NISSAN NAVARA 2005 Repair Workshop Manual

CYLINDER BLOCK
EM-129
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PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
lUsing bore gauge, measure cylinder inner diameters at six posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
lIf the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or bore the inner
wall.
lOversize piston is provided. When using oversize piston, hone
the cylinder so that the clearance between piston and cylinder
satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with over-
size piston rings.
Piston Outer Diameter
Use micrometer to measure piston outer diameter.
Calculation of Piston to Cylinder Bore Clearance
lCalculate using piston outer diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter)-(Piston outer diameter)
lIf it exceeds the limit, replace piston and piston pin assembly. Refer toEM-121, "HOW TO SELECT PIS-
TON".
Reboring Cylinder Bore
1. Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.Cylinder bore inner diameter
: 89.000 – 89.030 mm (3.5039 – 3.5051 in)
Wear limit
:0.07mm(0.028in)
Out-of-round limit (Difference between X and Y)
: 0.015 mm (0.0006 in)
Taper limit (Difference between A and C)
: 0.010 mm (0.0004 in)
SEM899G
Oversize (OS) : 0.25 mm (0.0098 in)
: 0.50 mm (0.0197 in)FEM110
Piston outer diameter
Measurement position : 11.0 mm (0.43 in)
Distance from the bottom
Standard : 88.928 – 88.962 mm
(3.5011 – 3.5024 in)
0.25 (0.0098) O/S : 89.188 – 89.202
(3.5113 – 3.5119 in)
0.50 (0.0197) O/S : 89.438 – 89.452
(3.5212 – 3.5217 in)
PBIC0125E
Specifications at room temperature [20°C(68°F)]:
Standard : 0.058 - 0.082 mm (0.0023 - 0.0032 in)
Rebore size calculation:
D=A+B–C
Where,
D: Bored diameter

EM-130
CYLINDER BLOCK
2. Install main bearing caps and tighten bolts to the specified torque. Refer toEM-114, "ASSEMBLY".This
will prevent distortion of cylinder bores.
3. Cut cylinder bore.
NOTE:
lWhen any cylinder needs boring, all other cylinders must also be bored.
lDo not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
lMeasurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
lUse micrometer to measure crankshaft main journal diameter.
lIf out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer toEM-132, "
MAIN BEAR-
ING OIL CLEARANCE".
CRANKSHAFT PIN JOURNAL DIAMETER
lUse micrometer to measure crankshaft pin journal diameter.
lIf out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer toEM-131,
"CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT OUT-OF-ROUND AND TAPER
lUsing micrometer, measure each journal and pin at four points
showninthefigure.
lOut-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
lTaper value is indicated by difference in dimensions between
points A and B in directions X and Y.
lIf the measured value exceeds the limit, correct or replace crankshaft.A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
FEM114
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
PBIC0127E
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E

CYLINDER BLOCK
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lIf corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer toEM-132, "
MAIN BEARING OIL CLEARANCE"and/orEM-
131, "CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
lPlace V-block onto surface plate to support journals at both ends
of crankshaft.
lPosition dial gauge vertically onto No. 3 journal.
lRotate crankshaft to read needle movement on dial gauge.
(Total indicator reading)
lIf it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement
lInstall connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer toEM-114,
"ASSEMBLY". Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter)-
(Crankshaft pin outer diameter)
lIf clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin outer diameter to obtain specified bearing oil
clearance. Refer toEM-122, "
HOW TO SELECT CONNECTING
ROD BEARING".
Method of Using Plastigage
lRemove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.
lCut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
lInstall connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft.
lRemove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.039 - 0.070 mm (0.0015 - 0.0028 in)
PBIC1642E
EM142

EM-132
CYLINDER BLOCK
MAIN BEARING OIL CLEARANCE
Method by Measurement
lInstall main bearings to cylinder block and bearing cap, and
tighten the bolts to the specified torque. Refer toEM-114,
"ASSEMBLY". Then, measure the inner diameter of main bear-
ings.
(Bearing clearance) = (Bearing inner diameter)-(Crankshaft
journal outer diameter)
lIf out of the standard, check main bearing housing inner diame-
ter and crankshaft journal outer diameter, and select appropriate
main bearing to adjust clearance to specifications. Refer toEM-
123, "HOW TO SELECT MAIN BEARING".
Method of Using Plastigage
lRemove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.
lCut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.
lInstall main bearings and bearing cap and tighten to the speci-
fied torque. Refer toEM-114, "
ASSEMBLY"for the tightening
procedure.
CAUTION:
Do not rotate crankshaft.
lRemove main bearings and bearing caps, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.
CRUSH HEIGHT OF MAIN BEARING
lWhen bearing cap is removed after being tightened to the speci-
fied torque with main bearings installed, the tip end of bearing
must protrude. Refer toEM-114, "
ASSEMBLY".
lIf out of the standard, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING
lWhen connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer toEM-114,
"ASSEMBLY".
lIf out of the standard, replace connecting rod bearings.Standard : 0.047 - 0.077 mm (0.0019 - 0.0030 in)
PBIC1644E
EM142
Standard : There must be crush height.
SEM502G
Standard : There must be crush height.
PBIC1646E

