NISSAN NAVARA 2005 Repair Workshop Manual

MA-6
DESCRIPTION
ROAD TEST
Check clutch operation
Check foot brake operation
Check parking brake operation
Check steering operation, self-centering and steering wheel alignment
Check engine performance
Check for squeaks, rattles and noise from interior, suspension and brakes
Check heating, ventilation and air conditioning operation
Check radio, cassette and CD player operation
Check odometer and trip meter operation and cancelling
Check instruments for operation
Check automatic transmission/transaxle shift pattern and kickdown operation (if applicable)
Check cruise control and navigation system operation (if applicable)
ENGINE OPERATING AND HOT
Check idle speed
Check automatic transmission/transaxle oil level (if applicable)
FINAL INSPECTION
Remove vehicle protection kit
Fit interior mats and wheel covers
Check for interior and exterior metal and paint damage
Wash, clean interior and exterior
: Not applicable to this model

GENERAL MAINTENANCE
MA-7
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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-8
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PFP:00026
Periodic MaintenanceELS001J9
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric con-
ditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent mainte-
nance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
ENGINE AND EMISSION CONTROL MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, D = Check filter and drain water
NOTE:
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
l(1) If valve noise increases, check valve clearance.
l(2) Never use CG-4 oil.
l(3) Oil filter element assembly and O-ring seal are replacement parts.
l(4) First replace at 100,000 Km (60,000 miles)/60 months, then every 60,000Km (36,000 miles)/36 months. After first
replacement, perform "I" (checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of
replacement interval.
l(5) If engine power decreases, black exhaust smoke is emitted or engine noise increases, perform this maintenance item. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles) or months, which-
ever comes first.km x 1,000
(Miles x
1,000)
Months30
(18)
2460
(36)
4890
(54)
72120
(72)
96
Engine compartment and under vehicle
Intake & exhaust valve clearanceSee
NOTE (1)EM-66
Drive beltsIIIIMA-17
Engine oil (Use recommended oil.)See
NOTE (2)RRRRMA-25
Engine oil filter (Use NISSAN genuine part or equivalent)See
NOTE (3)RRRRMA-26
Engine anti-freeze coolant (Use Genuine NISSAN Anti-freeze
Coolant (L250) or equivalent)See
NOTE (4)IIIIMA-19
Cooling system I I I IMA-21
Fuel linesIIIIMA-23
Air cleaner filter (Dry paper type)RRMA-25
Fuel filterDRDRMA-23
Fuel injectorSee
NOTE (5)EM-44

PERIODIC MAINTENANCE
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CHASSIS AND BODY MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
*1: Replace at 60,000 km (36,000 miles) or 24 months, whichever comes first.
*2: Replace at 120,000 km (72,000 miles) or 48 months, whichever comes first.
NOTE:
l(1) Inspect once per year.
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles) or months,
whichever comes first.km x 1,000
(Miles x 1,000)
Months30
(18)
2460
(36)
4890
(54)
72120
(72)
96
Underhood and under vehicle
Headlampaiming IIIILT- 2 8
Brake&clutch,systemsandfluid(Forlevel&leaks) IIIIMA-35,
MA-28
Brake fluidRRRRMA-35
Brakeboostervacuumhoses,connections&checkvalve IIIIBR-22
Powersteeringfluid&lines(Forlevel&leaks) IIIIMA-37
Manual transmission gear oil (For leaks)IIIIMA-28
Automatic transmission fluid (For level & leaks)IIIIMA-29
Transferfluid(Forlevel&leaks) IIIIMA-31
Differential gear oil (For level & leaks or replace)IIIIMA-32,
MA-33
Limited-slip differential (LSD) gear oil
(for level and leaks)IIIIMA-33
Limited-slip differential (LSD) gear oil (for replace)R*1R*2MA-34
Steering gear & linkage, axle & suspension parts, propeller
shaft, drive shafts & exhaust systemIIIIMA-37
,
MA-38
,
MA-32
,
MA-38
,
MA-28
Wheelalignment(Ifnecessary,rotate&balancewheels) IIIIFSU-7,
MA-34
Brake pads, rotors & other brake componentsIIIIMA-36
,
MA-35
,
MA-36
Brake linings, drums & other brake & componentsIIIIMA-37
,
MA-36
,
MA-36
Foot brake, parking brake & clutch (For free play, stroke &
operation)IIIIBR-6,
PB-2
,
CL-6
Air conditioner filterRRRRATC-122,
MTC-101
Body corrosionSee
NOTE (1)MA-40

