roof rack NISSAN NAVARA 2005 Repair Workshop Manual

REMOVAL AND INSTALLATION
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Tw e e t e rEKS00Q6Z
REMOVAL
1. Remove speaker grille.
2. Remove screws (A) and remove tweeter (1).
INSTALLATION
Installation is the reverse order of removal.
Roof AntennaEKS00Q70
REMOVAL
l: Vehicle front
1. Remove headlining. Refer toEI-40, "
HEADLINING".
2. Remove nut (A) and antenna base.
INSTALLATION
Installation is the reverse order of removal.
NAVI Control UnitEKS00Q71
REMOVAL
l: Vehicle front
1. Slide front seat RH fully forward.
2. Disconnect connectors.
3. Remove screws (A) and remove NAVI control unit (1).
4. Remove screws and brackets (2) from NAVI control unit (1).
INSTALLATION
Installation is the reverse order of removal.
SKIB4581E
SKIB6657E
SKIB4531E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

EI-1
EXTERIOR & INTERIOR
IBODY
CONTENTS
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SECTIONEI
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EI
EXTERIOR & INTERIOR
PRECAUTIONS .......................................................... 3
Service Notice .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for SRS “AIR BAG” and “SEAT BELT
PRE-TENSIONER” Service ..................................... 3
Precautions for Procedures without Cowl Top Cover..... 4
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 6
Work Flow ................................................................ 6
CUSTOMER INTERVIEW ..................................... 6
DUPLICATE THE NOISE AND TEST DRIVE ....... 7
CHECK RELATED SERVICE BULLETINS ........... 7
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 7
REPAIR THE CAUSE ........................................... 7
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
OVERHEAD CONSOLE (FRONT AND REAR)..... 8
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
CLIP AND FASTENER ............................................. 12
Clip and Fastener ................................................... 12
FRONT BUMPER ..................................................... 15
Removal and Installation ........................................ 15
FRONT BUMPER ............................................... 15
REAR BUMPER ....................................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18FRONT GRILLE ........................................................ 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 19
COWL TOP ............................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
FENDER PROTECTOR ............................................ 21
Components ........................................................... 21
Removal and Installation of Front Fender Protector... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
Removal and Installation of Rear Fender Protector... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
MUDGUARD ............................................................. 23
Removal and Installation ........................................ 23
RUNNING BOARDS ................................................. 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
ROOF RACK ............................................................. 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
DOOR OUTSIDE MOLDING ..................................... 27
Removal and Installation ........................................ 27
FRONT DOOR OUTSIDE MOLDING .................. 27
SIDE GUARD MOLDING .......................................... 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
DOOR FINISHER ...................................................... 30
Removal and Installation ........................................ 30
FRONT DOOR .................................................... 30
REAR DOOR - DOUBLE CAB ............................ 31
REAR DOOR - KING CAB .................................. 32
BODY SIDE TRIM ..................................................... 33
Components ........................................................... 33

EI-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
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 apply-
ing felt cloth tape or silicone spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
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.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lens loose.
3. Loose screws at console attachment points.

EI-26
ROOF RACK
ROOF RACK
PFP:73155
Removal and InstallationEIS00DYJ
REMOVAL
1. Remove RH/LH side rail bolts from roof panel.
2. Pry outward releasing end caps and remove from side rails.
3. Remove the bolts and remove rear crossbar from side rails.
4. Remove the bolts and remove front crossbar from side rails.
INSTALLATION
Installation is in the reverse order of removal.
1. RH side rail 2. Front crossbar 3. LH side rail
4. Roof panel 5. Rear crossbar 6. End cap
MIIB9127E

HEADLINING
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REMOVAL
CAUTION:
Disconnect both the positive and negative battery terminals in advance.
1. Remove body side trim panels. Refer toEI-33, "
BODY SIDE TRIM".
2. Remove rear trim. Refer toEI-36, "
REAR".
3. Remove sun visor assemblies, both LH and RH.
4. Remove sun visor holders LH and RH.
5. Remove roof console (if equipped).
lDisconnect harness.
6. Remove room lamp.
lDisconnect harness.
7. Remove microphone assembly (if equiped).
8. Remove inside mirror finisher, and inside mirror harness finisher (if equipped). Refer toGW-46, "
Removal
and Installation".
lDisconnect harness, then release it, from headlining.
9. Remove striker covers (King Cab only).
10. Remove assist grips.
11. Remove headlining.
NOTE:
Use an assistant to steady the headlining while lowering from roof.
lRemove clips from center of headlining (if equipped).
12. Remove assist grip brackets from roof.
INSTALLATION
CAUTION:
Use only Nissan available process to fix harness with Headlining.
Installation is in the reverse order of removal.
1. Sunroof shade cover (if equipped) 2. Sunroof welt (if equipped) 3. Assist grip
4. Sun visor assembly RH 5. Sun visor holder RH/LH 6. Sun visor assembly LH
7. Striker cover outer RH (King Cab) 8. Striker cover inner RH (King Cab) 9. Roof console with front room lamp
and sunglass bin (if equipped)
10. Striker cover outer LH (King Cab) 11. Striker cover inner LH (King Cab) 12. Coat hook
13. Headlining (King Cab) 14. Headlining (Double cab w/sunroof) 15. Room lamp
16. Microphone assembly (if equipped) 17. Inside miror harness finisher
(if equipped)18. Inside miror finisher (if equipped)

FUEL SYSTEM
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS01E71
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS01E72
WARNING:
When replacing fuel line parts, be sure to observe the following.
lPut a “CAUTION: INFLAMMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
lUse diesel fuel required by the regulations for cetane number. Refer toGI-6, "DIESEL ENGINE".
lBefore removing fuel line parts, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Disconnect the battery cable from the negative terminal.
lAlways replace O-ring and clamps with new ones.
lDo not kink or twist tubes when they are being installed.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lAfter connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
lAfter installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
SBIA0504E

GI-60
IDENTIFICATION INFORMATION
Dimensions
EAS001DO
KING CAB
Unit: mm (in)
DOUBLE CAB
Unit: mm (in)
Wheels & TyresEAS001DP
Drive Type 2WD 4WD
Tyre size 235/70R16 255/70R16 235/70R16 255/70R16 265/70R16 255/65R17
Overall length 5220 (205.5)
Overall width 1850 (72.8)
Overall height 1743 (68.6) 1756 (69.1) 1751 (68.9) 1766 (69.5) 1777 (70.0) 1771 (69.7)
Front tread width
1570 (61.8)
Rear tread width
Wheelbase 3200 (126.0)
Drive Type 2WD 4WD
Tyre size 255/70R16 255/65R17 235/70R16 255/70R16 265/70R16 255/65R17
Overall length 5220 (205.5)
Overall width 1850 (72.8)
Overall height
(with Roof Rack)1881 (74.1) 1885 (74.2) 1873 (73.7) 1888 (74.3) 1899 (74.8) 1893 (74.5)
Overall height
(without Roof Rack)1771 (69.7) 1775 (69.9) 1764 (69.4) 1779 (70.0) 1789 (70.4) 1784 (70.2)
Front tread width
1570 (61.8)
Rear tread width
Wheelbase 3200 (126.0)
Drive Type Road wheel Tyre Spare tyre size
All16 X 7J Steel 235/70R16 235/70R16
16 X 7J Aluminum Alloy235/70R16 235/70R16
255/70R16 255/70R16
17 X 7J Aluminum Alloy 255/65R17 255/65R17

GW-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lens loose.
3. Loose screws at console attachment points.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.