2005 NISSAN NAVARA Repair Workshop Manual

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Page 1401 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual CHARGE AIR COOLER
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INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler

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NISSAN NAVARA 2005 Repair Workshop Manual EM-20
INTAKE MANIFOLD
INTAKE MANIFOLD
PFP:14003
ComponentsEBS01EJE
PBIC4042E

Page 1403 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual INTAKE MANIFOLD
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lRefer toGI-10, "Components"for symbol marks except in the above.
Removal and InstallationEBS01EJF
REMOVAL
WARNING:
To avoid the danger of being scalded

INTAKE MANIFOLD
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lRefer toGI-10, "Components"for symbol marks except in the above.
Removal and InstallationEBS01EJF
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer toCO-7, "
Changing Engine Coolant".
2. Remove engine cover (1).
CAUTION:
Be careful not to damage engine cover surface.
3. Disconnect air inlet hose from throttle chamber. Refer toEM-18, "
CHARGE AIR COOLER".
4. Remove fuel filter. Refer toFL-4, "
FUEL FILTER".
5. Remove oil level gauge guide. Refer toEM-36, "
OIL PAN AND OIL STRAINER".
6. Remove fuel hoses and fuel gallery. Refer toEM-44, "
INJECTION TUBE AND FUEL INJECTOR".
lTo prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
lAdd marks as necessary for easier installation.
7. Remove vacuum galleries and vacuum hoses.
lAdd marks as necessary for easier installation.
8. Disconnect EGR volume control valve water hoses and wiring harness.
9. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
10. Remove EGR cooler (A/T models) or EGR tube (M/T models).
11. Remove injection tube center. Refer toEM-44, "
Removal and Installation".
CAUTION:
Be careful not to spill fuel in the engine component.
12. Remove water pipe.
1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose
4. Bracket 5. Bracket 6. Gasket
7. Bracket 8. Intake manifold 9. Water hose
10. Heater feed pipe (M/T models) 11. O-ring 12. Vacuum hose
13. Vacuum gallery 14. Vacuum hose 15. Gasket
16. Throttle chamber 17. Gasket 18. Gasket
19. EGR passage 20. Gasket 21. Bracket
22. EGR volume control valve 23. Vacuum gallery 24. Bracket
25. Washer 26. Gasket 27. EGR tube (M/T models)
28. Water hose 29. Water hose 30. Clip (A/T models)
31. Water hose (A/T models) 32. Heater feed pipe (A/T models) 33. Water hose (A/T models)
34. EGR cooler (A/T models) 35. Gasket (A/T models) 36. EGR tube (A/T models)
37. Bracket (A/T models)
C. To heater return pipe E. To cylinder head F. To water outlet
G. To exhaust manifold H. To air inlet hose
Vehicle front
PBIC3409E

Page 1404 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual EM-22
INTAKE MANIFOLD
13. Loosen bolts and nuts in the reverse order of that shown in the
figure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
14. Re

Page 1405 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual INTAKE MANIFOLD
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lInstall EGR cooler (A/T models).
–Tighten fixing bolts and nuts in numerical order as shown in the figure.
lInstall water hoses and heater feed hose.

Page 1406 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual EM-24
INTAKE MANIFOLD
–Install water hose by referring to paint marks avoiding twisting.
–When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is

Page 1407 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual INTAKE MANIFOLD
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–When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully

Page 1408 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual EM-26
CATALYST
CATALYST
PFP:20905
ComponentsEBS01EJG
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E5V
REMOVAL
1. Remove engine undercover.
2. Remove catalys

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