MA-10
PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage <30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving condition Maintenance itemMainte-
nance
operationMaintenance intervalReference
page
A........AircleanerfilterCleanEvery 5,000 km (3,000 miles)
or 4 months
MA-25
ReplaceEvery 30,000 km (18,000
miles) or 24 months
ABCD.....Engine oil & engine oil fil-
terReplaceEvery 15,000 km (9,000
miles) or 12 monthsMA-25
,
MA-26
A . . . E . . . . Fuel filterCheck &
drain
waterEvery 15,000 km (9,000
miles) or 12 monthsMA-25
ReplaceEvery 30,000 km (18,000
miles) or 24 monthsMA-23
. . . . . F . . . Brake fluid ReplaceEvery 15,000 km (9,000
miles) or 12 monthsMA-35
..C....H.Differential gear oil
ReplaceEvery 30,000 km (18,000
miles) or 24 monthsMA-33
,
MA-34
Limited-slip differential
(LSD) gear oilEvery 30,000 km (18,000
miles) or 12 monthsMA-34
..C....H.Limited-slip differential
(LSD) gear oilInspect
(for level)Every 15,000 km (9,000
miles) or 12 monthsMA-33
..C....H.Automatic transmission
fluidReplaceEvery 30,000 km (18,000
miles) or 24 monthsMA-31
......GH.Steering gear & linkage,
axle & suspension parts,
propeller shaft, drive
shafts & exhaust systemInspectEvery 15,000 km (9,000
miles) or 12 monthsMA-37
,
MA-38
,
MA-32
,
MA-38
,
MA-28
A.C. . .GHIBrake pads, rotors & other
brake componentsInspectEvery 15,000 km (9,000
miles) or 12 monthsMA-36
,
MA-35
,
MA-36
A.C. . .GHIBrake linings, drums &
other brake componentsInspectEvery 15,000 km (9,000
miles) or 12 monthsMA-37
,
MA-36
,
MA-36
A . . . . . . . . Air conditioner filter ReplaceEvery 15,000 km (9,000
miles) or 12 monthsAT C - 1 2 2,
MTC-101

PERIODIC MAINTENANCE
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ENGINE AND EMISSION CONTROL MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, D = Check filter and drain water
NOTE:
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
l(1) If valve noise increases, check valve clearance.
l(2)NeveruseCG-4oil.
l(3) Oil filter element assembly and O-ring seal are replacement parts.
l(4) First replace at 100,000 Km (60,000 miles), then every 60,000Km (36,000 miles). After first replacement, perform "I"
(checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
l(5) If engine power decreases, black exhaust smoke is emitted or engine noise increases, perform this maintenance item.
CHASSIS AND BODY MAINTENANCE (YD25DDTI DIESEL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x 1,000)30
(18)60
(36)90
(54)120
(72)
Engine compartment and under vehicle
Intake & exhaust valve clearanceSee
NOTE (1)EM-66
Drive beltsIIIIMA-17
Engine oil (Use recommended oil.)See
NOTE (2)RRRRMA-25
Engine oil filter (Use NISSAN genuine part or equivalent)See
NOTE (3)RRRRMA-26
Engine anti-freeze coolant (Use Genuine NISSAN Anti-freeze
Coolant (L250) or equivalent)See
NOTE (4)IIIIMA-19
Cooling system I I I IMA-21
Fuel linesIIMA-23
Air cleaner filter (Dry paper type)RRMA-25
Fuel filterDRDRMA-23
Fuel injectorSee
NOTE (5)EM-44
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x
1,000)30
(18)60
(36)90
(54)120
(72)
Underhood and under vehicle
Headlamp aiming I I I ILT- 2 8
Brake & clutch, systems and fluid (For level & leaks) I I I IMA-35,
MA-28
Brake fluidRRMA-35
Brake booster vacuum hoses, connections & check valve I IBR-22
Power steering fluid & lines (For level & leaks) I I I IMA-37
Manual transmission gear oil (For leaks) I I I IMA-28
Automatic transmission fluid (For level & leeaks)IIIIMA-29
Transfer fluid (For level & leaks) I I I IMA-31
Differential gear oil (For level & leaks or replace)IIIIMA-32,
MA-33

MA-12
PERIODIC MAINTENANCE
NOTE:
l(1) Inspect once per year.
lMaintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”. Limited-slip differential (LSD) gear oil
(for level and leaks or replace)IRIRMA-33
,
MA-34
Steering gear & linkage, axle & suspension parts, propeller
shaft, drive shafts & exhaust systemIIIIMA-37
,
MA-38
,
MA-32
,
MA-38
,
MA-28
Wheel alignment (If necessary, rotate & balance wheels) I I I IFSU-7,
MA-34
Brake pads, rotors & other brake componentsIIIIMA-36
,
MA-35
,
MA-36
Brake linings, drums & other brake componentsIIIIMA-37
,
MA-36
,
MA-36
Foot brake, parking brake & clutch (For free play, stroke & oper-
ation)IIIIBR-6,
PB-2
,
CL-6
Air conditioner filterRRRRAT C - 1 2 2,
MTC-101
Body corrosionSee
NOTE (1)MA-40
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page
Perform at number of kilometers (miles) basis only.km x 1,000
(Miles x
1,000)30
(18)60
(36)90
(54)120
(72)

