light NISSAN NAVARA 2005 Repair Workshop Manual

MODELD40 SERIES
2005 NISSAN EUROPE S.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.
A GENERAL INFORMATION
B ENGINE
C TRANSMISSION/TRANSAXLE
D DRIVELINE/AXLE
E SUSPENSION F BRAKES
G STEERING H RESTRAINTS
I BODY
J AIR CONDITIONER
K ELECTRICAL
L MAINTENANCE
M INDEXGI General Information
EM Engine Mechanical
LU Engine Lubrication System
CO Engine Cooling System
EC Engine Control System
FL Fuel System
EX Exhaust System
ACC Accelerator Control System
CL Clutch
MTManualTransmission
AT Automatic Transmission
TF Transfer
PR Propeller Shaft
FFD Front Final Drive
RFD Rear Final Drive
FAX Front Axle
RAX Rear Axle
FSU Front Suspension
RSU Rear Suspension
WT Road Wheels & Tires
BR Brake System
PB Parking Brake System
BRC Brake Control System
PS Power Steering System
SB Seat Belts
SRS Supplemental Restraint System (SRS)
BL Body, Lock & Security System
GW Glasses, Window System & Mirrors
RF Roof
EI Exterior & Interior
IP Instrument Panel
SE Seat
ATC Automatic Air Conditioner
MTC Manual Air Conditioner
SC Starting & Charging System
LT Lighting System
DI Driver Information System
WW Wiper, Washer & Horn
BCS Body Control System
LAN LAN System
AV Audio, Visual & Telephone System
ACS Auto Cruise Control System
PG Power Supply, Ground & Circuit Elements
MA Maintenance
IDX Alphabetical Index
QUICK REFERENCE INDEX
A
B
C
D
E
F
G
H
I
J
K
L
M

AT-46
TROUBLE DIAGNOSIS
ROAD TEST
Description
lThe road test inspects overall performance of A/T and analyzes possible malfunction causes.
lThe road test is perform in the following three stages.
1. Check before engine is started. Refer toAT-46
.
2. Check at idle. Refer toAT-47
.
3. Cruise test.
lInspect all the items from Part 1 to Part 3. Refer toAT-48,AT-50,AT-51.
lBefore beginning the road test, check the test procedure and inspection items.
lTest all inspection items until the symptom is uncovered. Diagnose NG items when all road tests are com-
plete.
CheckBeforeEngineIsStartedECS00FX1
1.CHECK OD OFF INDICATOR LAMP
1. Park vehicle on level surface.
2. Move selector lever to “P” position.
3. Turn ignition switch OFF and wait at least 10 seconds.
4. Turn ignition switch ON. (Do not start engine.)
Does OD OFF indicator lamp light up for about 2 seconds?
YES >> 1. Turn ignition switch OFF.
2. Perform self-diagnosis and record all NG items onAT-38, "
DIAGNOSTIC WORKSHEET".
Refer toAT-80, "
SELF-DIAGNOSTIC RESULT MODE",AT-89, "TCM SELF-DIAGNOSTIC
PROCEDURE (WITHOUT CONSULT-II)".
3. Go toAT-47, "
Check at Idle".
NO >> Stop the road test and go toAT- 1 7 7 , "
OD OFF Indicator Lamp Does Not Come On".
Stall speedOil pressure does not
rise higher than the oil
pressure for idle.Possible causes include a sensor malfunction or malfunction in the pressure adjustment
function.
For example
lAccelerator pedal position signal malfunction
lTCM malfunction
lLine pressure solenoid malfunction (shorting, sticking in ON state)
lPressure regulator valve or plug sticking
lPilot valve sticking or pilot filter clogged
The pressure rises, but
does not enter the stan-
dard position.Possible causes include malfunctions in the pressure supply system and malfunction in the
pressure adjustment function.
For example
lAccelerator pedal position signal malfunction
lLine pressure solenoid malfunction (sticking, filter clog)
lPressure regulator valve or plug sticking
lPilot valve sticking or pilot filter clogged
Only low for a specific
positionPossible causes include an oil pressure leak in a passage or device related to the position
after the pressure is distributed by the manual valve. Judgement Possible cause

