2005 NISSAN NAVARA service

BR-36
SERVICE DATA AND SPECIFICATIONS (SDS)
Rear Disc Brake
EFS005TD
Unit: mm (in)
Brake modelLT 3 0
Brake liningStandard thickness 5.5 (0.22)
Repair limit thickness 1.5 (0.06)
DrumStandard inner diameter 295 (11.61)
Repair limit inner diameter 296.5 (11.67)

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
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M
SECTIONBRC
A
B
BRC
BRAKE CONTROL SYSTEM
ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 3
PREPARATION ........................................................... 4
Special Service Tools (SST) ..................................... 4
SYSTEM DESCRIPTION ............................................ 5
System Diagram ....................................................... 5
Functions .................................................................. 5
Operation That Is Not “System Error” ...................... 5
Fail-Safe Function .................................................... 5
ABS, EBD SYSTEM .............................................. 5
Hydraulic Circuit Diagram ........................................ 6
CAN COMMUNICATION ............................................ 7
System Description .................................................. 7
TROUBLE DIAGNOSIS .............................................. 8
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ....................................................... 8
INTRODUCTION ................................................... 8
DIAGNOSIS FLOWCHART .................................. 9
ASKING COMPLAINTS ...................................... 10
EXAMPLE OF DIAGNOSIS SHEET ................... 10
Component Parts Location ...................................... 11
Schematic — ABS — ............................................. 12
Wiring Diagram — ABS — ..................................... 13
CONSULT- II Functions .......................................... 17
CONSULT-II MAIN FUNCTION ........................... 17
CONSULT-II BASIC OPERATION PROCEDURE
... 17
Self-Diagnosis ........................................................ 18
OPERATION PROCEDURE ............................... 18
ERASE MEMORY ............................................... 18
DISPLAY ITEM LIST ........................................... 18
Data Monitor ........................................................... 20
OPERATION PROCEDURE ............................... 20
DISPLAY ITEM LIST ........................................... 20Active Test .............................................................. 21
OPERATION PROCEDURE ................................ 21
SOLENOID VALVE .............................................. 22
ABS MOTOR ....................................................... 22
For Fast and Accurate Diagnosis ........................... 23
PRECAUTIONS FOR DIAGNOSIS ..................... 23
Basic Inspection ..................................................... 23
BASIC INSPECTION 1 BRAKE FLUID LEVEL,
LEAKS, AND BRAKE PADS ................................ 23
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 23
BASIC INSPECTION 3 ABS WARNING LAMP
AND BRAKE WARNING LAMP INSPECTION .... 24
Inspection 1 Wheel Sensor System ........................ 24
Inspection 2 ABS Actuator and Electric Unit (Control
Unit) ........................................................................ 26
Inspection 3 ABS Actuator Relay or ABS Motor
Relay Circuit ........................................................... 26
Inspection 4 CAN Communication Circuit .............. 28
Inspection 5 ABS Actuator and Electric Unit (Control
Unit) Power Supply and Ground Circuit .................. 28
Inspection 6 Brake Fluid Level Switch Circuit ......... 30
Inspection 7 Parking Brake Switch Circuit .............. 32
Inspection 8 Warning lamp system ......................... 33
Symptom 1: Excessive ABS Function Operation
Frequency ............................................................... 33
Symptom 2: Unexpected Pedal Reaction ............... 34
Symptom 3: The Stopping Distance Is Long .......... 34
Symptom 4: ABS Function Does Not Operate ....... 35
Symptom 5: Pedal Vibration or ABS Operation
Sound Occurs ......................................................... 35
Symptom 6: ABS Warning Lamp Indication Is Not
Normal .................................................................... 35
WHEEL SENSORS ................................................... 37
Removal and Installation ........................................ 37
REMOVAL ........................................................... 38
INSTALLATION ................................................... 38

PRECAUTIONS
BRC-3
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
[ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS006DM
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.
Precautions for Brake SystemEFS005TG
lRecommended fluid is brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.If brake fluid is splashed, wipe it off and flush area
with water immediately.
lNever use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
lUse flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tighten flare nuts.
lBrake system is an important safety part.If a brake fluid leak is
detected, always disassemble the affected part.If a malfunction
is detected, replace part with new one.
lBefore working, turn ignition switch OFF and disconnect con-
nector of ABS actuator and electric unit (control unit) or the bat-
tery cables.
lWhen installing brake tube and hose, be sure to torque.
WARNING:
Clean brake pads and shoes with a waster cloth, then wipe with
a dust collector.
Precautions for Brake ControlEFS005TH
lJust after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may
be heard from engine room. This is a normal status of operation check.
lStopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
lWhen an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnostic servicing. Besides electrical system inspection, check brake booster operation, brake fluid
level, and fluid leaks.
lIf tyre size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
lIf there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ABS function
may have a malfunction or error.
lIf aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.
SBR820BA

