weight NISSAN NAVARA 2005 Repair Workshop Manual

PRECAUTIONS
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS00IPT
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.
PrecautionsECS00IPR
lBefore connecting or disconnecting the A/T assembly har-
ness connector, turn ignition switch OFF and disconnect
the battery cable from the negative terminal. Because bat-
tery voltage is applied to TCM even if ignition switch is
turned OFF.
lAfter performing each TROUBLE DIAGNOSIS, perform
“DTC Confirmation Procedure”.
If the repair is completed the DTC should not be displayed
in the “DTC Confirmation Procedure”.
lAlways use the specified brand of ATF. Refer toMA-14, "REC-
OMMENDED FLUIDS AND LUBRICANTS".
lUse lint-free paper not cloth rags during work.
lAfter replacing ATF, dispose of the waste oil using the methods prescribed by law, ordinance, etc.
lBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
lDisassembly should be done in a clean work area.
lUse lint-free paper or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
lPlace disassembled parts in order for easier and proper assembly.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lGaskets, seals and O-rings should be replaced any time the transmission is disassembled.
lIt is very important to perform functional tests whenever they are indicated.
lThe valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
lProperly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
lBefore assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
lExtreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
lAfter overhaul, refill the transmission with new ATF.
lWhen the drain plug is removed, only some of the ATF is drained. Old ATF will remain in torque converter
and A/T fluid cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
toAT-11, "
Changing A/T Fluid",AT-12, "Checking A/T Fluid".
SEF289H

AT-16
A/T CONTROL SYSTEM
Shift Mechanism
ECS00FWH
The A/T uses compact triple planetary gear systems to improve power transmission efficiency, simplify con-
struction and reduce weight.
It also employs an optimum shift control and super wide gear ratios. They improve starting performance and
acceleration during medium and high-speed operation.
CONSTRUCTION
FUNCTION OF CLUTCH AND BRAKE
1. Front brake 2. Input clutch 3. Direct clutch
4. High and low reverse clutch 5. Reverse brake 6. Forward brake
7. Low coast brake 8. 1st one-way clutch 9. Forward one-way clutch
10. 3rd one-way clutch 11. Front sun gear 12. Input shaft
13. Mid internal gear 14. Front internal gear 15. Rear carrier
16. Rear sun gear 17. Mid sun gear 18. Front carrier
19. Mid carrier 20. Rear internal gear 21. Output shaft
22. Parking gear 23. Parking pawl
PCIA0002J
Name of the Part Abbreviation Function
Front brake (1) FR/B Fastens the front sun gear (11).
Input clutch (2) I/CConnects the input shaft (12), the front internal gear (14) and the mid internal gear
(13).
Direct clutch (3) D/C Connects the rear carrier (15) and the rear sun gear (16).
High and low reverse clutch (4) HLR/C Connects the mid sun gear (17) and the rear sun gear (16).
Reverse brake (5) R/B Fastens the rear carrier (15).
Forward brake (6) Fwd/B Fastens the mid sun gear (17).
Low coast brake (7) LC/B Fastens the mid sun gear (17).
1st one-way clutch (8) 1st OWCAllows the rear sun gear (16) to turn freely forward relative to the mid sun gear (17)
but fastens it for reverse rotation.
Forward one-way clutch (9) Fwd OWCAllows the mid sun gear (17) to turn freely in the forward direction but fastens it for
reverse rotation.
3rd one-way clutch (10) 3rd OWCAllows the front sun gear (11) to turn freely in the forward direction but fastens it for
reverse rotation.

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTIONAT C
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AUTOMATIC 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
Components ........................................................... 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 DOORS CONTROL .............................. 26
BLOWER SPEED CONTROL ............................. 26
INTAKE DOOR 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
AUTO SWITCH ................................................... 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE CONTROL) (DRIVER SIDE) ..................... 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE CONTROL) (PASSENGER SIDE) ............ 29
TEMPERATURE CONTROL DIAL (TEMPERA-
TURE AND MODE CONTROL) (REAR) ............. 29
RECIRCULATION (REC) SWITCH ..................... 29
DEFROSTER (DEF) SWITCH ............................. 29
REAR WINDOW DEFOGGER SWITCH ............. 29
OFF SWITCH ...................................................... 29
A/C SWITCH ....................................................... 29
MODE SWITCH (FRONT) ................................... 29
FRONT BLOWER CONTROL DIAL .................... 29
MODE SWITCH (REAR) ..................................... 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 Function (BCM) ................................. 33
CONSULT-II BASIC OPERATION ....................... 33