AT-50
TROUBLE DIAGNOSIS
8.CHECK LOCK-UP RELEASE
Check lock-up cancellation by depressing brake pedal lightly to decelerate.
With CONSULT-II
Select “TCC SOLENOID” with “MAIN SIGNALS” mode for “A/T”. Refer toAT-77, "
CONSULT-II REFERENCE
VA L U E".
Does lock-up cancel?
YES >> GO TO 9.
NO >> Enter a check mark at “Lock-up Is Not Released” onAT-38, "
DIAGNOSTIC WORKSHEET",then
continue the road test.
9.CHECK SHIFT-DOWN D5®D4
Decelerate by pressing lightly on brake pedal.
With CONSULT-II
Read the gear position and engine speed. Refer toAT-83, "
DATA MONITOR MODE".
When the A/T shift-down D
5®D4, does the engine speed drop smoothly back to idle?
YES >> 1. Stop the vehicle.
2. Go toAT-50, "
Cruise Test - Part 2".
NO >> Enter a check mark at “Engine Speed Does Not Return to Idle” onAT-38, "
DIAGNOSTIC WORK-
SHEET", then continue the road test. Go toAT-50, "Cruise Test - Part 2".
CruiseTest-Part2ECS00FX4
1.CHECK STARTING FROM D1
1. Move selector lever to “D” position.
2. Accelerate at half throttle.
With CONSULT-II
Read the gear position. Refer toAT-83, "
DATA MONITOR MODE".
Does it start from D
1?
YES >> GO TO 2.
NO >> Enter a check mark at “Vehicle Cannot Be Started from D
1”onAT-38, "DIAGNOSTIC WORK-
SHEET", then continue the road test.
2.CHECK SHIFT-UP D1®D2
Press accelerator pedal down all the way and inspect whether or not the A/T shifts up (D1®D2)atthecor-
rect speed. Refer toAT-52, "
Vehicle Speed at Which Gear Shifting Occurs".
With CONSULT-II
Read the gear position, throttle degree and vehicle speed. Refer toAT-83, "
DATA MONITOR MODE".
Does the A/T shift-up D
1®D2at the correct speed?
YES >> GO TO 3.
NO >> Enter a check mark at “A/T Does Not Shift: D
1®D2”onAT-38, "DIAGNOSTIC WORKSHEET",
then continue the road test.
3.CHECK SHIFT-UP D2®D3
Press accelerator pedal down all the way and inspect whether or not the A/T shifts up (D2®D3)atthecor-
rect speed. Refer toAT-52, "
Vehicle Speed at Which Gear Shifting Occurs".
With CONSULT-II
Read the gear position, throttle degree and vehicle speed. Refer toAT-83, "
DATA MONITOR MODE".
Does the A/T shift-up D
2®D3at the correct speed?
YES >> GO TO 4.
NO >> Enter a check mark at “A/T Does Not Shift: D
2®D3”onAT-38, "DIAGNOSTIC WORKSHEET",
then continue the road test.

TROUBLE DIAGNOSIS
AT-77
D
E
F
G
H
I
J
K
L
MA
B
AT
CONSULT-II Function (A/T)ECS00FXA
CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
FUNCTION
CONSULT-II REFERENCE VALUE
NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each sole-
noid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Man-
ual may differ slightly. This occurs because of the following reasons:
–Actual shift schedule has more or less tolerance or allowance,
–Shift schedule indicated in Service Manual refers to the point where shifts start, and
–Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Display of solenoid valves on CONSULT-II changes at the start of shifting, while gear position is displayed
upon completion of shifting (which is computed by TCM).
Diagnostic test mode Function Reference page
Self-diagnostic results Self-diagnostic results can be read and erased quickly.AT- 8 0
Data monitor Input/Output data in the ECU can be read.AT- 8 3
CAN diagnostic support
monitorThe results of transmit/receive diagnosis of CAN communication can be read.AT- 8 6
Function testConducted by CONSULT-II instead of a technician to determine whether each system
is “OK” or “NG”.—
DTC work support Select the operating condition to confirm Diagnostic Trouble Codes.AT- 8 6
ECU part number ECU part number can be read. —
Item name Condition Display value (Approx.)
VHCL/S SE-A/T
During drivingApproximately matches the speed-
ometer reading.
VHCL/S SE-MTR
ACCELE POSIReleased accelerator pedal. 0.0/8
Fully depressed accelerator pedal. 8.0/8
CLSD THL POSReleased accelerator pedal. ON
Fully depressed accelerator pedal. OFF
W/O THL POSFully depressed accelerator pedal. ON
Released accelerator pedal. OFF
BRAKE SWDepressed brake pedal. ON
Released brake pedal. OFF
ENGINE SPEED Engine runningClosely matches the tachometer
reading.
TURBINE REV During driving (lock-up ON)Approximately matches the engine
speed.
ATFTEMPSE1
0°C(32°F)-20°C(68°F)-80°C (176°F)3.3 - 2.7 - 0.9 V
ATFTEMPSE23.3 - 2.5 - 0.7 V
TCC SOLENOID When perform lock-up 0.4 - 0.6 A
LINE PRES SOL During driving 0.2 - 0.6 A
FR/B SOLENOIDFront brake engaged. Refer toAT- 1 7
. 0.6 - 0.8 A
Front brake disengaged. Refer toAT- 1 7
.0-0.05A

