power steering NISSAN NAVARA 2005 Repair Owner's Guide

HOW TO USE THIS MANUAL
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AbbreviationsEAS001GZ
The followingABBREVIATIONSare used:
ABBREVIATION DESCRIPTION
A/C Air Conditioner
A/T Automatic Transaxle/Transmission
ATF Automatic Transmission Fluid
D
1Drive range 1st gear
D
2Drive range 2nd gear
D
3Drive range 3rd gear
D
4Drive range 4th gear
FR, RR Front, Rear
LH, RH Left-Hand, Right-Hand
M/T Manual Transaxle/Transmission
OD Overdrive
P/S Power Steering
SAE Society of Automotive Engineers, Inc.
SDS Service Data and Specifications
SST Special Service Tools
2WD 2-Wheel Drive
2
22nd range 2nd gear
2
12nd range 1st gear
1
21st range 2nd gear
1
11st range 1st gear

TOW TRUCK TOWING
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TOW TRUCK TOWINGPFP:00000
To w Tr u c k To w i n gEAS001DI
WARNING:
lNever get under the vehicle while it is supported only by the jack. Always use safety stands to
support the frame when you have to get under the vehicle.
lPlace wheel chocks at both front and back of the wheels on the ground.
CAUTION:
lAll applicable local laws regarding the towing operation must be obeyed.
lIt is necessary to use proper towing equipment to avoid possible damage during towing opera-
tion. Towing is in accordance with Towing Procedure Manual at dealer.
lAlways attach safety chains before towing.
lWhen towing, make sure that the transmission, steering system and powertrain are in good order.
If any unit is damaged, dollies must be used.
lNever tow an automatic transmission model from the rear
(i.e., backward) with four wheels on the ground as this may
cause serious and expensive damage to the transmission.
4X2 MODEL
NISSAN does not recommend towing automatic transmission
equipped vehicles with the drive wheels on the ground.
CAUTION:
lWhen towing with the front wheels on the ground: Turn the
ignition key to the OFF position and move the transmission
selector lever to N (neutral) position, turn the ignition key to
OFF position and secure the steering wheel in a straight
ahead position with a rope or similar device. Never place
the ignition key in the LOCK position. This will result in
damage to the steering lock mechanism.
Observe the following restricted towing speeds and distances.
AGI077
Speed : Below 50 km/h (30 MPH)
Distance : Less than 65 km (40 miles)
SGI976

