height NISSAN NAVARA 2005 Repair User Guide

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-35
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEFS005T8
Unit: mm (in)
Brake PedalEFS005T9
Unit: mm (in)
Brake BoosterEFS005TA
Va c u u m t y p e
Unit: mm (in)
Check ValveEFS005TB
Front Disc BrakeEFS005TC
Unit: mm (in) Front brake Brake model CLZ33VB
Cylinder bore diameter 46.4 (1.83)´2
Pad length´width´thickness 140´47.8´11 ( 5 . 5 1´1.88´0.43)
Rotor outer diameter´thickness 296´28 (11.65´1.10)
Rear brake Brake model LT30
Cylinder bore diameter 38.1 (1.50)
Lining Length´width´thickness 295´55´5.5 (11.61´2.17´0.22)
Drum inner diameter 295 (11.61)
Master cylinder Cylinder bore diameter 25.4 (1.0)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
Diaphragm diameterPrimary 228.5 (9.0)
Secondary 203 (8.0)
Recommended brake fluid DOT 3 or DOT 4
Brake pedal height (From dash lower panel top surface)LHD modelA/T 164.1-174.1 (6.46-6.85)
M/T 171.2-181.2 (6.74-7.13)
RHD modelA/T 174.7-184.7 (6.88-7.27)
M/T 182.1-192.1 (7.17-7.56)
Brake pedal depressed height [Under a force of 490 N (50 kg, 110 lb)
with the engine running]LHD model 120 (4.72) or more
RHD model 110 (4.33) or more
Clearance between bracket and the threaded end of the stop lamp switch 0.74 - 1.96 (0.0291 - 0.0772)
Pedal play3-11(0.12-0.43)
Input rod installation standard dimension 145 - 152 (5.71 - 5.98)
Vacuum leakage
[at vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg)]within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Brake modelCLZ33VB
Brake padStandard thickness 11.0 (0.43)
Repair limit thickness 2.0 (0.08)
Disc rotorStandard thickness 28.0 (1.102)
Repair limit 26.0 (1.024)
Thickness variation (measured at 8 positions) 0.005 (0.0002)
Runout limit (with it attached to the vehicle) 0.05 (0.002)

CL-10
CLUTCH MASTER CYLINDER
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer toCL-6, "
On-Vehicle Inspection and Adjustment"andCL-8, "Air Bleeding Proce-
dure".
Disassembly and AssemblyECS00ICL
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove dust cover from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly
popping out.
6. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
lDamaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
lDamaged or deformed nipple or reservoir tank
lSettling of return spring
lCracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup. Insert return spring and piston assembly to cylinder body.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install dust cover to cylinder body.
4. Install seal and nipple to cylinder body.
5. Install spring pin using a pin punch.
6. Install clevis to push rod.
7. Check and adjust the positions of clevis and push rod. After
adjusting “L”, tighten lock nut to the specified torque. Refer to
CL-9, "
Components".
PCIB0274E
Length “L”
RHD models : 111.0 mm (4.37 in)
LHD models : 120.5 mm (4.74 in)
SCIA5158E

CL-18
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
lMeasure the depth to clutch disc facing rivet heads using a cali-
pers. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
lCheck clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
lWorn thrust ring will generate a beating noise when tapped at
therivetwithahammer.
lBroken thrust ring will make a clinking sound when cover is shaken up and down.
lIf a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Measure the runout at the flywheel clutch contact surface using a
dial indicator. If runout is outside the specification, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1. Apply recommended grease to clutch disc and main drive gear splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness
: 0.7 mm (0.028 in) or less
Tool number : ST20050240
PCIB0276E
Allowable flywheel runout
:RefertoEM-134, "
FLYWHEEL DEFLECTION".
PBIC2646E

CL-20
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Clutch Control SystemECS00ICS
Clutch Master CylinderECS00ICT
Clutch Operating CylinderECS00ICU
Clutch DiscECS00ICV
Clutch CoverECS00ICW
Clutch PedalECS00ICX
Type of clutch controlHydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Facing size (outer dia. x inner dia. x thickness) 240 mm´160 mm´3.15 mm (9.45 in´6.30 in´0.1240 in)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 230 mm (9.06 in) dia.
Maximum spline backlash (at outer edge of disc) 1.0 mm (0.039 in)
Set-load9,810 N (1,000 kg, 2,205 lb)
Diaphragm spring lever height 39.0 - 41.0 mm (1.535 - 1.614 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
Clearance²C²between pedal stopper rubber and clutch interlock
switch threaded while clutch pedal is fully depressed0.1 - 1.0 mm (0.004 - 0.039 in)

