washer fluid NISSAN NAVARA 2005 Repair User Guide

SECONDARY TIMING CHAIN
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a. Install tension guide on the back surface of front chain case.
lHold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
b. Apply a continuous bead of liquid gasket on both ends of arched
area (locations where rear chain case is adjoined) as shown in
the figure.
lUse Genuine Liquid Gasket or equivalent.
c. Install front chain case.
lWhen installing, align dowel pin on oil pump housing with the pin hole.
lInstall No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
6. Hereafter, install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
lBefore starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer toMA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS".
lUse procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
lBleed air from lines and hoses of applicable lines, such as in cooling system.
lAfter cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
SBIA0189E
JEF370Y
JEM121G

PRECAUTIONS
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lTo prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
lDispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
lDo not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.
lClean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
lReplace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
lReplace inner and outer races of tapered roller bearings and needle bearings as a set.
lArrange the disassembled parts in accordance with their assembled locations and sequence.
lDo not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
lAfter disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
lUse only the fluids and lubricants specified in this manual.
lUse approved bonding agent, sealants or their equivalents when required.
lUse tools and recommended special tools where specified for safe and efficient service repairs.
lWhen repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
lBefore servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for Three Way CatalystEAS001GL
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
lUse unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
lWhen checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
lDo not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS001GM
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
SGI233
SGI234

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

IDX-4
ALPHABETICAL INDEX
Engine control system diagram and chart .........EC-15
Engine coolant ....................................................CO-7
Engine coolant temperature sensor (ECTS) ....EC-103
Engine oil .............................................................LU-5
Engine oil filter replacement .............................MA-26
Engine oil precautions ..........................................GI-7
Engine removal ...............................................EM-106
Engine room cover ............................................EM-20
Engine serial number ..........................................GI-58
Evaporator ....................................ATC-149,MTC-129
Exhaust manifold ..............................................EM-34
Exhaust system ...................................................EX-2
Exhaust system inspection ..................................EX-2
Expansion valve ............................ATC-150,MTC-130
F
F/FOG - Wiring diagram .....................................LT-74
F/PUMP - Wiring diagram ..EC-248,EC-254,EC-260,
EC-266
Final drive pre-inspection .................................FFD-18
Final drive removal and installation ..RFD-14,RFD-81
Flow charts .........................................................GI-24
Fluid temperature sensor (A/T) ........................AT-118
Fluids ................................................................MA-14
Fluorescent leak detector .............ATC-150,MTC-131
Flywheel (clutch) ................................................CL-17
Flywheel runout ..............................................EM-134
Fog lamp, front ....................................................LT-71
Foot lamp ..........................................................LT-145
Fork rod (M/T) ....................................................MT-23
Freeze frame data .............................................EC-28
Front brake solenoid valve .................AT-137,AT-139
Front bumper ......................................................EI-15
Front case (Transfer) ..........................TF-114,TF-120
Front combination lamp removal and installationLT-30
Front door ................BL-118,BL-120,BL-126,GW-35
Front Door Trim ..................................................EI-30
Front drive shaft (Transfer) ...TF-114,TF-120,TF-133
Front final drive removal and installation (4WD) ...........
FFD-15
Front fog lamp .....................................................LT-71
Front passenger air bag ..................................SRS-40
Front seat ...........................................................SE-20
Front seat belt ............................................SB-3,SB-5
Front seat belt pre-tensioner ...............SRS-3,SRS-47
Front side air bag ............................................SRS-43
Front washer ......................................................WW-4
Front wiper .........................................................WW-4
FRPS - Wiring diagram ....................................EC-120
FTS - Wiring diagram .......................................EC-115
Fuel cut control (at no load high engine speed) .EC-20
Fuel filler lid ......................................................BL-136
Fuel filter ............................................................EC-23
Fuel filter replacement ..........................................FL-4
Fuel gauge ............................................................DI-4
Fuel injection control system .............................EC-18
Fuel injector ............EC-25,EC-123,EC-125,EC-237
Fuel injector and fuel tube ................................EM-44
Fuel leak ............................................................EC-88
Fuel line inspection ..............................................FL-3
Fuel pumpEC-86,EC-217,EC-245,EC-251,EC-258,
EC-263
Fuel pump(Learning Value Clearing) .................EC-24
Fuel rail pressure sensor .................................EC-118
Fuel system .........................................................FL-3
Fuel tank ..............................................................FL-9
Fuel temperature sensor ..................................EC-113
Fuse ......................................................PG-74,PG-84
Fuse and fusible link box ..................................PG-84
Fusible link ............................................PG-74,PG-84
G
Garage jack and safety stand .............................GI-52
Gauges .................................................................DI-4
Gear components (M/T) ....................................MT-21
Generator ...........................................................SC-14
Generator - See Alternator ................................SC-14
Glass ........................GW-11,GW-35,GW-38,GW-43
Glove box lamp ................................................LT-162
GLOW - Wiring diagram ..................................EC-296
Glow plug ............................................EM-41,EC-295
Glow relay ........................................................EC-295
Grease ..............................................................MA-14
Ground distribution ...........................................PG-27
H
H/AIM - Wiring diagram .....................................LT-66
Harness connector ............................................PG-75
Harness layout ..................................................PG-38
Hazard warning lamp .........................................LT-97
Headlamp aiming control ...................................LT-66
Headlamp leveler - See Headlamp aiming control ........
LT-66
Headlamp removal and installation ....................LT-30
Heat up switch .................................................EC-319
Heated seat .......................................................SE-12
Heater and cooling unit (Heater core) ..........ATC-124,
ATC-127
,MTC-103,MTC-106
Heater unit (heater core) ..............ATC-124,ATC-127,
MTC-103
,MTC-106
HEATUP - Wiring diagram ...............................EC-320
Height (Dimensions) ...........................................GI-60
HFC134a (R134a) system precaution .ATC-4,MTC-4
HFC134a (R134a) system service procedureATC-138,
MTC-118
HFC134a (R134a) system service tools ........ATC-16,
MTC-16
HFC134a system service equipment precaution ..........
ATC-12
,MTC-12
High and low reverse clutch solenoid valve ....AT-147,
AT-149
HLC - Wiring diagram ......................................WW-41
Horn .................................................................WW-59
HORN - Wiring diagram ...................................WW-59
How to erase DTC .............................................EC-27