IDX-6
ALPHABETICAL INDEX
P
P/SCKT - Wiring diagram ................................WW-57
Park/Neutral position switch ............................EC-342
Park/neutral position switch (A/T) ......................AT-99
Park/neutral position switch (M/T) ........MT-12,MT-19
Parking brake control ...........................................PB-2
Personal lamp ...................................................LT-145
Pilot bushing replacement ..............................EM-111
Piston pin inspection .......................................EM-125
Piston ring inspection ......................................EM-126
Piston to bore clearance .................................EM-129
Planetary carrier (Transfer) ..............................TF-129
PNP/SW - Wiring diagram ...............................EC-343
POWER - Wiring diagram ....................................PG-5
Power seat .........................................................SE-10
Power steering fluid level ..................................MA-37
Power steering gear ...........................................PS-14
Power steering oil pump ....................................PS-25
Power steering system bleeding ..........................PS-6
Power supply routing ...........................................PG-4
Power window ...................................................GW-15
Precations for Leak detection dye ....ATC-14,MTC-14
Precautions (General) ...........................................GI-4
Pre-delivery inspection .......................................MA-5
Pressure plate - See Clutch cover .....................CL-17
Pressure switch 1 ..............................AT-139,AT-156
Pressure switch 2 ............................................AT-154
Pressure switch 3 ..............................AT-134,AT-158
Pressure switch 5 ..............................AT-144,AT-160
Pressure switch 6 ..............................AT-149,AT-162
Pressure test (A/T) .............................................AT-44
Priming pump .....................................................EC-23
Propeller shaft ............................................PR-3,PR-7
Propeller shaft inspection .................................MA-32
Propeller shaft on vehicle service ........................PR-7
Propeller shaft vibration .............................PR-3,PR-7
Q
Quick-glow system ...........................................EC-295
R
R/FOG - Wiring diagram .....................................LT-89
Radiator ................................................CO-11,CO-15
Rear bumper .......................................................EI-17
Rear case (Transfer) ...........................TF-114,TF-120
Rear combination lamp removal and installation ..........
LT-144
Rear cover packing replacement diff. ..............FFD-14
Rear door ..........................................................GW-38
Rear seat ...........................................................SE-29
Rear seat belt ............................................SB-7,SB-9
Rear window .....................................................GW-43
Rear window defogger ......................................GW-47
Refrigerant connection precaution ........ATC-5,MTC-5
Refrigerant discharging evacuating chargingATC-138,
MTC-118
Refrigerant general precaution ............ATC-5,MTC-5
Refrigerant lines ...........ATC-138,ATC-146,ATC-147,
MTC-118
,MTC-126,MTC-127
Refrigerant pressure sensor ............EC-325,ATC-92,
ATC-147
,MTC-85,MTC-127
Refrigeration cycle ...........................ATC-20,MTC-20
Relay box ..........................................................PG-85
Removal and installation (A/T) .........................AT-247
Removal and installation (Transfer) .................TF-111
Reverse idler shaft (M/T) ..................................MT-21
Reverse lamp switch (M/T) - See Back-up lamp switch
(M/T) .....................................................MT-12
,MT-19
Reverse main gear (M/T) ..................................MT-21
Revolution sensor (A/T) .....................AT-103,AT-238
Road wheel size .................................................GI-60
Rocker cover .....................................................EM-56
Room lamp ......................................................LT-145
Room lamp - See Interior lamp ........................LT-145
ROOM/L - Wiring diagram ...............................LT-149
RP/SEN - Wiring diagram ................................EC-326
S
S/SIG - Wiring diagram ....................................EC-348
SCTC/V - Wiring diagram ................................EC-219
SEAT - Wiring diagram ..........................SE-10,SE-11
Seat belt inspection ..............................SB-11,MA-40
Seat belt pre-tensioner ...................................SRS-47
Seat belt pre-tensioner disposal .....................SRS-49
Seat belt, front ...........................................SB-3,SB-5
Seat belt, rear ............................................SB-7,SB-9
Seat, front ..........................................................SE-20
Seat, rear ...........................................................SE-29
Self-diagnosis (Transfer) ...................................TF-49
SHIFT - Wiring diagram ...................................AT-213
Shift control (Transfer) .....................................TF-135
Shift control components (M/T) .........................MT-23
Shift fork (M/T) ..................................................MT-23
Shift lever ..........................................................MT-13
Shift lock system ..............................................AT-212
Shock absorber (front) ....................................FSU-11
Shock absorber (rear) .......................................RSU-6
Side air bag .....................................................SRS-43
Side air bag (satellite) sensor .........................SRS-46
Side curtain air bag .........................................SRS-44
Side trim ..............................................................EI-33
SMJ (super multiple junction) ...........................PG-81
Spare tire size .....................................................GI-60
Speedometer ........................................................DI-4
Spiral cable .....................................................SRS-38
SROOF - Wiring diagram ...................................RF-14
SRS - See Supplemental Restraint System .....SRS-6
SRS - Wiring diagram .....................................SRS-13
SRS Trouble diagnoses ....................................SRS-9
Stabilizer bar (front) ........................................FSU-12
Stall test (A/T) ....................................................AT-43
Standardized relay ............................................PG-79
START - Wiring diagram ....................................SC-28
Start signal .......................................................EC-348

INSTRUMENT PANEL ASSEMBLY
IP-13
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LOWER INSTRUMENT PANEL LH
Removal
1. Remove LH front kick plate.
2. Remove lower dash side finisher. Refer toEI-34, "
Removal".
3. Remove front pillar finisher. Refer toEI-35, "
Removal".
4. Remove screws using power tool, and remove lower instrument
panel LH.
5. Pull rearward to release clips, disconnect connectors, and
remove lower instrument panel LH.
Installation
Installation is in the reverse order of removal.
COMBINATION METER
Removal
1. Disconnect the negative battery cable.
2. Remove the lower instrument panel LH. Refer toIP-13, "
LOWER INSTRUMENT PANEL LH".
3. Remove cluster lid A.
4. Remove screws using power tool and remove the combination meter assembly.
lDisconnect electrical connectors.
Installation
Installation is in the reverse order of removal.
MIIB9139E
1. Combination meter 2. Screws 3. Cluster lid A
4. Ignition key lamp assembly 5. Steering lock escutcheon 6. Screw
MIIB9140E

MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTIONMA
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MAINTENANCE
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
DESCRIPTION ............................................................ 5
Pre-Delivery Inspection Items .................................. 5
GENERAL MAINTENANCE ....................................... 7
General Maintenance ............................................... 7
PERIODIC MAINTENANCE ....................................... 8
Periodic Maintenance ............................................... 8
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD25DDTI DIESEL ENGINE) ................ 8
CHASSIS AND BODY MAINTENANCE
(YD25DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD25DDTI DIESEL ENGINE) ............... 11
CHASSIS AND BODY MAINTENANCE
(YD25DDTI DIESEL ENGINE) ............................. 11
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 13
RECOMMENDED FLUIDS AND LUBRICANTS ...... 14
Fluids and Lubricants ............................................. 14
SAE Viscosity Number ........................................... 15
DIESEL ENGINE ................................................. 15
GEAR OIL ........................................................... 15
Engine Coolant Mixture Ratio ................................ 16
ENGINE MAINTENANCE ......................................... 17
Checking Drive Belts .............................................. 17
Deflection Adjustment ............................................ 18
POWER STEERING OIL PUMP BELT ............... 18
A/C COMPRESSOR, ALTERNATOR AND
WATER PUMP BELT .......................................... 19
Changing Engine Coolant ...................................... 19
DRAINING ENGINE COOLANT ......................... 19
REFILLING ENGINE COOLANT ........................ 20FLUSHING COOLING SYSTEM ......................... 21
Checking Cooling System ...................................... 21
CHECKING COOLING SYSTEM HOSES ........... 21
CHECKING RADIATOR ...................................... 21
CHECKING RESERVOIR TANK CAP ................. 21
CHECKING RADIATOR SYSTEM FOR LEAKS... 22
Checking Fuel Lines ............................................... 23
Changing Fuel Filter ............................................... 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 24
Draining Water from Fuel Filter .............................. 25
Changing Engine Air Cleaner Filter ........................ 25
DRY PAPER TYPE .............................................. 25
Changing Engine Oil ............................................... 25
Changing Oil Filter .................................................. 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
INSPECTION AFTER INSTALLATION ................ 27
CHASSIS AND BODY MAINTENANCE ................... 28
Checking the Exhaust System ................................ 28
Checking Clutch Fluid Level and Leaks ................. 28
Checking Clutch System ........................................ 28
Checking M/T Oil .................................................... 28
Changing M/T Oil .................................................... 29
Checking A/T Fluid ................................................. 29
Changing A/T Fluid ................................................. 31
Checking Transfer Fluid ......................................... 31
FLUID LEAKAGE AND FLUID LEVEL ................ 31
Changing Transfer Fluid ......................................... 32
DRAINING ........................................................... 32
FILLING ............................................................... 32
Checking Propeller Shaft ........................................ 32
Checking Front Final Drive Oil (Front Differential
Gear Oil) ................................................................. 32
OIL LEAKAGE AND OIL LEVEL ......................... 32
Changing Front Final Drive Oil (Front Differential
Gear Oil) ................................................................. 33
DRAINING ........................................................... 33
FILLING ............................................................... 33

MA-2
Checking Rear Final Drive Oil (Rear Differential
Gear Oil) ................................................................. 33
OIL LEAKAGE AND OIL LEVEL ......................... 33
Changing Rear Final Drive Oil (Rear Differential
Gear Oil) ................................................................. 34
DRAINING ........................................................... 34
FILLING ............................................................... 34
Balancing Wheels ................................................... 34
Tire Rotation ........................................................... 34
Checking Brake Fluid Level and Leaks .................. 35
Checking Brake Lines and Cables ......................... 35
Changing Brake Fluid ............................................. 35
Checking Disc Brake .............................................. 35
ROTOR ................................................................ 35
CALIPER ............................................................. 36
PAD ..................................................................... 36
Checking Drum Brake ............................................ 36
DRUM .................................................................. 36
WHEEL CYLINDER ............................................. 36
LINING ................................................................. 37
Checking Steering Gear and Linkage ..................... 37
STEERING GEAR ............................................... 37
STEERING LINKAGE .......................................... 37
Checking Power Steering Fluid and Lines .............. 37CHECKING FLUID LEVEL .................................. 37
CHECKING LINES ............................................... 37
Checking Axle and Suspension Parts ..................... 38
FRONT AND REAR AXLE AND SUSPENSION
PARTS ................................................................. 38
FRONT DRIVE SHAFT ........................................ 38
Lubricating Locks, Hinges and Hood Latches ......... 39
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 40
Checking Body Corrosion ....................................... 40
HEMMED PANELS .............................................. 40
PANEL JOINT ...................................................... 40
PANEL EDGE ...................................................... 40
PARTS CONTACT ............................................... 40
PROTECTORS .................................................... 40
ANTI-CORROSION MATERIALS ........................ 40
DRAIN HOLES ..................................................... 40
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 41
Standard and Limit .................................................. 41
BELT DEFLECTION ............................................ 41
RESERVOIR TANK ............................................. 41
ENGINE COOLANT CAPACITY (APPROXI-
MATE) .................................................................. 41
ENGINE OIL CAPACITY (APPROXIMATE) ........ 41

