SRS NISSAN NAVARA 2005 Repair Service Manual

MTC-1
MANUAL AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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L
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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-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS005QE
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 Working with HFC-134a (R-134a)EJS00627
WARNING:
lCFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed and compressor
malfunction is likely occur.
lUse only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor malfunction is likely to occur.
lThe specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
–When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refriger-
ant. If accidental system discharge occurs, ventilate work area before resuming service. Addi-
tional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
–Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
Contaminated RefrigerantEJS0063C
If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are:
lExplain to the customer that environmental regulations prohibit the release of contaminated refrigerant
into the atmosphere.
lExplain that recovery of the contaminated refrigerant could damage your service equipment and refriger-
ant supply.
lSuggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
lIf you choose to perform the repair, recover the refrigerant using onlydedicated equipment and contain-
ers. Do not recover contaminated refrigerant into your existing service equipment.If your facility
does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for avail-
able service. This refrigerant must be disposed of in accordance with all federal and local regulations. In
addition, replacement of all refrigerant system components on the vehicle is recommended.

PG-1
POWER SUPPLY, GROUND & CIRCUIT ELEMENTS
K ELECTRICAL
CONTENTS
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SECTIONPG
A
B
PG
POWER SUPPLY, GROUND & CIRCUIT ELEMENTS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
POWER SUPPLY ROUTING CIRCUIT ...................... 4
Schematic ................................................................ 4
Wiring Diagram — POWER — ................................. 5
BATTERY POWER SUPPLY — IGNITION SW.
IN ANY POSITION ................................................ 5
ACCESSORY POWER SUPPLY — IGNITION
SW. IN ACC OR ON ............................................ 10
IGNITION POWER SUPPLY — IGNITION SW.
IN ON ................................................................... 11
IGNITION POWER SUPPLY — IGNITION SW.
IN ON AND/OR START ....................................... 12
IPDM E/R (INTELLIGENT POWER DISTRIBUTION
MODULE ENGINE ROOM) ...................................... 14
System Description ................................................ 14
SYSTEMS CONTROLLED BY IPDM E/R ........... 14
CAN COMMUNICATION LINE CONTROL ......... 14
IPDM E/R STATUS CONTROL ........................... 15
CAN Communication System Description .............. 15
Function of Detecting Ignition Relay Malfunction ... 15
CONSULT-II Function (IPDM E/R) ......................... 16
CONSULT-II BASIC OPERATION ...................... 16
SELF-DIAGNOSTIC RESULTS .......................... 17
DATA MONITOR ................................................. 17
CAN DIAG SUPPORT MNTR ............................. 18
ACTIVE TEST ..................................................... 18
Auto Active Test ..................................................... 19
DESCRIPTION .................................................... 19
OPERATION PROCEDURE ............................... 19
INSPECTION IN AUTO ACTIVE TEST MODE... 20
Schematic .............................................................. 22
IPDM E/R Terminal Arrangement ........................... 23
Check IPDM E/R Power Supply and Ground Circuit... 24Inspection with CONSULT-II (Self-Diagnosis) ........ 25
Removal and Installation of IPDM E/R ................... 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
GROUND CIRCUIT ................................................... 27
Ground Distribution ................................................. 27
MAIN HARNESS ................................................. 27
ENGINE ROOM HARNESS ................................ 30
ENGINE CONTROL HARNESS .......................... 34
BODY HARNESS (LH SIDE) .............................. 35
BODY HARNESS (RH SIDE) .............................. 36
DEFOGGER CABLE ........................................... 37
HARNESS ................................................................. 38
Harness Layout ...................................................... 38
HOW TO READ HARNESS LAYOUT ................. 38
OUTLINE/DOUBLE CAB MODELS .................... 39
OUTLINE/KING CAB MODELS .......................... 40
MAIN HARNESS/LHD MODELS ......................... 41
MAIN HARNESS/RHD MODELS ........................ 44
ENGINE ROOM HARNESS/LHD MODELS ........ 47
ENGINE ROOM HARNESS/RHD MODELS ....... 49
ENGINE CONTROL HARNESS .......................... 51
CHASSIS HARNESS .......................................... 53
BODY HARNESS (LH SIDE)/DOUBLE CAB
MODELS ............................................................. 54
BODY HARNESS (RH SIDE)/DOUBLE CAB
MODELS ............................................................. 56
BODY HARNESS (LH SIDE)/KING CAB MOD-
ELS ...................................................................... 58
BODY HARNESS (RH SIDE)/KING CAB MOD-
ELS ...................................................................... 60
ROOM LAMP HARNESS .................................... 62
FRONT DOOR LH HARNESS/LHD MODELS .... 63
FRONT DOOR RH HARNESS/LHD MODELS ... 63
FRONT DOOR LH HARNESS/RHD MODELS ... 64
FRONT DOOR RH HARNESS/RHD MODELS ... 64
REAR DOOR LH HARNESS/DOUBLE CAB
MODELS ............................................................. 65
REAR DOOR RH HARNESS/DOUBLE CAB
MODELS ............................................................. 65

