height NISSAN NAVARA 2005 Repair Owner's Manual

CYLINDER HEAD
EM-105
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Valve Spring Dimensions and Valve Spring Pressure Load
lUsing valve spring tester, check the following.
lIf out of the standard, replace the valve spring.Standard:
Free height : 44.74 mm (1.76 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during
valve open: 24.82 mm (0.9772 in)
Load with valve
open:320-360N
(32.65 - 36.73 kg, 71.9 - 80.9 lb)
SEM113

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

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

EM-140
SERVICE DATA AND SPECIFICATIONS (SDS)
CAMSHAFT
Unit: mm (in)
*: Total indicator readingDiameter “d2”Intake (A) 26.00 - 26.50 (1.0236 - 1.0433) —
Exhaust (B) —
Diameter “d3”Intake (A) 25.3 - 25.7(0.996 - 1.012)
Exhaust (B) 23.3 - 23.7 (0.917 - 0.933)
Angle “a”43°30¢-46°30¢
Height “h1”Intake (A) 7.0 - 7.1 (0.276 - 0.280) 6.6 - 6.7 (0.260 - 0.264)
Exhaust (B) 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
Height “h2”Intake (A) 2.23 - 2.43 (0.0878 - 0.0957) 2.13 - 2.53 (0.0839 - 0.0996)
Exhaust (B) 2.76 - 2.96 (0.1087 - 0.1165) 2.66 - 3.06 (0.1047 - 0.1205)
Depth “H”Intake 8.83 - 9.13 (0.3476 - 0.3594)
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Projection (L)Intake 36.53 - 36.98 (1.4382 - 1.4559)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
Item Standard Limit
Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
— Camshaft bracket inner diameterNo.1 30.500 - 30.521 (1.2008 - 1.2016)
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457)
Camshaft journal outer diameterNo. 1 30.435 - 30.455 (1.1982 - 1.1990)
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
Cam height “A”Intake 39.505 - 39.695 (1.5553 - 1.5628)
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
SEM671

FRONT FINAL DRIVE ASSEMBLY
FFD-17
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Disassembly and AssemblyEDS00357
COMPONENTS
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Pinion front bearing 5. Gear carrier 6. Side oil seal
7. Bushing 8. Side shaft 9. Side shaft bearing
10. Snap ring 11. Snap ring 12. Gasket
13. Drain plug 14. Collapsible spacer 15. Pinion rear bearing
16. Pinion height adjusting washer 17. Drive pinion 18. Side bearing adjusting washer
19. Side bearing 20. Side gear thrust washer 21. Side gear
22. Pinion mate shaft 23. Lock pin 24. Pinion mate gear
25. Pinion mate thrust washer 26. Drive gear 27. Differential case
28. Housing spacer 29. Bearing cap 30. Filler plug
31. Rear cover
PDIA0954E

FFD-20
FRONT FINAL DRIVE ASSEMBLY
4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
lIf the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear.
Refer toFFD-38, "
Pinion Height Adjusting Washer".
lIf the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer toFFD-38, "
Pinion Height Adjusting Washer".
Backlash
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Fit a dial indicator to the drive gear face to measure the back-
lash.
lIf the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
SDIA0517E
PDIA0440E
PDIA0441E
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is greater than specification:
Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
When the backlash is less than specification:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
SPD513

FRONT FINAL DRIVE ASSEMBLY
FFD-25
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FFD
4. Put matching mark on the end of drive pinion. The matching
mark should be in line with the matching mark A on companion
flange.
CAUTION:
Use paint for matching mark. Do not damage companion
flange or drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
5. Remove companion flange using suitable tool.
6. Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)
CAUTION:
Do not drop drive pinion assembly.
7. Remove pinion rear bearing inner race and drive pinion height
adjusting washer using Tool.
8. Remove front oil seal using suitable tool.
CAUTION:
Do not damage gear carrier.
9. Remove pinion front bearing inner race.
10. Remove collapsible spacer.
PDIA0675E
PDIA0703E
PDIA0704E
Tool number : ST30031000
S-PD179
PDIA0716E

FFD-28
FRONT FINAL DRIVE ASSEMBLY
Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting
washer thickness.
2. Select the proper pinion height adjusting washer. Refer toFFD-38, "
Pinion Height Adjusting Washer".
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using Tools.
CAUTION:
lFirst tap the bearing outer race until it becomes flat to the
gear carrier.
lDo not reuse pinion front and rear bearing outer race.Washer selection equation:
T=T
0+(t1-t2)
T: Correct washer thickness
T
0: Removed washer thickness
t
1: Old drive pinion head letter “H´0.01”
(“H”: machined tolerance 1/100 mm´100)
t
2: New drive pinion head letter “H´0.01”
(“H”: machined tolerance 1/100 mm´100)
Example:
T = 3.21 + [(2´0.01) - (-1´0.01)] = 3.24
T
0:3.21
t
1:+2
t
2:-1
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
SDIA0249J
Tool number A: ST30611000
B: ST30613000
C: KV38100200
PDIA0707E

FRONT FINAL DRIVE ASSEMBLY
FFD-29
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2. Temporarily install pinion height adjusting washer.
When hypoid gear set has been replaced
lSelect pinion height adjusting washer. Refer toFFD-28, "Pin-
ion Gear Height".
When hypoid gear set has been reused
lTemporarily install the removed pinion height adjusting
washer or same thickness washer to drive pinion.
3. Install selected pinion height adjusting washer to drive pinion.
Press pinion rear bearing inner race to it using Tool.
CAUTION:
lPay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)
lDo not reuse pinion rear bearing inner race.
4. After checking and adjusting the tooth contact and backlash of
the hypoid gear following the procedure below.
a. Apply gear oil to the drive pinon rear bearing, and assemble the
drive pinion to the gear carrier.
CAUTION:
Do not assemble a collapsible spacer.
b. Apply gear oil to drive pinon front bearing, and assemble pinion front bearing inner race to drive pinion.
CAUTION:
Do not reuse pinion front bearing inner race.
c. Press the pinion front bearing inner race to drive pinion as far as
drive pinion lock nut can be tightened using drift.
d. Install companion flange.
CAUTION:
Do not assemble a front oil seal.
NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange.
SDIA1666E
Tool number : ST30901000
Tool number : ST33200000
SDIA0048E
PDIA0709E
PDIA0675E

FFD-38
SERVICE DATA AND SPECIFICATIONS (SDS)
Pinion Height Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Side Bearing Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Thickness Part number* Thickness Part number*
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)38154 EA000
38154 EA001
38154 EA002
38154 EA003
38154 EA004
38154 EA005
38154 EA006
38154 EA007
38154 EA008
38154 EA0093.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)38154 EA010
38154 EA011
38154 EA012
38154 EA013
38154 EA014
38154 EA015
38154 EA016
38154 EA017
38154 EA018
38154 EA019
Thickness Part number* Thickness Part number*
1.95 (0.0768)
2.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)38453 EA000
38453 EA001
38453 EA002
38453 EA003
38453 EA004
38453 EA005
38453 EA006
38453 EA0072.35 (0.0925)
2.40 (0.0945)
2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)38453 EA008
38453 EA009
38453 EA010
38453 EA011
38453 EA012
38453 EA013
38453 EA014