2005–2008 Nissan Navara D40 Service Manual (P/N C4256-90954)

• Identifies European-spec Nissan Navara D40 configurations by King Cab or Double Cab body, left- or right-hand drive, 2WD or 4WD, XE or SE grade, and the listed YD25DDTi powertrain combinations.
• Covers YD25DDTi engine repair from turbocharger and common-rail fuel-system diagnosis through injector and fuel-pump service, valve-clearance adjustment, primary and secondary timing-chain work, cylinder-head overhaul, engine removal, and cylinder-block rebuilding.
• Takes the FS6R31A six-speed manual and RE5R05A five-speed automatic beyond routine service with removal, disassembly, inspection, selective fitting, reassembly, adjustment, and operational testing. The TX15B transfer section adds 4WD control diagnosis and internal repair.
• Maps factory fault-finding for the ECM, TCM, CAN network, transfer and differential-lock control units, ABS/EBD, BCM, IPDM E/R, meters, SRS, climate control, lighting, locks, wipers, audio, and navigation systems.
• Documents R180A front and M226 rear final-drive repair, including limited-slip and electronic-locking differential variants, plus axle, propeller-shaft, suspension, steering, hydraulic brake, clutch, and wheel-bearing procedures.
• Supplies wiring diagrams, connector and pin views, harness layouts, diagnostic charts, exploded assemblies, system schematics, and factory specification tables for torque, capacity, pressure, clearance, wear, preload, backlash, alignment, and electrical checks.

Match the D40 Configuration

This Nissan Europe Electronic Service Manual carries a 2005 copyright and contains 3,171 PDF pages across 46 files. It is suited to professional technicians and experienced repairers who can work with CONSULT-II diagnostics, pressure gauges, lifting equipment, and the specified engine, transmission, and differential service tools.

The model table makes the limits clear. Engine repair information is for the YD25DDTi diesel; this is not a VQ40DE gasoline-engine manual. King Cab models are listed with the FS6R31A manual transmission. The RE5R05A automatic appears only under Double Cab applications, with separate 2WD and 4WD transmission codes. Both LHD and RHD layouts are represented where the system differs.

PDF Set Breakdown

3,171 pages total — foreword and General Information: 66; engine systems: 572; clutch and transmissions: 416; transfer, propeller shafts, final drives, and axles: 318; suspension and wheels: 40; brakes: 84; steering: 36; restraints: 74; body and interior: 394; automatic and manual HVAC: 290; electrical and electronics: 832; maintenance: 42; alphabetical index: 7.

Engine, Gearbox, and Axle Work

The engine volumes cover compression testing, turbocharger fault diagnosis, injector adjustment-value registration, fuel-pump learning-value clearing, camshaft and valve service, timing-chain installation, piston and bearing selection, and post-repair leak checks. The manual-transmission chapter explains the double- and triple-cone synchronizers before taking the FS6R31A through a full teardown and build.

Automatic-transmission coverage pairs TCM signal data and 29 indexed DTC paths with stall, line-pressure, cruise, shift-speed, and lockup testing. It also covers the control valve with integrated TCM, solenoid and pressure-switch circuits, transmission removal, clutch and planetary repairs, selective adjustment, and final assembly. The 4WD material adds transfer-switch adjustment, control-unit diagnosis, power-flow diagrams, TX15B disassembly, and differential-lock troubleshooting.

Circuit Diagnosis and Controlled Systems

The 306-page LAN section separates 17 CAN configurations and provides check sheets for isolating opens, shorts, and failed modules. Diagnostic paths extend from YD25DDTi fuel pressure, injector, boost, crank/cam, and accelerator-pedal faults to transmission solenoids, ABS wheel sensors, SRS flash codes, HVAC door motors, IPDM power distribution, NATS, Super Lock, and lighting complaints.

Representative drawings include the engine-control system diagram, 2WD and 4WD automatic-transmission cross-sections, TX15B power-transfer diagram, M226 differential-lock schematic, ABS hydraulic circuit, and CAN wiring/check-sheet layouts. Related connector views and terminal-reference tables support circuit testing at the module rather than only at the component.

Factory Data and Service Cautions

Named tools include the KV10112100 angle wrench, ST2505S001 transmission pressure-gauge set, KV31102400 clutch spring compressor, and ST3127S000 differential preload-gauge set. The service-data sections provide the matching torque sequences, fluid specifications, pressure tests, inspection limits, selective-part tables, and electrical reference values.

Nissan warns that unapproved or mixed ATF can damage the RE5R05A, while incorrect R-134a compressor lubricant can cause compressor failure. The transmission-removal procedure also removes the crankshaft position sensor before separating the gearbox, protecting its magnetic face from impact and metal contamination. Air bag and seat-belt pre-tensioner work is restricted by Nissan to authorized Nissan/Infiniti service personnel; brake, refrigerant, and supported powertrain work require the appropriate training and safety equipment.