service NISSAN NAVARA 2005 Repair Workshop Manual

PR-12
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
General SpecificationsEDS0035N
2WD Models
4WD Models
Snap RingEDS0035O
Model 2S1330
Unit: mm (in)
*Always check with the Parts Department for the latest parts information.
Model 2F S1300 and 3S S1310
Unit: mm (in)
*Always check with the Parts Department for the latest parts information.Applied modelYD25DDTi
6M/T 5A/T
Propeller shaft model 3S S1310
Number of joints3
Coupling method with rear final drive Flange type
Coupling method with transmission Sleeve type
1st Shaft length (Center bearing to spider) 675 mm (26.57 in) 742 mm (29.21 in)
2nd Shaft length (Spider to spider) 897 mm (35.31 in)
Shaft outer diameter 75.64 mm (2.9779 in)
Journal axial play 0.02 mm (0.0008 in) or less
Propeller shaft run out limit 0.6 mm (0.024 in) or less
Propeller shaft joint flex effort 1.96 N·m (0.20 kg-m, 17 in-lb) or less
Applied modelYD25DDTi
Propeller shaft modelFront Rear
2F S1300 2S1330 (aluminum tube)
Number of joints2
Coupling method with front final drive Flange type
Coupling method with transfer Flange type Sleeve type
Shaft length (Spider to spider) 718 mm (28.27 in) 1266.8 mm (35.51 in)
Shaft outer diameter 65 mm (2.56 in) 102.5 mm (2.97 in)
Journal axial play 0.02 mm (0.0008 in) or less
Propeller shaft run out limit 0.6 mm (0.024 in) or less 1.02 mm (0.0402 in) or less
Propeller shaft joint flex effort 1.96 N·m (0.20 kg-m, 17 in-lb) or less 2.26 N·m (0.23 kg-m, 20 in-lb) or less
Thickness Part number* Thickness Part number*
1.600 - 1.638 (0.0630 - 0.0645)
1.549 - 1.588 (0.0610 - 0.0625)37146-7S000
37147-7S0001.524 - 1.562 (0.0600 - 0.0615)
1.499 - 1.537 (0.0590 - 0.0605)37148-7S000
37149-7S000
Thickness Part number* Thickness Part number*
1.45 (0.0571)
1.50 (0.0591)
1.55 (0.0610)
1.60 (0.0630)37146 7F000
37147 7F000
37148 7F000
37149 7F0001.65 (0.0650)
1.70 (0.0669)
1.75 (0.0689)37150 7F000
37151 7F000
37152 7F000

PS-1
POWER STEERING SYSTEM
G STEERING
CONTENTS
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SECTIONPS
A
B
PS
POWER STEERING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions for Steering System .............................. 2
PREPARATION ........................................................... 3
Special Service Tools [SST] ..................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
POWER STEERING FLUID ........................................ 6
Checking Fluid Level ................................................ 6
Checking Fluid Leakage ........................................... 6
Air Bleeding Hydraulic System ................................. 6
STEERING WHEEL .................................................... 8
On-Vehicle Inspection and Service .......................... 8
CHECKING CONDITION OF INSTALLATION ...... 8
CHECKING STEERING WHEEL PLAY ................ 8
CHECKING NEUTRAL POSITION STEERING
WHEEL ................................................................. 8
CHECKING STEERING WHEEL TURNING
FORCE .................................................................. 8
CHECKING FRONT WHEEL TURNING ANGLE..... 9
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
STEERING COLUMN ................................................11
Removal and Installation ......................................... 11
COMPONENT ...................................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
POWER STEERING GEAR AND LINKAGE ............ 14Removal and Installation ........................................ 14
COMPONENT ..................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Disassembly and Assembly .................................... 16
COMPONENT ..................................................... 16
DISASSEMBLY ................................................... 17
INSPECTION AFTER DISASSEMBLY ................ 18
ASSEMBLY ......................................................... 20
POWER STEERING OIL PUMP ............................... 25
On-Vehicle Inspection and Service ......................... 25
CHECKING RELIEF OIL PRESSURE ................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 26
Disassembly and Assembly .................................... 26
COMPONENT ..................................................... 26
INSPECTION BEFORE DISASSEMBLY ............. 26
DISASSEMBLY ................................................... 27
INSPECTION AFTER DISASSEMBLY ................ 27
ASSEMBLY ......................................................... 28
HYDRAULIC LINE .................................................... 30
Component (RHD Models) ..................................... 30
Component (LHD Models) ...................................... 32
Removal and Installation ........................................ 33
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
Steering Wheel ....................................................... 34
Steering Angle ........................................................ 34
Steering Column ..................................................... 34
Steering Outer Socket and Inner Socket ................ 34
Steering Gear ......................................................... 35
Oil Pump ................................................................. 35
Steering Fluid .......................................................... 35

