2005 NISSAN NAVARA check engine

HEATER & COOLING UNIT ASSEMBLY
MTC-105
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Removal and InstallationEJS005GY
REMOVAL
1. Discharge the refrigerant from the A/C system. Refer toMTC-118, "Discharging Refrigerant".
2. Drain the coolant from the engine cooling system. Refer toCO-8, "
DRAINING ENGINE COOLANT".
3. Remove the cowl top extension. Refer toEI-20, "
Removal and Installation".
4. Remove the exhaust system. Refer toEX-3, "
Removal and Installation".
5. Disconnect the heater hoses from the heater core.
6. Disconnect the high/low pressure pipes from the expansion valve.
7. Move the two front seats to the rearmost position on the seat track.
8. Remove the instrument panel and console panel. Refer toIP-10, "
Removal and Installation".
9. Remove the steering column. Refer toPS-11, "
Removal and Installation".
10. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (J/B) electrical connectors. Refer toPG-38, "
Harness Layout".
11. Disconnect the steering member from each side of the vehicle body.
12. Remove the heater and cooling unit assembly with it attached to the steering member, from the vehicle.
CAUTION:
Use care not to damage the seats and interior trim panels when removing the heater and cooling
unit assembly with it attached to the steering member.
13. Remove the heater and cooling unit assembly from the steering member.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply
compressor oil to it when installing it.
lAfter charging the refrigerant, check for leaks.
NOTE:
lFill the engine cooling system with the specified coolant mixture. Refer toCO-8, "REFILLING ENGINE
COOLANT".
lRecharge the A/C system. Refer toMTC-118, "Evacuating System and Charging Refrigerant".

MTC-122
REFRIGERANT LINES
Removal and Installation for Compressor
EJS005HC
A/C Compressor Mounting
REMOVAL
1. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
2. Remove the front right wheel and tire assembly. Refer toWT-5, "
Rotation".
3. Remove the engine under cover and the splash shield using power tool.
4. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
5. Remove the drive belt. Refer toEM-12, "
DRIVE BELTS".
6. Disconnect the compressor electrical connector.
7. Disconnect the high-pressure flexible hose and low-pressure flexible hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
8. Remove the compressor bolts and nut using power tools.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
lReplace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new
one, apply compressor oil to the O-rings before installation.
lAfter recharging the A/C system with refrigerant, check for leaks.
MJIB0179E
1. Compressor 2. Alternator and A/C compressor
bracket3. Timing chain case
4. Cylinder block

REFRIGERANT LINES
MTC-125
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2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
4. Install the clutch disc on the compressor shaft, together with the
original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc
from turning and tighten the bolt to specification. Refer toMTC-
120, "Components".
CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as
shown.
7. If the specified clearance is not obtained, replace the adjusting
spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer toEM-12, "
DRIVE BELTS".
10. Install the engine under cover and the splash shield.Tool number : KV99106200
MJIB0290E
WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
WHA194

MTC-126
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 Low-pressure Flexible HoseEJS005HE
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
3. Remove the cowl top extension. Refer toEI-20, "
COWL TOP".
4. Discharge the refrigerant. Refer toMTC-118, "
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 hose. Refer toMTC-120, "
Components".
INSTALLATION
Installation is in the reverse order of removal.
Refer toMTC-120, "
Components".
CAUTION:
lReplace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseEJS005HF
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer toEM-15, "
AIR CLEANER AND AIR DUCT"
3. Discharge the refrigerant. Refer toMTC-118, "HFC-134a (R-134a) Service Procedure".
4. Remove the high-pressure flexible hose. Refer toMTC-120, "
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 toMTC-120, "
Components".
CAUTION:
lReplace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
lAfter charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeEJS005HG
REMOVAL
1. Remove the cowl top extension. Refer toEI-20, "COWL TOP".
2. Disconnect the battery negative cable.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer toWT-5, "
Rotation".
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer toMTC-118, "
HFC-134a (R-134a) Service Procedure".
7. Remove the low pressure pipe. Refer toMTC-127, "
Removal and Installation for Low-pressure Pipe".
8. Remove the high-pressure pipe. Refer toMTC-120, "
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 toMTC-120, "
Components".

REFRIGERANT LINES
MTC-131
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Checking for Refrigerant LeaksEJS0062F
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 DetectorEJS0062G
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.
Clean with a dry cloth or blow off with shop air.
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.
Dye InjectionEJS0062H
(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.

