power steering NISSAN NAVARA 2005 Repair Owner's Manual

PRIMARY TIMING CHAIN
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h. Tighten fixing bolt another 120 degrees (angle tightening) (turn
by 2 notch).
18. Install secondary timing chain and the associated parts.
Refer toEM-75, "
INSTALLATION".
19. 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.
Summary of the inspection items:
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
A : Indicate embossments
B : Alignment mark
PBIC3476E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

EM-98
CYLINDER HEAD
lBefore installing, remove carbon depositing on mounting hole of glow plug with a reamer.
6. Install engine coolant temperature sensor.
7. 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.
Summary of the inspection items:
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

ENGINE ASSEMBLY
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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).

ENGINE ASSEMBLY
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Summary of the inspection items:
*1: Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS01E6H
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3(cu in)2,488 (151.82)
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.5
Compression pressure
Unit: kPa (bar, kg/cm
2, psi)/200 rpmStandard 3,100 (31, 31.6, 450)
Minimum 2,500 (25, 25.5, 363)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
226 210 2 28 -2 48
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
pump belt2.9 - 3.4
(0.114 - 0.134)3.9 - 4.4
(0.154 - 0.173)8.5 (0.335)
Power steering oil pump belt4.6 - 5.4
(0.181 - 0.213)7.1 - 7.7
(0.280 - 0.303)11.3 (0.445)

FFD-10
FRONT OIL SEAL
CAUTION:
Do not pull on the ABS sensor harness.
6. Support the lower link using a suitable jack.
7. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using a jack.
8. Remove the engine under cover rear using power tool.
9. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
10. Remove the front propeller shaft. Refer toPR-4, "
Removal and
Installation".
11. Measure the total preload with the preload gauge.
NOTE:
Record the preload measurement.
12. Remove the drive pinion lock nut using flange wrench.
13. Put a matching mark on the end of the drive pinion in line with
the matching mark B on the companion flange.
CAUTION:
Use paint to make the matching mark on the drive pinion.
Do not damage the companion flange or drive pinion.
NOTE:
The matching mark B on the final drive companion flange indi-
cates the maximum vertical runout position.Tool number : ST29020001
Tool number A: ST3127S000WEIA0119E
PDIA1002E
PDIA1004E
SDIA0270E

SIDE OIL SEAL
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FFD
SIDE OIL SEALPFP:33142
Removal and InstallationEDS00354
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer toBR-26, "
Removal and Installation of
Brake Caliper Assembly".
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using jack.
6. Remove the engine under cover rear using power tool.
7. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
8. Remove the side oil seal using suitable tool.
CAUTION:
Be careful not to damage gear carrier.
INSTALLATION
Installation is the reverse order of removal.
lDrive the side oil seal in evenly until it becomes flush with the
case end using Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
lWhen installing the drive shaft assembly into the front
final drive assembly, do not damage the side oil seal.
lCheck the final drive gear oil level. Refer toFFD-8, "Checking Differential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
WEIA0119E
LDIA0173E
Tool number A: ST30720000
B: ST27863000
PDIA0826E

FFD-16
FRONT FINAL DRIVE ASSEMBLY
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using a jack.
6. Remove the engine under cover rear using power tool.
7. Drain the front final drive fluid. Refer toFFD-8, "
Changing Differ-
ential Gear Oil".
8. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
9. Remove the front crossmember.
10. Disconnect the front propeller shaft from the front final drive. Then reposition the front propeller shaft
aside using suitable wire. Refer toPR-4, "
Removal and Installation".
11. Disconnect the vent hose from the front final drive.
12. Support the front final drive using a suitable jack.
13. Remove the front final drive bolts, then remove the front final
drive assembly.
CAUTION:
Secure rear the front final drive assembly to a suitable jack
while removed it.
INSTALLATION
Installation is the reverse order of removal.
lInstall new side oil seals into the front final drive assembly. Refer toFFD-13, "Removal and Installation".
CAUTION:
lWhen installing the drive shaft assembly into the front final drive assembly, do not damage the
side oil seal.
lMake sure there are no pinched or restricted areas on the breather hose caused by bending or
winding when installing it.
lFill the final drive with recommended gear oil after installation. Refer toFFD-8, "Changing Differ-
ential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
WEIA0119E
WDIA0145E

ON-VEHICLE SERVICE
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3. Put a mark on base line of the tread (rear side) of both front tires
at the same height as hub center as shown. These marks are
measuring points.
4. Measure the distance “A” on the rear side of the front tires as
shown.
5. Push the vehicle slowly ahead to rotate the wheels 180°
degrees (1/2 a turn).
CAUTION:
If the wheels have rotated more than 180°degrees (1/2
turn), start this procedure again from the beginning. Never
push the vehicle backward.
6. Measure the distance “B” on the front side of the front tires at the
same marks as shown. Total toe-in is calculated as “A” – “B”.
7. Adjust the toe-in by varying the length of the steering outer tie-
rods.
a. Loosen the outer tie-rod lock nuts.
b. Adjust the toe-in by screwing the outer tie-rods in or out.
c. Tighten the outer tie-rod lock nuts to specification.
FRONT WHEEL TURNING ANGLE
NOTE:
Check front wheel turning angle after the toe-in inspection.
1. Place front wheels on turning radius gauges in straight ahead
position and rear wheels on stands so that vehicle can be level.
Check the maximum inner and outer wheel turning angles for LH
and RH road wheels.
2. Start engine and run at idle, turn steering wheel all the way right
and left, measure the turning angle.
lAny turning angles are not adjustable. If any of steering
angles are out of the specification, check if the following parts
are worn or damaged.
–Steering gear
–Steering column
–Front suspension components
If found that they are worn or damaged, replace them with new ones.
AFA050
Total toe-in : Refer toFSU-19, "Wheel Alignment
(Unladen*1)".
SFA234AC
Standard length “L” : Refer toPS-14, "POWER
STEERING GEAR AND LINK-
AGE".
Lock nut : Refer toPS-14, "
Removal and
Installation".
SFA486A
Wheel turning angle
(full turn):RefertoFSU-19, "Wheel
Alignment (Unladen*1)".
SFA439BA

GI-4
PRECAUTIONS
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the²ACC²position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the²LOCK²position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
General PrecautionsEAS001GJ
lDo not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
lBefore jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.
lWhen removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance and
drop them. Also, do not allow them to strike adjacent parts,
especially the brake tubes and master cylinder.
lBefore starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
lIf the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
SGI285
SGI231
SEF289H