air filter NISSAN NAVARA 2005 Repair User Guide

EC-314
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
PFP:16188
DescriptionEBS01KM5
Vibration when stopping the engine can be controlled by cutting
intake air right before the fuel is cut. The intake air control valve con-
trol solenoid valve (1) controls the ON-OFF load of the intake air
control valve actuator. As a result, the intake air control valve control
solenoid valve will be turned ON when the ignition switch is turned
OFF with the engine running and when the engine stalls. After the
engine has stopped, the intake air control valve control solenoid
valve will return to fully open.
l: Vehicle front
lElectronic controlled engine mount control solenoid valve (2)
lOil filter (3)
ECM Terminals and Reference ValueEBS01KM6
Specification data are reference valves, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
MBIB1226E
TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
15 GRIntake air control valve
control solenoid valve[Engine is running]BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
[Ignition switch OFF]
lFor a few seconds after turning ignition
switch OFFApproximately 0.3V
105
11 3BR
BRECM relay (self shut-off)[Ignition switch OFF]
lFor a few seconds after turning ignition
switch OFFApproximately 1.0V
[Ignition switch OFF]
lMore than a few seconds after turning igni-
tion switch OFFBATTERY VOLTAGE
(11 - 14V)
11 9
120R
GPower supply for ECM[Ignition switch ON]BATTERY VOLTAGE
(11 - 14V)

INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
EC-317
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4.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect intake air control valve control solenoid valve (1)
harness connector.
–: Vehicle front
–Electronic controlled engine mount control solenoid valve (2)
–Oil filter (3)
3. Turn ignition switch ON.
4. Check voltage between intake air control valve control solenoid
valve terminal 2 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.
5.DETECT MALFUNCTIONING PART
Check the following.
lHarness connectors E9, F4
lHarness for open or short between IPDM E/R and intake air control valve control solenoid valve
lHarness for open or short between ECM and intake air control valve control solenoid valve
>> Repair open circuit or short to power in harness or connectors.
6.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 15 and intake air control valve control solenoid valve ter-
minal 1. Refer to Wiring Diagram.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
7.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
Refer toEC-318, "
Component Inspection".
OK or NG
OK >> GO TO 8.
NG >> Replace intake air control valve control solenoid valve.
MBIB1226E
Voltage: Battery voltage
PBIB0192E
Continuity should exist.

EC-318
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
8.CHECK VACUUM PUMP
Refer toEM-42, "
VACUUM PUMP".
OK or NG
OK >> GO TO 9.
NG >> Replace vacuum pump assembly.
9.CHECK INTAKE AIR CONTROL VALVE ACTUATOR
1. Turn ignition switch OFF.
2. Install a vacuum pump A to intake air control valve actuator (1).
3. Make sure that the intake air control valve actuator rod moves
smoothly when applying vacuum of -53.3 kPa (-533 mbar, -400
mmHg, -15.75 inHg) and releasing it.
OK or NG
OK >> GO TO 10.
NG >> Replace intake air control valve actuator.
10.CHECK INTERMITTENT INCIDENT
Refer toEC-70, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT".
>>INSPECTION END
Component InspectionEBS01KM9
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
1. Disconnect intake air control valve control solenoid valve (1)
harness connector.
l: Vehicle front
lElectronic controlled engine mount control solenoid valve (2)
lOil filter (3)
2. Apply 12V direct current between turbocharger boost control
solenoid valve terminals.
3. Check air passage continuity of intake air control valve control
solenoid valve under the following conditions.
Operation takes less than 1 second.
If NG, replace intake air control valve control solenoid valve.
MBIB1239E
MBIB1226E
CONDITIONSAir passage continuity
between (A) and (B)Air passage continuity
between (A) and (C)
12V direct current supply
between terminals (1) and (2)Ye s N o
No supply No Yes
MEC488B

