check engine NISSAN NAVARA 2005 Repair Workshop Manual

SECONDARY TIMING CHAIN
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a. Install tension guide on the back surface of front chain case.
lHold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
b. Apply a continuous bead of liquid gasket on both ends of arched
area (locations where rear chain case is adjoined) as shown in
the figure.
lUse Genuine Liquid Gasket or equivalent.
c. Install front chain case.
lWhen installing, align dowel pin on oil pump housing with the pin hole.
lInstall No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
6. 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.
SBIA0189E
JEF370Y
JEM121G

EM-78
SECONDARY TIMING CHAIN
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.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-84
PRIMARY TIMING CHAIN
20. Remove rear chain case.
lLoosen fixing bolts in the reverse order of that shown in the
figure and remove them.
lU s e t h e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ] f o r r e m o v a l .
21. Remove balancer unit (4WD models).
lLoosen mounting bolts in the reverse order as shown in the
figure.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
SBIA0211E
: Engine front
PBIC4049E
SEM984C

PRIMARY TIMING CHAIN
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Balancer Unit Mounting Bolt Outer Diameter (4WD Models)
lMeasure the outer diameters (“d1”,“d2”)attwopositionsas
showninthefigure.
lIf reduction appears in “A” range, regard it as “d2”.
lIf it exceeds the limit (large difference in dimensions), replace it
with a new one.
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
CAUTION:
Before starting work, make sure that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure (4WD models).
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer toEM-85, "
Balancer Unit Mounting
Bolt Outer Diameter (4WD Models)".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten all bolts.Limit (“d
1”-“d2
”): 0.15 mm (0.0059 in)
PBIC1137E
1. Chain tensioner 2. Slack guide 3. Fuel pump sprocket
4. Chain guide 5. Primary timing chain 6. Vacuum pump sprocket
7. Slack guide 8. Chain tensioner 9. Crankshaft sprocket
10. Key 11. Tension guide 12. Tension guide
13. Tension guide 14. Camshaft sprocket 15. Secondary timing chain
A. Alignment mark (silver link) B. Alignment mark (punched mark) C. Alignment mark (cut-out area)
D. Alignment mark (yellow link)
: Engine front
PBIC3473E
PBIC4049E

EM-86
PRIMARY TIMING CHAIN
c. Turn all bolts 65 degrees clockwise (angle tightening).
d. Completely loosen.
CAUTION:
In this step, loosen bolts in the reverse order as shown in
the figure.
e. Tighten all bolts.
f. Turn them another 65 degrees clockwise (angle tightening).
CAUTION:
Check tightening angle with an angle wrench [SST] (A) or a protractor. Do not make judgment by
visual check alone.
2. Install rear chain case.
a. Apply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] on locations shown in the figure.
Use Genuine Liquid Gasket or equivalent.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
c. Install rear chain case.
lWhen installing, align the dowel pin with the pin hole.: 29.4 N·m (3.0 kg-m, 22 ft-lb)
1 : Balancer unit
A : KV10112100
: 0 N·m (0 kg-m, 0 ft-lb)
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC3474E
PBIC1255E
JEM141G

EM-90
PRIMARY TIMING CHAIN
b. Install O-ring into the groove of rear chain case.
c. Install oil pump housing.
lWhen installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
lWhen installing, align the dowel pin with the pin hole.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
16. Check gaps on upper oil pan mounting surface.
lUsing straightedge and feeler gauge, measure gaps between
the locations of the following parts:
lIf the measured value is out of the standard, install again.
17. Install crankshaft pulley.
CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Hold crankshaft pulley with the pulley holder [SST].
d. Tighten crankshaft pulley fixing bolt.
e. Completely loosen.
f. Tighten crankshaft pulley bolt.
g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.
PBIC3470E
Oil pump housing and rear chain case:
Standard : – 0.09 to 0.09 mm (– 0.0035 to 0.0035 in)
Rear chain case and cylinder block:
Standard : – 0.19 to 0.07 mm (– 0.0075 to 0.0028 in)
JEM146G
: 75.0 N·m (7.7 kg-m, 55 ft-lb)
:0N·m(0kg-m,0ft-lb)
: 75.0 N·m (7.7 kg-m, 55 ft-lb)
PBIC3469E

PRIMARY TIMING CHAIN
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h. Tighten fixing bolt another 120 degrees (angle tightening) (turn
by 2 notch).
18. Install secondary timing chain and the associated parts.
Refer toEM-75, "
INSTALLATION".
19. 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.
A : Indicate embossments
B : Alignment mark
PBIC3476E
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-92
CYLINDER HEAD
CYLINDER HEAD
PFP:11041
On-Vehicle ServiceEBS01E6A
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer toEC-38,
"Basic Inspection".
lDo not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. To prevent fuel from being injected during inspection, remove fuse [EGI (20A)] (1) from fuse box.
5. Remove glow plugs from all the cylinders. Refer toEM-41, "
GLOW PLUG".
CAUTION:
lBefore removal, clean the surrounding area to prevent entry of any foreign materials into
engine.
lCarefully remove glow plugs to prevent any damage or breakage.
lHandle with care to avoid applying any shock to glow plugs.
6. Install compression gauge adapter [SST] to installation holes of
glow plugs and connect compression gauge for diesel engine.
7. Connect the battery cable to the negative terminal.
8. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.
lAlways use a fully-charged battery to obtain specified engine
speed.
A : LHD models
: Vehicle front
PBIC3623E
A : RHD models
2 : Water hose (to reservoir tank)
3:Airreliefplug
PBIC3624E
: 20.0 N·m (2.0 kg-m, 15 ft-lb)
SEM112G

CYLINDER HEAD
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Compression pressure
Unit: kPa (bar, kg/cm2, psi)/rpm
lWhen engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
lIf engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
lIf compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
lIf compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
9. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuse [EGI (20A)].
e. Connect the battery cable to the negative terminal.
f. Using CONSULT-II make sure no DTC is indicated for items of self-diagnosis.
ComponentsEBS01EKC
Standard Minimum Difference limit between cylinders
3,100 (31, 31.6, 450)/200 2,500 (25, 25.5, 363)/200 490 (4.9, 5.0, 71)/200
PBIC3477E

CYLINDER HEAD
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*: Measured with head bolts tightened
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] as shown in the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
3. Install cylinder head assembly.
lTighten bolts in numerical order as shown in the figure
according to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten all bolts.
c. Tighten 180 degrees (angle tightening).
d. Loosen completely in the reverse order of that shown in the fig-
ure.
e. Tighten all bolts.
f. Tighten 90 degrees (angle tightening).
g. Tighten another 90 degrees (angular tightening).
CAUTION:
lWhen the angle wrench [SST] is not used, paint an alignment mark on the head of cylinder head
bolt and cylinder head surface before tightening. Check the angle with a protractor.
4. After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head.
lIf out of the standard, check fitting of dowel pins and cylinder
head.
5. Install glow plug.
CAUTION:
lTo avoid damage, glow plugs should be removed only when required.
lHandle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
PBIC1256E
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM149G
:0N·m(0kg-m,0ft-lb)
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)
JEM166G
JEM172G