ignition NISSAN NAVARA 2005 Repair Workshop Manual

PRECAUTIONS
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PRECAUTIONSPFP:00001
DescriptionEAS001GG
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EAS001GH
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 NATS (NISSAN ANTI-THEFT SYSTEM)EAS001GI
NATS will immobilize the engine if someone tries to start it without the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
lWhen NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.
lWhen servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-
II operation manual, NATS.
Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly con-
fidential to maintain the integrity of the anti-theft function.
lWhen servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to
receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS.
lWhen failing to start the engine first time using the key of NATS, start as follows.
1. Leave the ignition key in "ON" position for approximately 5 seconds.
2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds.
3. Repeat step 1 and 2 again.
4. Restart the engine while keeping the key separate from any others on key-chain.
Precautions Necessary for Steering Wheel Rotation After Battery DisconnectEAS001HY
NOTE:
lThis Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
lRemove and install all control units after disconnecting both battery cables with the ignition knob in the
²LOCK²position.
lAlways use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.

GI-4
PRECAUTIONS
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the²ACC²position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the²LOCK²position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
General PrecautionsEAS001GJ
lDo not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
lBefore jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.
lWhen removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance and
drop them. Also, do not allow them to strike adjacent parts,
especially the brake tubes and master cylinder.
lBefore starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
lIf the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
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SGI231
SEF289H

PRECAUTIONS
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lTo prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
lDispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
lDo not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.
lClean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
lReplace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
lReplace inner and outer races of tapered roller bearings and needle bearings as a set.
lArrange the disassembled parts in accordance with their assembled locations and sequence.
lDo not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
lAfter disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
lUse only the fluids and lubricants specified in this manual.
lUse approved bonding agent, sealants or their equivalents when required.
lUse tools and recommended special tools where specified for safe and efficient service repairs.
lWhen repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
lBefore servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for Three Way CatalystEAS001GL
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
lUse unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
lWhen checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
lDo not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS001GM
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
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SGI234