RADIATOR (ALUMINUM TYPE)
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2. Install sealing rubber while pushing it with fingers.
CAUTION:
Be careful not to twist sealing rubber.
3. Caulk tank in numerical order as shown in the figure with radia-
tor plate pliers A [SST].
lUse pliers in the locations where radiator plate pliers A cannot
be used.
4. Make sure that the rim is completely crimped down.
SLC917A
SLC904
PBIC2076E
SLC897
Standard height “H”: 8.0 - 8.4 mm (0.315 - 0.331 in)
SLC554A

GLOW CONTROL SYSTEM
EC-301
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EC
15.CHECK INTERMITTENT INCIDENT
Refer toEC-70, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT".
>>INSPECTION END
Component InspectionEBS01KLP
GLOW RELAY
Check continuity between glow relay terminals (3) and (5) under the
following conditions.
Operation takes less than 1 second.
GLOW PLUG
1. Remove glow plug connecting plate.
2. Check glow plug resistance.
NOTE:
lDo not bump glow plug heating element. If it is bumped,
replace glow plug with a new one.
lIf glow plug is dropped from a height of 10 cm (3.94 in) or
higher, replace with a new one.
lIf glow plug installation hole is contaminated with car-
bon, remove it with a reamer or suitable tool.
lHand-tighten glow plug by turning it two or three times,
then tighten using a tool to specified torque.
Removal and InstallationEBS01KLQ
GLOW PLUG
Refer toEM-41, "GLOW PLUG".
Conditions Continuity
12V direct current supply between ter-
minals (1) and (2)Ye s
No current supply No
PBIB0428E
Resistance: Approximately 0.8W[at 25°C(77°F)]
: 20.1 N-m (2.1 kg-m, 15 ft-lb)
MBIB1130E

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

GLOW PLUG
EM-41
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GLOW PLUGPFP:22401
ComponentsEBS01EJL
Removal and InstallationEBS01E60
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect glow harness from glow plate.
2. Remove glow nut to remove glow plate.
3. Remove glow plug.
CAUTION:
lWhen removing or installing, do not use such tools as an air impact wrench.
lHandle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install remaining parts in the reverse order of removal.
1. Glow plate 2. Glow harness 3. Glow nut
4. Cap 5. Glow plug
PBIC2436E

CAMSHAFT
EM-61
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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-94
CYLINDER HEAD
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E6B
REMOVAL
1. Drain engine coolant. Refer toCO-7, "Changing Engine Coolant".
2. Remove the following:
lRocker cover (Refer toEM-56, "ROCKER COVER".)
lSpill tube and fuel injector (Refer toEM-44, "INJECTION TUBE AND FUEL INJECTOR".)
lIntake manifold (Refer toEM-20, "INTAKE MANIFOLD".)
lTurbocharger (Refer toEM-28, "TURBO CHARGER".)
lExhaust manifold (Refer toEM-34, "EXHAUST MANIFOLD".)
lSecondary timing chain (Refer toEM-73, "SECONDARY TIMING CHAIN".)
lCamshaft (Refer toEM-59, "CAMSHAFT".)
3. Remove cylinder head assembly.
lRemove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser-
vice tool).
lLift up cylinder head assembly to avoid interference with
dowel pins located between the cylinder block and cylinder
head, and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder
head, or, place wood blocks beneath both ends of cylin-
der head to keep the cylinder bottom from any contact.
lFor glow plug removal, the following shall be noted.
CAUTION:
lTo avoid breakage, do not remove glow plug unless necessary.
lPerform continuity test with glow plug installed.
lKeep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
lDo not use air impact wrench.
INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation
lUsing micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.
lIf the necking point can be identified, set it as measuring point
d1.
lCalculate the difference between d1 and d2.
lIf it exceeds the limit, replace cylinder head bolt.
Cylinder Head Distortion
1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
1. Cylinder head bolt 2. Cylinder head assembly 3. Gasket
4. Dowel pin 5. Cylinder block
A. Refer toEM-96
.
JEM149G
Limit : 0.15 mm (0.0059 in)
JEM171G