grease NISSAN NAVARA 2005 Repair Service Manual

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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FELT CLOTHTAPE
Used to insulate where movement does not occur. Ideal for instrument panel applications.
68370-4B000: 15´25 mm (0.59´0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll
The following materials, not available through NISSAN Parts Department, can also be used to repair squeaks
and rattles.
UHMW(TEFLON) TAPE
Insulates where slight movement is present. Ideal for instrument panel applications.
SILICONE GREASE
Used in place of UHMW tape that will be visible or not fit.
Note: Will only last a few months.
SILICONE SPRAY
Use when grease cannot be applied.
DUCT TAPE
Usetoeliminatemovement.
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle TroubleshootingEIS00C03
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by
applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate
wiring harness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you
will not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.

FRONT DOOR GLASS AND REGULATOR
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7. Disconnect the harness connector from the regulator assembly.
8. Remove the mounting bolts and remove the regulator assembly.
Installation
Install in the reverse order of removal.
Inspection after Removal
Check the regulator assembly for the following items. If a malfunction is detected, replace or grease it.
lWire wear
lRegulator deformation
lGrease condition for each sliding part.
Disassembly and AssemblyEIS00BQ9
REGULATOR ASSEMBLY
Disassembly
Remove the power window motor from the regulator assembly.
Assembly
Assemble in the reverse order of disassembly.
Inspection after InstallationEIS00BQA
FITTING INSPECTION
lCheck that glass is securely fit into glass run groove.
lWhile raising and lowering the window, check for abnormal operation.
lLower the glass slightly [approximately 10 to 20 mm (0.39 to 0.79 in)] and check that the clearance to the
sash is parallel. If the clearance between the glass and sash is not parallel, loosen the regulator bolts,
guide rail bolts, and glass and guide rail bolts to correct the glass position.
RESET OPERATION
The anti pinch requires resetting after removal of the regulator motor, also if the glass installation or glass runs
have be changed.
lOperate the power window motor switch so the glass is fully up, followed by a full down operation.
MIIB0566E

GW-40
REAR DOOR GLASS AND REGULATOR
8. Remove the mounting bolts and remove the regulator assembly.
Installation
Install in the reverse order of removal.
Inspection after Removal
Check the regulator assembly for the following items. If a malfunction is detected, replace or grease it.
lWire wear
lRegulator deformation
lGrease condition for each sliding part.
Disassembly and AssemblyEIS00BQC
REGULATOR ASSEMBLY
Disassembly
Remove the power window motor from the regulator assembly.
Assembly
Assemble in the reverse order of disassembly.
Inspection after InstallationEIS00BQD
FITTING INSPECTION
lCheck that glass is securely fit into glass run groove.
lWhile raising and lowering the window, check for abnormal operation.
lLower the glass slightly [approximately 10 to 20 mm (0.39 to 0.79 in)] and check that the clearance to the
sash is parallel. If the clearance between the glass and sash is not parallel, loosen the regulator bolts,
guide rail bolts, and glass and guide rail bolts to correct the glass position.
MIIB0569E

GW-66
DOOR MIRROR
5. Lightly lift up lower side of mirror surface from mirror surface, and detach two pawls of upper side as if
pulling it out. Remove mirror surface from mirror body.
NOTE:
Be certain not to allow grease on sealing agent in center of mirror body assembly (actuator) or back side of
mirror surface (mirror holder).
ASSEMBLY
1. Place mirror holder bracket and mirror body assembly (actuator) in a horizontal position.
2. Connect two terminals of heater installed mirror.
3. Fit the upper two pawls on the mirror face onto the mirror holder
bracket first, then press the lower side of mirror face until a click
sound is heard to engage the lower pawls.
NOTE:
After installation, visually check that lower two pawls are securely
engaged from the bottom of mirror face.
MIIB0573E