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PRECAUTIONS
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
lAbove –7°C(20°F) ... Summer type diesel fuel.
lBelow –7°C(20°F) ... Winter type diesel fuel.
CAUTION:
lDo not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
lDo not use summer fuel at temperatures below –7°C(20°F). The cold temperatures will cause wax
to form in the fuel. As a result, it may prevent the engine from running smoothly.
lDo not add gasoline or other alternate fuels to diesel fuel.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS001GN
lBefore connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS001GO
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
lAlways use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
lAvoid accelerating engine to a high rpm immediately after start-
ing.
lIf engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS001GP
HOSE REMOVAL AND INSTALLATION
lTo prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
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HOW TO USE THIS MANUAL
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How to Follow Trouble DiagnosesEAS001GX
DESCRIPTION
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
1.Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the
“Work Flow”.
2.After repairs, re-check that the problem has been completely eliminated.
3.Refer to Component Parts and Harness Connector Location for the Systems described in each
section for identification/location of components and harness connectors.
4.Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness connectors in more detail, such as when a
sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG
section for identification of harness connectors.
5.When checking circuit continuity, ignition switch should be OFF.
6.Before checking voltage at connectors, check battery voltage.
7.After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure
that all harness connectors are reconnected as they were.
HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES
1.Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed test groups.
2.Questions and required results
Questions and required results are indicated in bold type in test group.
The meaning of are as follows:
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HOW TO USE THIS MANUAL
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Harness Indication
lLetter designations next to test meter probe indicate harness
(connector) wire color.
lConnector numbers in a single circle M33 indicate harness con-
nectors.
Component Indication
Connector numbers in a double circle F211 indicate component connectors.
Switch Positions
Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition.
A vehicle is in the “normal” condition when:
lignition switch is “OFF”,
ldoors, hood and trunk lid/back door are closed,
lpedals are not depressed, and
lparking brake is released.
AGI070
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GI-28
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
VOLTAGE CHECK METHOD
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for the presence of voltage.
This is done by switching the DMM to the voltage function.
lConnect one probe of the DMM to a known good ground.
lBegin probing at one end of the circuit and work your way to the other end.
lWith SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
lClose SW1 and probe at relay.
voltage; open is further down the circuit than the relay.
no voltage; open is between SW1 and relay (point B).
lClose the relay and probe at the solenoid.
voltage; open is further down the circuit than the solenoid.
no voltage; open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the previous example.
Testing for “Shorts” in the Circuit
To simplify the discussion of shorts in the system, please refer to the following schematic.
RESISTANCE CHECK METHOD
lDisconnect the battery negative cable and remove the blown fuse.
lDisconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the
fuse.
lConnect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known
good ground.
lWith SW1 open, check for continuity.
continuity; short is between fuse terminal and SW1 (point A).
no continuity; short is further down the circuit than SW1.
lClose SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good
ground. Then, check for continuity.
continuity; short is between SW1 and the relay (point B).
no continuity; short is further down the circuit than the relay.
lClose SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and
a known good ground. Then, check for continuity.
continuity; short is between relay and solenoid (point C).
no continuity; check solenoid, retrace steps.
VOLTAGE CHECK METHOD
lRemove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid discon-
nected) powered through the fuse.
lTurn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse
terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).
lWith SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage; short is between fuse block and SW1 (point A).
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CONTROL UNIT CONFIGURATION PROCEDURE
Work Procedure
EAS001HB
NOTE:
The configuration procedure may differ according to the replaced unit, those always use the work item code to
determinate a appropriate procedure.
Work item code Confirmation procedure Refer page
A1.“Configuration” on CONSULT-II. (At ignition switch LOCK position.)GI-37, "
Configuration (BCM)"
2. Turn ignition switch ON with mechanical key. —
3. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
4. “REGIST I-KEY ID” on CONSULT-II. CONSULT-II operation manual NATS.
B1. “Configuration” on CONSULT-II. (At ignition switch LOCK position.)GI-37, "
Configuration (BCM)"
2. “STEERING LOCK RELEASE” on CONSULT-II. CONSULT-II operation manual NATS.
3. Turn ignition switch ON with mechanical key. —
4. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
5. “REGIST I-KEY ID” on CONSULT-II. CONSULT-II operation manual NATS.
C1. “Configuration” on CONSULT-II. (At ignition switch LOCK position.)GI-37, "
Configuration (BCM)"
2. “STEERING LOCK RELEASE” on CONSULT-II. CONSULT-II operation manual NATS.
3. Turn ignition switch ON with mechanical key. —
4. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
D1. “STEERING LOCK RELEASE” on CONSULT-II. CONSULT-II operation manual NATS.
2. Turn ignition switch ON with mechanical key. —
3. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
4. “REGIST I-KEY ID” on CONSULT-II. CONSULT-II operation manual NATS.
E1. Turn ignition switch ON with mechanical key. —
2. “REGIST I-KEY ID” on CONSULT-II. CONSULT-II operation manual NATS.
F Turn ignition switch ON with mechanical key. —
G1. “Configuration” on CONSULT-II.GI-37, "
Configuration (BCM)"
2. Turn ignition switch ON with mechanical key. —
3. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
H1. “STEERING LOCK RELEASE” on CONSULT-II. CONSULT-II operation manual NATS.
2. “C/U INITIALIZATION” on CONSULT-II. CONSULT-II operation manual NATS.
3. “REGIST I-KEY ID” on CONSULT-II. CONSULT-II operation manual NATS.
J1.“Configuration” on CONSULT-II. (At ignition switch ON position.)GI-37, "
Configuration (BCM)"
2. Erase the DTC (P1612) using CONSULT-II —
I “Configuration” on CONSULT-II. (At ignition switch ON position.)GI-37, "
Configuration (BCM)"
K Turn ignition switch ON with ignition key. —

CONTROL UNIT CONFIGURATION PROCEDURE
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Configuration (BCM)EAS001Q6
DESCRIPTION
CONFIGURATION has two functions as follows:
lREAD CONFIGURATION is the function to confirm vehicle configuration of current BCM.
lWRITE CONFIGURATION is the function to write vehicle configuration on BCM.
CAUTION:
lWhen replacing BCM, you must perform WRITE CONFIGURATION with CONSULT-II.
lComplete the procedure of WRITE CONFIGURATION in order.
lIf you set incorrect WRITE CONFIGURATION, incidents will occur.
lConfiguration is different for each vehicle model. Confirm configuration of each vehicle model.
READ CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With ignition switch OFF, connect CONSULT-II and CONSULT-II
CONVERTER to data link connector, and then turn ignition
switch ON.
2. Touch “START (NISSAN BASED VHCL)”.
3. Touch “BCM” on “SELECT SYSTEM” screen.
If “BCM” is not indicated, refer toGI-50, "
CONSULT-II Data Link
Connector (DLC) Circuit"in “GI” section.
PKIC0644E
BCIA0029E
BCIA0030E

CONTROL UNIT CONFIGURATION PROCEDURE
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WRITE CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With ignition switch OFF, connect CONSULT-II and CONSULT-II
CONVERTER to data link connector, and then turn ignition
switch ON.
2. Touch “START (NISSAN BASED VHCL)”.
3. Touch “BCM” on “SELECT SYSTEM” screen.
If “BCM” is not indicated, refer toGI-50, "
CONSULT-II Data Link
Connector (DLC) Circuit"in “GI” section.
4. Touch “BCM” on “SELECT TEST ITEM” screen.
PKIC0644E
BCIA0029E
BCIA0030E
PKIA5226E