DESCRIPTION
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DESCRIPTIONPFP:00000
Pre-Delivery Inspection ItemsELS001K2
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)

PERIODIC MAINTENANCE
MA-9
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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.
*1: Replace at 60,000 km (36,000 miles) or 24 months, whichever comes first.
*2: Replace at 120,000 km (72,000 miles) or 48 months, whichever comes first.
NOTE:
l(1) Inspect once per year.
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles) or months,
whichever comes first.km x 1,000
(Miles x 1,000)
Months30
(18)
2460
(36)
4890
(54)
72120
(72)
96
Underhood and under vehicle
Headlampaiming IIIILT- 2 8
Brake&clutch,systemsandfluid(Forlevel&leaks) IIIIMA-35,
MA-28
Brake fluidRRRRMA-35
Brakeboostervacuumhoses,connections&checkvalve IIIIBR-22
Powersteeringfluid&lines(Forlevel&leaks) IIIIMA-37
Manual transmission gear oil (For leaks)IIIIMA-28
Automatic transmission fluid (For level & leaks)IIIIMA-29
Transferfluid(Forlevel&leaks) IIIIMA-31
Differential gear oil (For level & leaks or replace)IIIIMA-32,
MA-33
Limited-slip differential (LSD) gear oil
(for level and leaks)IIIIMA-33
Limited-slip differential (LSD) gear oil (for replace)R*1R*2MA-34
Steering gear & linkage, axle & suspension parts, propeller
shaft, drive shafts & exhaust systemIIIIMA-37
,
MA-38
,
MA-32
,
MA-38
,
MA-28
Wheelalignment(Ifnecessary,rotate&balancewheels) IIIIFSU-7,
MA-34
Brake pads, rotors & other brake componentsIIIIMA-36
,
MA-35
,
MA-36
Brake linings, drums & other brake & componentsIIIIMA-37
,
MA-36
,
MA-36
Foot brake, parking brake & clutch (For free play, stroke &
operation)IIIIBR-6,
PB-2
,
CL-6
Air conditioner filterRRRRATC-122,
MTC-101
Body corrosionSee
NOTE (1)MA-40

PERIODIC MAINTENANCE
MA-11
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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-14
RECOMMENDED FLUIDS AND LUBRICANTS
RECOMMENDED FLUIDS AND LUBRICANTS
PFP:00000
Fluids and LubricantsELS001JA
*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Genuine NISSAN Anti-freeze Coolant (L250) or equivalent in its quality, in order to avoid possible aluminum corrosion within the
engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRON
™III/MER-
CON™ Automatic Transmission Fluid.
*5:Using automatic transmission fluid other than Genuine NISSAN ATF Matic Fluid J will cause deterioration in driveability
and automatic transmission durability, and may damage the automatic transmission, which is not covered by the warranty.
*6: DEXRON™III type ATF can be used.
*7: Never mix different types of fluids (DOT 3 and DOT 4).Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refillWith oil filter change 7.6 6-5/8 qt
lDiesel engine
API CF-4*1, *2
ACEA B1, B3, B4, B5*1 Without oil filter change 7.1 6-1/4 qt
Dry engine (engine overhaul) 7.9 7 qt
Cooling sys-
tem (with res-
ervoir)LHD models 9.9 8-3/4 qt
lGenuine NISSAN Anti-freeze Coolant (L250) or
equivalent in its quality*3 RHD models 10.2 9 qt
Reservoir tank 0.8 3/4 qt
Manual transmission gear oil2WD 3.99 7 pt
lGenuine NISSAN gear oil or API GL-4, Viscosity
SAE 75W-85 or 75W-90
4WD 4.32 7-5/8 pt
Transfer fluid 2.0 1-3/4 qt
lGenuine NISSAN ATF or equivalent*4
Differential gear oilFront 0.85 1-1/2 pt
lStandard differential gear:
Gear Oil Hypoid LSD (Part No.: KLD31-8090403)
or API GL-5, Viscosity SAE 80W-90*1
lLimited-slip differential (LSD) gear:
Gear Oil Hypoid LSD (Part No. KLD31-8090403)
or equivalent Rear 2.01 3-1/2 pt
Automatic transmission fluid 10.3 9-1/8 qt Genuine NISSAN ATF Matic Fluid J*5
Power steering fluid — — Genuine NISSAN PSF or equivalent*6
Brake and clutch fluid — —
lDOT 3 or DOT 4 (US FMVSS No. 116)*7
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)