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTIONEM
A
EM
ENGINE MECHANICAL
PRECAUTIONS .......................................................... 4
Precautions for Draining Engine Coolant ................. 4
Precautions for Disconnecting Fuel Piping .............. 4
Precautions for Removal and Disassembly ............. 4
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 4
Precautions for Assembly and Installation ............... 4
Parts Requiring Angle Tightening ............................. 4
Precautions For Liquid Gasket ................................. 5
REMOVAL OF LIQUID GASKET .......................... 5
LIQUID GASKET APPLICATION PROCEDURE..... 5
PREPARATION ........................................................... 6
Special Service Tools ............................................... 6
Commercial Service Tools ........................................ 8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 10
NVH Troubleshooting — Engine Noise .................. 10
Use the Chart Below to Help You Find the Cause
of the Symptom. ...................................................... 11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Deflection Adjustment ............................................ 13
POWER STEERING OIL PUMP BELT ............... 13
A/C COMPRESSOR, ALTERNATOR AND
WATER PUMP BELT .......................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Components ........................................................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
CHANGING AIR CLEANER FILTER ................... 17
CHARGE AIR COOLER ........................................... 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19INTAKE MANIFOLD ................................................. 20
Components ........................................................... 20
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 25
CATALYST ................................................................ 26
Components ........................................................... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
TURBO CHARGER ................................................... 28
Components ........................................................... 28
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSPECTION AFTER REMOVAL ....................... 30
TROUBLE DIAGNOSIS OF TURBOCHARGER... 32
INSTALLATION ................................................... 33
EXHAUST MANIFOLD ............................................. 34
Components ........................................................... 34
Removal and Installation ........................................ 34
REMOVAL ........................................................... 34
INSPECTION AFTER REMOVAL ....................... 35
INSTALLATION ................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
OIL PAN AND OIL STRAINER ................................. 36
Components ........................................................... 36
Removal and Installation ........................................ 36
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ....................... 38
INSTALLATION ................................................... 38
INSPECTION AFTER INSTALLATION ................ 40
GLOW PLUG ............................................................ 41
Components ........................................................... 41
Removal and Installation ........................................ 41
REMOVAL ........................................................... 41
INSTALLATION ................................................... 41
VACUUM PUMP ........................................................ 42

AIR CLEANER AND AIR DUCT
EM-15
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AIR CLEANER AND AIR DUCTPFP:16500
ComponentsEBS01EJC
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E5S
REMOVAL
1. Remove mass air flow sensor harness clamp from air cleaner case (upper).
2. Disconnect harness connector from mass air flow sensor.
3. Remove air cleaner case (upper) and air cleaner filter.
lAdd marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
lDo not shock it.
lDo not disassemble it.
lDo not touch its sensor.
5. Remove air duct with ventilation hose and vacuum hoses disconnected.
lAdd marks as necessary for easier installation.
1. Air duct 2. Air inlet pipe 3. Gasket
4. Bracket 5. Mass air flow sensor 6. O-ring
7. Air cleaner case (upper) 8. Air cleaner filter 9. Air cleaner case (lower)
10. Mounting rubber 11. Air duct side
A. To turbocharger
PBIC4040E

AIR CLEANER AND AIR DUCT
EM-17
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CHANGING AIR CLEANER FILTER
Removal
1. Remove mass air flow sensor harness clamp from air cleaner case (upper).
2. Disconnect harness connector from mass air flow sensor.
3. Unfasten clips and lift up air cleaner case (upper).
4. Remove air cleaner filter.
Installation
Installation is the reverse order of removal.

INTAKE MANIFOLD
EM-21
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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

INJECTION TUBE AND FUEL INJECTOR
EM-47
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4. Perform air tightness test for spill tube.
lConnect a handy vacuum pump to spill connector. Make sure
that vacuum is retained while applying following vacuum.
lIf outside of standard, reconnect spill tube. (Replace gasket in
this case.)
5. Install rocker cover. Refer toEM-56, "
Removal and Installation".
6. Install nozzle oil seal.
lInsert it straight until its flange fully contacts rocker cover.
CAUTION:
lCheck gutter spring in nozzle oil seal on fuel injector for missing.
7. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
8. Install fuel hoses, spill hose and fuel gallery as shown in the figure.Standard:
–53.3to–66.7kPa(–533to–667mbar,–400to
– 500 mmHg, – 15.75 to – 19.69 inHg)
JEF250Z
SBIA0203E
1. Rocker cover 2. Fuel filter (standard models) 3. Fuel pump
4. Fuel rail 5. Fuel filter (models for cold area)
PBIC3437E