ENGINE OIL
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3. Loosen oil filler cap (1) and then remove drain plug (3).
4. Drain engine oil.
5. Install drain plug with new washer. Refer toEM-36, "
OIL PAN AND OIL STRAINER".
CAUTION:
Be sure to clean drain plug and install with new washer.
6. Refill with new engine oil.
Engine oil specification and viscosity:
Refer toMA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS".
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
lWhen filling engine oil, do not pull out oil level gauge.
lThe refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
lAlways use the oil level gauge to determine when the proper amount of engine oil is in the
engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check the engine oil level. Refer toLU-5, "
ENGINE OIL LEVEL".
2 : Oil filter
: Engine front
PBIC3335E
Oil pan drain plug:
: 34.3 N·m (3.5 kg-m, 25 ft-lb)
Drain and refillWith oil filter change 7.6 (6-5/8)
Without oil filter change 7.1 (6-1/4)
Dry engine (Overhaul)7.9 (7)

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)

GENERAL MAINTENANCE
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GENERAL MAINTENANCEPFP:00000
General MaintenanceELS001HT
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge.
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified.
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the
vehicle, etc.
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel.Item Reference page
TiresCheck the pressure with a gauge periodically when at a service station, includ-
ing the spare, and adjust to the specified pressure if necessary. Check carefully
for damage, cuts or excessive wear.—
Windshield wiper
bladesCheck for cracks or wear if not functioning correctly. —
Doors and engine
hoodCheck that all doors, the engine hood, the trunk lid and back door operate prop-
erly. Also ensure that all latches lock securely. Lubricate if necessary. Make sure
that the secondary latch keeps the hood from opening when the primary latch is
released.
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.MA-39
,BL-12
Tire rotationTires should be rotated every 10,000 km (6,000 miles) for 2WD models and
every 5,000 km (3,000 miles) for 4WD models.MA-34
Item Reference page
LampsMake sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and
other lamps are all operating properly and installed securely. Also check
headlamp aim.—
Warning lamps and
chimesMake sure that all warning lamps and buzzers/chimes are operating properly. —
Steering wheelCheck that it has the specified play.
Check for changes in the steering conditions, such as excessive free play, hard
steering or strange noises.
Free play: Less than 35 mm (1.38 in)—
Seat beltsCheck that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the
belt webbing for cuts, fraying, wear or damage.MA-40
Item Reference page
Windshield washer
fluidCheck that there is adequate fluid in the tank. —
Engine coolant levelCheck the coolant level when the engine is cold.MA-19
(YD25DDTi)
Engine oil levelCheck the level after parking the vehicle (on level ground) and turning off the
engine.MA-25
(YD25DDTi)
Brake and clutch fluid
levelsMake sure that the brake and clutch fluid levels are between the “MAX” and
“MIN” lines on the reservoir.MA-28
,MA-35
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN”
lines.—

