2005 NISSAN NAVARA ESP

SIDE GUARD MOLDING
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REMOVAL
CAUTION:
Never apply tack-paper adhesive remover to body panel surface finished with lacquer-based paints.
lOriginal side guard molding is affixed to body panel with double-faced adhesive tape.
1. Heat molding to between 30°and 40°C(86°to 104°F) with a heat gun.
2. Raise end of molding and cut away tape to remove molding. Remove all traces of tape.
INSTALLATION
lOn vehicles coated with Hard Clear Coat, use double-faced 3M adhesive tape Product No. 4210 or equiv-
alent, after priming with 3M primer Product No. N200, C-100 or equivalent.
lThe repair parts are also affixed with double-faced adhesive tape.
lTo re-use existing molding, clean all traces of double sided tape from the molding and apply new double-
facedtapetothemolding.
1. Clean the panel surface with isopropyl alcohol or equivalent to degrease the surface.
2. Heat the panel and molding tape surface to 30°to 40°C(86°to 104°F).
3. Remove the backing sheet from the tape surface.
lAlign the locating pin into the hole in the outer door.
lContinue aligning the pins into their corresponding holes in the outer door during installation.
4. Press ends by hand and use a roller to apply 5 kg-f (11 lbs-f) to press molding to door surface.
lApply even pressure along molding to insure proper wet out.
CAUTION:
To secure contact, do not wash vehicle for 24 hours after installation.

EM-44
INJECTION TUBE AND FUEL INJECTOR
INJECTION TUBE AND FUEL INJECTOR
PFP:00018
ComponentsEBS01EK6
lRefer toGI-10, "Components"for symbol marks except in the above.
Removal and InstallationEBS01E63
REMOVAL
1. Remove engine cover. Refer toEM-20, "INTAKE MANIFOLD".
2. Remove fuel filter. Refer toFL-4, "
FUEL FILTER".
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
1. Eye-bolt 2. Cooper washer 3. Spill tube
4. Nozzle support 5. Pin 6. Fuel injector
7. O-ring 8. Nozzle gasket 9. Rocker cover
10. Nozzle oil seal 11. Washer 12. Injection tube No. 4
13. Injection tube No. 3 14. Injection tube No. 2 15. Injection tube No. 1
16. Insert rubber 17. Clip 18. Injection tube center
19. Spill hose 20. Fuel gallery 21. Spill hose
22. Fuel hose 23. Fuel pump 24. Cylinder head
25. Cooper washer 26. Fuel hose 27. Fuel rail
A. To fuel filter B.To fuel cooler (under floor) (4WD
models)
To fuel tank (2WD models)
Vehicle front
PBIC4046E

INJECTION TUBE AND FUEL INJECTOR
EM-45
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3. Disconnect harness connector from fuel injector.
4. Remove spill hose.
5. Following steps below, remove injection tubes.
a. Put a paint mark or tag on injection tubes to identify each cylinder.
lUse a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel.
6. Remove nozzle oil seal.
lUsing the flat-bladed screwdriver, pry flange to remove oil
seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.
7. Remove rocker cover. Refer toEM-56, "
ROCKER COVER".
8. Remove spill tube mounting bolts and nut.
lLoosen bolts and nut to the reverse order in the figure and
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
ner.
SBIA0203E
PBIC0944E
PBIC2038E

EM-56
ROCKER COVER
ROCKER COVER
PFP:13264
ComponentsEBS01EK4
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E65
REMOVAL
1. Remove engine cover. Refer toEM-20, "INTAKE MANIFOLD".
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose. Refer toEM-20,
"INTAKE MANIFOLD"andEM-15, "AIR CLEANER AND AIR DUCT".
3. Disconnect harness connector from fuel injector. Refer toEM-44, "
INJECTION TUBE AND FUEL INJEC-
TOR".
4. Following steps below, remove injection tube. Refer toEM-44, "
INJECTION TUBE AND FUEL INJEC-
TOR".
a. Put a paint mark or tag on injection tubes to identify each cylinder.
lUse a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
1. Nozzle oil seal 2. Rocker cover 3. Ventilation hose
4. Washer 5. Oil filler cap 6. Gasket
A. Refer to “INSTALLATION” in “ROCKER COVER” B. To ventilation hose
PBIC3440E

EM-68
CAMSHAFT
4. Withvalvespringinacompressedstate,removethecamshaft
pliers [SST] by securely setting the outer circumference of the
valve lifter with the end of the lifter stopper [SST].
lHold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as cam-
shaft will be damaged.
5. Move the round hole of adjusting shim to the front with the very
thin screwdriver or like that.
lWhen adjusting shim on valve lifter will not rotate smoothly,
restart from step 3 to release the end of the lifter stopper
[SST] from touching adjusting shim.
6. Remove adjusting shim from valve lifter by blowing air through
the round hole of the adjusting shim with the air gun.
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.
7. Remove adjusting shim by using the magnet hand.
8. Measure the thickness of adjusting shim using the micrometer.
lMeasure near the center of the shim (the part that touches
camshaft).
9. Select the new adjusting shim from the following methods.
PBIC2322E
PBIC2323E
PBIC2324E
FEM032
Calculation method of the adjusting shim thickness:
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N=R+[M-0.28mm(0.0010in)]
Exhaust
N=R+[M-0.30mm(0.0118in)]

PRIMARY TIMING CHAIN
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Balancer Unit Mounting Bolt Outer Diameter (4WD Models)
lMeasure the outer diameters (“d1”,“d2”)attwopositionsas
showninthefigure.
lIf reduction appears in “A” range, regard it as “d2”.
lIf it exceeds the limit (large difference in dimensions), replace it
with a new one.
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
CAUTION:
Before starting work, make sure that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure (4WD models).
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer toEM-85, "
Balancer Unit Mounting
Bolt Outer Diameter (4WD Models)".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten all bolts.Limit (“d
1”-“d2
”): 0.15 mm (0.0059 in)
PBIC1137E
1. Chain tensioner 2. Slack guide 3. Fuel pump sprocket
4. Chain guide 5. Primary timing chain 6. Vacuum pump sprocket
7. Slack guide 8. Chain tensioner 9. Crankshaft sprocket
10. Key 11. Tension guide 12. Tension guide
13. Tension guide 14. Camshaft sprocket 15. Secondary timing chain
A. Alignment mark (silver link) B. Alignment mark (punched mark) C. Alignment mark (cut-out area)
D. Alignment mark (yellow link)
: Engine front
PBIC3473E
PBIC4049E

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

FUEL TANK
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CAUTION:
lQuick connector can be disconnected when the tabs are
completely depressed. Do not twist it more than necessary.
lDo not use any tools to disconnect quick connector.
lKeep resin tube away from heat. Be especially careful when
welding near the resin tube.
lPrevent acid liquid such as battery electrolyte etc. from get-
ting on resin tube.
lDo not bend or twist resin tube during installation and
removal.
lDo not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is replaced.
lWhen resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one. Replace same color
retainer as before replacing.
lTo keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
6. Using a transmission jack (A), support the bottom of fuel tank
(1).
CAUTION:
Support the position that fuel tank bands do not engage.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC3377E