checking oil NISSAN NAVARA 2005 Repair Owner's Guide

EM-32
TURBO CHARGER
Turbocharger Boost Control Actuator
lConnect the handy vacuum pump (B) to the turbocharger boost
control actuator (1), and make sure that the rod (2) strokes
smoothly in compliance with the following pressure.
lPressure to be applied at the turbocharger boost control actua-
tor (1) part to move rod (2) end as follows:
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
lMake sure that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil
amount is more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbo-
charger is misjudged malfunction.)
lAsk the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
lReplace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
lIf no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
A: Large possibility
B: Medium possibility
C: Small possibilityA : Dial gauge
Standard (Pressure/rod stroke amount):
:–52.0 to –54.6 kPa (–520 to –546 mbar, –390 to –410
mmHg, –15.4 to –16.1 inHg)/0.2 mm (0.0079 in)
: –32.0 to –40.0 kPa (–320 to –400 mbar, –240 to –300
mmHg, –9.45 to –11.8 inHg)/5.0 mm (0.197 in)
PBIC3421E
Inspection item Inspection resultSymptom
(when each inspection item meets each inspection result)
Engine oil
leakageSmoke NoiseInsufficient power/accel-
eration malfunction
Turbine wheelEngine oil leaks C A C C
Carbon is accumulated C A B B
Friction with housing C B A B
Blades are bent or broken — — A A
Compressor wheelInside the air inlet is seriously con-
taminated by engine oil.BB— —
Friction with housing C B A B
Blades are bent or broken — — A A
After checking both turbine and
compressor, inspect rotor shaft
end play.There is resistance when the rotor
shaft is rotated by your fingertips.—CC B
The rotor shaft sometimes does not
rotate by your fingertips.——— A
There is too much play in the bear-
ing.CCB C
Oil return portCarbon or sludge is accumulated in
the waste oil hole.CAC C

CAMSHAFT
EM-65
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7. Apply liquid gasket to cylinder head rear cover as shown in the
figure.
Use Genuine Liquid Gasket or Equivalent.
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure.
9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
toEM-66, "
Valve Clearance".
10. 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.
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.
PBIC3446E
M6´50 mm : Bolt No.1, 2
M6´20 mm : Bolt No.3, 4
M8´20 mm : Bolt No.5, 6
PBIC3445E
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 —

SECONDARY TIMING CHAIN
EM-77
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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

PRIMARY TIMING CHAIN
EM-91
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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-96
CYLINDER HEAD
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.
lCylinder head gasket to be installed is selected by its thickness through the following procedure.
–When replacing gasket alone
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of cut-outs on
the rear RH side.
*: Measured with head bolts tightened
• Gasket (3) thickness can be identified at the location (A)
shown in the figure by the numbers of cut-outs before
removal.
• Heater return tube is omitted for explanation.
NOTE:
Use mirrors for checking at points out of clear sight.
–When the following parts have been repaired/replaced:
lWith cylinder block upper surface and/or crankshaft pin journal ground
lWith cylinder block, pistons, connecting rods, and/or crankshaft replaced
a. Set piston at a point close to TDC.
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized.
c. Movethedialgaugestandsothatthetipofdialgaugecancon-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
Gasket thickness* mm (in) Number of grade Number of cut-outs
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1
0.950 (0.0374) 3 2
0.975 (0.0384) 4 3
1.000 (0.0394) 5 4
1.025 (0.0404) 6 5
1 : Cylinder head rear cover
2:Oilfilter
: Vehicle front
MBIA0020E
PBIC3478E
SEM507G
Piston protrusion mm (in) Gasket thickness* mm (in)Identification
Number of cut-outs
0.230 - 0.255 (0.0091 - 0.0100) 0.900 (0.0354) 0
0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
0.355 - 0.400 (0.0140 - 0.0157) 1.025 (0.0404) 5