TROUBLE DIAGNOSIS
AT-89
D
E
F
G
H
I
J
K
L
MA
B
AT
Diagnostic Procedure Without CONSULT-IIECS00FXB
TCM SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)
Description
In the unlikely event of a malfunction in the electrical system, when the ignition switch is switched ON, the OD
OFF indicator lamp lights up for 2 seconds. If there is no malfunction, when the ignition switch is turned ON,
the indicator lamp lights up for 2 seconds. As a method for locating the suspect circuit, when the self-diagnos-
tics start signal is input, the memory for the malfunction location is output and OD OFF indicator lamp flashes
to display the corresponding DTC.
Diagnostic Procedure
1.CHECK OD OFF INDICATOR LAMP
1. Start the engine with selector lever in “P” position. Warm engine to normal operating temperature.
2. Turn ignition switch ON and OFF at least twice, then leave it in the OFF position.
3. Wait 10 seconds.
4. Turn ignition switch ON. (Do not start engine.)
Does OD OFF indicator lamp come on for about 2 seconds?
YES >> GO TO 2.
NO >> GO TOAT- 1 7 7 , "
OD OFF Indicator Lamp Does Not Come On".
2.JUDGEMENT PROCEDURE
1. Turn ignition switch OFF.
2. Keep pressing shift lock release button.
3. Move selector lever from “P” to “D” position.
4. Release accelerator pedal. (Set the closed throttle position signal ON.)
5. Depress brake pedal. (Stop lamp switch signal ON.)
6. Turn ignition switch ON.
7. Wait 3 seconds.
8. Move selector lever from “D” to “3” position.
9. Release brake pedal. (Stop lamp switch signal OFF.)
10. Move selector lever from “3” to “2” position.
11. Depress brake pedal. (Stop lamp switch signal ON.)
12. Release brake pedal. (Stop lamp switch signal OFF.)
13. Depress accelerator pedal fully and release it.
>> GO TO 3.
3.CHECK SELF-DIAGNOSIS CODE
Check OD OFF indicator lamp. Refer toAT-90, "
Judgement Self-diagnosis Code".
If the system does not go into self-diagnosis. Refer toAT-99, "
DTC P0705 PARK/NEUTRAL POSITION
SWITCH",AT- 1 6 8 , "CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION CIRCUIT",
AT- 1 6 9 , "
BRAKE SIGNAL CIRCUIT".
>>DIAGNOSIS END

AT-90
TROUBLE DIAGNOSIS
Judgement Self-diagnosis Code
If there is a malfunction, the lamp lights up for the time corresponding to the suspect circuit.
Erase Self-diagnosis
lIn order to make it easier to find the cause of hard-to-duplicate malfunctions, malfunction information is
stored into the control unit as necessary during use by the user. This memory is not erased no matter how
many times the ignition switch is turned ON and OFF.
lHowever, this information is erased by turning ignition switch OFF after executing self-diagnosis or by
erasing the memory using the CONSULT-II.
No. Malfunctioning item No. Malfunctioning item
1. Revolution sensorAT- 1 0 3
10. A/T fluid temperature sensorAT- 11 8
2. Direct clutch solenoid valveAT- 1 4 2,AT-14411. Turbine revolution sensorAT- 1 2 3
3. Torque converter clutch solenoid valveAT- 11 0,AT- 11 212. A/T interlockAT-127
4. Line pressure solenoid valveAT- 11 413. A/T 1st engine brakingAT-130
5. Input clutch solenoid valveAT- 1 3 2,AT- 1 3 414. Start signalAT- 9 4
6. Front brake solenoid valveAT-137,AT- 1 3 915. Accelerator pedal position sensorAT- 11 6
7. Low coast brake solenoid valveAT- 1 5 2,AT- 1 5 416. Engine speed signalAT-108
8. High and low reverse clutch solenoid valveAT-147,AT- 1 4 917. CAN communication lineAT- 9 1
9. PNP switchAT- 9 9
SCIA6862E

