2005 NISSAN NAVARA engine coolant

GLOW CONTROL SYSTEM
EC-297
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Diagnostic ProcedureEBS01KLO
1.INSPECTION START
Check fuel level, fuel supplying system, starter motor, etc.
OK or NG
OK >> GO TO 2.
NG >> Correct.
2.CHECK INSTALLATION
Check that glow plug nut (1) and all glow plug connecting plate nuts
(2) are installed properly.
OK or NG
OK >> GO TO 3.
NG >> Install properly.
3.CHECK GLOW INDICATOR LAMP OPERATION
With CONSULT-II
1. Turn ignition switch ON.
2. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with
CONSULT-II.
3. Confirm that “COOLAN TEMP/S” indicates below 80°C(176°F).
If it indicates above 80°C(176°F), cool down engine.
4. Turn ignition switch OFF, wait at least 5 seconds and then turn
ON.
5. Make sure that glow indicator lamp is turned ON for 1.5 seconds
or more after turning ignition switch ON, and then glow indicator
lamp turned OFF.
Without CONSULT-II
1. Set the tester probe between ECM terminal 51 (engine coolant
temperature sensor signal) and ground.
2. Confirm that the voltage indicates above 1.53V. If it indicates
below 1.53V, cool down engine.
3. Turn ignition switch OFF, wait at least 5 seconds and then turn
ON.
4. Make sure that glow indicator lamp is turned ON for 1.5 seconds
or more after turning ignition switch ON, and then glow indicator
lamp turned OFF.
OK or NG
OK >> GO TO 4.
NG >> GO TO 5.
MBIB1219E
SEF013Y
PBIB2216E

EC-298
GLOW CONTROL SYSTEM
4.CHECK GLOW CONTROL SYSTEM OVERALL FUNCTION
With CONSULT-II
1. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with
CONSULT-II.
2. Confirm that “COOLAN TEMP/S” indicates approximately 25°C
(77°F). If NG, cool down engine.
3. Turn ignition switch OFF.
4. Set voltmeter probe between glow plug and engine body.
5. Turn ignition switch ON.
6. Check the voltage between glow plug and engine body under
the following conditions.
Without CONSULT-II
1. Set the tester probe between ECM terminal 51 (engine coolant
temperature sensor signal) and ground.
2. Confirm that the voltage indicates approximately 3.62V. If NG,
cool down engine.
3. Turn ignition switch OFF.
4. Set voltmeter probe between glow plug and engine body.
5. Turn ignition switch ON.
6. Check the voltage between glow plug and engine body under
the following conditions.
OK or NG
OK >>INSPECTION END
NG >> GO TO 7.
SEF013Y
Conditions Voltage
For 20 seconds after turning ignition switch ON Battery voltage
More than 20 seconds after turning ignition
switch ONApprox. 0V
PBIB0425E
PBIB2216E
Conditions Voltage
For 20 seconds after turning ignition switch ON Battery voltage
More than 20 seconds after turning ignition
switch ONApprox. 0V
PBIB0425E

EC-302
EGR VOLUME CONTROL SYSTEM
EGR VOLUME CONTROL SYSTEM
PFP:14710
DescriptionEBS01KLR
SYSTEM DESCRIPTION
*: This signal is sent to the ECM through CAN communication line.
This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor
moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for opti-
mum engine control. The optimum value stored in the ECM is determined by considering various engine con-
ditions.
The EGR volume control valve remains close under the following conditions.
lEngine stopped
lEngine starting
lLow engine coolant temperature
lExcessively high engine coolant temperature
lHigh engine speed
lAccelerator pedal fully depressed
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the ECM.
Two windings are turned ON and OFF in sequence. Each time an
ON pulse is issued, the valve opens or closes, changing the flow
rate. When no change in the flow rate is needed, the ECM does not
issue the pulse signal. A certain voltage signal is issued so that the
valve remains at that particular opening.
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
EGR volume control EGR volume control valve Vehicle speed sensor* Vehicle speed
Engine coolant temperature sensor Engine coolant temperature
Ignition switch Start signal
Accelerator pedal position sensor Accelerator pedal position
Mass air flow sensor Amount of intake air
Air conditioner switch* Air conditioner operation
SEF908Y
SEF411Y