CYLINDER BLOCK
EM-133
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MAIN BEARING CAP BOLT DEFORMATION
lMeasure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
lWhen the necked point is identified at a point other than where
specified, measure at the point as d2.
lCalculate the difference between d1 and d2.
lIf it exceeds the limit, replace main bearing cap bolt.
CONNECTING ROD BOLT DEFORMATION
lInstall nuts to connecting rod bolts. Make sure that the nut can
be screwed smoothly on bolt threads by hand to the last thread
on the bolt.
lIf the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.
lIf a necked point is identified, measure at that point.
lIf it exceeds the limit, replace connecting rod bolts and nuts.
OIL JET
lCheck nozzle for deformation and damage.
lBlow compressed air from nozzle, and check for clogs.
lIf out of the standard, replace oil jet.
OIL JET RELIEF VALVE
lUsing clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force.
lIf out of the standard, replace oil jet relief valve.Limit : 0.13 mm (0.0051 in)
JEM219G
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit : 8.75 mm (0. 3445 in) dia.
JEM220G
Standard : No deformation and no damage.
JEM221G
Standard:
Valve moves smoothly with proper reaction force.
JEM222G

EM-134
CYLINDER BLOCK
FLYWHEEL DEFLECTION
lMeasure the deflection of flywheel contact surface to clutch with
a dial indicator.
lMeasure the deflection at 210 mm (8.27 in) dia.
lIf measured value is out of the standard, replace flywheel.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL
CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
lMeasure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.
lIf measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
lTighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transmis-
sion side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transmission side.
lIf measured value is out of the standard, replace flywheel.
DRIVE PLATE
lCheck drive plate and signal plate for deformation or cracks.
CAUTION:
lDo not disassemble drive plate.
lDo not place drive plate with signal plate facing down.
lWhen handling signal plate, take care not to damage or
scratch it.
lHandle signal plate in a manner that prevents it from
becoming magnetized.
lIf anything is found, replace drive plate.Standard : 0.45 mm (0.0177 in) or less.
PBIC2646E
Standard : 1.3 mm (0.051 in) or less
Standard: 32.0 mm (1.620 in) or less.
PBIC1263E
SEM760G

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-135
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS01E6H
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3(cu in)2,488 (151.82)
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.5
Compression pressure
Unit: kPa (bar, kg/cm
2, psi)/200 rpmStandard 3,100 (31, 31.6, 450)
Minimum 2,500 (25, 25.5, 363)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
226 210 2 28 -2 48
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
pump belt2.9 - 3.4
(0.114 - 0.134)3.9 - 4.4
(0.154 - 0.173)8.5 (0.335)
Power steering oil pump belt4.6 - 5.4
(0.181 - 0.213)7.1 - 7.7
(0.280 - 0.303)11.3 (0.445)

EM-136
SERVICE DATA AND SPECIFICATIONS (SDS)
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*: Approximately 80°C (176°F) Item Standard Limit
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)
JEM204G
Valve head diameter “D”Intake 28.0 - 28.3 (1.102 - 1.114)
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Valve length “L”Intake 106.72 (4.2016)
Exhaust 106.36 (4.1874)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “a” Intake and exhaust 45 degrees 15¢- 45 degrees 45¢
Valvemargin“T”Intake 1.60 (0.0630)
Exhaust2WD models 1.80 (0.0709)
4WD models 1.48 (0.0583)
Valvemargin“T”limitMore than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
SEM188
Item Cold Hot* (Reference data)
Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)

SERVICE DATA AND SPECIFICATIONS (SDS)
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Available Shims
Stamped mark Thickness mm (in)
2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858)
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882)
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921)
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
2.40 2.40 (0.0954)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961)
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000)
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024)
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063)
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
SEM512G

EM-138
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Spring
Valve Lifter
Unit: mm (in)
Valve Guide
Unit: mm (in) Valve spring square mm (in) 1.9 (0.075)
Free height mm (in) 44.74 (1.761)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Height during valve open mm (in) 24.82 (0.9772)
Load with valve open N (kg, lb) 320 - 360 (32.65 - 36.73, 71.9 - 80.9)
Item Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
Item Standard Service
Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Item Standard Limit
Valve guide clearanceIntake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0039)
Projection length 10.4 - 10.6 (0.409 - 0.417)
JEM156G