PG-2
REAR DOOR LH HARNESS/KING CAB MOD-
ELS ...................................................................... 66
REAR DOOR RH HARNESS/KING CAB MOD-
ELS ...................................................................... 66
TAIL HARNESS ................................................... 67
Wiring Diagram Codes (Cell Codes) ....................... 68
ELECTRICAL UNITS LOCATION ............................. 71
Electrical Units Location ......................................... 71
ENGINE COMPARTMENT .................................. 71
PASSENGER COMPARTMENT .......................... 72
Fuse ........................................................................ 74
Fusible Link ............................................................ 74
Circuit Breaker (Built Into BCM) ............................. 74
HARNESS CONNECTOR ......................................... 75
Description .............................................................. 75
HARNESS CONNECTOR (TAB-LOCKING
TYPE) .................................................................. 75
HARNESS CONNECTOR (SLIDE-LOCKINGTYPE) .................................................................. 76
HARNESS CONNECTOR (DIRECT-CONNECT
SRS COMPONENT TYPE) .................................. 77
ELECTRICAL UNITS ................................................ 78
Terminal Arrangement ............................................. 78
STANDARDIZED RELAY .......................................... 79
Description .............................................................. 79
NORMAL OPEN, NORMAL CLOSED AND
MIXED TYPE RELAYS ........................................ 79
TYPE OF STANDARDIZED RELAYS .................. 79
SUPER MULTIPLE JUNCTION (SMJ) ...................... 81
Terminal Arrangement ............................................. 81
FUSE BLOCK - JUNCTION BOX (J/B) .................... 83
Terminal Arrangement ............................................. 83
FUSE AND FUSIBLE LINK BOX .............................. 84
Terminal Arrangement ............................................. 84
FUSE AND RELAY BOX ........................................... 85
Terminal Arrangement ............................................. 85

PRECAUTIONS
PG-3
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MA
B
PG
PRECAUTIONSPFP:00011
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EKS00N4A
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.
Wiring Diagrams and Trouble DiagnosisEKS00LIU
When you read wiring diagrams, refer to the following:
lRefer toGI-15, "HowtoReadWiringDiagrams"in GI section.
lRefer toPG-4, "POWER SUPPLY ROUTING CIRCUIT"for power distribution.
When you perform trouble diagnosis, refer to the following:
lRefer toGI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"in GI section.
lRefer toGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident"in GI section.

HARNESS
PG-69
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PG
FTS EC Fuel Pump Temperature Sensor
GLOW EC Glow Control System
H/AIM LT Headlamp Aiming Control System
H/LAMP LT Headlamp
HEATUP EC Heat Up Switch
HLC WW Headlamp Washer
HORN WW Horn
HSEAT SE Heated Seat
I/KEY BL Intelligent Key System
I/MIRR GW Inside Mirror (Auto Anti-dazzling Mirror)
IATS EC Intake Air Temperature Sensor
ILL LT Illumination
INJ/PW EC Fuel Injector Power Supply
INJECT EC Fuel Injector
INT/L LT Room and Map Lamps
INT/V EC Intake Air Control Valve Control Solenoid Valve
MAFS EC Mass Air Flow Sensor
MAIN AT Main Power Supply and Ground Circuit
MAIN EC Main Power Supply and Ground Circuit
METER DI Speedometer, Tachometer, Temp. and Fuel Gauges
MIL/DL EC Malfunction Indicator Lamp, Data Link Connector
MIRROR GW Door Mirror
MMSW AT Manual Mode Switch
MULTI BL Multi-remote Control System
NATS BL NATS (Nissan Anti-Theft System)
NAVI AV Navigation System
NONDTC AT NON-detective Items
P/SCKT WW Power Socket
PHONE AV Telephone
PNP/SW AT Park/Neutral Position Switch
PNP/SW EC Park/Neutral Position Switch
POWER PG Power Supply Routing
R/FOG LT Rear Fog Lamp
RP/SEN EC Refrigerant Pressure Sensor
S/LOCK BL Power Door Lock — Super Lock
S/SIG EC Start Signal
SEAT SE Power Seat
SHIFT AT A/T Shift Lock System
SROOF RF Sunroof
SRS SRS Supplemental Restraint System
START SC Starting System
STOP/L LT Stop Lamp
STSIG AT Start Signal Circuit
T/F TF TransferCode Section Wiring Diagram Name