MA-26
ENGINE MAINTENANCE
CAUTION:
Be sure to clean drain plug and install with new washer.
6. Refill with new engine oil.
Engine oil specification and viscosity:
Refer toMA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS".
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
lWhen filling engine oil, do not pull out oil level gauge.
lThe refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
lAlways use the oil level gauge to determine when the proper amount of engine oil is in the
engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check the engine oil level. Refer toLU-5, "
ENGINE OIL LEVEL".
Changing Oil FilterELS001JY
REMOVAL
1. Remove engine undercover middle.
2. Place a pan to catch the engine oil under the lower part of drain hose outlet before removing oil filter.
3. Using the oil filter wrench, remove oil filter.
CAUTION:
lBe careful not to get burned when engine and engine oil are hot.
lWhen removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
lDo not allow engine oil to adhere to drive belts.
lCompletely wipe off any engine oil that adhere to engine and vehicle.
lOil filter is provided with a relief valve. Use Genuine NISSAN Oil Filter or equivalent.
INSTALLATION
1. Remove foreign materials adhering to the oil filter installation surface.
2. Apply new engine oil to the oil seal circumference of new oil fil-
ter.
Use Genuine NISSAN Oil Filter or equivalent.Oil pan drain plug:
: 34.3 N·m (3.5 kg-m, 25 ft-lb)
Drain and refillWith oil filter change 7.6 (6-5/8)
Without oil filter change 7.1 (6-1/4)
Dry engine (Overhaul)7.9 (7)
SMA010

REFRIGERANT LINES
MTC-131
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MTC
Checking for Refrigerant LeaksEJS0062F
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS0062G
1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future mis-
diagnosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionEJS0062H
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

PS-6
POWER STEERING FLUID
POWER STEERING FLUID
PFP:KLF20
Checking Fluid LevelEGS001LD
lCheck fluid level with engine stopped.
lMake sure that fluid level is between MIN and MAX.
lFluid levels at HOT and COLD are different. Do not confuse
them.
CAUTION:
lThe fluid level should not exceed the MAX line. Excessive
fluid will cause fluid leakage from the cap.
lDo not reuse drained power steering fluid.
lRecommended fluid is Type DEXRONTMIII or equivalent.
Checking Fluid LeakageEGS001LE
Check hydraulic connections for fluid leakage, cracks, damage,
looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80°C(122
to 176°F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right
stop.
3. Hold steering wheel at each lock position for five seconds and
carefully, check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 10 seconds. (There is the possibility that oil pump may
be damaged.)
4. If fluid leakage at connections is noticed, then loosen flare nut and then retighten. Do not over-tighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer toPS-25, "
POWER STEERING OIL
PUMP".
6. Check steering gear boots for accumulation of fluid, indicating from steering gear.
Air Bleeding Hydraulic SystemEGS001LF
If air bleeding is not complete, the following symptoms can be observed.
lBubbles are created in reservoir tank.
lClicking noise can be heard from oil pump.
lExcessive buzzing in the oil pump
NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of
the system.
1. Turn steering wheel several times from full left to full right stop with engine off.
CAUTION:
Turn steering wheel while filling reservoir tank with fluid so as not to lower fluid level below the
MIN line.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
3. Repeat step 2 above several times at approximately 3 second intervals.
CAUTION:
Do not hold the steering wheel in a locked position for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and while contamination.HOT : Fluid temperature 50 - 80°C (122 - 176°F)
COLD : Fluid temperature 0 - 30°C(32-86°F)
SGIA0232J
SGIA0506E