2005 NISSAN NAVARA 4WD

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTIONFL
A
FL
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 COOLER
FL-7
C
D
E
F
G
H
I
J
K
L
MA
FL
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
FL-9
C
D
E
F
G
H
I
J
K
L
MA
FL
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

FSU-6
FRONT SUSPENSION ASSEMBLY
FRONT SUSPENSION ASSEMBLY
PFP:54010
ComponentsEES002KL
1. Washer 2. Spacer 3. Shock absorber mounting insulator
4. Upper spring seat 5. Dust cover cap 6. Coil spring
7. Dust cover 8. Shock absorber 9. Upper link
10. Steering knuckle 11. Cotter pin 12. Drive shaft (4WD models only)
13. Lower link 14. Cam bolt 15. Jounce bumper
16. Cam washer 17. Stabilizer bar 18. Stabilizer bar bushing
19. Stabilizer bar mounting bracket 20. Connecting rod
MEIB9038E

ON-VEHICLE SERVICE
FSU-7
C
D
F
G
H
I
J
K
L
MA
B
FSU
ON-VEHICLE SERVICEPFP:00000
Front Suspension PartsEES002KM
Check front suspension parts for excessive play, cracks, wear and
other damage.
lShake each front wheel to check for excessive play.
If looseness is noted, inspect wheel bearing end play, then
check ball joint end play. Refer toFSU-15, "
Inspection".
lMake sure that the cotter pin is inserted in drive shaft end (4WD
models only).
lRetighten all nuts and bolts to the specified torque.
lCheck shock absorber for oil leakage and other damage.
lCheck suspension ball joint for grease leakage and ball joint
dust cover for cracks and other damage.
Front Wheel AlignmentEES002KN
PRELIMINARY INSPECTION
WARNING:
Always adjust the alignment with the vehicle on a flat surface.
NOTE:
If alignment is out of specification, inspect and replace any damaged or worn rear suspension parts before
making any adjustments.
1. Check and adjust the wheel alignment with the vehicle under unladen conditions. “Unladen conditions”
means that the fuel, coolant, and lubricant are full; and that the spare tire, jack, hand tools and mats are in
their designated positions.
2. Check the tires for incorrect air pressure and excessive wear.
3. Check the wheels for run out and damage. Refer toWT-3, "
Inspection".
4. Check the wheel bearing axial end play. Refer toFA X - 5 , "
WHEEL BEARING INSPECTION".
5. Check the shock absorbers for leaks or damage.
6. Check each mounting point of the suspension components for any excessive looseness or damage.
7. Check each link, arm, and the rear suspension member for any damage.
8. Check the vehicle height. Refer toFSU-21, "
Wheelarch Height (Unladen*1)". Suspension component torques : Refer toFSU-6,
"Components".SMA525A
SFA392B

FSU-16
KNUCKLE
KNUCKLE
PFP:40014
On-Vehicle Inspection and ServiceEES002KV
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are within specifications. Refer toFSU-20, "
Ball Joint".
Removal and InstallationEES002KW
REMOVAL
1. Remove wheel.
2. Without disassembling the hydraulic lines, remove brake caliper. Reposition it aside with wire. Refer to
BR-26, "
Removal and Installation of Brake Caliper Assembly".
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
3. Put alignment marks on disc rotor and wheel hub and bearing
assembly, then remove disc rotor.
4. Disconnect wheel sensor and remove bracket from steering knuckle.
CAUTION:
Do not pull on wheel sensor harness.
5. On 4WD models remove cotter pin, then using a hub lock nut wrench, remove lock nut from drive shaft.
6. Remove steering outer socket cotter pin at steering knuckle, then loosen mounting nut.
1. Disc rotor 2. Wheel hub and bearing assembly 3. Wheel stud
4. Splash guard 5. Steering knuckle 6. Wheel sensor bracket
MDIB9011E
WDIA0044E

KNUCKLE
FSU-17
C
D
F
G
H
I
J
K
L
MA
B
FSU
7. Disconnect steering outer socket from steering knuckle using
Tool. Be careful not to damage ball joint boot.
CAUTION:
To prevent damage to threads and to prevent Tool from
coming off suddenly, temporarily tighten mounting nut.
8. On 4WD models remove drive shaft from wheel hub and bearing
assembly using a suitable extractor.
9. Remove cotter pin and nut from upper link ball joint.
10. Separate upper link ball joint from steering knuckle using Tool.
11. Remove pinch bolt from steering knuckle, then separate lower
link ball joint from steering knuckle.
12. Remove steering knuckle from vehicle.
13. Remove wheel hub and bearing assembly bolts.
14. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
CAUTION:
Do not pull on wheel sensor harness.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each part, replace if necessary.
lPerform ball joint inspection. Refer toFSU-15, "Inspection". Tool number : HT72520000
SDIA1434E
MDIB9013E
Tool number : ST29020001
WEIA0119E
LEIA0097E

SERVICE DATA AND SPECIFICATIONS (SDS)
FSU-19
C
D
F
G
H
I
J
K
L
MA
B
FSU
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General Specifications (Front)EES002KX
Wheel Alignment (Unladen*1)EES002KY
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Target value 35°28¢(35.47°)
*3: Target value 31°19¢(31.32°)
*4: Target value 35°46¢(35.77°)
*5: Target value 31°37¢(31.62°) Suspension type Independent double wishbone coil over shock
Shock absorber type Double-acting hydraulic
StabilizerStandard equipment
Drive type2WD 4WD
Camber
Degree minute (decimal degree)Minimum -0°45¢(-0.75°)-0°10¢(-0.17°)
Nominal 0°15¢(0.25°)0°20¢(0.33°)
Maximum 0°45¢(0.75°)0°50¢(0.83°)
Left and right difference 0°45¢(0.75°)orless
Caster
Degree minute (decimal degree)Minimum 2°5¢(2.08°)-0°56¢(-0.93°)
Nominal 2°35¢(2.58°)2°26¢(2.43°)
Maximum 3°5¢(3.08°)2°56¢(2.93°)
Left and right difference 0°45¢(0.75°)orless
Kingpin inclination
Degree minute (decimal degree)Minimum 12°31¢(12.52°)12°10¢(12.17°)
Nominal 13°1¢(13.02°)12°40¢(12.67°)
Maximum 13°31¢(13.52°)13°10¢(13.17°)
Drive type2WD 4WD
Total toe-inDistance (A-B)Minimum 1.7 mm (0.07 in) 1.2 mm (0.05 in)
Nominal 2.7 mm (0.11 in) 2.2 mm (0.09 in)
Maximum 3.7 mm (0.15 in) 3.2 mm (0.13 in)
Angle (left, right)
Degree minute (Decimal degree)Minimum 0°4¢(0.07°)0°3¢(0.05°)
Nominal 0°6¢(0.10°)0°5¢(0.08°)
Maximum 0°8¢(0.13°)0°7¢(0.12°)
Wheel turning angle (full turn)Inside
Degree minute (Decimal degree)33°28¢–35°28¢*
2
(33.47°– 35.47°)33°46¢–35°46¢*
4
(33.77°– 35.77°)
Outside
Degree minute (Decimal degree)29°19¢–31°19¢*
3
(29.32°– 31.32°)29°37¢–31°37¢*
5
(29.62°– 31.62°)
SFA234AC