PERIODIC MAINTENANCE
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MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage >30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving condition Maintenance itemMaintenance
operationMaintenance intervalReference
page
A........Aircleaner filterCleanEvery 5,000 km (3,000
miles)
MA-25
ReplaceEvery 30,000 km (18,000
miles)
ABCD.....Engine oil & engine oil
filterReplaceEvery 15,000 km (9,000
miles)MA-25
,
MA-26
A...E....FuelfilterCheck &
drain waterEvery 15,000 km (9,000
miles)MA-25
ReplaceEvery 30,000 km (18,000
miles)MA-23
.....F...Brakefluid ReplaceEvery 30,000 km (18,000
miles)MA-35
..C....H.Differential gear oil
ReplaceEvery 30,000 km (18,000
miles)MA-33
,
MA-34
Limited-slip differential
(LSD) gear oilMA-34
..C....H.Limited-slip differential
(LSD) gear oilInspect
(for level)Every 15,000 km (9,000
miles)MA-33
..C....H.Automatic transmission
fluidReplaceEvery 60,000 km (36,000
miles)MA-31
......GH.Steering gear & link-
age, axle & suspension
parts, propeller shaft,
drive shafts & exhaust
systemInspectEvery 15,000 km (9,000
miles)MA-37
,
MA-38
,
MA-32
,
MA-38
,
MA-28
A.C...GHIBrake pads, rotors &
other brake compo-
nentsInspectEvery 15,000 km (9,000
miles)MA-36
,
MA-35
,
MA-36
A.C...GHIBrake linings, drums &
other brake compo-
nentsInspectEvery 15,000 km (9,000
miles)MA-37MA-36,
MA-36
,
A........Airconditioner filter ReplaceEvery 15,000 km (9,000
miles)ATC-122
,
MTC-101

MA-14
RECOMMENDED FLUIDS AND LUBRICANTS
RECOMMENDED FLUIDS AND LUBRICANTS
PFP:00000
Fluids and LubricantsELS001JA
*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Genuine NISSAN Anti-freeze Coolant (L250) or equivalent in its quality, in order to avoid possible aluminum corrosion within the
engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRON
™III/MER-
CON™ Automatic Transmission Fluid.
*5:Using automatic transmission fluid other than Genuine NISSAN ATF Matic Fluid J will cause deterioration in driveability
and automatic transmission durability, and may damage the automatic transmission, which is not covered by the warranty.
*6: DEXRON™III type ATF can be used.
*7: Never mix different types of fluids (DOT 3 and DOT 4).Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refillWith oil filter change 7.6 6-5/8 qt
lDiesel engine
API CF-4*1, *2
ACEA B1, B3, B4, B5*1 Without oil filter change 7.1 6-1/4 qt
Dry engine (engine overhaul) 7.9 7 qt
Cooling sys-
tem (with res-
ervoir)LHD models 9.9 8-3/4 qt
lGenuine NISSAN Anti-freeze Coolant (L250) or
equivalent in its quality*3 RHD models 10.2 9 qt
Reservoir tank 0.8 3/4 qt
Manual transmission gear oil2WD 3.99 7 pt
lGenuine NISSAN gear oil or API GL-4, Viscosity
SAE 75W-85 or 75W-90
4WD 4.32 7-5/8 pt
Transfer fluid 2.0 1-3/4 qt
lGenuine NISSAN ATF or equivalent*4
Differential gear oilFront 0.85 1-1/2 pt
lStandard differential gear:
Gear Oil Hypoid LSD (Part No.: KLD31-8090403)
or API GL-5, Viscosity SAE 80W-90*1
lLimited-slip differential (LSD) gear:
Gear Oil Hypoid LSD (Part No. KLD31-8090403)
or equivalent Rear 2.01 3-1/2 pt
Automatic transmission fluid 10.3 9-1/8 qt Genuine NISSAN ATF Matic Fluid J*5
Power steering fluid — — Genuine NISSAN PSF or equivalent*6
Brake and clutch fluid — —
lDOT 3 or DOT 4 (US FMVSS No. 116)*7
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)

RECOMMENDED FLUIDS AND LUBRICANTS
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SAE Viscosity NumberELS001JB
DIESEL ENGINE
l5W-30 is preferable.
If 5W-30 is not available, select the viscosity, from the chart, that
is suitable for the outside temperature range.
GEAR OIL
lFor warm and cold areas: 80W-90 for the differential gear and
75W-85 for transmission gear are preferable.
lFor hot areas: 90 is suitable for ambient temperatures below
40°C (104F°).
SMA204D
SLIA0015E