torque NISSAN NAVARA 2005 Repair Workshop Manual

FSU-20
SERVICE DATA AND SPECIFICATIONS (SDS)
Ball Joint
EES002KZ
Swinging force “A” 7.8 - 54.9 N (0.8 - 5.6 kg-f, 1.8 - 12.3 lb-f)
Turning torque “B” 0.49 - 3.43 N·m (0.05 - 0.35 kg-m, 4 - 30 in-lb)
Vertical end play “C”0mm(0in)
SFA858A

GI-2
TIGHTENING TORQUE OF STANDARD BOLTS .... 55
Tightening Torque Table ......................................... 55
IDENTIFICATION INFORMATION ............................ 56
Model Variation ....................................................... 56
Identification Number .............................................. 57
VEHICLE IDENTIFICATION NUMBER
ARRANGEMENT ................................................. 57
IDENTIFICATION PLATE .................................... 58
ENGINE SERIAL NUMBER ................................ 58TRANSFER SERIAL NUMBER ........................... 58
AUTOMATIC TRANSMISSION NUMBER ........... 58
MANUAL TRANSMISSION NUMBER ................. 59
Dimensions ............................................................. 60
KING CAB ............................................................ 60
DOUBLE CAB ...................................................... 60
Wheels & Tyres ....................................................... 60
TERMINOLOGY ........................................................ 61
ISO 15031-2 Terminology List ................................. 61

HOW TO USE THIS MANUAL
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HOW TO USE THIS MANUALPFP:00008
DescriptionEAS001GS
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
TermsEAS001GT
lThe captionsWARNINGandCAUTIONwarn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WARNINGindicates the possibility of personal injury if instructions are not followed.
CAUTIONindicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTSexceptWARNINGandCAUTIONgive you helpful information.
Standard value:Tolerance at inspection and adjustment.
Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjust-
ment.
UnitsEAS001GU
lTheUNITSgiven in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about
the standard tightening torque.
“Example”
Range
Standard
ContentsEAS001GV
lALPHABETICAL INDEXis provided at the end of this manual so that you can rapidly find the item and
page you are searching for.
lA QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find
the first page of each section by matching it to the section's black tab.
lTHE CONTENTSare listed on the first page of each section.
lTHE TITLEis indicated on the upper portion of each page and shows the part or system.
lTHE PAGE NUMBERof each section consists of two or three letters which designate the particular sec-
tion and a number (e.g. “BR-5”).
lTHE SMALL ILLUSTRATIONSshow the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

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

TIGHTENING TORQUE OF STANDARD BOLTS
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TIGHTENING TORQUE OF STANDARD BOLTSPFP:00000
Tightening Torque TableEAS001DK
*: Nominal diameter
1.Special parts are excluded.
2.This standard is applicable to bolts having the following marks embossed on the bolt head. Grade Bolt sizeBolt diam-
eter *
mmPitch
mmTightening torque (Without lubricant)
Hexagon head bolt Hexagon flange bolt
N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
4TM6 6.0 1.0 5.5 0.56 4 49 7 0.71 5 62
M8 8.01.25 13.5 1.4 10 — 17 1.7 13 —
1.0 13.5 1.4 10 — 17 1.7 13 —
M10 10.01.5282.921— 353.626—
1.25 28 2.9 21 — 35 3.6 26 —
M12 12.01.75 45 4.6 33 — 55 5.6 41 —
1.25 45 4.6 33 — 65 6.6 48 —
M14 14.0 1.5 80 8.2 59 — 100 10 74 —
7TM6 6.0 1.0 9 0.92 7 80 11 1.1 8 97
M8 8.01.25 22 2.2 16 — 28 2.9 21 —
1.0222.216— 282.921—
M10 10.01.5454.633— 555.641—
1.25 45 4.6 33 — 55 5.6 41 —
M12 12.01.75 80 8.2 59 — 100 10 74 —
1.25 80 8.2 59 — 100 10 74 —
M14 14.0 1.5 130 13 96 — 170 17 125 —
9TM6 6.0 1.0 11 1.1 8 — 13.5 1.4 10 —
M8 8.01.25 28 2.9 21 — 35 3.6 26 —
1.0282.921— 353.626—
M10 10.01.5555.641— 808.259—
1.25 55 5.6 41 — 80 8.2 59 —
M12 12.01.75 100 10 74 — 130 13 96 —
1.25 100 10 74 — 130 13 96 —
M14 14.0 1.5 170 17 125 — 210 21 155 —
MGI044A

TERMINOLOGY
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Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnosis
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
Park/neutral position switch PNP switchPark/neutral switch
Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system ***
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control sole-
noid valvePAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
Simultaneous multiport fuel injection sys-
tem*** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter
systemTWC + OC system ***
Throttle body TBThrottle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valveLock-up cancel solenoid
Lock-up solenoid NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

