NISSAN NAVARA 2005 Repair Workshop Manual

FUEL PUMP
EM-49
C
D
E
F
G
H
I
J
K
L
MA
EM
FUEL PUMPPFP:17042
ComponentsEBS01EK3
lRefer toGI-10, "Components"for symbol marks except in the above.
Removal and InstallationEBS01E64
CAUTION:
lBefore removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
lAfter removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
lWhen installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
lWhen fuel pump is replaced with new one or another one, perform fuel pump leaning value clean-
ing before starting engine. Refer toEC-24, "
Fuel Pump Learning Value Clearing".
REMOVAL
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer toEM-20, "INTAKE MANIFOLD".
1. Washer 2. Fuel pump sprocket 3. Seal washer
4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel hose
13. Spill hose
Engine front
PBIC3438E

EM-50
FUEL PUMP
2. Remove fuel hose and spill hose from fuel pump. Refer toEM-44, "INJECTION TUBE AND FUEL INJEC-
TOR".
CAUTION:
Be careful not to spill fuel in the engine component.
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube center, clip and insert rubber. Refer toEM-44, "
INJECTION TUBE AND FUEL
INJECTOR".
CAUTION:
Be careful not to spill fuel in the engine component.
5. Remove secondary timing chain. Refer toEM-73, "
SECONDARY TIMING CHAIN".
6. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin [SST] into the hole 6 mm (0.24
in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench [SST], turn pump shaft little by little to
adjust the position of fuel pump sprocket so that the holes align.
c. Push the positioning stopper pin [SST] through fuel pump
sprocket to fuel pump body to hold fuel pump sprocket.
lInsert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
7. Using the hexagon wrench [SST] remove tightening bolts of fuel
pump sprocket.
MBIA0049E
PBIC2535E
PBIC2404E
MBIA0074E

FUEL PUMP
EM-51
C
D
E
F
G
H
I
J
K
L
MA
EM
8. Using the sprocket holder [SST], hold fuel pump sprocket to pre-
vent falling.
lFor sprocket holder, use KV11106060 machined as shown in
the figure, because the previous bore is not fitting.
lWhen the sprocket holder is installed, if the positioning stop-
per pin [SST] interferes, pull out the positioning stopper pin
approximately 10 mm (0.39 in), then install it.
lAfter the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore.
lThe length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
lMake sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket (small diameter side).
CAUTION:
Do not remove the sprocket holder [SST] until fuel pump is installed.
lAfter the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
9. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), remove the tightening bolts.
CAUTION:
Do not disassemble or adjust fuel pump.
10. Remove the fuel pump toward the rear of engine.
CAUTION:
For removal, be careful not to drop the seal washer into the engine.
NOTE:
The seal washer of the tightening bolts cannot be reused.
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.
SBIA0217E
PBIC2534E
MBIA0075E
PBIC2405E

EM-52
FUEL PUMP
13. Loosen sprocket nut with the TORX wrench [SST].
14. Remove coupling with a suitable puller.
15. Remove spacer from fuel pump.
16. Remove oil seal from spacer.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
INSTALLATION
1. Install new oil seal to spacer.
2. Install spacer to fuel pump.
MBIA0013E
MBIA0014E
SEM984C
MBIA0045E

FUEL PUMP
EM-53
C
D
E
F
G
H
I
J
K
L
MA
EM
3. Install coupling to fuel pump of spacer.
lUsing the TORX wrench [SST], tighten the sprocket nut to fix
the coupling.
4. Install adjusting shim.
lFor shim adjustment, measure dimension L [Distance
between front surface of coupling and the fuel pump flange
(spacer)] at two opposing points near the coupling bolt center.
Use the average of these two measurements to select the
shim grade that marked on adjusting shim.
lThe shim adjustment is required only when the fuel pump is
replaced.
MBIA0013E
MBIA0077E
PBIC3439E
Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type
16614 8H800 0.5 t 38.23 - 39.77 (1.5051 - 1.5657) A
16614 8H810 1.0 t 38.76 - 38.23 (1.5260 - 1.5051) B
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A + C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B + B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C + B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D + B

