NISSAN NAVARA 2005 Repair Workshop Manual

CHARGE AIR COOLER
EM-19
C
D
E
F
G
H
I
J
K
L
MA
EM
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
lBe careful not to deform core fins.
lFor cleaning procedure of charge air cooler core, refer toCO-13, "Checking Radiator".
INSTALLATION
Note the following, and install in the reverse order of removal.
lPay attention to identification mark color and direction when installing air inlet hose.
lAlign marks. Attach each joint. Screw clamps firmly.

EM-20
INTAKE MANIFOLD
INTAKE MANIFOLD
PFP:14003
ComponentsEBS01EJE
PBIC4042E

INTAKE MANIFOLD
EM-21
C
D
E
F
G
H
I
J
K
L
MA
EM
lRefer toGI-10, "Components"for symbol marks except in the above.
Removal and InstallationEBS01EJF
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer toCO-7, "
Changing Engine Coolant".
2. Remove engine cover (1).
CAUTION:
Be careful not to damage engine cover surface.
3. Disconnect air inlet hose from throttle chamber. Refer toEM-18, "
CHARGE AIR COOLER".
4. Remove fuel filter. Refer toFL-4, "
FUEL FILTER".
5. Remove oil level gauge guide. Refer toEM-36, "
OIL PAN AND OIL STRAINER".
6. Remove fuel hoses and fuel gallery. Refer toEM-44, "
INJECTION TUBE AND FUEL INJECTOR".
lTo prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
lAdd marks as necessary for easier installation.
7. Remove vacuum galleries and vacuum hoses.
lAdd marks as necessary for easier installation.
8. Disconnect EGR volume control valve water hoses and wiring harness.
9. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
10. Remove EGR cooler (A/T models) or EGR tube (M/T models).
11. Remove injection tube center. Refer toEM-44, "
Removal and Installation".
CAUTION:
Be careful not to spill fuel in the engine component.
12. Remove water pipe.
1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose
4. Bracket 5. Bracket 6. Gasket
7. Bracket 8. Intake manifold 9. Water hose
10. Heater feed pipe (M/T models) 11. O-ring 12. Vacuum hose
13. Vacuum gallery 14. Vacuum hose 15. Gasket
16. Throttle chamber 17. Gasket 18. Gasket
19. EGR passage 20. Gasket 21. Bracket
22. EGR volume control valve 23. Vacuum gallery 24. Bracket
25. Washer 26. Gasket 27. EGR tube (M/T models)
28. Water hose 29. Water hose 30. Clip (A/T models)
31. Water hose (A/T models) 32. Heater feed pipe (A/T models) 33. Water hose (A/T models)
34. EGR cooler (A/T models) 35. Gasket (A/T models) 36. EGR tube (A/T models)
37. Bracket (A/T models)
C. To heater return pipe E. To cylinder head F. To water outlet
G. To exhaust manifold H. To air inlet hose
Vehicle front
PBIC3409E

EM-22
INTAKE MANIFOLD
13. Loosen bolts and nuts in the reverse order of that shown in the
figure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
14. Remove EGR volume control valve and throttle chamber from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
lCheck distortion on the mounting surface with a straightedge
and feeler gauge.
lIf it exceeds the limit, replace intake manifold.
INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall intake manifold.
–Tighten fixing bolts and nuts in numerical order as shown in the
figure.
–If stud bolts were removed, tighten them to the specified torque.
lInstall EGR tube (M/T models).
–Tighten fixing bolts and nuts in numerical order as shown in the figure.
PBIC3410E
Limit : 0.1 mm (0.004 in)
PBIC3411E
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
PBIC3410E

INTAKE MANIFOLD
EM-23
C
D
E
F
G
H
I
J
K
L
MA
EM
lInstall EGR cooler (A/T models).
–Tighten fixing bolts and nuts in numerical order as shown in the figure.
lInstall water hoses and heater feed hose.
1. EGR volume control valve 2. EGR tube
PBIC4105E
1. EGR volume control valve 2. EGR cooler 3. Bracket
4. EGR tube
PBIC4106E

EM-24
INTAKE MANIFOLD
–Install water hose by referring to paint marks avoiding twisting.
–When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully until it reaches the end.
–When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
lInstall vacuum hoses.
–Install vacuum hose by referring to paint marks avoiding twisting.
1. Heater return pipe 2. Heater feed pipe 3. EGR volume control valve
4.EGR cooler (A/T models)
EGR tube (M/T models)5. Water outlet
A. Paint mark B. A/T models only
Vehicle front
Dimension A : 27 - 32 mm (1.063 - 1.260 in)
1. EGR volume control valve 2. Throttle chamber 3. Intake shutter control solenoid valve
A. Yellow paint B. White paint C. To brake booster
D. To vacuum pump Vehicle front
PBIC3412E
PBIC3899E

INTAKE MANIFOLD
EM-25
C
D
E
F
G
H
I
J
K
L
MA
EM
–When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully until it reaches the end.
–When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
lBefore starting engine, bleed air from fuel piping. Refer toFL-5, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.Dimension A : 15 – 20 mm (0.591 – 0.787 in)

EM-26
CATALYST
CATALYST
PFP:20905
ComponentsEBS01EJG
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E5V
REMOVAL
1. Remove engine undercover.
2. Remove catalyst cover and exhaust outlet cover.
3. Remove exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
4. Remove air inlet hose and air inlet tube. Refer toEM-18, "
CHARGE AIR COOLER".
5. Remove exhaust manifold cover. Refer toEM-34, "
EXHAUST MANIFOLD".
6. Remove catalyst and exhaust outlet.
7. Remove catalyst from exhaust outlet, as necessary.
1. Gasket 2. Exhaust outlet 3. Exhaust outlet cover
4. Gasket 5. Gasket cap 6. Catalyst
7. Catalyst cover 8. Bracket
A. To exhaust front tube
PBIC3414E

CATALYST
EM-27
C
D
E
F
G
H
I
J
K
L
MA
EM
INSTALLATION
Note the following, and install in the reverse order of removal.
lIf stud bolts of turbocharger were removed, tighten them to the specified torque.
lIf stud bolts of catalyst were removed, tighten them to the specified torque.
lPushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And
then tighten it to the specified torque.: 25.5 N·m (2.6 kg-m, 19 ft-lb)
: 45.0 N·m (4.6 kg-m, 33 ft-lb)

EM-28
TURBO CHARGER
TURBO CHARGER
PFP:14411
ComponentsEBS01EJH
1. Exhaust manifold 2. Water hose (4WD models) 3. Water tube (4WD models)
4. Copper washer (4WD models) 5. Eye-bolt (4WD models) 6. Gasket (4WD models)
7. Gasket 8. Gasket 9. Exhaust outlet
10. Exhaust outlet cover 11. Air inlet pipe 12. Gasket
13. Turbocharger (4WD models) 14. Gasket (4WD models) 15. Copper washer(4WD models)
16.Oil feed tube and oil return tube
(4WD models)17. Washer 18. Connector
19. Oil return hose 20. Eye-bolt (4WD models) 21. Eye-bolt (2WD models)
22. Cooper washer (2WD models) 23. Oil feed tube (2WD models) 24. Cooper washer (2WD models)
25. Eye-bolt (2WD models) 26. Turbocharger (2WD models) 27. Gasket (2WD models)
PBIC4095E