lock NISSAN NAVARA 2005 Repair Workshop Manual

CYLINDER BLOCK
EM-121
C
D
E
F
G
H
I
J
K
L
MA
EM
How to Select Piston and BearingEBS01E6F
DESCRIPTION
lThe identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
lFor reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
lFor details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.
lThe part No. of piston is specified together with piston pin as
an assembly.
When Re-using an Old Cylinder Block
1. Measure cylinder bore inner diameter. Refer toEM-129, "Cylinder Bore Inner Diameter".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
3. Select piston of the same grade.
Piston Selection Table
Unit: mm (in) Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
JEM208G
MBIA0025E
Grade (punched) 1 2 3

EM-122
CYLINDER BLOCK
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
When Using New Crankshaft and Connecting Rod
1. Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
When Re-using the Removed Crankshaft and Connecting Rod
1. Measure the inner diameter of the big end of connecting rod and make sure it is within the specified
range. Refer toEM-127, "
CONNECTING ROD BIG END INNER DIAMETER".
2. Measure the outer diameter of the crankshaft pin. Refer toEM-130, "
CRANKSHAFT PIN JOURNAL
DIAMETER".
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
Selection Table of connecting Rod Bearing
Unit: mm (in)
Unit: mm (in)
Under Size Bearing Usage
lIf bearing clearance is out of the specifications for connecting rod bearings in standard size, use under
size bearings.
lWhen using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Connecting Rod Bearing Under Size List
Unit: mm (in) Cylinder bore
inner diameter89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston outer
diameter88.928 - 88.942 (3.5011 - 3.5016) 88.938 - 88.952 (3.5015 - 3.5020) 88.948 - 88.962 (3.5019 - 3.5024)
JEM215G
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin outer diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.492 - 1.496 (0.0587 - 0.0589) STD 0 Black
51.961 - 51.968 (2.0457 - 2.0460) 1 1.496 - 1.500 (0.0589 - 0.0591) STD 1 Brown
51.954 - 51.961 (2.0454 - 2.0457) 2 1.500 - 1.504 (0.0591 - 0.0592) STD 2 Green
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)

CYLINDER BLOCK
EM-123
C
D
E
F
G
H
I
J
K
L
MA
EM
CAUTION:
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
HOW TO SELECT MAIN BEARING
When Using New Cylinder Block and Crankshaft
1. Identify the crank journal grade (No. 0, 1, or 2) on LH surface at
the rear of the cylinder block, and locate the applicable grade on
the “Grade” row in the “Main Bearing Grade Table”.
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of
crankshaft, and locate the applicable grade under the “Grade”
column in the “Main Bearing Grade Table”.
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer toEM-128, "MAIN BEARING
HOUSING INNER DIAMETER".
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer toEM-130, "
CRANKSHAFT MAIN JOURNAL
DIAMETER".
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Main Bearing Grade Table
Unit: mm (in)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
JEM208G
JEM215G
Inner diameter of Cylinder block main bearing housing66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft journal
outer diameterGrade
(punched)012

EM-124
CYLINDER BLOCK
Under Size Bearing Usage
lIf bearing clearance is out of the specifications for main bearings in standard size, use under size bear-
ings.
lWhen using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to the specification.
Main Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)
Inspection After DisassemblyEBS01E6G
CRANKSHAFT END PLAY
lUsing dial gauge, measure crankshaft travel amount by moving
the crankshaft forward or backward.
lIf the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
62.967 - 62.975
(2.4790 - 2.4793)0
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
62.959 - 62.967
(2.4787 - 2.6790)1
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
62.951 - 62.959
(2.4784 - 2.4787)2
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
Size Thickness
US 0.25(0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
JEM202G

CYLINDER BLOCK
EM-125
C
D
E
F
G
H
I
J
K
L
MA
EM
CONNECTING ROD SIDE CLEARANCE
lUsing feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.
lIf measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.
Piston Pin Outer Diameter
Using micrometer, measure piston pin outer diameter.
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter)-(Piston pin outer diameter)
lIf out of the standard, replace piston/piston pin assembly.
NOTE:
Piston is available together with piston pin as assembly.Standard : 0.20 - 0.35 (0.0079 - 0.0138 in)
Limit : 0.40 mm (0.0157 in)
JEM203G
Standard : 28.003 - 28.009 mm (1.1025 - 1.1027 in)
PBIC0116E
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)