BRC-4
[ABS]
PREPARATION
PREPARATION
PFP:00002
Special Service Tools (SST)EFS005TI
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
a:10 mm (0.39 in)Installing brake tube and hose
ST30720000
Drift
a: 77 mm (0.03 in) dia.
b: 55 mm (2.17 in) dia.
Installation rear sensor rotor ST27863000
Drift
a: 75 mm (2.95 in) dia.
b: 62 mm (2.44 in) dia.
KV40104710
Drift
a: 76 mm (2.99 in) dia.
b: 68.5 mm (2.697 in) dia.
NT406
ZZA0701D
ZZA0832D
ZZA0832D

TROUBLE DIAGNOSIS
BRC-33
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Inspection 8 Warning lamp systemEFS005U7
INSPECTION PROCEDURE
1.CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis of ABS actuator and electric unit (control unit). Refer toBRC-18, "
Self-Diagnosis".
OK or NG
OK >> GO TO 2.
NG >> Check items displayed by self-diagnosis. Refer toBRC-18, "
Display Item List".
2.CHECK COMBINATION METER
Check if the indication and operation of combination meter are normal. Refer toDI-13, "
Self-Diagnosis Mode
of Combination Meter".
OK or NG
OK >> INSPECTION END
NG >> Repair or replace combination meter. Refer toDI-27, "
Removal and Installation of Combination
Meter".
Symptom 1: Excessive ABS Function Operation FrequencyEFS005U8
1.CHECK START
Check longitudinal brake force distribution using a brake tester. Refer toBR-35, "
SERVICE DATA AND SPEC-
IFICATIONS (SDS)".
OK or NG
OK >> GO TO 2.
NG >> Check the following system. If any malfunction is found, repair or replace malfunctioning parts.
lBrake booster. Refer toBR-19, "BRAKE BOOSTER".
lHydraulic line. Refer toBR-12, "BRAKE TUBE AND HOSE".
lFront brake caliper. Refer toBR-24, "FRONT DISC BRAKE".
lRear wheel cylinder. Refer toBR-30, "REAR DRUM BRAKE".
2.CHECK FRONT AND REAR AXLE
Make sure that there is no excessive play in the front and rear axles. Refer to Front:FAX-5, "
WHEEL BEAR-
ING INSPECTION",Rear:RAX-6, "Rear Axle Bearing".
OK or NG
OK >> GO TO 3.
NG >> Repair.
3.CHECK WHEEL SENSOR AND SENSOR ROTOR
Check wheel sensor and sensor rotor for the following.
lWheel sensor installation for damage
lWheel sensor rotor installation for damage
lWheel sensor connector connection
lWheel sensor harness inspection
OK or NG
OK >> GO TO 4.
NG >>
lReplace wheel sensor or sensor rotor.
lRepair harness.

CL-1
CLUTCH
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
I
J
K
L
M
SECTIONCL
A
B
CL
CLUTCH
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
CLUTCH PEDAL ........................................................ 6
On-Vehicle Inspection and Adjustment .................... 6
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ......................................................... 10
OPERATING CYLINDER ...........................................11
Components ............................................................ 11
Removal and Installation ......................................... 11REMOVAL ........................................................... 11
INSTALLATION ................................................... 12
Disassembly and Assembly .................................... 12
DISASSEMBLY ................................................... 12
INSPECTION AFTER DISASSEMBLY ................ 12
ASSEMBLY ......................................................... 12
CLUTCH PIPING ....................................................... 13
Removal and Installation ........................................ 13
CLUTCH RELEASE MECHANISM ........................... 14
Removal and Installation ........................................ 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 15
INSTALLATION ................................................... 15
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 17
Removal and Installation ........................................ 17
COMPONENTS ................................................... 17
REMOVAL ........................................................... 17
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 20
Clutch Control System ............................................ 20
Clutch Master Cylinder ........................................... 20
Clutch Operating Cylinder ...................................... 20
Clutch Disc ............................................................. 20
Clutch Cover ........................................................... 20
Clutch Pedal ........................................................... 20

CL-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
ServiceNoticeorPrecautionsECS00ICC
lRecommended clutch fluid is brake fluid “DOT 3” or “DOT 4”. Refer toMA-14, "RECOMMENDED FLUIDS
AND LUBRICANTS".
lDo not reuse drained clutch fluid.
lBe careful not to splash clutch fluid on painted areas.
lUse a flare nut wrench, when removing and installing clutch pip-
ing.
lUse new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
lDo not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.
SBR820BA

PREPARATION
CL-3
D
E
F
G
H
I
J
K
L
MA
B
CL
PREPARATIONPFP:00002
Special Service ToolsECS00ICD
Commercial Service ToolsECS00ICE
Tool number
Tool nameDescription
KV30101400
Drift
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.Installing release bearing
ST20050240
Diaphragm adjusting wrenchAdjusting unevenness of diaphragm spring of
clutch cover
KV30100100
Clutch aligning bar
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.Installing clutch disc
ZZA0838D
ZZA0508D
ZZA1178D
Tool nameDescription
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Removing and installing master cylinder
spring pin
GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)Removing and installing clutch piping
ZZA0515D
S-NT406