2005 NISSAN NAVARA engine

FFD-12
FRONT OIL SEAL
3. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
4. Tighten to drive pinion lock nut, while adjust total preload torque.
CAUTION:
lAdjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
lIf the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
5. Make a stamping for identification of front oil seal replacement
frequency. Refer toFFD-9, "
IDENTIFICATION STAMP OF REPLACEMENT FREQUENCY OF FRONT
OIL SEAL".
CAUTION:
Be sure to make a stamping after replacing front oil seal.
6. Install the front propeller shaft. Refer toPR-5, "
INSTALLATION".
7. Install the RH and LH drive shafts. Refer toFA X - 7 , "
DRIVE SHAFT".
CAUTION:
Do not reuse the front final drive side oil seals.
8. Install the engine under cover rear. Refer toFFD-15, "
Removal and Installation".
9. Tighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "
Components".
10. Install the ABS sensor harness.
11. Install the brake caliper.
12. Tighten the front wheel nuts to specification. Refer toWT-5, "
Rotation".
13. Refill gear oil to the final drive and check oil level. Refer toFFD-8, "
FILLING".
14. Check the final drive for oil leakage. Refer toFFD-8, "
OIL LEAKAGE AND OIL LEVEL". Tool number A: ST3127S000
Drive pinion lock nut tightening torque:
186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
Total preload torque:
Total preload torque should equal the measurement
taken during removal plus an additional 0.1 - 0.4 N·m
(0.01 - 0.04 kg-m, 1 - 3 in-lb).
PDIA1003E

SIDE OIL SEAL
FFD-13
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FFD
SIDE OIL SEALPFP:33142
Removal and InstallationEDS00354
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer toBR-26, "
Removal and Installation of
Brake Caliper Assembly".
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using jack.
6. Remove the engine under cover rear using power tool.
7. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
8. Remove the side oil seal using suitable tool.
CAUTION:
Be careful not to damage gear carrier.
INSTALLATION
Installation is the reverse order of removal.
lDrive the side oil seal in evenly until it becomes flush with the
case end using Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
lWhen installing the drive shaft assembly into the front
final drive assembly, do not damage the side oil seal.
lCheck the final drive gear oil level. Refer toFFD-8, "Checking Differential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
WEIA0119E
LDIA0173E
Tool number A: ST30720000
B: ST27863000
PDIA0826E

FRONT FINAL DRIVE ASSEMBLY
FFD-15
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FFD
FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationEDS00356
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer toBR-26, "
Removal and Installation of
Brake Caliper Assembly".
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
1. Breather hose 2. Front final drive assembly 3. Front crossmember
4. Engine under cover rear
PDIA1035E

FFD-16
FRONT FINAL DRIVE ASSEMBLY
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using a jack.
6. Remove the engine under cover rear using power tool.
7. Drain the front final drive fluid. Refer toFFD-8, "
Changing Differ-
ential Gear Oil".
8. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
9. Remove the front crossmember.
10. Disconnect the front propeller shaft from the front final drive. Then reposition the front propeller shaft
aside using suitable wire. Refer toPR-4, "
Removal and Installation".
11. Disconnect the vent hose from the front final drive.
12. Support the front final drive using a suitable jack.
13. Remove the front final drive bolts, then remove the front final
drive assembly.
CAUTION:
Secure rear the front final drive assembly to a suitable jack
while removed it.
INSTALLATION
Installation is the reverse order of removal.
lInstall new side oil seals into the front final drive assembly. Refer toFFD-13, "Removal and Installation".
CAUTION:
lWhen installing the drive shaft assembly into the front final drive assembly, do not damage the
side oil seal.
lMake sure there are no pinched or restricted areas on the breather hose caused by bending or
winding when installing it.
lFill the final drive with recommended gear oil after installation. Refer toFFD-8, "Changing Differ-
ential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
WEIA0119E
WDIA0145E

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTIONFL
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FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL FILTER .............................................................. 4
Components ............................................................. 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 5
INSPECTION AFTER INSTALLATION ................. 5
Air Bleeding .............................................................. 5
Draining Water from Fuel Filter ................................ 6
FUEL COOLER .......................................................... 7
Components (4WD Models Only) ............................ 7
Removal and Installation (4WD Models Only) ......... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 8
INSPECTION AFTER INSTALLATION ................. 8FUEL TANK ................................................................ 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ................ 13
FUEL LEVEL SENSOR UNIT ................................... 14
Components ........................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Standard and Limit .................................................. 16

FUEL SYSTEM
FL-3
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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
FL-5
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FL
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

FL-6
FUEL FILTER
lIf air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel pump. After that, operate priming pump and con-
firm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel FilterEBS01E75
1. Prepare a tray (A) under the drain plug (1).
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
lWater in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
lDrained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
5. Bleed air in fuel piping. Refer toFL-5, "
Air Bleeding".
6. Start engine and make sure there is no fuel leakage.Drain plug
: 1.3 N·m (0.13 kg-m, 12 in-lb)
PBIC3373E