EM-96
CYLINDER HEAD
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.
lCylinder head gasket to be installed is selected by its thickness through the following procedure.
–When replacing gasket alone
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of cut-outs on
the rear RH side.
*: Measured with head bolts tightened
• Gasket (3) thickness can be identified at the location (A)
shown in the figure by the numbers of cut-outs before
removal.
• Heater return tube is omitted for explanation.
NOTE:
Use mirrors for checking at points out of clear sight.
–When the following parts have been repaired/replaced:
lWith cylinder block upper surface and/or crankshaft pin journal ground
lWith cylinder block, pistons, connecting rods, and/or crankshaft replaced
a. Set piston at a point close to TDC.
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized.
c. Movethedialgaugestandsothatthetipofdialgaugecancon-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
Gasket thickness* mm (in) Number of grade Number of cut-outs
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1
0.950 (0.0374) 3 2
0.975 (0.0384) 4 3
1.000 (0.0394) 5 4
1.025 (0.0404) 6 5
1 : Cylinder head rear cover
2:Oilfilter
: Vehicle front
MBIA0020E
PBIC3478E
SEM507G
Piston protrusion mm (in) Gasket thickness* mm (in)Identification
Number of cut-outs
0.230 - 0.255 (0.0091 - 0.0100) 0.900 (0.0354) 0
0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
0.355 - 0.400 (0.0140 - 0.0157) 1.025 (0.0404) 5

ENGINE ASSEMBLY
EM-107
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lFor supporting points for lifting and jacking point at rear axle, refer toGI-52, "Pantograph Jack,
Garage Jack and Safety Stand".
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer toSC-5, "BATTERY".
2. Drain engine coolant from radiator drain plug. Refer toCO-7, "
Changing Engine Coolant".
3. Remove the following parts.
lEngine undercover front, engine undercover middle, engine undercover rear; Refer toEI-15, "FRONT
BUMPER".
lHood assembly; Refer toBL-12, "HOOD".
lEngine cover; Refer toEM-20, "INTAKE MANIFOLD".
lDrive belts; Refer toEM-12, "DRIVE BELTS".
lCooling fan, fan coupling and water pump pulley; Refer toCO-19, "COOLING FAN".
lAir duct and air cleaner case; Refer toEM-15, "AIR CLEANER AND AIR DUCT".
lAir inlet tube and air inlet hose; Refer toEM-18, "CHARGE AIR COOLER".
lAlternator; Refer toSC-23, "Removal and Installation".
lRadiator, radiator shroud (upper and lower) and cooling fan assembly; Refer toCO-11, "RADIATOR"
andCO-19, "COOLING FAN".
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room RH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer toEM-44,
"INJECTION TUBE AND FUEL INJECTOR".
2. Remove fuel filter. Refer toFL-4, "
FUEL FILTER".
3. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer toCO-23,
"THERMOSTAT AND WATER PIPING".
Engine room LH
1. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer toATC-142, "
Removal and Installation for Compressor"(automatic A/C
models) orMTC-122, "
Removal and Installation for Compressor"(manual A/C models).
Vehicle underbody
1. Remove exhaust front tube. Refer toEX-3, "Removal and Installation".
2. Remove front propeller shaft (4WD models) and rear propeller shaft. Refer toPR-3, "
FRONT PROPEL-
LER SHAFT"(4WD models) andPR-7, "REAR PROPELLER SHAFT".
3. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer toMT-16,
"TRANSMISSION ASSEMBLY"andCL-11, "OPERATING CYLINDER".
4. Disconnect power steering fluid piping at a point between body and engine. Refer toPS-30, "
HYDRAULIC
LINE".
5. Remove starter motor. Refer toSC-31, "
Removal and Installation".
6. Remove transmission assembly. Refer toMT-16, "
TRANSMISSION ASSEMBLY"(M/T models) orAT-
247, "TRANSMISSION ASSEMBLY"(A/T models).