IDX-7
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IDX
ALPHABETICAL INDEX
Starter ................................................................SC-27
Starting system ..................................................SC-27
Steering gear, linkage and transfer gear inspection .....
MA-36
,MA-37
Steering linkage .................................................PS-14
Steering wheel and column .................................PS-8
Step lamp .........................................................LT-145
Stop lamp .........................................................LT-121
Stop lamp switch .............................................EC-330
STOP/L - Wiring diagram .................................LT-121
Striking rod (M/T) ...............................................MT-23
Strut (front) ......................................................FSU-10
Sun roof, electric ................................................RF-10
Sunload sensor ..............................................ATC-112
Sunroof ..................................................RF-10,RF-21
Super lock ...........................................................BL-55
Supplemental Restraint System ........................SRS-6
Symbols and abbreviations .....................GI-10,GI-23
Symptom matrix chart ........................................EC-42
Synchronizer (M/T) ............................................MT-21
T
Tachometer ..........................................................DI-4
Tail lamp ...........................................................LT-125
TAIL/L - Wiring diagram ....................................LT-127
TC boost control solnoid valve ........................EC-309
TC boost sensor ..............................................EC-153
TCC/V - Wiring diagram ..................................EC-311
TCM circuit diagram ..........................................AT-42
TCM inspection table .........................................AT-76
Thermostat ........................................................CO-24
Three way catalyst precautions ............................GI-5
Throttle body ......................................................EM-20
Tie-rod ...............................................................PS-14
Timing chain .........................................EM-73,EM-79
Timing gear ........................................................EM-79
Tire rotation .......................................................MA-34
Tire size ..............................................................GI-60
Torque converter installation ...........................AT-250
Torque convertor clutch solenoid valveAT-110,AT-112
Tow truck towing .................................................GI-53
Towing point .......................................................GI-54
Transfer control device .............TF-74,TF-78,TF-105
Transfer control unit inspection table ..................TF-38
Transfer oil replacement ....................................MA-32
Transfer serial number .......................................GI-58
Transmission case (M/T) ...................................MT-19
Transmission serial number ....................GI-58,GI-59
Tread-FR&RR (Dimensions) ..............................GI-60
Trim .....................................................................EI-33
Trouble diagnoses ..............................................GI-11
Turbine revolution sensor ................................AT-123
Turbocharger .....................................................EM-28
Turbocharger charge air cooler .........................EM-18
Turbocharger precautions ....................................GI-6
TURN - Wiring diagram ....................................LT-100
Turn signal lamp .................................................LT-97
Two-pole lift ........................................................GI-52
V
Vacuum hose drawing (Engine control) .............EC-16
Vacuum pump ...................................................EM-42
Valve clearance ................................................EM-66
Valve guide .....................................................EM-101
Valve lifter .........................................................EM-62
Valve seat .......................................................EM-103
Valve spring ....................................................EM-104
Vanity mirror lamp .............................................LT-145
Vehicle identification number ..............................GI-57
Vehicle recovery (freeing a stuck vehicle) ..........GI-54
VEHSEC - Wiring diagram ...............................BL-143
Viscosity number (SAE) ....................................MA-15
W
Wait detection switch ..............................TF-63
,TF-66
WARN - Wiring diagram .....................................DI-30
Warning chime ....................................................DI-51
Warning lamps ....................................................DI-28
Washer, front .....................................................WW-4
Water pump ......................................................CO-21
Water temperature gauge .....................................DI-4
Wheel alignment (front) .....................................FSU-7
Wheel balance ..................................................MA-34
Wheel bearing (front) .........................................FAX-5
Wheel bearing (rear) .........................................RAX-6
Wheel sensors (ABS) .....................................BRC-37
Wheel size ..........................................................GI-60
Wheelbase (Dimensions) ....................................GI-60
Width (Dimensions) ............................................GI-60
WINDOW - Wiring diagram ...............................GW-20
Window, door ......................................GW-35,GW-38
Window, rear .....................................................GW-43
Windshield ........................................................GW-11
WIPER - Wiring diagram ..................................WW-12
Wiper, front ........................................................WW-4
Wiring Diagram (Cell code) list ..........................PG-68
Wiring diagrams ..................................................GI-15

LU-10
OIL FILTER BRACKET
INSTALLATION
Install all removed parts in the reverse order of removal.
lInstall fuel filter (1), and tighten mounting nuts (2) to the speci-
fied torque.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and add engine oil. Refer toLU-5, "ENGINE OIL".
2. After warming up engine, check there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level and adjust engine oil level. Refer toLU-5, "
ENGINE OIL".
: Vehicle front
Fuel filter mounting nut:
: 13.5 N·m(1.4 kg-m, 10 ft-lb)
PBIC3337E

LU-12
OIL COOLER
3. Remove mounting nuts (2) of fuel filter (1), and move it aside
with its hoses connected. Temporarily secure it with a rope to
avoid putting load on its hose.
4. Disconnect water hoses from oil cooler.
lWhen removing oil cooler only, pinching water hoses near oil cooler to prevent engine coolant spilling.
CAUTION:
lPerform this step when engine is cold.
lDo not spill engine coolant on drive belts.
5. Loosen connecting bolt and remove oil cooler.
CAUTION:
Do not spill engine oil and engine coolant to rubber parts such as drive belts and engine mounting
insulator.
6. Remove water hoses and water connector, as necessary.
INSPECTION AFTER REMOVAL
Oil Cooler
Check oil cooler for cracks. Check oil cooler for clogging by blowing through engine coolant inlet. If necessary,
replace oil cooler.
INSTALLATION
Installation is the reverse order of removal.
lMake sure that no foreign objects are adhering to the installation planes of oil cooler or oil filter bracket.
lTighten the connecting bolt after aligning the stopper on the oil
filter bracket side with protrusion of oil cooler (1).
lInstall fuel filter (1), and tighten mounting nuts (2) to the speci-
fied torque.
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and the engine coolant level, and add engine oil and engine coolant. Refer to
LU-5, "
ENGINE OIL"andCO-7, "ENGINE COOLANT".
: Vehicle front
PBIC3337E
A : Align the protrusion and the stopper.
: Vehicle front
PBIC3339E
: Vehicle front
Fuel filter mounting nut:
: 13.5 N·m(1.4 kg-m, 10 ft-lb)
PBIC3337E

DESCRIPTION
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DESCRIPTIONPFP:00000
Pre-Delivery Inspection ItemsELS001K2
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)