PS-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EGS001M0
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Steering SystemEGS001L9
lIn case of removing steering gear assembly, make the final tightening with grounded and unloaded vehi-
cle condition, and then check wheel alignment.
lObserve the following precautions when disassembling.
–Before disassembly, thoroughly clean the outside of the unit.
–Disassembly should be done in a clean work area. It is important to prevent the internal parts from becom-
ing contaminated by dirt or other foreign matter.
–For easier and proper assembly, place disassembled parts in order on a parts rack.
–Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere
with their operation.
–Do not reuse non-reusable parts.
–Before assembling, apply the specified grease to the directed parts.

PREPARATION
PS-3
C
D
E
F
H
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K
L
MA
B
PS
PREPARATIONPFP:00002
Special Service Tools [SST]EGS001LA
Tool number
Tool nameDescription
ST27180001
Steering wheel pullerRemoving steering wheel
ST3127 S000
Preload gauge
1. GG9103000
Torque wrench
2. HT62940000
Socket adapter
3. HT62900000
Socket adapterInspecting of rotating torque for ball joint
KV489Q0030
Rear cover wrench
a: 19 mm (0.75 in)
b: 34.9 mm (1.374 in)Removing and installing rear cover
KV489Q0020
Teflon ring correcting tool
a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in) dia.Installing rack Teflon ring
KV48103400
Preload adapterInspecting rotating torque
KV48103500
Pressure gaugeMeasuring oil pump relief pressure
KV48102500
Pressure gauge adapterMeasuring oil pump relief pressure
S-NT544
S-NT541
SGIA0516E
S-NT550
ZZA0824D
S-NT547
S-NT542

PS-4
PREPARATION
Commercial Service Tools
EGS001LB
Tool name Description
Power tool
lRemoving wheel nuts
lRemoving undercover
PBIC0190E

PS-8
STEERING WHEEL
STEERING WHEEL
PFP:48430
On-Vehicle Inspection and ServiceEGS001LG
CHECKING CONDITION OF INSTALLATION
lCheck installation conditions of steering gear assembly, front suspension assembly, axle and steering col-
umn assembly.
lCheck if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction.
lCheck steering gear assembly mounting bolts and nuts for looseness. Refer toPS-14, "COMPONENT".
CHECKING STEERING WHEEL PLAY
lTurn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn
steering wheel to the left and right until front wheels start to move. Measure steering wheel movement on
the outer circumference.
lWhen the measurement value is outside the standard value, check backlash for each joint of steering col-
umn assembly and installation condition of steering gear assembly.
CHECKING NEUTRAL POSITION STEERING WHEEL
lMake sure that steering gear assembly, steering column assembly and steering wheel are installed in the
correct position.
lPerform neutral position inspection after wheel alignment. Refer toFSU-7, "Front Wheel Alignment".
lSet vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
lLoosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustment if
steering wheel is not in the neutral position.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is
approximately 50 to 80°C(122to176°F).]
4. Check steering wheel turning force when steering wheel has
been turned 360°from neutral position.
NOTE:
Multiply the distance (L) from the hook of spring scale to the
center of steering wheel by the measurement value with a spring
scale.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump.
Regarding relief hydraulic pressure of oil pump, refer toPS-25,
"CHECKING RELIEF OIL PRESSURE".
a. Disconnect lower joint and steering knuckle from steering gear assembly. Refer toPS-11, "
COMPO-
NENT",FAX-5, "Removal and Installation".
b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature.Steering wheel axial end play : 0 mm (0 in)
Steering wheel play : 0 - 35 mm (0 - 1.38 in)
Steering wheel turn-
ing force: Less than 39 N (4.0 kg-m, 8.8 lb)
SGIA1136E

