water pump NISSAN NAVARA 2005 Repair Owner's Manual

FL-6
FUEL FILTER
lIf air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel pump. After that, operate priming pump and con-
firm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel FilterEBS01E75
1. Prepare a tray (A) under the drain plug (1).
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
lWater in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
lDrained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
5. Bleed air in fuel piping. Refer toFL-5, "
Air Bleeding".
6. Start engine and make sure there is no fuel leakage.Drain plug
: 1.3 N·m (0.13 kg-m, 12 in-lb)
PBIC3373E

PRECAUTIONS
GI-5
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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

GW-44
REAR WINDOW GLASS AND MOLDING
2. Apply a protective tape around the rear window glass to protect the painted surface from damage.
lIf the window glass is to be reused, mark the body and the glass with mating marks.
lRemove the glass using piano wire or power cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent
glass splinters from entering your eyes or cutting your hands.
CAUTION:
lBe careful not to scratch the glass when removing.
lDo not set or stand the glass on its edge. Small chips may develop into cracks.
INSTALLATION
lUse a genuine NISSAN Urethane Adhesive Kit (if available) or equivalent and follow the instructions fur-
nished with it.
lWhile the urethane adhesive is curing, open a door window. This will prevent the glass from being forced
out by passenger compartment air pressure when a door is closed.
lCheck gap along bottom to confirm that glass does not contact sheet metal.
lInform the customer that the vehicle should remain stationary until the urethane adhesive has completely
cured (preferably 24 hours). Curing time varies with temperature and humidity.
lInstall parts removed.
WARNING:
lKeep heat and open flames away as primers and adhesive are flammable.
lThe materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid
contact with the skin and eyes.
lUse in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if
inhaled. If affected by vapor inhalation, immediately move to an area with fresh air.
lDriving the vehicle before the urethane adhesive has completely cured may affect the perfor-
mance of the glass in case of an accident.
CAUTION:
lDo not use an adhesive which is past its usable term. Shelf life of this product is limited to six
months after the date of manufacture. Carefully adhere to the expiration or manufacture date
printed on the box.
lKeep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.
lDo not leave primers or adhesive cartridge unattended with their caps open or off.
lThe vehicle should not be driven for at least 24 hours or until the urethane adhesive has com-
pletely cured. Curing time varies depending on temperature and humidity. The curing time will
increase under lower temperatures and lower humidities.
Repairing Water Leaks for Rear window Glass
Leaks can be repaired without removing or reinstalling glass.
If water is leaking between urethane adhesive material and body or glass, determine the extent of leakage.
This can be done by applying water to the rear window area while pushing glass outward.
To stop leak, apply primer (if necessary) and then urethane adhesive to the leak point.

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

MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTIONMA
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MAINTENANCE
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
DESCRIPTION ............................................................ 5
Pre-Delivery Inspection Items .................................. 5
GENERAL MAINTENANCE ....................................... 7
General Maintenance ............................................... 7
PERIODIC MAINTENANCE ....................................... 8
Periodic Maintenance ............................................... 8
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD25DDTI DIESEL ENGINE) ................ 8
CHASSIS AND BODY MAINTENANCE
(YD25DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD25DDTI DIESEL ENGINE) ............... 11
CHASSIS AND BODY MAINTENANCE
(YD25DDTI DIESEL ENGINE) ............................. 11
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 13
RECOMMENDED FLUIDS AND LUBRICANTS ...... 14
Fluids and Lubricants ............................................. 14
SAE Viscosity Number ........................................... 15
DIESEL ENGINE ................................................. 15
GEAR OIL ........................................................... 15
Engine Coolant Mixture Ratio ................................ 16
ENGINE MAINTENANCE ......................................... 17
Checking Drive Belts .............................................. 17
Deflection Adjustment ............................................ 18
POWER STEERING OIL PUMP BELT ............... 18
A/C COMPRESSOR, ALTERNATOR AND
WATER PUMP BELT .......................................... 19
Changing Engine Coolant ...................................... 19
DRAINING ENGINE COOLANT ......................... 19
REFILLING ENGINE COOLANT ........................ 20FLUSHING COOLING SYSTEM ......................... 21
Checking Cooling System ...................................... 21
CHECKING COOLING SYSTEM HOSES ........... 21
CHECKING RADIATOR ...................................... 21
CHECKING RESERVOIR TANK CAP ................. 21
CHECKING RADIATOR SYSTEM FOR LEAKS... 22
Checking Fuel Lines ............................................... 23
Changing Fuel Filter ............................................... 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 24
Draining Water from Fuel Filter .............................. 25
Changing Engine Air Cleaner Filter ........................ 25
DRY PAPER TYPE .............................................. 25
Changing Engine Oil ............................................... 25
Changing Oil Filter .................................................. 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
INSPECTION AFTER INSTALLATION ................ 27
CHASSIS AND BODY MAINTENANCE ................... 28
Checking the Exhaust System ................................ 28
Checking Clutch Fluid Level and Leaks ................. 28
Checking Clutch System ........................................ 28
Checking M/T Oil .................................................... 28
Changing M/T Oil .................................................... 29
Checking A/T Fluid ................................................. 29
Changing A/T Fluid ................................................. 31
Checking Transfer Fluid ......................................... 31
FLUID LEAKAGE AND FLUID LEVEL ................ 31
Changing Transfer Fluid ......................................... 32
DRAINING ........................................................... 32
FILLING ............................................................... 32
Checking Propeller Shaft ........................................ 32
Checking Front Final Drive Oil (Front Differential
Gear Oil) ................................................................. 32
OIL LEAKAGE AND OIL LEVEL ......................... 32
Changing Front Final Drive Oil (Front Differential
Gear Oil) ................................................................. 33
DRAINING ........................................................... 33
FILLING ............................................................... 33