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 —

EM-108
ENGINE ASSEMBLY
Removal
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).
2. Lift with hoist and secure engine in position.
3. Loosen LH and RH engine mounting insulator mounting nuts.
4. Remove engine.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
INSTALLATION
Install in the reverse order of removal.
lDo not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer toEM-106, "
ENGINE ASSEMBLY".
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
lInsert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stop-
per is provided at vacuum gallery.
lInsert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
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.
–Before starting engine, 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.
1 : Engine slinger (front)
2 : Engine slinger (rear)
: Engine front
Engine slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
PBIC3480E
SEM896G

FFD-1
FRONT FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTIONFFD
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B
FFD
FRONT FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
DESCRIPTION ............................................................ 7
Cross-Sectional View ............................................... 7
DIFFERENTIAL GEAR OIL ........................................ 8
Changing Differential Gear Oil ................................. 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Checking Differential Gear Oil .................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
FRONT OIL SEAL ...................................................... 9
Removal and Installation .......................................... 9
IDENTIFICATION STAMP OF REPLACEMENT
FREQUENCY OF FRONT OIL SEAL ................... 9
REMOVAL ............................................................. 9
INSTALLATION .................................................... 11
SIDE OIL SEAL ........................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13REAR COVER GASKET ........................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
FRONT FINAL DRIVE ASSEMBLY .......................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Disassembly and Assembly .................................... 17
COMPONENTS ................................................... 17
ASSEMBLY INSPECTION AND ADJUSTMENT... 18
DISASSEMBLY ................................................... 21
INSPECTION AFTER DISASSEMBLY ................ 26
ADJUSTMENT AND SELECTION ADJUSTING
WASHERS .......................................................... 27
ASSEMBLY ......................................................... 28
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
General Specifications ............................................ 37
Inspection and Adjustment ..................................... 37
DRIVE GEAR RUNOUT ...................................... 37
DIFFERENTIAL SIDE GEAR CLEARANCE ....... 37
PRELOAD TORQUE ........................................... 37
BACKLASH ......................................................... 37
COMPANION FLANGE RUNOUT ....................... 37
SELECTIVE PARTS ............................................ 37

FFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartEDS0034Z
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
Refer toFFD-26, "
INSPECTION AFTER DISASSEMBLY
".
Refer toFFD-19, "
To o t h C o n t a c t
".
Refer toFFD-26, "
INSPECTION AFTER DISASSEMBLY
".
Refer toFFD-20, "
Backlash
".
Refer toFFD-21, "
Companion Flange Runout
".
Refer toFFD-8, "
Checking Differential Gear Oil
".
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise´´´´´´´´´´´´´

FFD-8
DIFFERENTIAL GEAR OIL
DIFFERENTIAL GEAR OIL
PFP:KLD30
Changing Differential Gear OilEDS00351
DRAINING
1. Stop the engine.
2. Remove the drain plug and gasket. Drain the gear oil.
3. Install the drain plug with a new gasket to the final drive assem-
bly. Tighten to the specified torque. Refer toFFD-17, "
COMPO-
NENTS".
CAUTION:
Do not reuse gasket.
FILLING
1. Remove the filler plug and gasket. Fill with new gear oil until the
oil level reaches the specified level near the filler plug hole.
2. After refilling oil, check the oil level. Install the filler plug with a
new gasket on it to the final drive assembly. Tighten to the spec-
ified torque. Refer toFFD-17, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilEDS00352
OIL LEAKAGE AND OIL LEVEL
lMake sure that oil is not leaking from the final drive assembly or around it.
lCheck oil level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
lInstall the filler plug with a new gasket on it to the final drive
assembly. Tighten to the specified torque. Refer toFFD-17,
"COMPONENTS".
CAUTION:
Do not reuse gasket.
LDIA0175E
Oil grade and Viscosity:
Refer toMA-14, "
Fluids and Lubricants".
Oil capacity:
Approx. 0.85 (1-1/2 Imp pt)
LDIA0176E
LDIA0176E