ATC-14
PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2²-16
ACME.
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset”and“Enter”at the same time.
2. Press “8787”.“A1” will be displayed.
3. Remove all weight from the scale.
4. Press “0”, then press “Enter”.“0.00” will be displayed and change to “A2”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb.) on the center
of the weight scale.
6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50)
7. Press “Enter”— the display returns to the vacuum mode.
8. Press“Shift/Reset”and“Enter”at the same time.
9. Press “6” — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00” will be displayed.
11. Press“Shift/Reset” to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.
Precautions for Leak Detection DyeEJS006AR
lThe A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
lAlways wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
lThe fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo-
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-
41995) to pin-point refrigerant leaks.
lFor your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions
and precautions prior to performing the work.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D
RHA274D

ATC-18
PREPARATION
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system.
(J-43872)
Refrigerant dye cleanerFor cleaning dye spills.
Manifold gauge set (with hoses
and couplers)Identification:
lThe gauge face indicates HFC-134a
(R-134a).
Fitting size: Thread size
l1/2²-16 ACME
Service hoses
lHigh-pressure side hose
lLow-pressure side hose
lUtility hoseHose color:
lLow hose: Blue with black stripe
lHigh hose: Red with black stripe
lUtility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
l1/2²-16 ACME
Service couplers
lHigh-pressure side coupler
lLow-pressure side couplerHose fitting to service hose:
M14 x 1.5 fitting is optional or
permanently attached.
Refrigerant weight scaleFor measuring of refrigerant
Fitting size: Thread size
1/2²-16 ACME
Vacuum pump
(Including the isolator valve)Capacity:
lAir displacement: 4 CFM
lMicron rating: 20 microns
lOil capacity: 482 g (17 oz.)
Fitting size: Thread size
l1/2²-16 ACME Tool number
Tool nameDescription
SHA440F
SHA441F
RJIA0196E
S-NT201
S-NT202
S-NT200
S-NT203

REFRIGERANT LINES
ATC-139
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4. Refrigerant container (HFC-134a) 5. Refrigerant weight scale (J-39699) 6. Vacuum pump (J-39649)
7. Manifold gauge set with hoses and
couplers (J-39183-C)
*1AT C - 2 4 , "
CHECKING AND
ADJUSTING".*3ATC-150, "
Checking for Refrigerant
Leaks".*5AT C - 4 , "
Contaminated Refrigerant".
*2ATC-150, "
Checking for Refrigerant
Leaks".*4ATC-94, "
PERFORMANCE TEST
DIAGNOSES".
WJIA0530E

HOOD
BL-13
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LONGITUDINAL AND LATERAL CLEARANCE ADJUSTMENT
1. Remove the hood lock, loosen the hood hinge nuts and close the hood.
2. Adjust the lateral and longitudinal clearance, and open the hood to tighten the mounting bolts to the spec-
ified torque.
3. Install the hood lock temporarily, and align the hood striker and lock so that the centers of striker and lock
become vertical viewed from the front, by moving the hood lock laterally.
4. Tighten hood lock mounting bolts to the specified torque.
FRONT END HEIGHT ADJUSTMENT
1. Remove the hood lock and adjust the height by rotating the bumper rubber until the hood becomes 1 to1.5
mm (0.04 to 0.059 in) lower than the fender.
2. Temporarily tighten the hood lock, and position it by engaging it with the hood striker. Check the lock and
striker for looseness, and tighten the hood lock mounting bolts to the specified torque.
CAUTION:
Adjust right/left clearance between hood and each part to the following specification.
SURFACE HEIGHT ADJUSTMENT
1. Remove the hood lock, and adjust the surface height difference of hood, fender and headlamp according
to the fitting standard dimension, by rotating RH and LH bumper rubbers.
2. Install hood lock temporarily, and move hood lock laterally until the centers of striker and lock become ver-
tical when viewed from the front.
3. Check that the hood lock secondary latch is properly engaged with the secondary striker with hood's own
weight.
4. Check that the hood lock primary latch is securely engaged with the hood striker with hood's own weight
by dropping hood from approx. 200 mm (7.87) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or more.
5. Move hood lockup and down until striker smoothly engages the lock when the hood is closed.
6. When pulling the hood opener lever gently, make sure that front end of the hood rises by approximately 20
mm (0.79) and that hood striker and hood lock primary latch is disengaged. Also make sure that hood
opener returns to the original position.
7. After adjustment, tighten lock bolts to the specified torque.
CAUTION:
lAfter installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
lAdjust evenness between hood and each part to the following specification.
Portion Clearance
Hood - Front grille A - A (a) 3.7 - 8.3 mm (0.146 - 0.327 in)
Hood - Front fender B - B (c) 3.6 - 5.6 mm (0.142 - 0.220 in)
Hood - Headlamp C - C (e) 6.0 - 8.0 mm (0.236 - 0.315 in)
Portion R / L difference
Hood - Front grille A - A (a) Less than 2.2 mm (0.087 in)
Hood - Front fender B - B (c) Less than 1.0 mm (0.039 In)
Portion Surface height
Hood - Front grille A - A (b) -1.7 - 3.1 mm (-0.067 - 0.122 in)
Hood - Front fender B - B (d) -1.0 - 1.0 mm (-0.039 - 0.039 in)
Hood - Headlamp C - C (f) -1.3 - 2.7 mm (-0.051 - 0.106 in)

