning.
REMOVAL
1. Set vehicle to the straight-ahead position.
2. Remove tyres from vehicle with a power tool.
3. Remove undercover from vehicle with a power tool.
4. Remove lower side fixing bolt of lower shaft.
5. Remove cotter pin (1), and then loosen the nut.
6. Remove steering outer socket (2) from steering knuckle (3) so
as not to damage ball joint boot (4) using the ball joint remover
(suitable tool).
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover (suitable tool) from
suddenly coming off.
1. Cotter pin 2. Steering gear assembly 3. Rack mounting bracket
4. Rack mounting insulator 5. Washer 6. RHD models
Refer toGI-10, "
Components"for the symbols in the figure.
SGIA1315E
SGIA1183E

PS-16
POWER STEERING GEAR AND LINKAGE
Disassembly and Assembly
EGS001LK
COMPONENT
CAUTION:
lDisassemble and assemble steering gear assembly by securing the mounting area in a vise using
copper plates.
lClean steering gear assembly with kerosene before disassembling. Be careful to avoid splashing
or applying any kerosene over connector of discharge port or return port.
1. Outer socket 2. Boot clamp 3. Boot
4. Inner socket 5. Boot clamp 6. Gear housing assembly
7. Cylinder tubes 8. Rear cover cap 9. Rear cover
10. O-ring A 11. Pinion assembly 12. Rack oil seal
13. Rack assembly 14. Rack Teflon ring 15. O-ring B
16. End cover assembly
Refer toGI-10, "
Components"and the followings for the symbols in the figure.
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Apply Type DEXRON
TMIII or equivalent.
:A p p l y G e n u i n e T h r e a d L o c k i n g S e a l a n t , T h r e e B o u n d T B 1111 o r e q u i v a l e n t .
:Apply multi-purpose grease.
SGIA1349E