ENGINE MAINTENANCE
MA-17
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ENGINE MAINTENANCEPFP:00000
Checking Drive BeltsELS001JO
lBefore inspecting engine, make sure engine has cooled down; wait approximately 30 minutes after engine
has been stopped.
lVisually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
lMeasure deflection at the marked point ( ).
CAUTION:
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid varia-
tion in deflection between pulleys.
lTighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
4. Crankshaft pulley 5.A/C compressor (Models with A/C)
Dummy pulley (Models without A/C)6. Alternator
7. Idler pulley 8. Water pump pulley 9.A/C compressor, alternator and
water pump belt
PBIC4038E
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)

MA-18
ENGINE MAINTENANCE
Deflection Adjustment
ELS001JP
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt tension immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with engine oil or engine coolant.
lDo not twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front. Refer toEI-15, "FRONT BUMPER".
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust. Refer toMA-17, "
Checking Drive Belts".
4. Tighten idler pulley lock nut (B).
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
4. Crankshaft pulley 5.A/C compressor (Models with A/C)
Dummypulley(ModelswithoutA/C)6. Alternator
7. Idler pulley 8. Water pump pulley 9.A/C compressor, alternator and
water pump belt
A. Adjusting bolt B. Idler pulley lock nut C. Adjusting nut
D. Idler pulley lock nut
PBIC4039E
Applied belt Belt adjustment method
Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
water pump beltAdjusting nut on idler pulley (C)
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)

ENGINE MAINTENANCE
MA-19
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A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT
1. Loosen idler pulley lock nut (D).
2. Turn adjusting nut (C) to adjust. Refer toMA-18, "
Deflection Adjustment".
3. Tighten lock nut (D).
Changing Engine CoolantELS001JQ
WARNING:
lTo avoid being scalded, do not change engine coolant when engine is hot.
lWrap a thick cloth around cap and carefully remove radiator cap. First, turn radiator cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and
remove radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
When draining all engine coolant in the system, also perform the following steps.
2. Remove air relief plug (1) on heater feed tube.
lLHD models
lRHD models
3. Open cylinder block drain plug. Refer toEM-110, "
CYLINDER BLOCK".
4. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
5. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer toMA-21, "
FLUSHING COOLING SYSTEM". Nut D:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
2 : Engine undercover front
A : Loosen.
: Vehicle front
PBIC3634E
2 : Water hose (from reservoir tank)
3:Fuelfilter
: Vehicle front
PBIC3348E
2 : Water hose (from reservoir tank)
: Vehicle front
PBIC3635E

ENGINE MAINTENANCE
MA-25
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Draining Water from Fuel FilterELS001JU
1. Prepare a tray (A) under the drain plug (1).
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
lWater in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
lDrained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
5. Bleed air in fuel piping. Refer toFL-5, "
Air Bleeding".
6. Start engine and make sure there is no fuel leakage.
Changing Engine Air Cleaner FilterELS001JW
DRY PAPER TYPE
It is necessary to clean the filter or replace it at the recommended
intervals, more often under dusty driving conditions.
Refer toMA-8, "
PERIODIC MAINTENANCE".
Changing Engine OilELS001JX
WARNING:
lBe careful not to burn yourself, as the engine oil is hot.
lProlonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer
toLU-5, "
ENGINE OIL LEAKAGE".
2. Stop engine and wait for 10 minutes.
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". Drain plug
: 1.3 N·m (0.13 kg-m, 12 in-lb)
PBIC3373E
SMA384C
2 : Oil filter
: Engine front
PBIC3335E

SERVICE DATA AND SPECIFICATIONS (SDS)
MA-41
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitELS001J8
BELT DEFLECTION
*: When engine is cold.
RESERVOIR TANK
Unit:kPa(bar,kg/cm2, psi)
ENGINE COOLANT CAPACITY (APPROXIMATE)
Unit: (lmp qt)
ENGINE OIL CAPACITY (APPROXIMATE)
Unit: (lmp qt) 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 belt 4.6 - 5.4 (0.181 - 0.213) 7.1 - 7.7 (0.280 - 0.303) 11.3 (0.445)
Cap relief pressureStandard 98.2 - 117.8 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Engine coolant capacity (With reser-
voir tank at “MAX” level)LHD models 9.9 (8-3/4)
RHD models 10.2 (9)
Reservoir tank coolant capacity (At “MAX” level) 0.8 (3/4)
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)