stop start NISSAN NAVARA 2005 Repair Repair Manual

EM-92
CYLINDER HEAD
CYLINDER HEAD
PFP:11041
On-Vehicle ServiceEBS01E6A
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer toEC-38,
"Basic Inspection".
lDo not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. To prevent fuel from being injected during inspection, remove fuse [EGI (20A)] (1) from fuse box.
5. Remove glow plugs from all the cylinders. Refer toEM-41, "
GLOW PLUG".
CAUTION:
lBefore removal, clean the surrounding area to prevent entry of any foreign materials into
engine.
lCarefully remove glow plugs to prevent any damage or breakage.
lHandle with care to avoid applying any shock to glow plugs.
6. Install compression gauge adapter [SST] to installation holes of
glow plugs and connect compression gauge for diesel engine.
7. Connect the battery cable to the negative terminal.
8. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.
lAlways use a fully-charged battery to obtain specified engine
speed.
A : LHD models
: Vehicle front
PBIC3623E
A : RHD models
2 : Water hose (to reservoir tank)
3:Airreliefplug
PBIC3624E
: 20.0 N·m (2.0 kg-m, 15 ft-lb)
SEM112G

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 —

CYLINDER HEAD
EM-103
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5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension
showninthefigure.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
6. Using the valve guide reamer (commercial service tool), perform
reaming to the press-fitted valve guides.
Valve Seat Contact
lBefore starting this check, confirm that the dimension of valve
guide and valves are as specified.
lApply red lead primer on contacting surfaces of valves seat and
of valve face to examine the conditions of contacting surfaces.
lMake sure that the paint on contacting surfaces is continuous
along the entire circumference.
lIf there are abnormal indications, grind the valve and check the
contact again. If malfunction indications still persist, replace
valve seat.
Valve Seat Replacement
When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer toEM-139, "
Valve Seat".
2. Ream cylinder head recess diameter for service valve seat.
lBe sure to ream in circles concentric to the valve guide center.
lThis will enable valve seat to fit correctly.Projection “L” : 10.4 - 10.6 mm (0.409 - 0.417 in)
PBIC2497E
Reaming specifications:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
SBIA0322E
Oversize [0.5 mm (0.020 in)]:
Intake : 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust : 29.500 - 29.516 mm (1.1614 - 1.1620 in)
SEM795A

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

ENGINE ASSEMBLY
EM-109
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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 —

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

FUEL FILTER
FL-5
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3. Using band-type fuel filter wrench (A) (commercial service tool),
remove fuel filter (1).
4. Turn fuel filter (1) upside down to drain fuel.
5. Remove drain plug (2) from fuel filter.
INSTALLATION
Note the following, and install in the reverse order of removal.
lReplace O-ring on drain plug with new one.
lScrew the fuel filter by hand until packing contacts sealing surface of fuel filter bracket. Then tighten it by
turning approximately 2/3 turn.
lInstall fuel filter (1), and tighten mounting nuts (2) to the speci-
fied torque.
lAfter installation, bleed air from fuel line. Refer toFL-5, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart the engine and rev it up and make sure there is no fuel leakage at connections.
Air BleedingEBS01E74
After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
lMove priming pump (1) up and down to bleed air from fuel path.
When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
lCrank engine until it starts. Do not crank engine for more than 30 seconds.
lIf engine does not start, stop cranking and repeat step 1 above.
lIf engine does not operate smoothly after it has started, race it two or three times.
PBIC3371E
Fuel filter (reference value)
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
: Vehicle front
Fuel filter mounting nuts
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
PBIC3337E
PBIC3372E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
GW-7
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FELT CLOTHTAPE
Used to insulate where movement does not occur. Ideal for instrument panel applications.
68370-4B000: 15´25 mm (0.59´0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll
The following materials, not available through NISSAN Parts Department, can also be used to repair squeaks
and rattles.
UHMW(TEFLON) TAPE
Insulates where slight movement is present. Ideal for instrument panel applications.
SILICONE GREASE
Used in place of UHMW tape that will be visible or not fit.
Note: Will only last a few months.
SILICONE SPRAY
Use when grease cannot be applied.
DUCT TAPE
Usetoeliminatemovement.
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle TroubleshootingEIS00C03
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by
applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate
wiring harness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you
will not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.

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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

IP-6
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Generic Squeak and Rattle Troubleshooting
EIS00DYX
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. The cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicone spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.