2005 NISSAN NAVARA Repair Workshop Manual

fuel cap clock tire size glove box child seat engine oil capacity

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NISSAN NAVARA 2005 Repair Workshop Manual BL-1
BODY, LOCK & SECURITY SYSTEM
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CONTENTS
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BODY, LOCK & SECURITY SYSTEM
PRECAUTIONS .......................................................... 4
Precautions

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BODY, LOCK & SECURITY SYSTEM
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CONTENTS
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BODY, LOCK & SECURITY SYSTEM
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for procedures with out cowl top cover..... 4
Precautions for Work ................................................ 4
Wiring Diagrams and Trouble Diagnosis .................. 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 ....................................... 8
Generic Squeak and Rattle Troubleshooting ........... 8
INSTRUMENT PANEL .......................................... 8
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 9
SUNROOF/HEADLINING ..................................... 9
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
HOOD ....................................................................... 12
Fitting Adjustment .................................................. 12
LONGITUDINAL AND LATERAL CLEARANCE
ADJUSTMENT .................................................... 13
FRONT END HEIGHT ADJUSTMENT ............... 13
SURFACE HEIGHT ADJUSTMENT ................... 13
Removal and Installation of Hood Assembly .......... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Removal and Installation of Hood Hinge ................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Removal and Installation of Hood Lock Control ..... 15REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Hood Lock Control Inspection ................................ 17
RADIATOR CORE SUPPORT .................................. 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
FRONT FENDER ...................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
POWER DOOR LOCK SYSTEM .............................. 21
Component Parts and Harness Connector Location... 21
KING CAB ........................................................... 21
DOUBLE CAB ..................................................... 22
System Description ................................................. 23
OUTLINE ............................................................. 24
CAN Communication System Description .............. 25
CAN Communication Unit ....................................... 25
Schematic ............................................................... 26
Wiring Diagram —D/LOCK— ................................. 27
Terminals and Reference Value for BCM ............... 34
CONSULT-II Function (BCM) ................................. 35
CONSULT-II BASIC OPERATION PROCEDURE
... 35
CONSULT-II APPLICATION ITEMS .................... 36
Work Flow ............................................................... 37
Trouble Diagnoses Chart by Symptom ................... 37
Check Power Supply and Ground Circuit ............... 37
Check Door Switch ................................................. 39
CHECK DOOR SWITCH (DOUBLE CAB) .......... 39
CHECK DOOR SWITCH (KING CAB) ................ 41
Check Key Switch ................................................... 43
Check Door Key Cylinder Switch (LHD Model Only)... 45
Check Front Door Lock Actuator (Driver Side) ....... 48
Check Front Door Lock Actuator (Passenger Side)... 49
Check Front Door Lock Actuator Switch ................. 50
Check Rear Door Lock Actuator LH (Double Cab
Model) ..................................................................... 50
Check Rear Door Lock Actuator RH (Double Cab

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NISSAN NAVARA 2005 Repair Workshop Manual BL-2
Model) ..................................................................... 51
Check RH and LH Rear Door Lock Actuator Switch... 51
Check Door Lock/Unlock Switch ............................ 52

