lock NISSAN NAVARA 2005 Repair Workshop Manual

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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Use the Chart Below to Help You Find the Cause of the Symptom.EBS01E5R
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-66
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-61EM-61
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearanceEM-125
EM-127
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-129EM-126
EM-126
EM-127
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance (Big
end)EM-127EM-131
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-132EM-131
Front of
engine
Timing
chain
caseTapping or
tickingA A —BBBTiming
chain and
chain
tensioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-75
EM-84
EM-79
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-12
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-21,
"WATER
PUMP"

EM-12
DRIVE BELTS
DRIVE BELTS
PFP:02117
Checking Drive BeltsEBS01EJ4
lBefore inspecting engine, make sure engine has cooled down; wait approximately 30 minutes after engine
has been stopped.
lVisually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
lMeasure deflection at the marked point ( ).
CAUTION:
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid varia-
tion in deflection between pulleys.
lTighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
4. Crankshaft pulley 5.A/C compressor (Models with A/C)
Dummypulley(ModelswithoutA/C)6. Alternator
7. Idler pulley 8. Water pump pulley 9.A/C compressor, alternator and
water pump belt
PBIC4038E
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
pump belt2.9 - 3.4
(0.114 - 0.134)3.9 - 4.4
(0.154 - 0.173)8.5 (0.335)
Power steering oil pump belt4.6 - 5.4
(0.181 - 0.213)7.1 - 7.7
(0.280 - 0.303)11.3 (0.445)

DRIVE BELTS
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Deflection AdjustmentEBS01EJ5
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with engine oil or engine coolant.
lDo not twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front. Refer toEI-15, "FRONT BUMPER".
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust. Refer toEM-13, "
Deflection Adjustment".
4. Tighten idler pulley lock nut (B).
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
4. Crankshaft pulley 5.Dummy pulley (Models without A/C)
A/C compressor (Models with A/C)6. Alternator
7. Idler pulley 8. Water pump pulley 9.A/C compressor, alternator and
water pump belt
A. Adjusting bolt B. Idler pulley lock nut C. Adjusting nut
D. Idler pulley lock nut
PBIC4039E
Applied belt Belt adjustment method
Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
water pump beltAdjusting nut on idler pulley (C)
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)

EM-14
DRIVE BELTS
A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT
1. Loosen idler pulley lock nut (D).
2. Turn adjusting nut (C) to adjust. Refer toEM-13, "
Deflection Adjustment".
3. Tighten lock nut (D).
Removal and InstallationEBS01EJ6
REMOVAL
1. Loosen each belt. Refer toEM-13, "Deflection Adjustment".
2. Remove power steering oil pump belt. Refer toEM-13, "
POWER STEERING OIL PUMP BELT".
3. Remove A/C compressor, alternator and water pump belt. Refer toEM-14, "
A/C COMPRESSOR, ALTER-
NATOR AND WATER PUMP BELT".
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer toEM-13, "
Deflection Adjustment".
3. Tighten nuts provided for adjustment to the specified torque.
4. Make sure again that each belt deflection is as specified.Nut D:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)

CATALYST
EM-27
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INSTALLATION
Note the following, and install in the reverse order of removal.
lIf stud bolts of turbocharger were removed, tighten them to the specified torque.
lIf stud bolts of catalyst were removed, tighten them to the specified torque.
lPushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And
then tighten it to the specified torque.: 25.5 N·m (2.6 kg-m, 19 ft-lb)
: 45.0 N·m (4.6 kg-m, 33 ft-lb)

TURBO CHARGER
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lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E5X
REMOVAL
lAfter applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
1. Drain engine coolant (4WD models). Refer toCO-7, "
Changing Engine Coolant".
2. Remove air inlet hose and air inlet pipe. Refer toEM-18, "
CHARGE AIR COOLER".
3. Remove air duct and air inlet pipes. Refer toEM-15, "
AIR CLEANER AND AIR DUCT".
4. Remove exhaust manifold cover. Refer toEM-34, "
EXHAUST MANIFOLD".
5. Remove exhaust outlet and catalyst. Refer toEM-26, "
CATALYST".
6. Remove eye bolt and water hose from water tube (4WD models).
7. Loosen and remove eye-bolts from oil feed tube.
8. Disconnect oil return hose from oil return tube.
9. Remove turbocharger with water tube (4WD models) and oil feed tube and oil return tube.
CAUTION:
Be careful not to deform water tube and oil feed tube and oil return tube.
10. Remove water tube (4WD models) and oil feed tube and oil return tube from turbocharger.
CAUTION:
lDo not disassemble or adjust the turbocharger.
lBe careful not to contact with the vehicle.
lDo not hold turbocharger boost control actuator and actuator rod.
Water Tube and Oil Tube
lClean inside of water tube (4WD models), oil feed tube and oil return tube, and check tubes for clogging.
lReplace water tube (4WD models), oil feed tube and/or oil return tube if clogging still exists after cleaning.
28. Oil return tube (2WD models)
A. To heater return pipe B. To cylinder block

EM-38
OIL PAN AND OIL STRAINER
15. Loosen bolts in the reverse order of illustration to remove oil pan
upper.
16. Remove oil pan upper.
lInsert the seal cutter [SST] between oil pan upper and cylin-
der block. Slide the seal cutter by tapping on the side of the
seal cutter with a hammer. Remove oil pan upper.
lBe careful not to damage aluminum mating surface.
lDo not insert screwdriver, or oil pan flange will be
deformed.
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall oil pan upper with the following procedure.
–Use the scraper (A) to remove old liquid gasket from mating sur-
face of oil pan upper (1).
•Also remove old liquid gasket from mating surface of cylin-
der block and rear chain case.
•Remove old liquid gasket from the bolt hole and thread.
–Apply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] to areas shown in the figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
lAt the 2 bolt holes marked , liquid gasket should be
applied outside holes.
lBe sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the liquid gasket bead is different around
the front.)
lAttaching should be done within 5 minutes after coating.
–Install oil pan upper.
: Vehicle front
PBIC3431E
SEM365EA
PBIC3432E
: Vehicle front
PBIC3433E

CAMSHAFT
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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-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
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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