service NISSAN NAVARA 2005 Repair Repair Manual

ATC-146
REFRIGERANT LINES
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for High-pressure Flexible A/C HoseEJS006CP
REMOVAL
1. Remove the front left wheel and tire assembly. Refer toWT-5, "Rotation".
2. Remove the front left mud guard.
3. Remove the front left splash shield.
4. Discharge the refrigerant. Refer toATC-138, "
HFC-134a (R-134a) Service Procedure".
5. Remove the high-pressure flexible A/C hose. Refer toATC-140, "
Components".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toATC-140, "
Components".
CAUTION:
lReplace the O-ring of the high-pressure flexible A/C hose with a new one, then apply compressor
oil to it for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for High-pressure A/C PipeEJS006CQ
REMOVAL
1. Remove the front right wheel and tire assembly. Refer toWT-5, "Rotation".
2. Remove the front right mud guard.
3. Remove the front right splash shield.
4. Discharge the refrigerant. Refer toATC-138, "
HFC-134a (R-134a) Service Procedure".
5. Remove the low pressure A/C pipe. Refer toATC-147, "
Removal and Installation for Low-pressure A/C
Pipe".
6. Remove the high-pressure A/C pipe. Refer toATC-146, "
Removal and Installation for High-pressure A/C
Pipe".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toATC-140, "
Components".
CAUTION:
lReplace the O-ring of the high-pressure A/C pipe with a new one, then apply compressor oil to it
for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Low-pressure Flexible A/C HoseEJS006CR
REMOVAL
1. Remove the front right wheel and tire assembly. Refer toWT-5, "Rotation".
2. Remove the front right mud guard.
3. Remove the front right splash shield.
4. Discharge the refrigerant. Refer toATC-138, "
HFC-134a (R-134a) Service Procedure".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
5. Remove the low-pressure flexible A/C hose. Refer toATC-140, "
Components".
INSTALLATION
Installation is in the reverse order of removal.
Refer toATC-140, "
Components".

REFRIGERANT LINES
ATC-147
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CAUTION:
lReplace the O-ring of the low-pressure flexible A/C hose with a new one, then apply compressor
oil to it for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Low-pressure A/C PipeEJS006CS
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the heater pump connector.
3. Remove the heater pump from the bracket and reposition out of the way. Do not disconnect the heater
hoses from the heater pump.
4. Remove the low-pressure A/C pipe. Refer toATC-140, "
Components".
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer toATC-140, "
Components".
CAUTION:
lReplace the O-ring of the low-pressure A/C pipe with a new one, then apply compressor oil to it for
installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for Refrigerant Pressure SensorEJS006CV
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the refrigerant pressure sensor harness connector
and remove the refrigerant pressure sensor from the condenser.
CAUTION:
Be careful not to damage the condenser fins.
INSTALLATION
Installation is in the reverse order of removal.
Refer toATC-140, "
Components".
CAUTION:
lBe careful not to damage the condenser fins.
lApply compressor oil to the O-ring of the refrigerant pressure sensor for installation.
lAfter charging refrigerant, check for leaks.
Removal and Installation for CondenserEJS006CW
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Remove the radiator. Refer toCO-11, "
RADIATOR".
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
3. Disconnect the high-pressure flexible A/C hose and the high-pressure A/C pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
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ATC-150
REFRIGERANT LINES
CAUTION:
Replace the O-rings on the A/C low-pressure flexible A/C hose and the high-pressure A/C pipe with
new ones. Apply compressor oil to the O-rings for installation.
Removal and Installation for Expansion ValveEJS006CZ
REMOVAL
1. Discharge the refrigerant. Refer toATC-138, "HFC-134a (R-134a) Service Procedure".
2. Remove the heater and cooling unit assembly. Refer toATC-126, "
REMOVAL".
3. Remove the heater core and evaporator pipes grommet.
4. Remove the expansion valve.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-rings on then expansion valve and the A/C refrigerant pipes with new ones, then
apply compressor oil to them for installation.
lAfter charging refrigerant, check for leaks.
Checking for Refrigerant LeaksEJS006D1
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS006D2
1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future mis-
diagnosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Cleanwithadryclothorblowoffwithshopair.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.Expansion valve bolts : 4 N·m (0.41 kg-m, 35 in-lb)
A/C refrigerant pipe to expansion valve bolt : Refer toATC-140, "
Components"
.