BL-2
Model) ..................................................................... 51
Check RH and LH Rear Door Lock Actuator Switch... 51
Check Door Lock/Unlock Switch ............................ 52
Check Door Lock/Unlock Switch Indicator .............. 53
POWER DOOR LOCK — SUPER LOCK — ............ 55
Component Parts and Harness Connector Location... 55
KING CAB ........................................................... 55
DOUBLE CAB ..................................................... 56
System Description ................................................. 57
OUTLINE ............................................................. 58
OPERATION ........................................................ 58
CAN Communication System Description .............. 59
CAN Communication Unit ....................................... 59
Schematic ............................................................... 60
Wiring Diagram —D/LOCK— ................................. 61
Terminals and Reference Value for BCM ................ 69
CONSULT-II Function (BCM) .................................. 70
CONSULT-II BASIC OPERATION PROCEDURE
... 70
CONSULT-II APPLICATION ITEMS .................... 71
Work Flow ............................................................... 72
Trouble Diagnoses Chart by Symptom ................... 72
Check Power Supply and Ground Circuit ............... 73
Check Door Switch ................................................. 74
CHECK DOOR SWITCH (DOUBLE CAB) .......... 74
CHECK DOOR SWITCH (KING CAB) ................ 76
Check Key Switch ................................................... 78
Check Front Door Lock Actuator (Driver Side) ....... 80
Check Front Door Lock Actuator (Passenger Side)... 81
Check Front Door Lock Actuator Switch ................. 81
Check Rear Door Lock Actuator LH (Double Cab
Models) ................................................................... 82
Check Rear Door Lock Actuator RH (Double Cab
Models) ................................................................... 82
Check RH and LH Rear Door Lock Actuator Switch
(Double Cab Models) .............................................. 83
Check Super Lock Actuator (Driver Side) ............... 83
Check Super Lock Actuator (Passenger Side) ....... 84
Check Super Lock Actuator (Rear LH) ................... 84
Check Super Lock Actuator (Rear RH) .................. 85
Check Door Lock/Unlock Switch ............................ 86
Check Door Lock/Unlock Switch Indicator .............. 87
MULTI-REMOTE CONTROL SYSTEM ..................... 89
Component Parts and Harness Connector Location... 89
KING CAB ........................................................... 89
DOUBLE CAB ..................................................... 90
System Description ................................................. 91
INPUTS ............................................................... 91
OPERATING PROCEDURE ................................ 91
CAN Communication System Description .............. 92
Wiring Diagram — MULTI — For LHD Models ....... 93
Wiring Diagram — MULTI — For RHD Models ...... 97
Terminals and Reference Value for BCM ..............101
CONSULT-II Function (BCM) ................................102
CONSULT-II Inspection Procedure .......................102
“MULTI REMOTE ENT” .....................................102
CONSULT-II Application Items .............................103
“MULTI REMOTE ENT” .....................................103
Trouble Diagnosis Procedure ...............................104Trouble Diagnosis Chart by Symptom ..................105
Check Keyfob Battery and Function .....................106
Check ACC Switch ................................................107
Check Door Switch ...............................................108
CHECK DOOR SWITCH (DOUBLE CAB) .........108
CHECK DOOR SWITCH (KING CAB) ...............110
Check Key Switch .................................................113
Check Hazard Function ........................................114
Check Map Lamp and Ignition Keyhole Illumination
Function ................................................................114
ID Code Entry Procedure ......................................115
KEYFOB ID SET UP ..........................................115
CONSULT-II INSPECTION PROCEDURE ........115
Remote Controller Battery Replacement ..............116
DOOR ......................................................................117
Fitting Adjustment (King Cab) ...............................117
FRONT DOOR ...................................................118
REAR DOOR .....................................................118
STRIKER ADJUSTMENT ..................................118
Fitting Adjustment (Double Cab) ...........................119
FRONT DOOR ...................................................120
REAR DOOR .....................................................120
STRIKER ADJUSTMENT ..................................120
Removal and Installation of Front Door ................120
REMOVAL ..........................................................120
INSTALLATION ..................................................121
Removal and Installation of Rear Door (King Cab).121
REMOVAL ..........................................................121
INSTALLATION ..................................................122
Removal and Installation of Rear Door (Double Cab)
.123
REMOVAL ..........................................................123
INSTALLATION ..................................................123
Removal and Installation of Door Weather-strip
(King Cab) .............................................................124
REMOVAL ..........................................................124
INSTALLATION ..................................................124
Removal and Installation of Door Weather-strip
(Double Cab) .........................................................125
REMOVAL ..........................................................125
INSTALLATION ..................................................125
FRONT DOOR LOCK ..............................................126
Removal and Installation .......................................126
REMOVAL ..........................................................126
INSTALLATION ..................................................129
REAR DOOR LOCK ................................................130
Removal and Installation of Rear Door Lock (King
Cab) ......................................................................130
REMOVAL ..........................................................130
INSTALLATION ..................................................131
Removal and Installation of Rear Door Lock (Double
Cab) ......................................................................132
REMOVAL ..........................................................132
INSTALLATION ..................................................134
TAIL GATE ...............................................................135
Component Parts Location ...................................135
FUEL FILLER LID OPENER ...................................136
Removal and Installation of Fuel Filler Lid ............136
REMOVAL ..........................................................136

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NISSAN NAVARA 2005 Repair Workshop Manual BL-3
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Removal and Installation of Fuel Lid Lock Striker. 137
REMOVAL .......................................

