NISSAN NAVARA 2005 Repair Workshop Manual

BED RAILS AND TRIM
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REMOVAL
1. Remove floor rail covers.
2. Remove tiedown cleats.
3. Remove floor rails LH/RH.
4. Remove bed side front and rear tiedown rails LH/RH.
5. Remove rope hooks.
6. Remove header tiedown rail.
INSTALLATION
Installation is in the reverse order of removal.
1. Header tiedown rail 2. Rope hook 3. Tiedown cleat
4. Floor rail cover LH 5. Floor rail LH 6. Bed side front tiedown rail LH
7. Bed side rear tiedown rail LH 8. Floor rail RH 9. Floor rail cover RH
10. Bed side rear tiedown rail RH 11. Bed side front tiedown rail RH

EI-44
TAIL GATE FINISHER
TAIL GATE FINISHER
PFP:93486
Removal and InstallationEIS00DYS
REMOVAL
Remove screws and remove tailgate protector (if equipped) and tailgate cover plate.
INSTALLATION
Installation is in the reverse order of removal.
1. Tailgate protector (if equipped) 2. Tailgate cover plate 3. Tailgate
MIIB9137E

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTIONEM
A
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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-2
Components ........................................................... 42
Removal and Installation ........................................ 42
INSPECTION BEFORE REMOVAL ..................... 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
INJECTION TUBE AND FUEL INJECTOR .............. 44
Components ........................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSTALLATION .................................................... 46
INSPECTION AFTER INSTALLATION ................ 48
FUEL PUMP .............................................................. 49
Components ........................................................... 49
Removal and Installation ........................................ 49
REMOVAL ........................................................... 49
INSPECTION AFTER REMOVAL ........................ 52
INSTALLATION .................................................... 52
ROCKER COVER ..................................................... 56
Components ........................................................... 56
Removal and Installation ........................................ 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 57
INSPECTION AFTER INSTALLATION ................ 58
CAMSHAFT ............................................................... 59
Components ........................................................... 59
Removal and Installation ........................................ 59
REMOVAL ........................................................... 59
INSPECTION AFTER REMOVAL ........................ 60
INSTALLATION .................................................... 63
INSPECTION AFTER INSTALLATION ................ 65
Valve Clearance ...................................................... 66
INSPECTION ....................................................... 66
ADJUSTMENTS .................................................. 67
OIL SEAL .................................................................. 70
Removal and Installation of Valve Oil Seal ............. 70
REMOVAL ........................................................... 70
INSTALLATION .................................................... 70
Removal and Installation of Front Oil Seal ............. 71
REMOVAL ........................................................... 71
INSTALLATION .................................................... 71
Removal and Installation of Rear Oil Seal .............. 72
REMOVAL ........................................................... 72
INSTALLATION .................................................... 72
SECONDARY TIMING CHAIN .................................. 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 73
INSPECTION AFTER REMOVAL ........................ 75
INSTALLATION .................................................... 75
INSPECTION AFTER INSTALLATION ................ 77
PRIMARY TIMING CHAIN ........................................ 79
Components ........................................................... 79
Removal and Installation ........................................ 80
REMOVAL ........................................................... 80
INSPECTION AFTER REMOVAL ........................ 84
INSTALLATION .................................................... 85
INSPECTION AFTER INSTALLATION ................ 91CYLINDER HEAD ..................................................... 92
On-Vehicle Service ................................................. 92
CHECKING COMPRESSION PRESSURE ......... 92
Components ............................................................ 93
Removal and Installation ......................................... 94
REMOVAL ............................................................ 94
INSPECTION AFTER REMOVAL ........................ 94
INSTALLATION .................................................... 96
INSPECTION AFTER INSTALLATION ................ 98
Components ............................................................ 99
Disassembly and Assembly .................................... 99
DISASSEMBLY .................................................... 99
ASSEMBLY ........................................................100
INSPECTION AFTER DISASSEMBLY ..............101
ENGINE ASSEMBLY ...............................................106
Components ..........................................................106
Removal and Installation .......................................106
REMOVAL ..........................................................107
INSTALLATION ..................................................108
INSPECTION AFTER INSTALLATION ..............108
CYLINDER BLOCK .................................................110
Components ..........................................................110
Disassembly and Assembly .................................. 111
DISASSEMBLY .................................................. 111
ASSEMBLY ........................................................114
How to Select Piston and Bearing ........................121
DESCRIPTION ..................................................121
HOW TO SELECT PISTON ...............................121
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................122
HOW TO SELECT MAIN BEARING ..................123
Inspection After Disassembly ................................124
CRANKSHAFT END PLAY ................................124
CONNECTING ROD SIDE CLEARANCE .........125
PISTON TO PISTON PIN CLEARANCE ...........125
PISTON RING SIDE CLEARANCE ...................126
PISTON RING END GAP ..................................126
CONNECTING ROD BEND AND TORSION .....127
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................127
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................127
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................128
MAIN BEARING HOUSING INNER DIAMETER.128
PISTON TO CYLINDER BORE CLEARANCE ..129
CRANKSHAFT MAIN JOURNAL DIAMETER ...130
CRANKSHAFT PIN JOURNAL DIAMETER ......130
CRANKSHAFT OUT-OF-ROUND AND TAPER.130
CRANKSHAFT RUNOUT ..................................131
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................131
MAIN BEARING OIL CLEARANCE ...................132
CRUSH HEIGHT OF MAIN BEARING ..............132
CRUSH HEIGHT OF CONNECTING ROD

