2005 NISSAN PATHFINDER Service Repair Manual

QUICK REFERENCE INDEX Edition: October 2004 Revision:November 2005 Publication No. SM5E-1R51U2

A GENERAL INFORMATION

GI

General Information

B ENGINE

EM

Engine Mechanical

LU

Engine Lubrication System

CO

Engine Cooling System

EC

Engine Control System

FL

Fuel System

EX

Exhaust System

ACC

Accelerator Control System

TRANSMISSION/ TRANSAXLE

AT

Automatic Transmission

D DRIVELINE/AXLE

TF

Transfer

PR

Propeller Shaft

FFD

Front Final Drive

RFD

Rear Final Drive

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

WT

Road Wheels & Tires

BR

Brake System

PB

Parking Brake System

BRC

Brake Control System

C

E SUSPENSION

F BRAKES

G STEERING

PS

Power Steering System

H RESTRAINTS

SB

Seat Belts

SRS

I

BODY

J AIR CONDITIONER K ELECTRICAL

Supplemental Restraint System (SRS)

BL

Body, Lock & Security System

GW

Glasses, Window System & Mirrors

RF

Roof

EI

Exterior & Interior

IP

Instrument Panel

SE

Seat

AP

Adjustable Pedal

ATC

Automatic Air Conditioner

MTC

Manual Air Conditioner

SC

Starting & Charging System

LT

Lighting System

DI

Driver Information System

WW

Wiper, Washer & Horn

BCS

Body Control System

LAN

LAN System

AV ACS

Audio Visual, Navigation & Telephone System Auto Cruise Control System

PG

Power Supply, Ground & Circuit Elements

L MAINTENANCE

MA

Maintenance

M INDEX

IDX

Alphabetical Index

© 2005 NISSAN NORTH AMERICA, INC. All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California.

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A B C D E F G H I J K L M

This manual contains maintenance and repair procedures for the 2005 NISSAN PATHFINDER. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.

The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.

Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended

by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

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QUICK REFERENCE CHART: PATHFINDER

2005

QUICK REFERENCE CHART: PATHFINDER Engine Tune-Up Data

PFP:00000 ELS000YK

Cylinder arrangement Displacement

3

cm

Bore and stroke

V-6 3,954 (241.30)

(cu in)

95.5 × 92.0 (3.76 × 3.622)

mm (in)

Valve arrangement

DOHC

Firing order

1-2-3-4-5-6

Number of piston rings

Compression

2

Oil

1

Number of main bearings

4

Compression ratio

9.7:1

Compression pressure kPa (kg/cm2 , psi)/300 rpm

Standard

1,275 (13.0, 185)

Minimum

981 (10.0, 142)

Differential limit between cylinders

98 (1.0, 14)

Cylinder number

SEM713A

Valve timing (Intake valve timing control - “OFF”)

PBIC0187E

Unit: degree a

b

c

d

e

f

244°

240°

−4°

64°

6°

58°

QUICK REFERENCE CHART: PATHFINDER 2005 Drive Belt Deflection and Tension Tension of drive belts

Auto adjustment by auto tensioner

Spark Plugs (Double Platinum Tipped) Make

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap (nominal)

1.1 mm (0.043 in)

Front Wheel Alignment (Unladen*1 )*6 Drive type

Camber Degree minute (decimal degree)

2WD

4WD

Minimum

-0° 30′ (-0.50°)

-0° 15′ (-0.25°)

Nominal

0° 15′ (0.25°)

0° 30′ (0.50°)

Maximum

1° 00′ (1.00°)

1° 15′ (1.25°)

0° 45′ (0.75°) or less

0° 45′ (0.75°) or less

Minimum

2° 15′ (2.25°)

2° 00′ (2.00°)

Nominal

3° 0′ (3.00°)

2° 45′ (2.75°)

Maximum

3° 45′ (3.75°)

3° 30′ (3.50°)

0° 45′ (0.75°) or less

0° 45′ (0.75°) or less

13° 0′ (13.00°)

12° 45′ (12.75°)

Cross camber

Caster Degree minute (decimal degree)

Cross caster Kingpin inclination Degree minute (decimal degree)

ELS00112

Nominal

SFA234AC

Distance (A − B) Total toe-in Angle (left wheel or right wheel) Degree minute (decimal degree)