REFRIGERANT LINES
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Dye InjectionEJS006D3
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak DetectorEJS006D4
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
SHA705EB
SHA707EA
SHA706E

ATC-152
REFRIGERANT LINES
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set (SST) to the A/C service valves.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50psi)above16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refriger-
ant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2,50psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal l). Refer toATC-140, "
Components". Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. MODE control dial: VENT (Ventilation)
c. Intake door position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
SHA708EA

ATC-154
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Service Data and Specifications (SDS)EJS006D5
COMPRESSOR
LUBRICANT
REFRIGERANT
ENGINE IDLING SPEED
Refer toEC-38, "Basic Inspection".
BELT TENSION
Refer toEM-13, "Deflection Adjustment".
Make ZEXEL VALEO CLIMATE CONTROL
Model DKS-17D
Type Swash plate
Displacement
175.5 cm
3(10.7 in3)/revolution
Cylinder bore´stroke 30.5 mm (1.20 in) x 24.0 mm (0.94 in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V
Make ZEXEL VALEO CLIMATE CONTROL
Model DKS-17D
Name Genuine NISSAN A/C System Lubricant Type S (DH-PS)
Part number KLH00-PAGS0
CapacityWithout rear A/C
180 m (6.3 Imp fl oz)
With rear A/C
210 m (7.4 Imp fl oz)
Type HFC 134a (R-134a)
CapacityWithout rear A/C 0.70±0.05 kg (1.54±0.11 lb)
With rear A/C 0.85±0.05 kg (1.87±0.11 lb)

PRECAUTIONS
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EKS00Q9X
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 DiagnosisEKS00PE1
When reading wiring diagrams, refer to the following:
lRefer toGI-15, "HowtoReadWiringDiagrams".
lRefer toPG-4, "POWER SUPPLY ROUTING CIRCUIT".
When performing 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".