POWER STEERING OIL PUMP
PS-25
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MA
B
PS
POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceEGS001LL
CHECKING RELIEF OIL PRESSURE
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer toPS-6, "
Air
Bleeding Hydraulic System".
2. Start engine. Run engine until oil temperature reaches 50 to
80°C(122to176°F).
CAUTION:
lLeave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
lBe sure to keep hose clear or belts and other parts when
engineisstarted.
3. Fully close the hydraulic pressure gauge [SST] valve with
engine at idle and measure the relief oil pressure.
CAUTION:
Never keep valve closed for 10 seconds or longer.
4. Open the valve slowly after measuring. Repair oil pump is the
relief oil pressure is outside the standard. Refer toPS-26, "
Dis-
assembly and Assembly".
5. After inspection, disconnect the hydraulic pressure gauge [SST] from hydraulic circuit, then add fluid and
bleed air. Refer toPS-6, "
Air Bleeding Hydraulic System".
Removal and InstallationEGS001LM
REMOVAL
1. Drain power steering fluid from reservoir tank.
2. Remove radiator shroud. Refer toCO-11, "
Components".
3. Loosen drive belt. Refer toEM-12, "
DRIVE BELTS".
4. Remove drive belt from oil pump pulley.
5. Disconnect the pressure sensor electrical connector.
6. Remove piping of high pressure and low pressure (drain fluid from their pipings). Refer toPS-30,
"HYDRAULIC LINE".
7. Remove oil pump mounting bolts, and then remove power steering pump. Refer toPS-30, "
HYDRAULIC
LINE". Relief oil pressure:
8,500 - 9,300 kpa (86.7 - 94.9 kg/cm
2, 1,233 - 1,349 psi)
SGIA1225E

PS-34
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Steering WheelEGS001LR
Steering AngleEGS001LS
Steering ColumnEGS001LT
Steering Outer Socket and Inner SocketEGS001LU
Steering wheel axial end play 0 mm (0 in)
Steering wheel play 0 - 35 mm (0 - 1.38 in)
Inner wheel
Degree minute (Decimal degree)2WD 33°31¢-35°31¢(33.5°- 36.5°)
4WD 33°48¢-35°48¢(33.8°- 35.8°)
Outer wheel
Degree minute (Decimal degree)2WD 29°23¢-31°23¢(29.4°- 31.4°)
4WD 29°40¢-31°40¢(29.7°- 31.7°)
Steering column length “L” 423.1 mm (16.66 in)
SGIA1222E
Steering gear typePR32AM
Outer socketSwinging torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Measurement on spring balance
Measuring point: cotter pin hole of stud4.84 - 46.7 N (0.5 - 4.8 kg, 1.1 - 10.6 lb)
Rotating torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Axial end play 0.5 mm (0.020 in) or less
Inner socketSwinging torque 1.0 - 7.8 N·m (0.11 - 0.79 kg-m, 9.0 - 69 in-lb)
lMeasurement on spring balance
lMeasuring point at *mark shown in the figure12.1 - 93.7 N (1.2 - 9.6 kg, 2.6 - 21.2 lb)
Axial end play 0.2 mm (0.008 in) or less
Inner socket length “L”79 mm (3.11 in)
SGIA0950E

SERVICE DATA AND SPECIFICATIONS (SDS)
PS-35
C
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F
H
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MA
B
PS
Steering GearEGS001LV
Oil PumpEGS001LW
Steering FluidEGS001LX
Steering gear modelPR32AM
Rack neutral position, dimension “L” (rack stroke) 84 mm (3.31 in)
SGIA0877E
Oil pump relief hydraulic pressure
8,500 - 9,300 kpa (86.7 - 94.9 kg/cm2, 1,233 - 1,349 psi)
Fluid capacity
Approx. 1.0 (1 - 1/8 US qt, 7/8 Imp qt)

PS-36
SERVICE DATA AND SPECIFICATIONS (SDS)