NISSAN NAVARA 2005 Repair Workshop Manual

FRONT FINAL DRIVE ASSEMBLY
FFD-35
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FFD
14. Alignmatchingmarkonbearingcapwiththatongearcarrier.
15. Install bearing caps and tighten bearing cap bolts to the speci-
fied torque. Refer toFFD-17, "
COMPONENTS".
16. Drive side oil seal until it becomes flush with the case end using
Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
17. Check and adjust drive gear runout, tooth contact, drive gear to
drive pinion backlash, and total preload torque. Refer toFFD-18, "
Drive Gear Runout",FFD-19, "To o t h
Contact",FFD-20, "Backlash",FFD-18, "Total Preload Torque".
Recheck above items. Readjust the above description, if necessary.
18. Apply recommended sealant to mating surface of rear cover.
Refer toFFD-17, "
COMPONENTS".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
19. Install rear cover on gear carrier and tighten bolts with the spec-
ified torque. Refer toFFD-17, "
COMPONENTS".
20. Install side shaft assembly. Refer toFFD-35, "
Side Shaft".
Side Shaft
1. Press side shaft bearing to side shaft.
CAUTION:
Do not reuse bearing.
2. Install snap ring (shaft side).
3. Install side shaft assembly into gear carrier.
4. Install snap ring (hole side).
PDIA0700E
Tool number A: ST30720000
B: ST27863000
PDIA0711E
PDIA0712E
PDIA0719E

FFD-36
FRONT FINAL DRIVE ASSEMBLY
5. Drive side oil seal until it becomes flush with the case end using
To o l s .
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.Tool number A: ST30720000
B: ST27863000
PDIA0828E

SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS00358
*: Option
Inspection and AdjustmentEDS00359
DRIVE GEAR RUNOUT
Unit: mm (in)
DIFFERENTIAL SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Applied modelYD25DDTi
6M/T 5A/T
Grade SE, XE* XE SE
Final drive modelR180A
Gear ratio 3.692 3.538
Number of teeth (Drive gear/Drive pinion) 48/13 46/13
Oil capacity (Approx.)
(lmp pt)0.85 (1-1/2)
Number of pinion gears2
Drive pinion adjustment spacer type Collapsible
Item Runout limit
Drive gear back face 0.08 (0.0031) or less
Item Specification
Side gear backlash (Clearance between side gear and differential
case)0.1 (0.004) or less
(Each gear should rotate smoothly without excessive resistance
during differential motion.)
Item Specification
Pinion bearing (P
1) 1.08 - 1.66 (0.11 - 0.16, 10 - 14)
Side bearing (P
2) 0.59 - 1.08 (0.06 - 0.11, 6 - 9)
Side bearing to pinion bearing (Total preload)
(Total preload = P
1+P2)1.67 - 2.74 (0.17 - 0.27, 15 - 24)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)
Item Runout limit
Companion flange face 0.1 (0.004) or less
Inner side of the companion flange 0.1 (0.004) or less
Thickness Part number* Thickness Part number*
0.75 (0.0295)
0.78 (0.0307)
0.81 (0.0319)
0.84 (0.0331)38424 W2010
38424 W2011
38424 W2012
38424 W20130.87 (0.0343)
0.90 (0.0354)
0.93 (0.0366)
0.96 (0.0378)38424 W2014
38424 W2015
38424 W2016
38424 W2017

FFD-38
SERVICE DATA AND SPECIFICATIONS (SDS)
Pinion Height Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Side Bearing Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Thickness Part number* Thickness Part number*
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)38154 EA000
38154 EA001
38154 EA002
38154 EA003
38154 EA004
38154 EA005
38154 EA006
38154 EA007
38154 EA008
38154 EA0093.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)38154 EA010
38154 EA011
38154 EA012
38154 EA013
38154 EA014
38154 EA015
38154 EA016
38154 EA017
38154 EA018
38154 EA019
Thickness Part number* Thickness Part number*
1.95 (0.0768)
2.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)38453 EA000
38453 EA001
38453 EA002
38453 EA003
38453 EA004
38453 EA005
38453 EA006
38453 EA0072.35 (0.0925)
2.40 (0.0945)
2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)38453 EA008
38453 EA009
38453 EA010
38453 EA011
38453 EA012
38453 EA013
38453 EA014