AV-4
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION
PFP:00000
System FunctionsEKS00Q5X
Refer to Owner's Manual for audio system operating instructions.
AUDIO
Speed Sensitive Volume (6CD Player Type)
Volume level of this system gone up and down automatically in proportion to the vehicle speed. And the con-
trol level can be selected by the customer.
NATS AUDIO LINK (WITHOUT NAVIGATION SYSTEM)
Description
The link with the NATS IMMU implies that the audio unit can basically only be operated if connected to the
matching NATS IMMU to which the audio unit was initially fitted on the production line.
Since radio operation is impossible after the link with the NATS is disrupted theft of the audio unit is basically
useless since special equipment is required to reset the audio unit.
Initialization Process for Audio Units That Are Linked to The NATS IMMU
New audio units will be delivered to the factories in the “NEW” state, i.e. ready to be linked with the vehicle's
NATS. When the audio unit in “NEW” state is first switched on at the factory, it will start up communication with
the vehicle's immobilizer control unit (IMMU) and send a code (the “audio unit Code”) to the IMMU. The IMMU
will then store this code, which is unique to each audio unit, in its (permanent) memory.
Upon receipt of the code by the IMMU, the NATS will confirm correct receipt of the audio unit code to the audio
unit. Hereafter, the audio unit will operate as normal.
During the initialization process, “NEW” is displayed on the audio unit display. Normally though, communica-
tion between audio unit and IMMU takes such a short time (300 ms) that the audio unit seems to switch on
directly without showing “NEW” on its display.
Normal Operation
Each time the audio unit is switched on afterwards, the audio unit code will be verified between the audio unit
and the NATS before the audio unit becomes operational. During the code verification process, “WAIT” is
shown on the audio unit display. Again, the communication takes such a short time (300 ms) that the audio
unit seems to switch on directly without showing “WAIT” on its display.
When The Radio Is Locked
In case of a audio unit being linked with the vehicle's NATS (immobilizer system), disconnection of the link
between the audio unit and the IMMU will cause the audio unit to switch into the lock (“SECURE”) mode in
which the audio unit is fully inoperative. Hence, repair of the audio unit is basically impossible, unless the
audio unit is reset to the “NEW” state for which special decoding equipment is required.
Clarion has provided their authorized service representatives with so called “decoder boxes” which can bring
the audio unit back to the “NEW” state, enabling the audio unit to be switched on after which repair can be per-
formed. Subsequently, when the repaired audio unit is delivered to the final user again, it will be in the “NEW”
state to enable re-linking the audio unit to the vehicle's immobilizer system. As a result of the above, repair of
the audio unit can only be done by an authorized Clarion representative (when the owner of the vehicle
requests repair and can show personal identification).
Service Procedure
Item Service procedure Description
Battery disconnection No additional action required. –
Radio needs repair Repair needs to be done by authorized
representative of radio manufacturer since
radio cannot be operated unless it is reset
to NEW state, using special decoding
equipment.–
Replacement of radio by new part No additional action required. Radio is delivered in NEW state.
Transferring radio to another vehicle/
replacement of radio by an “old” partRadio needs to be reset to NEW state by
authorized representative of radio manu-
facturer.–
Replacement of IMMU Radio needs to be reset to NEW state by
authorized representative of Clarion.After switching on the radio, it will display
“SECURE” after 1 minute.

SYSTEM DESCRIPTION
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Personal Audio Setting
The radio is designed to store several settings (volume, bass, treble, preset stations) with every NATS ignition
key used. Up to a maximum of 4 NATS keys can be registered. During the communication mentioned under
“Anti-Theft System”, the radio will recognize the used ignition key and select the accompanying settings.
VEHICLE INFORMATION SYSTEM
lThe status of audio system, fuel consumption, rear view monitor and navigation system are displayed.
lNAVI control unit receives the data signal from ECM, combination meter via CAN communication. It calcu-
lates the values of fuel economy, and trip computer from the received information and displays them.
NAVIGATION SYSTEM
Refer to Owner's Manual or navigation system Owner's Manual for navigation system operating instructions.
Location Detection Principle
The navigation system periodically calculates the vehicle's current
position according to the following three signals:
lTravel distance of the vehicle as determined by the vehicle
speed sensor
lTurning angle of the vehicle as determined by the gyroscope
(angular velocity sensor)
lDirection of vehicle travel as determined by the GPS antenna
(GPS information)
The current position of the vehicle is then identified by comparing the
calculated vehicle position with map data read from the map DVD-
ROM, which is stored in the DVD-ROM drive (map-matching), and
indicated on the screen as a vehicle mark. More accurate data is judged and used by comparing vehicle posi-
tion detection results found by the GPS with the result by map-matching.
The current vehicle position will be calculated by detecting the dis-
tance the vehicle moved from the previous calculation point and its
direction.
lTravel distance
Travel distance calculations are based on the vehicle speed
sensor input signal. Therefore, the calculation may become
incorrect as the tires wear down. To prevent this, an automatic
distance correction function has been adopted.
lTravel direction
Change in the travel direction of the vehicle is calculated by a
gyroscope (angular velocity sensor) and a GPS antenna (GPS
information). They have both advantages and disadvantages.
More accurate traveling direction is detected because priorities are set for the signals from these two
devices according to the situation.
No communication from IMMU to radio 1. If NATS is malfunctioning, check NATS
system.
2. After NATS is repaired, reset radio to
NEW state by authorized representative
of Clarion.After switching on the radio, the radio will
display “SECURE” after 1 minute. Further
use of radio is impossible until communica-
tion is established again, or after radio is
reset by authorized representative of Clar-
ion.
When initialized between ECM and IMMU. Radio needs to be reset to NEW status by
authorized representative of Clarion.After switching on the radio, it will display
“SECURE” after 1 minute. Item Service procedure Description
SKIB1058E
Type Advantage Disadvantage
Gyroscope
(angular velocity sensor)Can detect the vehicle's turning angle
quite accurately.Direction errors may accumulate when vehicle is
driven for long distances without stopping.
GPS antenna
(GPS information)Can detect the vehicle's travel direction
(North/South/East/West).Correct direction cannot be detected when vehi-
cle speed is low.
SEL684V