REFRIGERANT LINES
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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, 50 psi) above 16°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 toMTC-120, "
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.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
SHA839E

PG-1
POWER SUPPLY, GROUND & CIRCUIT ELEMENTS
K ELECTRICAL
CONTENTS
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SECTIONPG
A
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POWER SUPPLY, GROUND & CIRCUIT ELEMENTS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
POWER SUPPLY ROUTING CIRCUIT ...................... 4
Schematic ................................................................ 4
Wiring Diagram — POWER — ................................. 5
BATTERY POWER SUPPLY — IGNITION SW.
IN ANY POSITION ................................................ 5
ACCESSORY POWER SUPPLY — IGNITION
SW. IN ACC OR ON ............................................ 10
IGNITION POWER SUPPLY — IGNITION SW.
IN ON ................................................................... 11
IGNITION POWER SUPPLY — IGNITION SW.
IN ON AND/OR START ....................................... 12
IPDM E/R (INTELLIGENT POWER DISTRIBUTION
MODULE ENGINE ROOM) ...................................... 14
System Description ................................................ 14
SYSTEMS CONTROLLED BY IPDM E/R ........... 14
CAN COMMUNICATION LINE CONTROL ......... 14
IPDM E/R STATUS CONTROL ........................... 15
CAN Communication System Description .............. 15
Function of Detecting Ignition Relay Malfunction ... 15
CONSULT-II Function (IPDM E/R) ......................... 16
CONSULT-II BASIC OPERATION ...................... 16
SELF-DIAGNOSTIC RESULTS .......................... 17
DATA MONITOR ................................................. 17
CAN DIAG SUPPORT MNTR ............................. 18
ACTIVE TEST ..................................................... 18
Auto Active Test ..................................................... 19
DESCRIPTION .................................................... 19
OPERATION PROCEDURE ............................... 19
INSPECTION IN AUTO ACTIVE TEST MODE... 20
Schematic .............................................................. 22
IPDM E/R Terminal Arrangement ........................... 23
Check IPDM E/R Power Supply and Ground Circuit... 24Inspection with CONSULT-II (Self-Diagnosis) ........ 25
Removal and Installation of IPDM E/R ................... 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
GROUND CIRCUIT ................................................... 27
Ground Distribution ................................................. 27
MAIN HARNESS ................................................. 27
ENGINE ROOM HARNESS ................................ 30
ENGINE CONTROL HARNESS .......................... 34
BODY HARNESS (LH SIDE) .............................. 35
BODY HARNESS (RH SIDE) .............................. 36
DEFOGGER CABLE ........................................... 37
HARNESS ................................................................. 38
Harness Layout ...................................................... 38
HOW TO READ HARNESS LAYOUT ................. 38
OUTLINE/DOUBLE CAB MODELS .................... 39
OUTLINE/KING CAB MODELS .......................... 40
MAIN HARNESS/LHD MODELS ......................... 41
MAIN HARNESS/RHD MODELS ........................ 44
ENGINE ROOM HARNESS/LHD MODELS ........ 47
ENGINE ROOM HARNESS/RHD MODELS ....... 49
ENGINE CONTROL HARNESS .......................... 51
CHASSIS HARNESS .......................................... 53
BODY HARNESS (LH SIDE)/DOUBLE CAB
MODELS ............................................................. 54
BODY HARNESS (RH SIDE)/DOUBLE CAB
MODELS ............................................................. 56
BODY HARNESS (LH SIDE)/KING CAB MOD-
ELS ...................................................................... 58
BODY HARNESS (RH SIDE)/KING CAB MOD-
ELS ...................................................................... 60
ROOM LAMP HARNESS .................................... 62
FRONT DOOR LH HARNESS/LHD MODELS .... 63
FRONT DOOR RH HARNESS/LHD MODELS ... 63
FRONT DOOR LH HARNESS/RHD MODELS ... 64
FRONT DOOR RH HARNESS/RHD MODELS ... 64
REAR DOOR LH HARNESS/DOUBLE CAB
MODELS ............................................................. 65
REAR DOOR RH HARNESS/DOUBLE CAB
MODELS ............................................................. 65

PG-16
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
CONSULT-II Function (IPDM E/R)
EKS00PAB
CONSULT-II can display each diagnostic item using the diagnostic test mode shown following.
CONSULT-II BASIC OPERATION
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CON-
SULT-II CONVERTER to the data link connector, and then turn
ignition switch ON.
2. Touch “START (NISSAN BASED VHCL)”.
3. Touch “IPDM E/R” on “SELECT SYSTEM” screen.
If “IPDM E/R” is not displayed. Refer toGI-50, "
CONSULT-II
Data Link Connector (DLC) Circuit".
Inspection Item, Diagnosis Mode Description
SELF-DIAG RESULTS The IPDM E/R performs diagnosis of CAN communication and self-diagnosis.
DATA MONITOR The input/output data of the IPDM E/R is displayed in real time.
CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read.
ACTIVE TEST The IPDM E/R sends a drive signal to electronic components to check their operation.
BBIA0538E
BCIA0029E
BCIA0030E