NISSAN NAVARA 2005 Repair Workshop Manual

CAMSHAFT
EM-59
C
D
E
F
G
H
I
J
K
L
MA
EM
CAMSHAFTPFP:13001
ComponentsEBS01EK5
lRefer toGI-10, "Components"for symbol marks in the figure.
CAUTION:
lThis engine will have a different valve arrangement from
normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust camshafts, in this
chapter they are named as follows:
lRefer to the figure for intake and exhaust valve arrange-
ment.
(The camshafts have, alternately, either intake valve or an
exhaust valve.)
Removal and InstallationEBS01E66
REMOVAL
1. Drain engine coolant. Refer toCO-7, "Changing Engine Coolant".
2. Remove rocker cover. Refer toEM-56, "
ROCKER COVER".
1. Camshaft bracket 2. Camshaft (right side) 3. Camshaft (left side)
4. Signal plate 5. Rubber washer 6. Adjusting shim
7. Valve lifter 8. Camshaft sprocket 9. Cylinder head
10. Cylinder head rear cover 11. O-ring 12. Camshaft position sensor
Camshaft (right side) : Intake manifold side
Camshaft (left side) : Exhaust manifold side
PBIC3443E
SBIA0178E

EM-60
CAMSHAFT
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.
Loosen cylinder head rear cover mounting bolts in the reverse
order shown in the figure.
4. Remove fuel injector. Refer toEM-44, "
INJECTION TUBE AND FUEL INJECTOR".
5. Remove secondary timing chain. Refer toEM-73, "
SECONDARY TIMING CHAIN".
6. Remove camshaft sprockets and signal plate.
lLoosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft.
7. Remove camshaft.
lPlace distinguishing marks on the right and left sides with paint.
lLoosen and remove the camshaft sprocket bolts in the
reverse order shown in the figure.
8. Remove adjusting shim and valve lifter.
lRemove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
INSPECTION AFTER REMOVAL
Visual Check of Camshaft
lCheck the camshaft for one sided wear or scratches.
lReplace the camshaft if there are abnormalities.
PBIC3445E
JEM159G
JEM160G

CAMSHAFT
EM-61
C
D
E
F
G
H
I
J
K
L
MA
EM
Camshaft Runout
lPrepare V-block on a flat surface and secure camshaft journals
No. 2 and No. 5.
lSet the dial gauge vertically on journal No. 3.
lRotate camshaft in one direction by hand, then read needle
movement on dial gauge. (Total indicator reading)
lIf it exceeds the limit, replace camshaft.
Height of Cam Nose
lMeasure the height of cam nose using the micrometer.
lIf out of the standard, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
lMeasure outer diameter of camshaft journal with micrometer.
CAMSHAFT BRACKET INNER DIAMETER
lInstall camshaft bracket and tighten bolts to the specified torque. Refer toEM-63, "INSTALLATION"for
the tightening procedure.
lMeasure inner diameter of camshaft bracket using the inside
micrometer.
CAMSHAFT OIL CLEARANCE CALCULATIONS
l(Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)Limit : 0.02 mm (0.0008 in)
JEM161G
Standard:
Intake : 39.505 - 39.695 mm (1.5553 - 1.5628 in)
Exhaust : 39.905 - 40.095 mm (1.5711 - 1.5785 in)
SEM549A
Standard:
No. 1 : 30.435 - 30.455 mm
(1.1982 - 1.1990 in)
No.2,3,4,5 :23.935-23.955mm
(0.9423 - 0.9431 in)
SEM012A
Standard:
No. 1 : 30.500 - 30.521 mm
(1.2008 - 1.2016 in)
No.2,3,4,5 :24.000-24.021mm
(0.9449 - 0.9457 in)
JEM162G

EM-62
CAMSHAFT
lIf out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the cam-
shaft bracket.
Camshaft End Play
lInstall dial gauge in thrust direction on front end of camshaft.
Measure end play of dial gauge when camshaft is moved for-
ward/backward (in direction to axis).
lMeasure the following parts if out of the standard.
–Dimension “A” for camshaft
–Dimension “B” for cylinder head
lRefer to the standards above, and then replace camshaft and/or
cylinder head.
Camshaft Sprocket Runout
1. Install camshaft in cylinder head. Refer toEM-63, "INSTALLATION"for the tightening procedure.
2. Install sprocket on camshaft. Refer toEM-63, "
INSTALLATION".
3. Measure camshaft sprocket runout. (Total indicator reading)
lIf it exceeds the limit, replace camshaft sprocket.
Visual Inspection of Valve Lifter and Adjusting Shim
Check if surface of valve lifter and adjusting shim has any wear or
cracks.
lIf anything above is found, replace valve lifter or adjusting shim.Standard : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
Standard : 0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit : 0.24 mm (0.0094 in)
PBIC0366E
Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)
Standard : 7.000 - 7.030 mm (0.2755 - 0.2767 in)
PBIC2320E
Limit : 0.15 mm (0.0059 in)
JEM164G
SEM160D

