sensor NISSAN NAVARA 2005 Repair Workshop Manual

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTIONFL
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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-10
FUEL TANK
3. Check fuel level on level place. If fuel gauge indicates more than
the level shown in figure (full or almost full), drain fuel from fuel
tank until gauge indicates level as shown in the figure or below.
NOTE:
Because fuel will be spilled when removing fuel level sensor unit
for the top of the fuel is above fuel level sensor unit installation
surface.
lAs a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (4-3/8 lmp gal) of
fuel are drained from fuel tank.
lRefer to the following for draining fuel.
a. Insert fuel tube of less than 15 mm (0.59 in) in diameter into fuel filler tube through fuel filler opening to
draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
4. Disconnect the battery cable from the negative terminal.
5. Disconnect fuel feed tube (C) and fuel return tube (D).
Disconnect quick connector of fuel feed tube and fuel return tube as
follows.
NOTE:
lHold the sides of the connector, push in tubs and pull out the
tube.
lIf the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them by
pulling.
A : Harness connector
B : EVAP tube
E : Fuel filler hose
F : Vent hose
PBIC3631E
PBIC3375E
SFE562A

FUEL TANK
FL-11
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CAUTION:
lQuick connector can be disconnected when the tabs are
completely depressed. Do not twist it more than necessary.
lDo not use any tools to disconnect quick connector.
lKeep resin tube away from heat. Be especially careful when
welding near the resin tube.
lPrevent acid liquid such as battery electrolyte etc. from get-
ting on resin tube.
lDo not bend or twist resin tube during installation and
removal.
lDo not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is replaced.
lWhen resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one. Replace same color
retainer as before replacing.
lTo keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
6. Using a transmission jack (A), support the bottom of fuel tank
(1).
CAUTION:
Support the position that fuel tank bands do not engage.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC3377E

FL-14
FUEL LEVEL SENSOR UNIT
FUEL LEVEL SENSOR UNIT
PFP:17042
ComponentsEBS01F6N
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E76
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer toFL-9, "
FUEL TANK".
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
3. Remove fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit is free from foreign materials. If any are found, remove them.
1. Lock ring 2. Fuel level sensor unit 3. Seal packing
4. Fuel tank
A. Refer to text.
PBIC3374E
PBIC0240E

FUEL LEVEL SENSOR UNIT
FL-15
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INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall fuel level sensor unit (1) with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown in the figure.
lInstall lock ring (1), and tighten lock ring by hand. Then tighten
lock ring with a fuel tank lock ring wrench (commercial service
tool), aligning mating marks (A) on fuel tank and lock ring as
showninthefigure.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart engine and rev it up and make sure there is no fuel leakage at connections.
: Vehicle front
PBIC3506E
: Vehicle front
PBIC3632E

FSU-16
KNUCKLE
KNUCKLE
PFP:40014
On-Vehicle Inspection and ServiceEES002KV
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are within specifications. Refer toFSU-20, "
Ball Joint".
Removal and InstallationEES002KW
REMOVAL
1. Remove wheel.
2. Without disassembling the hydraulic lines, remove brake caliper. Reposition it aside with wire. Refer to
BR-26, "
Removal and Installation of Brake Caliper Assembly".
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
3. Put alignment marks on disc rotor and wheel hub and bearing
assembly, then remove disc rotor.
4. Disconnect wheel sensor and remove bracket from steering knuckle.
CAUTION:
Do not pull on wheel sensor harness.
5. On 4WD models remove cotter pin, then using a hub lock nut wrench, remove lock nut from drive shaft.
6. Remove steering outer socket cotter pin at steering knuckle, then loosen mounting nut.
1. Disc rotor 2. Wheel hub and bearing assembly 3. Wheel stud
4. Splash guard 5. Steering knuckle 6. Wheel sensor bracket
MDIB9011E
WDIA0044E

KNUCKLE
FSU-17
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FSU
7. Disconnect steering outer socket from steering knuckle using
Tool. Be careful not to damage ball joint boot.
CAUTION:
To prevent damage to threads and to prevent Tool from
coming off suddenly, temporarily tighten mounting nut.
8. On 4WD models remove drive shaft from wheel hub and bearing
assembly using a suitable extractor.
9. Remove cotter pin and nut from upper link ball joint.
10. Separate upper link ball joint from steering knuckle using Tool.
11. Remove pinch bolt from steering knuckle, then separate lower
link ball joint from steering knuckle.
12. Remove steering knuckle from vehicle.
13. Remove wheel hub and bearing assembly bolts.
14. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
CAUTION:
Do not pull on wheel sensor harness.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each part, replace if necessary.
lPerform ball joint inspection. Refer toFSU-15, "Inspection". Tool number : HT72520000
SDIA1434E
MDIB9013E
Tool number : ST29020001
WEIA0119E
LEIA0097E

GI-6
PRECAUTIONS
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
lAbove –7°C(20°F) ... Summer type diesel fuel.
lBelow –7°C(20°F) ... Winter type diesel fuel.
CAUTION:
lDo not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
lDo not use summer fuel at temperatures below –7°C(20°F). The cold temperatures will cause wax
to form in the fuel. As a result, it may prevent the engine from running smoothly.
lDo not add gasoline or other alternate fuels to diesel fuel.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS001GN
lBefore 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.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS001GO
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
lAlways use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
lAvoid accelerating engine to a high rpm immediately after start-
ing.
lIf engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS001GP
HOSE REMOVAL AND INSTALLATION
lTo prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
SGI787
SGI292
SMA019D

GI-10
HOW TO USE THIS MANUAL
Components
EAS001GW
lTHE LARGE ILLUSTRATIONSare exploded views (see the following) and contain tightening torques,
lubrication points, section number of thePARTS CATALOG(e.g. SEC. 440) and other information neces-
sary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriatePARTS CATALOG.
Components shown in an illustration may be identified by a circled number. When this style of illustration
is used, the text description of the components will follow the illustration.
SYMBOLS
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover
1: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease2: Rubber grease : Brake fluid
Refer to GI section for additional symbol definitions.
SFIA2959E
SAIA0749E

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
GI-25
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lHeat sensitive
lFreezing
lWater intrusion
lElectrical load
lCold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
Vehicle Vibration
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
CONNECTORS & HARNESS
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
HINT
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
SENSORS & RELAYS
Gentlyapply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
ENGINE COMPARTMENT
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
lConnectors not fully seated.
lWiring harness not long enough and is being stressed due to engine vibrations or rocking.
lWires laying across brackets or moving components.
lLoose, dirty or corroded ground wires.
lWires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
BEHIND THE INSTRUMENT PANEL
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
SGI839