SERVICE DATA AND SPECIFICATIONS (SDS)
EC-357
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00100
General SpecificationsEBS01KN4
*: Under the following conditions:
lHeat up switch: OFF
lAir conditioner switch: OFF
lElectric load: OFF (Lights, heater fan & rear window defogger)
lSteering wheel: Kept in straight-ahead position
Mass Air Flow SensorEBS01KN5
*: Engine is warmed up to normal operating temperature and running under no load.
Intake Air Temperature SensorEBS01KN6
Engine Coolant Temperature SensorEBS01KN7
Fuel Rail Pressure SensorEBS01KN8
Fuel InjectorEBS01KN9
Glow PlugEBS01KNA
EGR Volume Control ValveEBS01KNB
Crankshaft Position SensorEBS01KNC
Refer toEC-164, "Component Inspection".
Camshaft Position SensorEBS01KND
Refer toEC-175, "Component Inspection".
Target idle speedA/T No load* (in P or N position)
750±25 rpm
M/T No load* (in Neutral position)
Air conditioner: ONA/T In P or N position 750 rpm or more
M/T In Neutral position 800 rpm or more
Maximum engine speed4,900 rpm
Supply voltageBattery voltage (11 - 14V)
Ignition switch ON (Engine stopped.) Approx. 0.4V
Idle (Engine is warmed up to normal operating temperature.) 1.3 - 1.7V *
Temperature°C(°F) Resistance kW
25 (77)1.800 - 2.200
80 (176)0.283 - 0.359
Temperature°C(°F) Resistance kW
20 (68)2.1 - 2.9
50 (122)0.68 - 1.00
90 (194)0.236 - 0.260
Supply voltageApproximately 5V
Idle (Engine is warmed up to normal operating temperature.) 1.7 - 2.0V
2,000 rpm (Engine is warmed up to normal operating tempera-
ture.)2.0 - 2.3V
Resistance [at 10 - 60°C (50 - 140°F)] 0.2 - 0.8W
Resistance [at 25°C(77°F)] Approximately 0.8W
Resistance [at 25°C(77°F)] 13 - 17W

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-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Draining Engine CoolantEBS01E5H
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS01E5I
lBefore starting work, make sure no fire or spark producing items are in the work area.
lAfter disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS01E5J
lWhen instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or
uninstructed operations.
lExercise maximum care to avoid damage to mating or sliding surfaces.
lCover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
lMark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
lWhen loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS01E5K
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS01E5L
lUsetorquewrenchtotightenboltsornutstospecification.
lWhen tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
lReplace with new liquid gasket, packing, oil seal or O-ring.
lDowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
lThoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
lAvoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
lRelease air within route when refilling after draining engine coolant.
lAfter repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS01E5M
lUse an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
lDo not use a torque value for final tightening.
lThe torque value for these parts are for a preliminary step.
lEnsure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS
EM-5
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Precautions For Liquid GasketEBS01E5N
REMOVAL OF LIQUID GASKET
lAfter removing the mounting bolts and nuts, separate the mating
surface using the seal cutter [SST] and remove the old liquid
gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
lTap seal cutter to insert it, and then slide it by tapping on the
side as shown in the figure.
lIn areas where seal cutter [SST] is difficult to use, use plastic
hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket tube to the tube presser [SST].
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
lAs for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the text of this manual.
lWithin five minutes of liquid gasket application, install the mat-
ing component.
lIf the 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
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

DRIVE BELTS
EM-13
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Deflection AdjustmentEBS01EJ5
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with engine oil or engine coolant.
lDo not twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front. Refer toEI-15, "FRONT BUMPER".
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust. Refer toEM-13, "
Deflection Adjustment".
4. Tighten idler pulley lock nut (B).
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
4. Crankshaft pulley 5.Dummy pulley (Models without A/C)
A/C compressor (Models with A/C)6. Alternator
7. Idler pulley 8. Water pump pulley 9.A/C compressor, alternator and
water pump belt
A. Adjusting bolt B. Idler pulley lock nut C. Adjusting nut
D. Idler pulley lock nut
PBIC4039E
Applied belt Belt adjustment method
Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
water pump beltAdjusting nut on idler pulley (C)
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)