EM-3
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EMA BEARING .......................................................... 132
MAIN BEARING CAP BOLT DEFORMATION .. 133
CONNECTING ROD BOLT DEFORMATION .... 133
OIL JET ............................................................. 133
OIL JET RELIEF VALVE ................................... 133
FLYWHEEL DEFLECTION ............................... 134
MOVEMENT AMOUNT OF FLYWHEEL ........... 134
DRIVE PLATE ................................................... 134
SERVICE DATA AND SPECIFICATIONS (SDS) .... 135
Standard and Limit ............................................... 135
GENERAL SPECIFICATIONS .......................... 135
INTAKE MANIFOLD AND EXHAUST MANI-FOLD .................................................................135
DRIVE BELTS ...................................................135
CYLINDER HEAD .............................................136
VALVE ...............................................................136
CAMSHAFT .......................................................140
CYLINDER BLOCK ...........................................141
PISTON, PISTON RING AND PISTON PIN ......141
CONNECTING ROD .........................................144
CRANKSHAFT ..................................................144
AVAILABLE MAIN BEARING ............................145
AVAILABLE CONNECTING ROD BEARING ....145
MISCELLANEOUS COMPONENTS .................145

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
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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

EM-6
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEBS01E5O
Tool number
Tool nameDescription
KV10115600
Valve oil seal driftInstalling valve oil seal
UsesideA.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV11103000
Pulley pullerRemoving crankshaft pulley
ED19600610
Compression gauge adapterChecking compression pressure
KV101056S0
Ring gear stopper
1. KV10105630
Adapter
2. KV10105610
PlatePreventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopperChanging adjusting shim
NT603
S-NT605
NT676
ZZA1188D
NT617
NT041

PREPARATION
EM-7
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KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
AdapterDisassembling and assembling valve
mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.
ST16610001
Pilot bushing pullerRemoving crankshaft pilot bush
KV10111100
Seal cutterRemoving oil pan upper, oil pan lower and
rear chain case, etc.
WS39930000
Tube presserPressing the tube of liquid gasket
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc.
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
KV11106010
Hexagon wrenchRemoving and installing chain tensioner
a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in) Tool number
Tool nameDescription
PBIC1650E
NT045
NT046
NT052
NT014
NT044
NT801

EM-8
PREPARATION
Commercial Service Tools
EBS01E5P
KV11106020
Hexagon wrenchRemoving and installing slack guide
a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pinFixing fuel pump sprocket
a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrenchRemoving and installing fuel pump sprocket
nut
a: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrenchRemoving and installing fuel pump sprocket
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
KV11106060
Sprocket holderHolding fuel pump sprocket Tool number
Tool nameDescription
NT803
NT804
NT805
SBIA0224E
SBIA0225E
Tool nameDescription
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
NT048
NT030