NISSAN NAVARA 2005 Repair Workshop Manual

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS00ICR
COMPONENTS
CAUTION:
lBe careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel
surface.
lIf the flywheel is removed, align the dowel pin with smallest hole of flywheel. Refer toEM-114,
"ASSEMBLY".
REMOVAL
1. Remove manual transmission from the vehicle. Refer toMT-16, "Removal and Installation from Vehicle".
2. Loosen clutch cover mounting bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
lMeasure circumferential runout relative to clutch disc center
spline. If it is outside the specification, replace clutch disc.
lMeasure backlash to clutch disc spline and main drive gear
spline at the circumference of clutch disc. If outside the specifi-
cation, replace clutch disc.
1. Flywheel 2. Clutch disc 3. Clutch cover
PCIB1394E
Runout limit/diameter of the area to be measured
: 1.0 mm (0.039 in)/230 mm (9.06 in) dia.
Maximum allowable spline backlash
: 1.0 mm (0.039 in)
SCL221

CL-18
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
lMeasure the depth to clutch disc facing rivet heads using a cali-
pers. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
lCheck clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
lWorn thrust ring will generate a beating noise when tapped at
therivetwithahammer.
lBroken thrust ring will make a clinking sound when cover is shaken up and down.
lIf a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Measure the runout at the flywheel clutch contact surface using a
dial indicator. If runout is outside the specification, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1. Apply recommended grease to clutch disc and main drive gear splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness
: 0.7 mm (0.028 in) or less
Tool number : ST20050240
PCIB0276E
Allowable flywheel runout
:RefertoEM-134, "
FLYWHEEL DEFLECTION".
PBIC2646E

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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2. Install clutch disc using the clutch aligning bar.
3. Install clutch cover. Pre-tighten clutch cover mounting bolts.
4. Tighten clutch cover mounting bolts evenly in two steps in the
order shown in the figure. Refer toCL-17, "
COMPONENTS".
5. Install manual transmission. Refer toMT-16, "
Removal and
Installation from Vehicle". Tool number : KV30100100
PCIB1630E

CL-20
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Clutch Control SystemECS00ICS
Clutch Master CylinderECS00ICT
Clutch Operating CylinderECS00ICU
Clutch DiscECS00ICV
Clutch CoverECS00ICW
Clutch PedalECS00ICX
Type of clutch controlHydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Facing size (outer dia. x inner dia. x thickness) 240 mm´160 mm´3.15 mm (9.45 in´6.30 in´0.1240 in)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 230 mm (9.06 in) dia.
Maximum spline backlash (at outer edge of disc) 1.0 mm (0.039 in)
Set-load9,810 N (1,000 kg, 2,205 lb)
Diaphragm spring lever height 39.0 - 41.0 mm (1.535 - 1.614 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
Clearance²C²between pedal stopper rubber and clutch interlock
switch threaded while clutch pedal is fully depressed0.1 - 1.0 mm (0.004 - 0.039 in)

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTIONCO
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ENGINE COOLING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions For Liquid Gasket ................................. 2
LIQUID GASKET APPLICATION PROCEDURE..... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
OVERHEATING CAUSE ANALYSIS .......................... 4
Troubleshooting Chart .............................................. 4
COOLING SYSTEM .................................................... 6
Cooling Circuit .......................................................... 6
ENGINE COOLANT .................................................... 7
Inspection ................................................................. 7
LEVEL CHECK ..................................................... 7
CHECKING RADIATOR SYSTEM FOR LEAKS..... 7
Changing Engine Coolant ........................................ 7
DRAINING ENGINE COOLANT ........................... 8
REFILLING ENGINE COOLANT .......................... 8
FLUSHING COOLING SYSTEM ........................... 9
RADIATOR .................................................................11
Components ............................................................ 11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 13
INSTALLATION ................................................... 14
INSPECTION AFTER INSTALLATION ............... 14
RADIATOR (ALUMINUM TYPE) .............................. 15
Components ........................................................... 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18COOLING FAN .......................................................... 19
Components (Crankshaft Driven Type) .................. 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
Removal and Installation (Motor Driven Type) (Mod-
els with A/C) ........................................................... 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 20
WATER PUMP .......................................................... 21
Components ........................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
THERMOSTAT AND WATER PIPING ...................... 23
Components ........................................................... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
ENGINE COOLANT CAPACITY .......................... 26
THERMOSTAT .................................................... 26
RESERVOIR TANK ............................................. 26

CO-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions For Liquid GasketEBS01E6J
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
lRemove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser [SST].
Use Genuine Liquid Gasket or equivalent.
lWithin five minutes of liquid gasket application, install the mat-
ing component.
lIf liquid gasket protrudes, wipe it off immediately.
lDo not retighten mounting bolts or nuts after the installation.
lAfter 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
PBIC2160E

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEBS01E6K
Commercial Service ToolsEBS01E6L
Tool number
Tool nameDescription
WS39930000
Tube presserPressing the tube of liquid gasket
EG17650301
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV99103510
Radiator plate pliers AInstalling radiator upper and lower tanks
KV99103520
Radiator plate pliers BRemoving radiator upper and lower tanks
S-NT052
S-NT564
S-NT224
S-NT225
Tool nameDescription
Radiator cap tester Checking radiator and reservoir tank cap
PBIC1982E

CO-4
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS
PFP:00012
Troubleshooting ChartEBS01E6M
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ateRefer toEC-132, "
DTC
P0217 ENGINE OVER
TEMPERATURE"
—
Highresistancetofanrota-
tion
Fan assembly
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

OVERHEATING CAUSE ANALYSIS
CO-5
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Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items

CO-6
COOLING SYSTEM
COOLING SYSTEM
PFP:21020
Cooling CircuitEBS01E6N
PBIC4099E