Minimum

2.1 mm (0.08 in)

2.1 mm (0.08 in)

Nominal

3.1 mm (0.12 in)

3.1 mm (0.12 in)

Maximum

4.1 mm (0.16 in)

4.1 mm (0.16 in)

Minimum

0° 5′ (0.08°)

0° 5′ (0.08°)

Nominal

0° 7′ (0.12°)

0° 7′ (0.12°)

Maximum

0° 9′ (0.15°)

0° 9′ (0.15°)

Inside Degree minute (Decimal degree)

33° 26′ – 35° 26′ * (33.43° – 35.43°)

2

33° 33′ – 35° 33′ *4 (33.60° – 35.60°)

Outside Degree minute (Decimal degree)

29° 22′ – 31° 22′ *3 (29.37° – 31.37°)

29° 38′ – 31° 38′ *5 (29.73° – 31.73°)

Wheel turning angle (full turn)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Target value 35° 26′ (35.43°) *3: Target value 31° 22′ (31.37°) *4: Target value 35° 33′ (35.55°) *5: Target value 31° 38′ (31.63°) *6: Some vehicles may be equipped with straight (non-adjustable) lower link bolts and washers. In order to adjust camber and caster on these vehicles, first replace the lower link bolts and washers with adjustable (cam) bolts and washers.

QUICK REFERENCE CHART: PATHFINDER 2005

Rear Wheel Alignment (Unladen*1 )

ELS000ZS

Camber Degree minute (decimal degree)

Minimum

- 0° 32′ (- 0.53°)

Nominal

- 0° 2′ (- 0.03°)

Maximum

0° 28′ (0.47°)

SFA234AC

Distance (A - B) Total toe-in Angle (left, right) Degree minute (decimal degree)

Minimum

- 1.4 mm (- 0.055 in)

Nominal

1.9 mm (0.075 in)

Maximum

5.2 mm (0.205 in)

Cross toe

0 ± 2 mm (0 ± 0.079 in)

Minimum

- 0° 3' (-0.05°)

Nominal

0° 4' (0.07°)

Maximum

0° 11' (0.18°)

Brake

ELS000ZT

Unit: mm (in) Front brake

Brake model Rotor outer diameter × thickness Pad Length × width × thickness

Rear brake

CLZ33VB 296 × 28 (11.654 × 1.102) 111.0 × 73.5 × 10.0 (4.73 × 2.894 × 0.394)

Cylinder bore diameter

46.4 (1.83)

Brake model

CLZ14VB

Rotor outer diameter × thickness Pad Length × width × thickness Cylinder bore diameter Control valve

Valve model

Brake booster

Booster model Diaphragm diameter

Recommended brake fluid

308 × 18 (12.126 × 0.709) 83.0 × 33.0 × 11.0 (3.268 × 1.299 × 0.433) 38.1 (1.50) Electric brake force distribution C215T 215 (8.46) Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent DOT 3 (US FMVSS No. 116)

QUICK REFERENCE CHART: PATHFINDER 2005

Disc Brake - Repair Limits

ELS001O4

FRONT DISC BRAKE Unit: mm (in) Brake model Brake pad

Disc rotor

CLZ33VB Standard thickness (new)

10.0 (0.394)

Repair limit thickness

2.0 (0.079)

Standard thickness (new)

28.0 (1.102)

Repair limit thickness

26.0 (1.024)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006)

Runout limit (with it attached to the vehicle)

0.05 (0.0020)

REAR DISC BRAKE Unit: mm (in) Brake model Brake pad

CLZ14VB Standard thickness (new)

11.0 (0.433)

Repair limit thickness

2.0 (0.079)

Standard thickness (new)

18.0 (0.709)

Repair limit thickness Disc rotor

16.0 (0.630)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006)

Runout limit (with it attached to the vehicle)

0.05 (0.0020)

Brake Pedal

ELS000ZV

Unit: mm (in)

WFIA0160E

Free height "H" Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) with engine running] Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch "C1 " or "C2 " Pedal play "A"

182.1 - 192.1 (7.17 - 7.56) 105 - 115 (4.13 - 4.53) 0.74 - 1.96 (0.029 - 0.077) 3 - 11 (0.12 - 0.43)

QUICK REFERENCE CHART: PATHFINDER 2005

Refill Capacities

ELS000YO

Capacity (Approximate)

Description Metric

US measure

Imp measure

80

21 1/8 gal

17 5/8 gal

With oil filter change

5.1

5 3/8 qt

4 1/2 qt

Without oil filter change

4.8

5 1/8 qt

4 1/4 qt

6.3

6 5/8 qt

5 1/2 qt

Without rear A/C

10.2

2 3/4 gal

2 1/4 gal

With rear A/C

13.4

3 1/2 gal

3 gal

Automatic transmission fluid (ATF)

10.3

10 7/8 qt

9 1/8 qt

Rear final drive oil

1.4

3 pt

2 1/2 pt

ATX14B

3.0

3 1/8 qt

2 5/8 qt

TX15B

2.0

2 1/8 qt

1 3/4 qt

Front final drive oil

0.85

1 3/4 pt

1 1/2 pt

Power steering fluid (PSF)

1.0

2 1/8 pt

1 3/4 pt

Windshield washer fluid

4.5

1 1/4 gal

1 gal

Fuel Engine oil Drain and refill Dry engine (engine overhaul) Cooling system (with reservoir at “MAX” level)

Transfer fluid

A/C system refrigerant

Without rear A/C

0.70 ± 0.05 kg

1.54 ± 0.11 lb

1.54 ± 0.11 lb

With rear A/C

0.85 ± 0.05 kg

1.87 ± 0.11 lb

1.87 ± 0.11 lb

Without rear A/C

180 m

6.1 fl oz

6.3 fl oz

With rear A/C

210 m

7.1 fl oz

7.4 fl oz

A/C system lubricant

A GENERAL INFORMATION

SECTION

GI

GENERAL INFORMATION

GI

B

C

D

E

CONTENTS PRECAUTIONS .......................................................... 3 Description ............................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS) (If Equipped) ................................................................. 3 General Precautions ................................................ 4 Precautions for Three Way Catalyst ......................... 5 Precautions for Fuel (Unleaded Premium Gasoline Recommended) ........................................................ 5 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 6 Precautions for Hoses .............................................. 6 HOSE REMOVAL AND INSTALLATION ............... 6 HOSE CLAMPING ................................................ 6 Precautions for Engine Oils ...................................... 7 HEALTH PROTECTION PRECAUTIONS ............. 7 ENVIRONMENTAL PROTECTION PRECAUTIONS ................................................................... 7 Precautions for Air Conditioning ............................... 7 HOW TO USE THIS MANUAL ................................... 8 Description ............................................................... 8 Terms ....................................................................... 8 Units ......................................................................... 8 Contents ................................................................... 8 Relation between Illustrations and Descriptions ..... 9 Components ............................................................. 9 SYMBOLS ........................................................... 10 How to Follow Trouble Diagnoses .......................... 10 DESCRIPTION .................................................... 10 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ................................................11 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ....................................... 12 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES ............................... 13 How to Read Wiring Diagrams ............................... 15 CONNECTOR SYMBOLS ................................... 15

Revision: November 2005

SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 16 DESCRIPTION .................................................... 17 Abbreviations .......................................................... 22 SERVICE INFORMATION FOR ELECTRICAL INCIDENT ......................................................................... 24 How to Check Terminal ........................................... 24 CONNECTOR AND TERMINAL PIN KIT ............ 24 HOW TO PROBE CONNECTORS ...................... 24 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 27 WORK FLOW ...................................................... 27 INCIDENT SIMULATION TESTS ........................ 27 CIRCUIT INSPECTION ....................................... 30 Control Units and Electrical Parts ........................... 35 PRECAUTIONS .................................................. 35 CONSULT-II CHECKING SYSTEM .......................... 37 Description .............................................................. 37 Function and System Application ........................... 37 Nickel Metal Hydride Battery Replacement ............ 38 Checking Equipment .............................................. 38 CONSULT-II Start Procedure .................................. 38 CONSULT-II Data Link Connector (DLC) Circuit ... 39 LIFTING POINT ......................................................... 40 Pantograph Jack ..................................................... 40 Garage Jack and Safety Stand ............................... 40 2-Pole Lift ............................................................... 41 TOW TRUCK TOWING ............................................. 42 Tow Truck Towing ................................................... 42 2WD MODEL ....................................................... 42 4WD MODEL ....................................................... 43 Vehicle Recovery (Freeing a stuck vehicle) ............ 43 TIGHTENING TORQUE OF STANDARD BOLTS ... 44 Tightening Torque Table ......................................... 44 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ............................................................... 45 Recommended Chemical Products and Sealants... 45 IDENTIFICATION INFORMATION ............................ 46 Model Variation ....................................................... 46 Identification Number .............................................. 47 VEHICLE IDENTIFICATION NUMBER

GI-1

2005 Pathfinder

F

G

H

I

J

K

L

M

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PRECAUTIONS PRECAUTIONS Description

PFP:00001

GI EAS001AW

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

B

EAS001AX

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.