IDX-4
ALPHABETICAL INDEX
Engine control system diagram and chart .........EC-15
Engine coolant ....................................................CO-7
Engine coolant temperature sensor (ECTS) ....EC-103
Engine oil .............................................................LU-5
Engine oil filter replacement .............................MA-26
Engine oil precautions ..........................................GI-7
Engine removal ...............................................EM-106
Engine room cover ............................................EM-20
Engine serial number ..........................................GI-58
Evaporator ....................................ATC-149,MTC-129
Exhaust manifold ..............................................EM-34
Exhaust system ...................................................EX-2
Exhaust system inspection ..................................EX-2
Expansion valve ............................ATC-150,MTC-130
F
F/FOG - Wiring diagram .....................................LT-74
F/PUMP - Wiring diagram ..EC-248,EC-254,EC-260,
EC-266
Final drive pre-inspection .................................FFD-18
Final drive removal and installation ..RFD-14,RFD-81
Flow charts .........................................................GI-24
Fluid temperature sensor (A/T) ........................AT-118
Fluids ................................................................MA-14
Fluorescent leak detector .............ATC-150,MTC-131
Flywheel (clutch) ................................................CL-17
Flywheel runout ..............................................EM-134
Fog lamp, front ....................................................LT-71
Foot lamp ..........................................................LT-145
Fork rod (M/T) ....................................................MT-23
Freeze frame data .............................................EC-28
Front brake solenoid valve .................AT-137,AT-139
Front bumper ......................................................EI-15
Front case (Transfer) ..........................TF-114,TF-120
Front combination lamp removal and installationLT-30
Front door ................BL-118,BL-120,BL-126,GW-35
Front Door Trim ..................................................EI-30
Front drive shaft (Transfer) ...TF-114,TF-120,TF-133
Front final drive removal and installation (4WD) ...........
FFD-15
Front fog lamp .....................................................LT-71
Front passenger air bag ..................................SRS-40
Front seat ...........................................................SE-20
Front seat belt ............................................SB-3,SB-5
Front seat belt pre-tensioner ...............SRS-3,SRS-47
Front side air bag ............................................SRS-43
Front washer ......................................................WW-4
Front wiper .........................................................WW-4
FRPS - Wiring diagram ....................................EC-120
FTS - Wiring diagram .......................................EC-115
Fuel cut control (at no load high engine speed) .EC-20
Fuel filler lid ......................................................BL-136
Fuel filter ............................................................EC-23
Fuel filter replacement ..........................................FL-4
Fuel gauge ............................................................DI-4
Fuel injection control system .............................EC-18
Fuel injector ............EC-25,EC-123,EC-125,EC-237
Fuel injector and fuel tube ................................EM-44
Fuel leak ............................................................EC-88
Fuel line inspection ..............................................FL-3
Fuel pumpEC-86,EC-217,EC-245,EC-251,EC-258,
EC-263
Fuel pump(Learning Value Clearing) .................EC-24
Fuel rail pressure sensor .................................EC-118
Fuel system .........................................................FL-3
Fuel tank ..............................................................FL-9
Fuel temperature sensor ..................................EC-113
Fuse ......................................................PG-74,PG-84
Fuse and fusible link box ..................................PG-84
Fusible link ............................................PG-74,PG-84
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Garage jack and safety stand .............................GI-52
Gauges .................................................................DI-4
Gear components (M/T) ....................................MT-21
Generator ...........................................................SC-14
Generator - See Alternator ................................SC-14
Glass ........................GW-11,GW-35,GW-38,GW-43
Glove box lamp ................................................LT-162
GLOW - Wiring diagram ..................................EC-296
Glow plug ............................................EM-41,EC-295
Glow relay ........................................................EC-295
Grease ..............................................................MA-14
Ground distribution ...........................................PG-27
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H/AIM - Wiring diagram .....................................LT-66
Harness connector ............................................PG-75
Harness layout ..................................................PG-38
Hazard warning lamp .........................................LT-97
Headlamp aiming control ...................................LT-66
Headlamp leveler - See Headlamp aiming control ........
LT-66
Headlamp removal and installation ....................LT-30
Heat up switch .................................................EC-319
Heated seat .......................................................SE-12
Heater and cooling unit (Heater core) ..........ATC-124,
ATC-127
,MTC-103,MTC-106
Heater unit (heater core) ..............ATC-124,ATC-127,
MTC-103
,MTC-106
HEATUP - Wiring diagram ...............................EC-320
Height (Dimensions) ...........................................GI-60
HFC134a (R134a) system precaution .ATC-4,MTC-4
HFC134a (R134a) system service procedureATC-138,
MTC-118
HFC134a (R134a) system service tools ........ATC-16,
MTC-16
HFC134a system service equipment precaution ..........
ATC-12
,MTC-12
High and low reverse clutch solenoid valve ....AT-147,
AT-149
HLC - Wiring diagram ......................................WW-41
Horn .................................................................WW-59
HORN - Wiring diagram ...................................WW-59
How to erase DTC .............................................EC-27

