2005 NISSAN NAVARA Repair Workshop Manual

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Page 785 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual BODY REPAIR
BL-201
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BL
REAR BODY
Measurement
LIIA1803E

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NISSAN NAVARA 2005 Repair Workshop Manual BL-202
BODY REPAIR
Measurement Points
LIIA1804E

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NISSAN NAVARA 2005 Repair Workshop Manual BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTIONBR
A
B
BR
BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint Sy

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTIONBR
A
B
BR
BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
ADJUSTMENT ...................................................... 7
Removal and Installation .......................................... 8
COMPONENTS .................................................... 8
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 9
INSTALLATION ..................................................... 9
BRAKE FLUID .......................................................... 10
On-board Inspection ............................................... 10
CHECKING BRAKE FLUID LEVEL .................... 10
Drain and Refill ....................................................... 10
Bleeding Brake System ........................................... 11
LHD MODEL ........................................................ 11
RHD MODEL ........................................................ 11
BRAKE TUBE AND HOSE ....................................... 12
Hydraulic Circuit ..................................................... 12
Removal and Installation of Front Brake Tube and
Brake Hose ............................................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Removal and Installation of Rear Brake Tube and
Brake Hose ............................................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Inspection after Installation .................................... 14
LOAD SENSING VALVE .......................................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15INSTALLATION ................................................... 15
Inspection ............................................................... 16
INSPECTION ...................................................... 16
BRAKE MASTER CYLINDER .................................. 17
On-Board Inspection ............................................... 17
LEAK INSPECTION ............................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
Components ........................................................... 17
Disassembly and Assembly .................................... 18
DISASSEMBLY ................................................... 18
ASSEMBLY ......................................................... 18
BRAKE BOOSTER ................................................... 19
On-Vehicle Service ................................................. 19
OPERATING CHECK .......................................... 19
AIRTIGHT CHECK .............................................. 19
Removal and Installation ........................................ 20
COMPONENTS ................................................... 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 21
VACUUM LINES ....................................................... 22
Component ............................................................. 22
Removal and Installation ........................................ 23
Inspection ............................................................... 23
VISUAL INSPECTION ......................................... 23
CHECK VALVE INSPECTION ............................. 23
FRONT DISC BRAKE ............................................... 24
On-Board Inspection ............................................... 24
PAD WEAR INSPECTION ................................... 24
Components ........................................................... 24
Removal and Installation of Brake Pad .................. 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
Removal and Installation of Brake Caliper Assembly
... 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
Disassembly and Assembly of Brake Caliper

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NISSAN NAVARA 2005 Repair Workshop Manual BR-2
Assembly ................................................................ 26
DISASSEMBLY ................................................... 26
INSPECTION AFTER DISASSEMBLY ................ 27
AS

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NISSAN NAVARA 2005 Repair Workshop Manual PRECAUTIONS
BR-3
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS006DL
The Supplemental Restraint

PRECAUTIONS
BR-3
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BR
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS006DL
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake SystemEFS005SD
lClean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.
lRecommended fluid is brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed
on painted areas, wash it away with water immediately.
lTo clean or wash all parts of master cylinder, disc brake caliper, wheel cylinder, use new brake fluid.
lNever use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
lUse a flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tighten flare nuts.
lAlways tighten brake lines to the specified torque when install-
ing.
lBefore working, turn ignition switch OFF and disconnect electri-
cal connector of ABS actuator and electric unit (control unit) or
the battery cables.
lBurnish the new brake surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
Refer toBR-29, "
BRAKE BURNISHING PROCEDURE".
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.SBR820BA

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NISSAN NAVARA 2005 Repair Workshop Manual BR-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEFS005SE
Commercial Service ToolsEFS005TE
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
a:10 mm (0.39 in)Installing br

Page 791 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEFS005SF
Use the chart below

Page 792 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual BR-6
BRAKE PEDAL
BRAKE PEDAL
PFP:46501
Inspection and AdjustmentEFS005SG
Play and clearance inspection between brake pedal and floor panel with pedal depressed.
lCheck brake pedal play.
lCheck brake p

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