TROUBLE DIAGNOSIS
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Example of Symptoms Not MalfunctionEKS00Q6T
BASIC OPERATION
NOTE:
Locations stored in the Address Book and other memory functions may be lost if the vehicle's battery is disconnected or becomes dis-
charged. If this occurs, service the vehicle's battery as necessary and re-enter the information in the Address Book.
VEHICLE ICON
Symptom Possible cause Possible solution
No image is displayed.The brightness is at the lowest setting. Adjust the brightness of the display.
The display is turned off.
Press and hold to turn on the display.
No voice guidance is available.
The volume is too high or too low.The volume is not set correctly, or it is turned off. Adjust the volume of voice guidance.
Volume guidance is not provided for narrow streets
(roads displayed in gray).This is not a malfunction.
No map is displayed on the screen.The map DVD-ROM is not inserted, or it is inserted
upside down.Insert the map DVD-ROM correctly.
A screen other than map screen is displayed. Press “MAP”.
Thescreenistoodim.
The movement is slow.The temperature in the interior of the vehicle is low.Wait until the interior of the vehicle has
warmed up.
Some pixels in the display are
darker or brighter than others.This condition is an inherent characteristic of liquid
crystal displays.This is not a malfunction.
Some menu items cannot be
selected.Some menu items become unavailable while the
vehicle is driven.Park the vehicle in a safe location, and
then operate the navigation system.
Symptom Possible cause Possible solution
Names of roads and locations dif-
fer between Plan view and Bird-
view™.This is because the quantity of the displayed infor-
mation is reduced so that the screen does not
become too crowded. There is also a chance that
names of the roads or locations may be displayed
multiple times, and the names appearing on the a
screen may be different because of a processing
procedure.This is not a malfunction.
The vehicle icon is not displayed in
the correct position.The vehicle was transported after the ignition switch
was turned off, for example, by a ferry or car trans-
porter.Drive the vehicle for a while on a road
whereGPScanbereceived.
The position and direction of the vehicle may be
incorrect depending on the driving environments and
the levels of positioning accuracy of the navigation
system.This is not a malfunction. Drive the vehi-
cle for a while to automatically correct the
position and direction of the vehicle icon.
Whenthevehicleistravellingona
new road, the vehicle icon is
located on another road nearby.Because the new road is not stored in the map data,
the system automatically places the vehicle ion on
the nearest road available.Updated road information will be included
in the next version of the map DVD-ROM.
The screen does not switch to the
night screen even after turning on
the headlights.The daytime screen was set the last time the head-
lights were turned on.Set the screen to the night screen mode
using when turning on the headlights.
The map does not scroll even
when the vehicle is moving.The current location map screen is not displayed. Press “MAP”.
The vehicle icon is not displayed. The current location map screen is not displayed. Press “MAP”.
The GPS indicator on the screen
remains gray.GPS signals cannot be received depending on the
vehicle location, such as in a parking garage, on a
road that has numerous tall buildings, etc.Drive on an open, straight road for a
while.
GPS signals cannot be received because objects
are placed on the rear parcel shelf.Remove the objects from the rear parcel
shelf.
A sufficient amount of GPS satellites are not avail-
able.Wait for the satellites to move locations
available for navigation system.