ASSEMBLY
AT-303
D
E
F
G
H
I
J
K
L
MA
B
AT
15. Install seal rings to drum support.
16. Install return spring and spring retainer in transmission case.
17. Set the SST on spring retainer and install snap ring (fixing spring
retainer) in transmission case while compressing return spring.
CAUTION:
Securely assemble them using a flat-bladed screwdriver so
that snap ring tension is slightly weak.
SCIA3333E
SCIA2324E
SCIA6843E

ATC-16
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEJS006AT
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
HFC-134a (R-134a) Service Tools and EquipmentEJS006AU
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor malfunction will result.
Tool number
Tool nameDescription
KV99106200
Pulley installerInstalling pulley
KV99233130
Pulley pullerRemoving pulley
S-NT235
LHA172
Tool number
Tool nameDescription
HFC-134a (R-134a) refrigerantContainer color: Light blue
Container marking: HFC-134a (R-
134a)
Fitting size: Thread size
lLarge container 1/2²-16 ACME
KLH00-PAGS0
Nissan A/C System Oil Type S
(DH-PS)Type: Polyalkylene glycol oil (PAG),
type S (DH-PS)
Application: HFC-134a (R-134a)
wobble (swash) plate compressors
(Nissan only)
Lubricity: 40 m (1.4 Imp fl oz.)
S-NT196
S-NT197

PREPARATION
ATC-17
C
D
E
F
G
H
I
K
L
MA
B
AT C
Recovery/Recycling/
Recharging equipment (ACR4)Function: Refrigerant recovery and
recycling and recharging
Electrical leak detectorPower supply:
DC 12V (Cigarette lighter)
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleanerPower supply:
DC 12V (Battery terminal)
(J-42220)
UV lamp and UV safety gogglesPower supply:
DC 12V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application: For HFC-134a (R-134a)
PA G o i l
Container: 1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.) Tool number
Tool nameDescription
RJIA0195E
SHA705EB
ZHA200H
SHA438F
SHA439F

ATC-58
TROUBLE DIAGNOSIS
CHECKING DISCHARGE AIR
1. Press MODE switch four times and the DEF switch.
2. Each position indicator should change shape (on display).
3. Confirm that discharge air comes out according to the air distri-
bution table. Refer toAT C - 3 0 , "
Discharge Air Flow".
Mode door position is checked in the next step.
If NG, go to trouble diagnosis procedure forAT C - 6 3 , "
Mode Door
Motor Circuit".
If OK, continue the check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at fresh when the DEF or D/F
is selected.
CHECKING RECIRCULATION
1. Press recirculation ( ) switch one time. Recirculation indica-
tor should illuminate.
2. Press recirculation ( ) switch one more time. Recirculation
indicator should go off.
3. Listen for intake door position change (blower sound should
change slightly).
If NG, go to trouble diagnosis procedure forAT C - 7 7 , "
Intake Door
Motor Circuit".
If OK, continue next check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at fresh when the DEF or D/F is selected.
CHECKING TEMPERATURE DECREASE
1. Rotate temperature control dial (driver side) counterclockwise
until 18°C(60°F) is displayed.
2. Check for cold air at appropriate discharge air outlets.
If NG, listen for sound of air mix door motor operation. If OK, go to
trouble diagnosis procedure forAT C - 9 3 , "
Insufficient Cooling".Ifair
mix door motor appears to be malfunctioning, go toAT C - 7 1 , "
DIAG-
NOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER)"
orAT C - 7 3 , "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR
MOTOR (PASSENGER)".
If OK, continue the check.
MJIB0338E
MJIB0284E
MJIB0339E
MJIB0340E