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Removal and Installation of Fuel Lid Lock Striker. 137
REMOVAL ......................................................... 137
INSTALLATION ................................................. 137
THEFT WARNING SYSTEM .................................. 138
Component Parts and Harness Connector Location. 138
KING CAB ......................................................... 138
DOUBLE CAB ................................................... 139
System Description .............................................. 140
DESCRIPTION .................................................. 140
POWER SUPPLY AND GROUND CIRCUIT .... 141
INITIAL CONDITION TO ACTIVATE THE SYS-
TEM ................................................................... 141
THEFT WARNING SYSTEM ALARM OPERA-
TION .................................................................. 141
THEFT WARNING SYSTEM DEACTIVATION . 141
CAN Communication System Description ............ 141
Schematic ............................................................ 142
Wiring Diagram — VEHSEC — for LHD Models . 143
Wiring Diagram — VEHSEC — for RHD Models . 149
Terminals and Reference Value for BCM ............. 155
Terminals and Reference Value for IPDM E/R ..... 156
CONSULT-II Function (BCM) ............................... 156
CONSULT-II INSPECTION PROCEDURE ....... 156
CONSULT-II APPLICATION ITEM .................... 157
Trouble Diagnosis ................................................ 159
WORK FLOW .................................................... 159
Preliminary Check ................................................ 160
Symptom Chart .................................................... 161
Diagnostic Procedure 1 ........................................ 162
CHECK DOOR SWITCH (DOUBLE CAB) ........ 162
CHECK DOOR SWITCH (KING CAB) .............. 164
CHECK HOOD SWITCH ................................... 166
Diagnostic Procedure 2 ........................................ 168
Diagnostic Procedure 3 ........................................ 169
Diagnostic Procedure 4 ........................................ 169
NATS(NISSAN ANTI-THEFT SYSTEM) ................. 170Component Parts and Harness Connector Location.170
System Description ...............................................171
System Composition .............................................172
ECM Re-communicating Function ........................172
Wiring Diagram — NATS — .................................173
Terminals and Reference Value for BCM .............174
CONSULT-II Function ...........................................174
CONSULT-II INSPECTION PROCEDURE ........174
CONSULT-II DIAGNOSTIC TEST MODE FUNC-
TION ..................................................................175
HOW TO READ SELF-DIAGNOSTIC RESULTS.176
NATS SELF-DIAGNOSTIC RESULTS ITEM
CHART ..............................................................176
Trouble Diagnosis Procedure ...............................177
WORK FLOW ....................................................177
Trouble Diagnoses ...............................................178
SYMPTOM MATRIX CHART 1 ..........................178
SYMPTOM MATRIX CHART 2 ..........................178
Diagnostic Procedure 1 ........................................179
Diagnostic Procedure 2 ........................................181
Diagnostic Procedure 3 ........................................181
Diagnostic Procedure 4 ........................................184
Diagnostic Procedure 5 ........................................185
Diagnostic Procedure 6 ........................................187
Removal and Installation of NATS Antenna Amp . 188
REMOVAL .........................................................188
INSTALLATION .................................................188
CAB AND REAR BODY .........................................189
Body Mounting (King Cab) ...................................189
Body Mounting (Double Cab) ...............................190
BODY REPAIR ........................................................191
Body Alignment ....................................................191
DESCRIPTION ..................................................191
ENGINE COMPARTMENT ................................192
UNDERBODY ...................................................194
PASSENGER COMPARTMENT .......................196
REAR BODY .....................................................201

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NISSAN NAVARA 2005 Repair Workshop Manual BL-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EIS00DHW
The Supplemental Restraint System such as “AIR BAG

BL-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EIS00DHW
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 procedures with out cowl top coverEIS00DHY
When performing the procedure after removing cowl top cover,cover
the lower end of windshield with urethane,etc.
Precautions for WorkEIS00DHZ
lAfter removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check
their operation.
lCheck the lubrication level, damage, and wear of each part. If necessary, grease or replace it.
Wiring Diagrams and Trouble DiagnosisEIS00DI0
When you read wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams"
lPG-4, "POWER SUPPLY ROUTING CIRCUIT"
When you perform trouble diagnosis, refer to the following:
lGI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
lGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident"
Check for any Service bulletins before servicing the vehicle.
PIIB3706J