WARNING: ● To 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 performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do 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 NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM NATS) (If Equipped)

EAS001QO

NVIS/IVIS (NATS) will immobilize the engine if someone tries to start it without the registered key of NVIS/IVIS (NATS).

Both of the originally supplied ignition key IDs have been NVIS/IVIS (NATS) registered.

The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is functioning.

Therefore, NVIS/IVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system. ● When NVIS/IVIS (NATS) detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position.

This lighting up indicates that the anti-theft is not functioning, so prompt service is required. ● When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS/IVIS (NATS) ignition key IDs), CONSULT-II hardware and CONSULT-II NVIS/IVIS (NATS) software is necessary.

Regarding the procedures of NVIS/IVIS (NATS) initialization and NVIS/IVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual, NVIS/IVIS (NATS).

Therefore, CONSULT-II NVIS/IVIS (NATS) software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. ● When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS/IVIS (NATS) ignition key IDs), it may be necessary to re-register original key identification.

Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NVIS/IVIS (NATS). ● When failing to start the engine first time using the key of NVIS/IVIS (NATS), start as follows.

1. Leave the ignition key in "ON" position for approximately 5 seconds.

2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds.

3. Repeat step 1 and 2 again.

4. Restart the engine while keeping the key separate from any others on key-chain.

Revision: November 2005

GI-3

2005 Pathfinder

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PRECAUTIONS General Precautions ●

EAS001AY

Do not operate the engine for an extended period of time without proper exhaust ventilation.

Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials.

Do not smoke while working on the vehicle.

SGI285

●

●

Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle.

These operations should be done on a level surface.

When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

SGI231

●

●

Before starting repairs which do not require battery power: Turn off ignition switch.

Disconnect the negative battery terminal.

If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

SEF289H

●

● ●

● ● ● ● ● ● ●

To prevent serious burns: Avoid contact with hot metal parts.

Do not remove the radiator cap when the engine is hot.

Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically.

Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.

Clean all disassembled parts in the designated liquid or solvent SGI233 prior to inspection or assembly.

Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones.

Replace inner and outer races of tapered roller bearings and needle bearings as a set.

Arrange the disassembled parts in accordance with their assembled locations and sequence.

Do not touch the terminals of electrical components which use microcomputers (such as ECM).

Static electricity may damage internal electronic components.

After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.

Use only the fluids and lubricants specified in this manual.

Revision: November 2005

GI-4

2005 Pathfinder

PRECAUTIONS ● ●

●

Use approved bonding agent, sealants or their equivalents when required.

Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs.

When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

GI

B

C

PBIC0190E

●

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers.

Take caution that keys, buckles or buttons do not scratch paint.

D

E

F

G

SGI234

H

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

I

Precautions for Three Way Catalyst

J

EAS001RA

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. ● Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. ● When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. ● Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst.

Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precautions for Fuel (Unleaded Premium Gasoline Recommended)

EAS001WU

Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91).

For improved vehicle performance, NISSAN/INFINITI recommend the use of unleaded premium gasoline with an octane rating of at least 91 AKI number (Research octane number 96). E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) may only be used in vehicles specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models).

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Revision: November 2005

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PRECAUTIONS Precautions for Multiport Fuel Injection System or Engine Control System ●

● ●

EAS001RC

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position.

Disconnect negative battery terminal.

Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure.

Be careful not to jar components such as ECM and mass air flow sensor.

SGI787

Precautions for Hoses

EAS001RD

HOSE REMOVAL AND INSTALLATION ●

To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

SMA019D

●

To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA020D

HOSE CLAMPING ●

If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

SMA021D

●

Discard old clamps; replace with new ones.

Revision: November 2005

GI-6

2005 Pathfinder