EM-54
FUEL PUMP
5. Before fuel pump is installed, make sure that spacer and the 6
mm (0.24 in) dia. hole on coupling are aligned.
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
Be careful not to drop the seal washer into engine.
7. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder [SST].
9. Using the TORX wrench [SST], turn the pump shaft gradually to
adjust the position of fuel pump sprocket. Then, insert the posi-
tioning stopper pin [SST] to the 6 mm (0.24 in) dia. hole of the
fuel pump sprocket through the pump body.
10. Remove the TORX wrench [SST].
11. Using the hexagon wrench [SST], tighten the sprocket tightening
bolt.
lWhen the washer of the fuel pump sprocket is removed,
install it with the marking “F” (front) facing the front of the
engine.
12. Pull out the positioning stopper pin [SST].
MBIA0016E
PBIC2438E
PBIC2405E
MBIA0049E
PBIC2404E

FUEL PUMP
EM-55
C
D
E
F
G
H
I
J
K
L
MA
EM
13. Install secondary timing chain. Refer toEM-73, "SECONDARY TIMING CHAIN".
14. Following steps below, install injection tube center. Refer toEM-44, "
INJECTION TUBE AND FUEL
INJECTOR".
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool.
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer toEM-44, "
INJECTION TUBE AND FUEL INJECTOR".
17. Hereafter, install in the reverse order of removal.
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump leaning value clean-
ing before starting engine. Refer toEC-24, "
Fuel Pump Learning Value Clearing".

EM-56
ROCKER COVER
ROCKER COVER
PFP:13264
ComponentsEBS01EK4
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E65
REMOVAL
1. Remove engine cover. Refer toEM-20, "INTAKE MANIFOLD".
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose. Refer toEM-20,
"INTAKE MANIFOLD"andEM-15, "AIR CLEANER AND AIR DUCT".
3. Disconnect harness connector from fuel injector. Refer toEM-44, "
INJECTION TUBE AND FUEL INJEC-
TOR".
4. Following steps below, remove injection tube. Refer toEM-44, "
INJECTION TUBE AND FUEL INJEC-
TOR".
a. Put a paint mark or tag on injection tubes to identify each cylinder.
lUse a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
1. Nozzle oil seal 2. Rocker cover 3. Ventilation hose
4. Washer 5. Oil filler cap 6. Gasket
A. Refer to “INSTALLATION” in “ROCKER COVER” B. To ventilation hose
PBIC3440E

ROCKER COVER
EM-57
C
D
E
F
G
H
I
J
K
L
MA
EM
lUsing the flat-bladed screwdriver, pry flange to remove nozzle
oil seal.
6. Remove rocker cover.
lLoosen holding bolts in the reverse order of that shown in the
figure and remove.
7. Remove gasket from rocker cover.
INSTALLATION
1. Install new gasket to rocker cover.
2. Apply liquid gasket with tube presser [SST: WS39930000] on
locations shown in the figure.
lUse Genuine Liquid Gasket or equivalent.
3. Tighten holding bolts in numerical order shown in the figure.
Re-tighten to the same torque in the same order as above.
4. Install nozzle oil seal.
lInsert it straight until flange fully contacts rocker cover.
5. Install remaining parts in the reverse order of removal.
6. Before starting engine, bleed air from fuel piping. Refer toFL-5, "
Air Bleeding".
PBIC0944E
: Engine front
PBIC3441E
1 : Cylinder head
2 : Cylinder head rear cover
A : Liquid gasket application area
: Engine front
PBIC3442E
: Engine front
: 7.8 N·m (0.8 kg-m, 69 in-lb)
PBIC3441E

EM-58
ROCKER COVER
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.