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NISSAN NAVARA 2005 Repair Workshop Manual PREPARATION
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PREPARATIONPFP:00002
Commercial Service ToolsEIS00DI1
Tool name Description
Engine ear Locating the noise
SIIA0995E

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NISSAN NAVARA 2005 Repair Workshop Manual BL-6
SQUEAK AND RATTLE TROUBLE DIAGNOSES
SQUEAK AND RATTLE TROUBLE DIAGNOSES
PFP:00000
Work FlowEIS00DI2
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist w

BL-6
SQUEAK AND RATTLE TROUBLE DIAGNOSES
SQUEAK AND RATTLE TROUBLE DIAGNOSES
PFP:00000
Work FlowEIS00DI2
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer toBL-10, "
Diagnostic Worksheet". This information is necessary to duplicate the
conditions that exist when the noise occurs.
lThe customer may not be able to provide a detailed description or the location of the noise. Attempt to
obtain all the facts and conditions that exist when the noise occurs (or does not occur).
lIf there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
is concerned about. This can be accomplished by test driving the vehicle with the customer.
lAfter identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
lSqueak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard sur-
faces=higher pitch noise/softer surfaces=lower pitch noises/edge to surface=chirping
lCreak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
dependent on materials/often brought on by activity.
lRattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
lKnock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
lTick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
lThump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
lBuzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
lOften the degree of acceptable noise level will vary depending upon the person. A noise that you may
judge as acceptable may be very irritating to the customer.
lWeather conditions, especially humidity and temperature, may have a great effect on noise level.
SBT842

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NISSAN NAVARA 2005 Repair Workshop Manual SQUEAK AND RATTLE TROUBLE DIAGNOSES
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If possible, drive the vehicle with the customer until the noise is duplicated. Note any additiona

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models).
6) Raisethevehicleonahoistandhitatirewitharubberhammer.
lDrive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
lIf it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Engine Ear or mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
lremoving the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
or lost during the repair, resulting in the creation of new noise.
ltapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.
lfeeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
lplacing a piece of paper between components that you suspect are causing the noise.
llooking for loose components and contact marks.
Refer toBL-8, "
Generic Squeak and Rattle Troubleshooting".
REPAIR THE CAUSE
lIf the cause is a loose component, tighten the component securely.
lIf the cause is insufficient clearance between components:
–separate components by repositioning or loosening and retightening the component, if possible.
–insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape are available through your authorized Nissan Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
NOTE:
Always check with the Parts Department for the latest parts information.
Each item can be ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100´135 mm (3.94´5.31 in)/76884-71L01: 60´85 mm (2.36´3.35 in)/76884-71L02: 15´
25 mm (0.59´0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
73982-9E000: 45 mm (1.77 in) thick, 50´50 mm (1.97´1.97 in)/73982-50Y00: 10 mm (0.39 in) thick, 50
´50 mm (1.97´1.97 in)
INSULATOR (Light foam block)
80845-71L00: 30 mm (1.18 in) thick, 30´50 mm (1.18´1.97 in)

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NISSAN NAVARA 2005 Repair Workshop Manual BL-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
FELT CLOTHTAPE
Used to insulate where movement does not occur. Ideal for instrument panel applications.
68370-4B000: 15´25 mm (0.59´0.98 in) pad/68239-13E00:

BL-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
FELT CLOTHTAPE
Used to insulate where movement does not occur. Ideal for instrument panel applications.
68370-4B000: 15´25 mm (0.59´0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll
The following materials, not available through NISSAN Parts Department, can also be used to repair squeaks
and rattles.
UHMW(TEFLON) TAPE
Insulates where slight movement is present. Ideal for instrument panel applications.
SILICONE GREASE
Used in place of UHMW tape that will be visible or not fit.
Note: Will only last a few months.
SILICONE SPRAY
Use when grease cannot be applied.
DUCT TAPE
Use to eliminate movement.
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle TroubleshootingEIS00DI3
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
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 silicon 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. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.

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