CAMSHAFT
EM-63
C
D
E
F
G
H
I
J
K
L
MA
EM
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
lMeasure the outer diameter of the valve lifter with the microme-
ter.
VALVE LIFTER BORE DIAMETER
lMeasure the bore diameter of the cylinder head valve lifter with
theinsidemicrometer.
VALVE LIFTER CLEARANCE CALCULATIONS
l(Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)
lIf out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter
and/or cylinder head.
INSTALLATION
1. Install valve lifter and adjusting shim.
lMake sure that these are installed in the same position as before the removal process.
2. Install camshaft.
lIdentify camshafts by the paint position and screw hole at the
rear end.Standard : 29.960 - 29.975 mm (1.1795 - 1.1801 in)
SEM961E
Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in)
PBIC0367E
Standard : 0.025 - 0.061 mm (0.0010 - 0.0024 in)
: Engine front
Camshaft (right side) Intake manifold side (1):
Paint is at position (C) (Blue) without screw hole (A).
Camshaft (left side) Exhaust manifold side (2):
No paint with screw hole (B).
PBIC3444E

EM-64
CAMSHAFT
lInstall so that knock pins are positioned in the directions
showninthefigure.
3. Install camshaft brackets.
lCompletely remove any foreign material on back surfaces of camshaft brackets and top surface of cyl-
inder head.
lInstall correctly, identifying brackets by the journal No. and
front mark on top surface.
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten all bolts.
lMake sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten all bolts.
c. Tighten all bolts.
5. Install camshaft sprockets and signal plate.
lCamshaft sprockets are commonly used for right side and left side.
lAlign camshaft sprocket and knock pin on camshaft, and install.
lHolding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and
signal plate.
6. Install rubber washer to cylinder head rear side.
PBIC2026E
JEM175G
:2N·m(0.2kg-m,1ft-lb)
:6N·m(0.6kg-m,4ft-lb)
:12-13N·m(1.2-1.4kg-m,9-10ft-lb)
JEM160G

CAMSHAFT
EM-65
C
D
E
F
G
H
I
J
K
L
MA
EM
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure.
Use Genuine Liquid Gasket or Equivalent.
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure.
9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
toEM-66, "
Valve Clearance".
10. Hereafter, install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
lBefore starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer toMA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS".
lUse procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
lBleed air from lines and hoses of applicable lines, such as in cooling system.
lAfter cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
PBIC3446E
M6´50 mm : Bolt No.1, 2
M6´20 mm : Bolt No.3, 4
M8´20 mm : Bolt No.5, 6
PBIC3445E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

EM-66
CAMSHAFT
Valve Clearance
EBS01E67
INSPECTION
lWhen the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the misadjustment of the valve clearance,
inspect as follows.
lInspect and adjust when the engine is cool (at normal temperature).
lBe careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
1. Remove rocker cover. Refer toEM-56, "
ROCKER COVER".
2. Remove fuel injector. Refer toEM-44, "
INJECTION TUBE AND FUEL INJECTOR".
3. Set the No. 1 piston to TDC on its compression stroke.
lTurn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
4. Remove undercover, put an alignment mark with paint, etc. on
crankshaft pulley and on oil pump housing as an angle indicator.
5. While referring to the figure, measure the valve clearance
marked in the table below.
NOTE:
lThe injection order is 1-3-4-2.
SBIA0178E
PBIC2533E
1 : Crankshaft pulley
A : Alignment mark
: Vehicle front
PBIC3447E
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCXXX X
SBIA0180E

CAMSHAFT
EM-67
C
D
E
F
G
H
I
J
K
L
MA
EM
lMeasure the valve clearance using the feeler gauge when
engine is cool (at normal temperature).
Valve clearance:
Unit: mm (in)
*: Reference data approximately 80°C(176°F)
6. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
7. While referring to the figure, measure the valve clearance
marked in the table below.
8. If the valve clearance is outside the specification, adjust as fol-
lows.
ADJUSTMENTS
lRemove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
3. Grip camshaft with the camshaft pliers [SST], then using cam-
shaft as a support point, push adjusting shim downward to com-
press valve spring.
CAUTION:
Do not damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.
SBIA0181E
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)
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDCXX XX
SBIA0182E
SBIA0183E
PBIC2321E

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)]