HARNESS CONNECTOR
PG-77
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PG
HARNESS CONNECTOR (DIRECT-CONNECT SRS COMPONENT TYPE)
lSRS direct-connect type harness connectors are used on certain SRS components such as air bag mod-
ules and seat belt pre-tensioners.
lAlways pull up to release black locking tab prior to removing connector from SRS component.
lAlways push down to lock black locking tab after installing connector to SRS component. When locked,
the black locking tab is level with the connector housing.
CAUTION:
lDo not pull the harness or wires when removing connectors
from SRS components.
WHIA0103E

PS-1
POWER STEERING SYSTEM
G STEERING
CONTENTS
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SECTIONPS
A
B
PS
POWER STEERING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions for Steering System .............................. 2
PREPARATION ........................................................... 3
Special Service Tools [SST] ..................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
POWER STEERING FLUID ........................................ 6
Checking Fluid Level ................................................ 6
Checking Fluid Leakage ........................................... 6
Air Bleeding Hydraulic System ................................. 6
STEERING WHEEL .................................................... 8
On-Vehicle Inspection and Service .......................... 8
CHECKING CONDITION OF INSTALLATION ...... 8
CHECKING STEERING WHEEL PLAY ................ 8
CHECKING NEUTRAL POSITION STEERING
WHEEL ................................................................. 8
CHECKING STEERING WHEEL TURNING
FORCE .................................................................. 8
CHECKING FRONT WHEEL TURNING ANGLE..... 9
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
STEERING COLUMN ................................................11
Removal and Installation ......................................... 11
COMPONENT ...................................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
POWER STEERING GEAR AND LINKAGE ............ 14Removal and Installation ........................................ 14
COMPONENT ..................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Disassembly and Assembly .................................... 16
COMPONENT ..................................................... 16
DISASSEMBLY ................................................... 17
INSPECTION AFTER DISASSEMBLY ................ 18
ASSEMBLY ......................................................... 20
POWER STEERING OIL PUMP ............................... 25
On-Vehicle Inspection and Service ......................... 25
CHECKING RELIEF OIL PRESSURE ................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 26
Disassembly and Assembly .................................... 26
COMPONENT ..................................................... 26
INSPECTION BEFORE DISASSEMBLY ............. 26
DISASSEMBLY ................................................... 27
INSPECTION AFTER DISASSEMBLY ................ 27
ASSEMBLY ......................................................... 28
HYDRAULIC LINE .................................................... 30
Component (RHD Models) ..................................... 30
Component (LHD Models) ...................................... 32
Removal and Installation ........................................ 33
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
Steering Wheel ....................................................... 34
Steering Angle ........................................................ 34
Steering Column ..................................................... 34
Steering Outer Socket and Inner Socket ................ 34
Steering Gear ......................................................... 35
Oil Pump ................................................................. 35
Steering Fluid .......................................................... 35

PS-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EGS001M0
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 Steering SystemEGS001L9
lIn case of removing steering gear assembly, make the final tightening with grounded and unloaded vehi-
cle condition, and then check wheel alignment.
lObserve the following precautions when disassembling.
–Before disassembly, thoroughly clean the outside of the unit.
–Disassembly should be done in a clean work area. It is important to prevent the internal parts from becom-
ing contaminated by dirt or other foreign matter.
–For easier and proper assembly, place disassembled parts in order on a parts rack.
–Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere
with their operation.
–Do not reuse non-reusable parts.
–Before assembling, apply the specified grease to the directed parts.

PS-10
STEERING WHEEL
Removal and Installation
EGS001LH
REMOVAL
NOTE:
When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. This
will omit neutral position alignment procedure during spiral installation.
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 lock nut after steering is locked.
4. Remove steering wheel with the steering wheel puller [SST:
ST27180001] (A).
INSTALLATION
Reverse the removal procedure for installation attentive to the following operation.
NOTE:
Make sure that the spiral cable is in the neutral position. The neutral
position is detected by turning left 2.6 revolutions from the right end
position and ending with the locating pin at the top.
CAUTION:
Do not run spiral cable idle needlessly. And do not turn it more
than necessary (or it leads to disconnection of the cable).
SGIA1323E
PHIA0275E