BL-14
HOOD
Removal and Installation of Hood Assembly
EIS00B4J
REMOVAL
1. Disconnect washer hose at the connecting point.
2. Support the hood striker with a proper material to prevent it from
falling.
WARNING:
Body injury may occur if no supporting rod is holding the
hood open when removing the food stay.
3. Remove the hinge nuts from the hood to remove the hood assembly.
CAUTION:
Operate with two workers, because of its heavy weight.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
lBefore installing hood hinge, apply anticorrosive agent onto the mounting surface of the vehicle
body.
lAfter installing, perform hood fitting adjustment. Refer toBL-12, "Fitting Adjustment".
lAfter installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
1. Hood assembly 2. Hood front sealing rubber 3. Hood insulator
4. Hood bumper rubber 5. Hood stay 6. Hood hinge
MIIB0627E
MIIB0555E

HOOD
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Hood Lock Control InspectionEIS00BQ1
CAUTION:
If the hood lock cable is bent or deformed, replace it.
1. Make sure that the hood lock secondary latch is properly engaged with the secondary striker with hood's
own weight.
2. Make sure that the hood lock primary latch is securely engaged with the hood striker with hood's own
weight by dropping it from approx. 200 mm (7.87 in) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or more.
3. When pulling hood opener lever gently, make sure that front end
of the hood rises by approximately 20 mm (0.79 in) and that
hood striker and hood lock primary latch are disengaged. Also
make sure that hood opener returns to the original position.
4. Install as static closing face of hood is 392 N·m (35 Kg-m, 253.0
ft-lb) ~ 441 N·m (45 Kg-m, 325.3 ft-lb).
5. Confirm hood lock is properly lubricated. If necessary, apply
grease at the point shown in the figure.
MIIB0639E
MIIB0640E

BL-120
DOOR
FRONT DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the front fender. Refer toBL-20, "Removal and Installation".
2. Loosen the hinge mounting bolts. Raise or lower the front door at rear end to adjust.
REAR DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the center pillar upper finisher. Refer toEI-35, "CENTER PILLAR UPPER FINISHER".
2. Loosen the lower hinge mounting bolts.
3. From inside the vehicle, loosen the upper hinge mounting nuts. Open the door, and raise or lower the rear
end of the door to adjust.
CAUTION:
After installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts and
mounting bolts.
STRIKER ADJUSTMENT
Adjust the striker so that it becomes parallel with the lock insertion
direction.
Removal and Installation of Front DoorEIS00B6A
CAUTION:
lWhen removing and installing the front door assembly, support the door with a jack and cloth to
protect the door and body.
lWhen removing and installing front door assembly, be sure to carry out the fitting adjustment
Refer toBL-117, "
Fitting Adjustment (King Cab)"andBL-119, "Fitting Adjustment (Double Cab)".
lCheck the hinge rotating part for poor lubrication. If necessary, apply “body grease”.
lAfter installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
lOperate with two workers, because of its heavy weight.
lAfter installing, check operation.
REMOVAL
1. Remove the front kicking plate and the dash side finisher. Refer toEI-33, "BODY SIDE TRIM".
Portion Clearance
Front fender- Front door outer A - A (a) 3.5 - 5.5 mm (0.138 - 0.217 in)
Front door outer - Rear door outer B - B (c) 3.5 - 5.5 mm (0.138 - 0.217 in)
Portion Surface height
Front fender- Front door outer A - A (b) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
Front door outer - Rear door outer B - B (d) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
: 16.7 N·m (1.7 kg-m, 12.4 ft-lb)
PIIB2804J