LT-4
PRECAUTIONS
PRECAUTIONS
PFP:00011
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EKS00N1L
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.
General Precautions for Service OperationsEKS00L4H
lNever work with wet hands.
lTurn the lighting switch OFF before disconnecting and connecting the connector.
lWhen checking the headlamp on/off operation, check it on vehicle and with the power connected to the
vehicle-side connector.
lDo not touch the headlamp bulb glass surface with bare hands or allow oil or grease to get on it. Do not
touch the headlamp bulb just after the headlamp is turned off, because it is very hot.
lWhen the bulb has burned out, wrap it in a thick vinyl bag and discard. Do not break the bulb.
lLeaving the bulb removed from the headlamp housing for a long period of time can deteriorate the perfor-
mance of the lens and reflector (dirt, clouding). Always prepare a new bulb and have it on hand when
replacing the bulb.
lDo not use organic solvent (paint thinner or gasoline) to clean lamps and to remove old sealant.
Wiring Diagrams and Trouble DiagnosisEKS00L4I
When you read wiring diagrams, refer to the following:
lRefer toGI-15, "How to Read Wiring Diagrams".
lRefer toPG-4, "POWER SUPPLY ROUTING CIRCUIT".
When you perform trouble diagnosis, refer to the following:
lRefer toGI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES".
lRefer toGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident".

LT-86
FRONT FOG LAMP
Bulb Replacement
EKS00P4E
1. Disconnect front fog lamp connector.
2. Turn the bulb socket counterclockwise to remove it.
CAUTION:
lNever touch the glass of bulb directly by hand. Keep
grease and other oily substances away from it. Do not
touch bulb by hand while it is lit or right after being
turned off. Burning may result.
lNever leave bulb out of fog lamp reflector for a long time
because dust, moisture smoke, etc. may affect the perfor-
mance of fog lamp. When replacing bulb, be sure to
replace it with new one.
Removal and Installation of Front Fog LampEKS00P4F
REMOVAL
The front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb.
CAUTION:
lNever leave fog lamp assembly without bulb for a long period of time. Dust, moisture, smoke, etc.
entering the fog lamp body may affect the performance. Remove the bulb from the headlamp
assembly just before replacement bulb is installed.
lGrasp only the plastic base when handling the bulb. Never touch the glass envelope. Touching the
glass could significantly affect the bulb life and/or fog lamp performance.
1. Remove front portion of fender protector. Refer toEI-22, "
Removal and Installation of Front Fender Pro-
tector".
2. Disconnect front fog lamp connector.
3. Remove front fog lamp screws and pull fog lamp rearward out of
front bumper.
INSTALLATION
Installation is the reverse order of removal.Front fog lamp : 12V - 55W (H11)
LKIA0573E
LKIA0574E

LU-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Liquid GasketEBS01E52
LIQUID GASKET APPLICATION PROCEDURE
1. Remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface.
lRemove the liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser [SST].
Use Genuine Liquid Gasket or equivalent.
lWithin five minutes of liquid gasket application, install the mating
component.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten mounting bolts and nuts after the installation.
lAfter 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
PBIC2160E

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)

CHASSIS AND BODY MAINTENANCE
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LINING
lCheck for lining thickness.
Checking Steering Gear and LinkageELS001J3
STEERING GEAR
lCheck the steering gear housing for looseness, damage and oil
leakage as shown.
lCheck the steering column connections for looseness.
STEERING LINKAGE
lCheck the ball joint, dust cover and other component parts for looseness, wear, damage and grease leak-
age.
Checking Power Steering Fluid and LinesELS001J4
CHECKING FLUID LEVEL
lCheck the power steering fluid level with the engine off.
lCheck fluid level on reservoir. Use “HOT” range at fluid tempera-
tures of 50°to 80°C(122°to 176°F). Use “COLD” range at fluid
temperatures of 0°to 30°C(32°to 86°F).
CAUTION:
lDo not overfill.
lFill with the recommended fluid or equivalent. Refer toMA-
14, "Fluids and Lubricants".
CHECKING LINES
lCheck lines for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.Standard thickness : 5.5 mm (0.22 in)
Repair limit thickness : 1.5 mm (0.66 in)
SBR021A
SGIA0506E
LGIA0021E
SGIA0506E