fuel system NISSAN NAVARA 2005 Repair Repair Manual

FUEL SYSTEM
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS01E71
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS01E72
WARNING:
When replacing fuel line parts, be sure to observe the following.
lPut a “CAUTION: INFLAMMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
lUse diesel fuel required by the regulations for cetane number. Refer toGI-6, "DIESEL ENGINE".
lBefore removing fuel line parts, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Disconnect the battery cable from the negative terminal.
lAlways replace O-ring and clamps with new ones.
lDo not kink or twist tubes when they are being installed.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lAfter connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
lAfter installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
SBIA0504E

FUEL FILTER
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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

FUEL COOLER
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FUEL COOLERPFP:17511
Components (4WD Models Only)EBS01FEY
Removal and Installation (4WD Models Only)EBS01FEZ
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove protector (fuel tube).
2. Remove protector (fuel cooler) mounting bolts (3 pieces) then disconnect fuel tubes from fuel cooler
assembly.
CAUTION:
lPlug fuel tubes and fuel cooler assembly to prevent fuel from draining.
lDo not splash fuel during removal. If fuel is splashed, immediately wipe it off.
3. Remove fuel cooler assembly from protector (fuel cooler)
CAUTION:
lDo not bend fuel tubes during removal.
lAvoid impacts such as falling when handling components.
1. Fuel tube (return) (to fuel tank) 2. Fuel tube (return) (to engine) 3. Bracket
4. Protector (fuel cooler) 5. Protector (fuel tube) 6. Fuel cooler assembly
7. Bracket
PBIC4059E

FUEL TANK
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FUEL TANKPFP:17202
ComponentsEBS01F6O
Removal and InstallationEBS01E77
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank.
1. Fuel filler cap 2. Grommet 3. Fuel filler tube (Double cab models)
4. EVAP tube 5. Fuel tank 6. Fuel tank band
7. Fuel tank band 8. Fuel feed tube 9. Fuel return tube
10. Vent hose 11. Fuel filler hose (Double cab models) 12. Fuel filler hose (King cab models)
13. Fuel filler tube (King cab models)
A. To fuel filter B.To fuel cooler (under floor) (4WD
models)
To fuel return tube (2WD models)
PBIC4094E

FL-14
FUEL LEVEL SENSOR UNIT
FUEL LEVEL SENSOR UNIT
PFP:17042
ComponentsEBS01F6N
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E76
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer toFL-9, "
FUEL TANK".
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
3. Remove fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit is free from foreign materials. If any are found, remove them.
1. Lock ring 2. Fuel level sensor unit 3. Seal packing
4. Fuel tank
A. Refer to text.
PBIC3374E
PBIC0240E

GI-1
GENERAL INFORMATION
A GENERAL INFORMATION
CONTENTS
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SECTIONGI
GENERAL INFORMATION
PRECAUTIONS .......................................................... 3
Description ............................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for NATS (NISSAN ANTI-THEFT SYS-
TEM) ........................................................................ 3
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 3
OPERATION PROCEDURE ................................. 4
General Precautions ................................................ 4
Precautions for Three Way Catalyst ......................... 5
Precautions for Fuel ................................................. 5
GASOLINE ENGINE ............................................. 5
DIESEL ENGINE ................................................... 6
Precautions for Multiport Fuel Injection System or
Engine Control System ............................................ 6
Precautions for Turbocharger (If Equipped) ............. 6
Precautions for Hoses .............................................. 6
HOSE REMOVAL AND INSTALLATION ............... 6
HOSE CLAMPING ................................................ 7
Precautions for Engine Oils ...................................... 7
HEALTH PROTECTION PRECAUTIONS ............. 7
ENVIRONMENTAL PROTECTION PRECAU-
TIONS ................................................................... 8
Precautions for Air Conditioning ............................... 8
HOW TO USE THIS MANUAL ................................... 9
Description ............................................................... 9
Terms ....................................................................... 9
Units ......................................................................... 9
Contents ................................................................... 9
Components ........................................................... 10
SYMBOLS ........................................................... 10
How to Follow Trouble Diagnoses ........................... 11
DESCRIPTION ..................................................... 11
HOW TO FOLLOW TEST GROUPS IN TROU-
BLE DIAGNOSES ................................................ 11
HARNESS WIRE COLOR AND CONNECTOR
NUMBER INDICATION ....................................... 12
KEY TO SYMBOLS SIGNIFYING MEASURE-MENTS OR PROCEDURES ............................... 13
How to Read Wiring Diagrams ............................... 15
CONNECTOR SYMBOLS ................................... 15
SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 16
DESCRIPTION .................................................... 17
Abbreviations .......................................................... 23
SERVICE INFORMATION FOR ELECTRICAL INCI-
DENT ......................................................................... 24
How to Perform Efficient Diagnosis for an Electrical
Incident ................................................................... 24
WORK FLOW ...................................................... 24
INCIDENT SIMULATION TESTS ........................ 24
CIRCUIT INSPECTION ....................................... 27
Control Units and Electrical Parts ........................... 32
PRECAUTIONS .................................................. 32
CONTROL UNIT CONFIGURATION PROCEDURE... 34
Description .............................................................. 34
Part Replacement procedure Reference Table ...... 34
Work Procedure ...................................................... 36
Configuration (BCM) ............................................... 37
DESCRIPTION .................................................... 37
READ CONFIGURATION PROCEDURE ............ 37
WRITE CONFIGURATION PROCEDURE .......... 41
CONSULT-II CHECKING SYSTEM .......................... 47
Description .............................................................. 47
Function and System Application ........................... 47
Nickel Metal Hydride Battery Replacement ............ 48
Checking Equipment .............................................. 49
CONSULT-II Start Procedure .................................. 49
CONSULT-II Data Link Connector (DLC) Circuit .... 50
INSPECTION PROCEDURE .............................. 51
LIFTING POINT ......................................................... 52
Pantograph Jack, Garage Jack and Safety Stand... 52
2-Pole Lift ............................................................... 52
TOW TRUCK TOWING ............................................. 53
Tow Truck Towing ................................................... 53
4X2 MODEL ........................................................ 53
4X4 MODEL ........................................................ 54
TOWING POINT .................................................. 54
Vehicle Recovery (Freeing a Stuck Vehicle) ........... 54

PRECAUTIONS
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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

GI-6
PRECAUTIONS
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
lAbove –7°C(20°F) ... Summer type diesel fuel.
lBelow –7°C(20°F) ... Winter type diesel fuel.
CAUTION:
lDo not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
lDo not use summer fuel at temperatures below –7°C(20°F). The cold temperatures will cause wax
to form in the fuel. As a result, it may prevent the engine from running smoothly.
lDo not add gasoline or other alternate fuels to diesel fuel.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS001GN
lBefore connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS001GO
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
lAlways use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
lAvoid accelerating engine to a high rpm immediately after start-
ing.
lIf engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS001GP
HOSE REMOVAL AND INSTALLATION
lTo prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
SGI787
SGI292
SMA019D

TERMINOLOGY
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TERMINOLOGYPFP:00011
ISO 15031-2 Terminology ListEAS001H9
All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve

GI-62
TERMINOLOGY
Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM