2005 NISSAN NAVARA check engine

EC-312
TC BOOST CONTROL SOLENOID VALVE
Diagnostic Procedure
EBS01KM2
1.CHECK OVERALL FUNCTION
1. Start engine and let it idle.
2. Make sure that turbocharger control actuator (1) rod moves
slightly when engine is started.
OK or NG
OK >>INSPECTION END
NG >> GO TO 2.
2.CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect turbocharger boost control solenoid valve (1) har-
ness connector.
–: Vehicle front
–Alternator (2)
3. Turn ignition switch ON.
4. Check voltage between turbocharger boost control solenoid
valve terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.
3.DETECT MALFUNCTIONING PART
Check the following.
lHarness connectors E9, F4
lHarness for open or short between ECM and turbocharger boost control solenoid valve
lHarness for open or short between IPDM E/R and turbocharger boost control solenoid valve
>> Repair open circuit or short to ground or short to power in harness or connectors.
MBIB1207E
MBIB1206E
Voltage: Battery voltage
MBIB1242E

EC-316
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
Diagnostic Procedure
EBS01KM8
1.CHECK OVERALL FUNCTION
1. Start engine and let it idle.
2. Make sure that intake air control valve actuator (1) rod moves
when turning ignition switch OFF.
OK or NG
OK >>INSPECTION END
NG >> GO TO 2.
2.CHECK VACUUM SOURCE
1. Turn ignition switch OFF.
2. Disconnect vacuum hose connected to intake air control valve
actuator (1).
3. Start engine and let it idle.
4. Check vacuum hose for vacuum existence under the following
conditions.
OK or NG
OK >> GO TO 9.
NG >> GO TO 3.
3.CHECK VACUUM HOSE
1. Turn ignition switch OFF.
2. Check vacuum hoses and vacuum gallery for clogging, cracks
or improper connection.
Refer toEC-16, "
Vacuum Hose Drawing".
OK or NG
OK >> GO TO 4.
NG >> Repair or replace vacuum hoses and vacuum gallery.
MBIB1228E
CONDITIONS vacuum
For a few seconds after turning ignition switch OFF should exist
Except above should not exist
MBIB1238E
SEF109L

INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
EC-317
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4.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect intake air control valve control solenoid valve (1)
harness connector.
–: Vehicle front
–Electronic controlled engine mount control solenoid valve (2)
–Oil filter (3)
3. Turn ignition switch ON.
4. Check voltage between intake air control valve control solenoid
valve terminal 2 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.
5.DETECT MALFUNCTIONING PART
Check the following.
lHarness connectors E9, F4
lHarness for open or short between IPDM E/R and intake air control valve control solenoid valve
lHarness for open or short between ECM and intake air control valve control solenoid valve
>> Repair open circuit or short to power in harness or connectors.
6.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 15 and intake air control valve control solenoid valve ter-
minal 1. Refer to Wiring Diagram.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
7.CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
Refer toEC-318, "
Component Inspection".
OK or NG
OK >> GO TO 8.
NG >> Replace intake air control valve control solenoid valve.
MBIB1226E
Voltage: Battery voltage
PBIB0192E
Continuity should exist.

EC-318
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
8.CHECK VACUUM PUMP
Refer toEM-42, "
VACUUM PUMP".
OK or NG
OK >> GO TO 9.
NG >> Replace vacuum pump assembly.
9.CHECK INTAKE AIR CONTROL VALVE ACTUATOR
1. Turn ignition switch OFF.
2. Install a vacuum pump A to intake air control valve actuator (1).
3. Make sure that the intake air control valve actuator rod moves
smoothly when applying vacuum of -53.3 kPa (-533 mbar, -400
mmHg, -15.75 inHg) and releasing it.
OK or NG
OK >> GO TO 10.
NG >> Replace intake air control valve actuator.
10.CHECK INTERMITTENT INCIDENT
Refer toEC-70, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT".
>>INSPECTION END
Component InspectionEBS01KM9
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
1. Disconnect intake air control valve control solenoid valve (1)
harness connector.
l: Vehicle front
lElectronic controlled engine mount control solenoid valve (2)
lOil filter (3)
2. Apply 12V direct current between turbocharger boost control
solenoid valve terminals.
3. Check air passage continuity of intake air control valve control
solenoid valve under the following conditions.
Operation takes less than 1 second.
If NG, replace intake air control valve control solenoid valve.
MBIB1239E
MBIB1226E
CONDITIONSAir passage continuity
between (A) and (B)Air passage continuity
between (A) and (C)
12V direct current supply
between terminals (1) and (2)Ye s N o
No supply No Yes
MEC488B

REFRIGERANT PRESSURE SENSOR
EC-327
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Diagnostic ProcedureEBS01KMJ
1.CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1. Start engine and warm it up to normal operating temperature.
2. Turn A/C switch and blower switch ON.
3. Check voltage between ECM terminal 53 and ground with CON-
SULT-II or tester.
OK or NG
OK >>INSPECTION END
NG >> GO TO 2.
2.CHECK GROUND CONNECTIONS
1. Turn ignition switch OFF.
2. Loosen and retighten three ground screws on the body.
Refer toEC-78, "
Ground Inspection".
OK or NG
OK >> GO TO 3.
NG >> Repair or replace ground connections.Voltage: 1.0 - 4.0V
MBIB1248E
: Vehicle front
1. Body ground E21 2. ECM 3. Body ground E41
4. A/C high-pressure service valve 5. ABS actuator and electric unit
(control unit)6. Body ground E61
MBIB1218E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
EI-7
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DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
6) Raisethevehicleonahoistandhitatirewitharubberhammer.
lDrive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
lIf it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area.To help pinpoint the source of the noise, use a listening tool
(Engine Ear and mechanic's stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
lremoving the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be bro-
ken or lost during the repair, resulting in the creation of new noise.
ltapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.
lfeeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
lplacing a piece of paper between components that you suspect are causing the noise.
llooking for loose components and contact marks.
Refer toEI-7, "
Generic Squeak and Rattle Troubleshooting".
REPAIR THE CAUSE
lIf the cause is a loose component, tighten the component securely.
lIf the cause is insufficient clearance between components:
–separate components by repositioning or loosening and retightening the component, if possible.
–insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
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 TroubleshootingEIS00DY6
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

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTIONEM
A
EM
ENGINE MECHANICAL
PRECAUTIONS .......................................................... 4
Precautions for Draining Engine Coolant ................. 4
Precautions for Disconnecting Fuel Piping .............. 4
Precautions for Removal and Disassembly ............. 4
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 4
Precautions for Assembly and Installation ............... 4
Parts Requiring Angle Tightening ............................. 4
Precautions For Liquid Gasket ................................. 5
REMOVAL OF LIQUID GASKET .......................... 5
LIQUID GASKET APPLICATION PROCEDURE..... 5
PREPARATION ........................................................... 6
Special Service Tools ............................................... 6
Commercial Service Tools ........................................ 8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 10
NVH Troubleshooting — Engine Noise .................. 10
Use the Chart Below to Help You Find the Cause
of the Symptom. ...................................................... 11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Deflection Adjustment ............................................ 13
POWER STEERING OIL PUMP BELT ............... 13
A/C COMPRESSOR, ALTERNATOR AND
WATER PUMP BELT .......................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Components ........................................................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
CHANGING AIR CLEANER FILTER ................... 17
CHARGE AIR COOLER ........................................... 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19INTAKE MANIFOLD ................................................. 20
Components ........................................................... 20
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 25
CATALYST ................................................................ 26
Components ........................................................... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
TURBO CHARGER ................................................... 28
Components ........................................................... 28
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSPECTION AFTER REMOVAL ....................... 30
TROUBLE DIAGNOSIS OF TURBOCHARGER... 32
INSTALLATION ................................................... 33
EXHAUST MANIFOLD ............................................. 34
Components ........................................................... 34
Removal and Installation ........................................ 34
REMOVAL ........................................................... 34
INSPECTION AFTER REMOVAL ....................... 35
INSTALLATION ................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
OIL PAN AND OIL STRAINER ................................. 36
Components ........................................................... 36
Removal and Installation ........................................ 36
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ....................... 38
INSTALLATION ................................................... 38
INSPECTION AFTER INSTALLATION ................ 40
GLOW PLUG ............................................................ 41
Components ........................................................... 41
Removal and Installation ........................................ 41
REMOVAL ........................................................... 41
INSTALLATION ................................................... 41
VACUUM PUMP ........................................................ 42

EM-2
Components ........................................................... 42
Removal and Installation ........................................ 42
INSPECTION BEFORE REMOVAL ..................... 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
INJECTION TUBE AND FUEL INJECTOR .............. 44
Components ........................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSTALLATION .................................................... 46
INSPECTION AFTER INSTALLATION ................ 48
FUEL PUMP .............................................................. 49
Components ........................................................... 49
Removal and Installation ........................................ 49
REMOVAL ........................................................... 49
INSPECTION AFTER REMOVAL ........................ 52
INSTALLATION .................................................... 52
ROCKER COVER ..................................................... 56
Components ........................................................... 56
Removal and Installation ........................................ 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 57
INSPECTION AFTER INSTALLATION ................ 58
CAMSHAFT ............................................................... 59
Components ........................................................... 59
Removal and Installation ........................................ 59
REMOVAL ........................................................... 59
INSPECTION AFTER REMOVAL ........................ 60
INSTALLATION .................................................... 63
INSPECTION AFTER INSTALLATION ................ 65
Valve Clearance ...................................................... 66
INSPECTION ....................................................... 66
ADJUSTMENTS .................................................. 67
OIL SEAL .................................................................. 70
Removal and Installation of Valve Oil Seal ............. 70
REMOVAL ........................................................... 70
INSTALLATION .................................................... 70
Removal and Installation of Front Oil Seal ............. 71
REMOVAL ........................................................... 71
INSTALLATION .................................................... 71
Removal and Installation of Rear Oil Seal .............. 72
REMOVAL ........................................................... 72
INSTALLATION .................................................... 72
SECONDARY TIMING CHAIN .................................. 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 73
INSPECTION AFTER REMOVAL ........................ 75
INSTALLATION .................................................... 75
INSPECTION AFTER INSTALLATION ................ 77
PRIMARY TIMING CHAIN ........................................ 79
Components ........................................................... 79
Removal and Installation ........................................ 80
REMOVAL ........................................................... 80
INSPECTION AFTER REMOVAL ........................ 84
INSTALLATION .................................................... 85
INSPECTION AFTER INSTALLATION ................ 91CYLINDER HEAD ..................................................... 92
On-Vehicle Service ................................................. 92
CHECKING COMPRESSION PRESSURE ......... 92
Components ............................................................ 93
Removal and Installation ......................................... 94
REMOVAL ............................................................ 94
INSPECTION AFTER REMOVAL ........................ 94
INSTALLATION .................................................... 96
INSPECTION AFTER INSTALLATION ................ 98
Components ............................................................ 99
Disassembly and Assembly .................................... 99
DISASSEMBLY .................................................... 99
ASSEMBLY ........................................................100
INSPECTION AFTER DISASSEMBLY ..............101
ENGINE ASSEMBLY ...............................................106
Components ..........................................................106
Removal and Installation .......................................106
REMOVAL ..........................................................107
INSTALLATION ..................................................108
INSPECTION AFTER INSTALLATION ..............108
CYLINDER BLOCK .................................................110
Components ..........................................................110
Disassembly and Assembly .................................. 111
DISASSEMBLY .................................................. 111
ASSEMBLY ........................................................114
How to Select Piston and Bearing ........................121
DESCRIPTION ..................................................121
HOW TO SELECT PISTON ...............................121
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................122
HOW TO SELECT MAIN BEARING ..................123
Inspection After Disassembly ................................124
CRANKSHAFT END PLAY ................................124
CONNECTING ROD SIDE CLEARANCE .........125
PISTON TO PISTON PIN CLEARANCE ...........125
PISTON RING SIDE CLEARANCE ...................126
PISTON RING END GAP ..................................126
CONNECTING ROD BEND AND TORSION .....127
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................127
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................127
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................128
MAIN BEARING HOUSING INNER DIAMETER.128
PISTON TO CYLINDER BORE CLEARANCE ..129
CRANKSHAFT MAIN JOURNAL DIAMETER ...130
CRANKSHAFT PIN JOURNAL DIAMETER ......130
CRANKSHAFT OUT-OF-ROUND AND TAPER.130
CRANKSHAFT RUNOUT ..................................131
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................131
MAIN BEARING OIL CLEARANCE ...................132
CRUSH HEIGHT OF MAIN BEARING ..............132
CRUSH HEIGHT OF CONNECTING ROD