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTIONFL
A
FL
FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL FILTER .............................................................. 4
Components ............................................................. 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 5
INSPECTION AFTER INSTALLATION ................. 5
Air Bleeding .............................................................. 5
Draining Water from Fuel Filter ................................ 6
FUEL COOLER .......................................................... 7
Components (4WD Models Only) ............................ 7
Removal and Installation (4WD Models Only) ......... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 8
INSPECTION AFTER INSTALLATION ................. 8FUEL TANK ................................................................ 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ................ 13
FUEL LEVEL SENSOR UNIT ................................... 14
Components ........................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Standard and Limit .................................................. 16

FL-2
PREPARATION
PREPARATION
PFP:00002
Commercial Service ToolsEBS01E70
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D

FUEL SYSTEM
FL-3
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS01E71
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS01E72
WARNING:
When replacing fuel line parts, be sure to observe the following.
lPut a “CAUTION: INFLAMMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
lUse diesel fuel required by the regulations for cetane number. Refer toGI-6, "DIESEL ENGINE".
lBefore removing fuel line parts, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Disconnect the battery cable from the negative terminal.
lAlways replace O-ring and clamps with new ones.
lDo not kink or twist tubes when they are being installed.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lAfter connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
lAfter installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
SBIA0504E

FL-4
FUEL FILTER
FUEL FILTER
PFP:16400
ComponentsEBS01F6M
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E73
REMOVAL
1. Disconnect fuel hoses at fuel filter.
CAUTION:
Plug the pipe to prevent fuel from draining.
2. Loosen mounting nuts (2) and remove fuel filter (1).
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
1. Fuel filter bracket 2. Fuel filter 3. O–ring
4. Drain plug
A. Refer toFL-5
.
PBIC3369E
1 : Fuel filter
2 : Fuel hose (feed)
3 : Fuel hose (return)
PBIC3370E
: Vehicle front
PBIC3337E

FUEL FILTER
FL-5
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FL
3. Using band-type fuel filter wrench (A) (commercial service tool),
remove fuel filter (1).
4. Turn fuel filter (1) upside down to drain fuel.
5. Remove drain plug (2) from fuel filter.
INSTALLATION
Note the following, and install in the reverse order of removal.
lReplace O-ring on drain plug with new one.
lScrew the fuel filter by hand until packing contacts sealing surface of fuel filter bracket. Then tighten it by
turning approximately 2/3 turn.
lInstall fuel filter (1), and tighten mounting nuts (2) to the speci-
fied torque.
lAfter installation, bleed air from fuel line. Refer toFL-5, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart the engine and rev it up and make sure there is no fuel leakage at connections.
Air BleedingEBS01E74
After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
lMove priming pump (1) up and down to bleed air from fuel path.
When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
lCrank engine until it starts. Do not crank engine for more than 30 seconds.
lIf engine does not start, stop cranking and repeat step 1 above.
lIf engine does not operate smoothly after it has started, race it two or three times.
PBIC3371E
Fuel filter (reference value)
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
: Vehicle front
Fuel filter mounting nuts
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
PBIC3337E
PBIC3372E

FL-6
FUEL FILTER
lIf air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel pump. After that, operate priming pump and con-
firm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel FilterEBS01E75
1. Prepare a tray (A) under the drain plug (1).
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
lWater in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
lDrained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
5. Bleed air in fuel piping. Refer toFL-5, "
Air Bleeding".
6. Start engine and make sure there is no fuel leakage.Drain plug
: 1.3 N·m (0.13 kg-m, 12 in-lb)
PBIC3373E