EM-126
CYLINDER BLOCK
PISTON RING SIDE CLEARANCE
lUsing feeler gauge, measure the side clearance between piston
ringandpistonringgroove.
Unit: mm (in)
lAlign top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.
lIf side clearance exceeds the limit, replace piston ring.
lCheck clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP
lMake sure that cylinder bore diameter is within the specifica-
tions. Refer toEM-129, "
PISTON TO CYLINDER BORE
CLEARANCE".
lLubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure piston ring end gap with feeler gauge.
Unit: mm (in)
lIf out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder
and use oversized piston and piston ring. Refer toEM-129, "
PISTON TO CYLINDER BORE CLEAR-
ANCE".
Item Standard Limit
Top ring 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
FEM100
Item Standard Limit
Top ring 0.21 - 0.28 (0.0083 - 0.0110)
1.0 (0.039) 2nd ring 0.32 - 0.47 (0.0126 - 0.0185)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)
FEM101

CYLINDER BLOCK
EM-127
C
D
E
F
G
H
I
J
K
L
MA
EM
CONNECTING ROD BEND AND TORSION
lUse connecting rod aligner to check bend and torsion.
lIf it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END INNER DIAMETER
lInstall connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Refer toEM-
11 4 , "ASSEMBLY".
lUsing inside micrometer, measure connecting rod big end inner
diameter.
lIf out of the standard, replace connecting rod.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Use inside micrometer to measure bushing inner diameter.Bend limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
Torsion limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
PBIC2077E
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
PBIC1641E
Standard : 28.026 - 28.038 mm (1.1034 - 1.1039 in)
PBIC0120E

EM-128
CYLINDER BLOCK
Piston Pin Outer Diameter
Use micrometer to measure piston pin outer diameter.
Calculation of Connecting Rod Bushing Clearance
(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter)-(Piston pin outer diameter)
lIf it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer toEM-122,
"HOW TO SELECT CONNECTING ROD BEARING"and/orEM-121, "HOW TO SELECT PISTON".
CYLINDER BLOCK TOP SURFACE DISTORTION
lUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as engine oil, scale, and car-
bon.
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.
lUse straightedge and feeler gauge to check block upper surface
for six distortion.
lIf it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
lWithout installing main bearings, install main bearing caps, and
tighten bolts to the specified torque. Refer toEM-114, "
ASSEM-
BLY"EM-114, "ASSEMBLY".
lMeasure the inner diameter of main bearing housing with a bore
gauge.
lIf the measurement is out of the standard, replace cylinder block
andmainbearingcaps.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.026 - 0.043 mm (0.0010 - 0.0017 in)
Limit : 0.057 mm (0.0022 in)
Limit : 0.1 mm (0.004 in)
SEM501G
Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in)
PBIC1643E

CYLINDER BLOCK
EM-129
C
D
E
F
G
H
I
J
K
L
MA
EM
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
lUsing bore gauge, measure cylinder inner diameters at six posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
lIf the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or bore the inner
wall.
lOversize piston is provided. When using oversize piston, hone
the cylinder so that the clearance between piston and cylinder
satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with over-
size piston rings.
Piston Outer Diameter
Use micrometer to measure piston outer diameter.
Calculation of Piston to Cylinder Bore Clearance
lCalculate using piston outer diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter)-(Piston outer diameter)
lIf it exceeds the limit, replace piston and piston pin assembly. Refer toEM-121, "HOW TO SELECT PIS-
TON".
Reboring Cylinder Bore
1. Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.Cylinder bore inner diameter
: 89.000 – 89.030 mm (3.5039 – 3.5051 in)
Wear limit
:0.07mm(0.028in)
Out-of-round limit (Difference between X and Y)
: 0.015 mm (0.0006 in)
Taper limit (Difference between A and C)
: 0.010 mm (0.0004 in)
SEM899G
Oversize (OS) : 0.25 mm (0.0098 in)
: 0.50 mm (0.0197 in)FEM110
Piston outer diameter
Measurement position : 11.0 mm (0.43 in)
Distance from the bottom
Standard : 88.928 – 88.962 mm
(3.5011 – 3.5024 in)
0.25 (0.0098) O/S : 89.188 – 89.202
(3.5113 – 3.5119 in)
0.50 (0.0197) O/S : 89.438 – 89.452
(3.5212 – 3.5217 in)
PBIC0125E
Specifications at room temperature [20°C(68°F)]:
Standard : 0.058 - 0.082 mm (0.0023 - 0.0032 in)
Rebore size calculation:
D=A+B–C
Where,
D: Bored diameter

EM-130
CYLINDER BLOCK
2. Install main bearing caps and tighten bolts to the specified torque. Refer toEM-114, "ASSEMBLY".This
will prevent distortion of cylinder bores.
3. Cut cylinder bore.
NOTE:
lWhen any cylinder needs boring, all other cylinders must also be bored.
lDo not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
lMeasurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
lUse micrometer to measure crankshaft main journal diameter.
lIf out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer toEM-132, "
MAIN BEAR-
ING OIL CLEARANCE".
CRANKSHAFT PIN JOURNAL DIAMETER
lUse micrometer to measure crankshaft pin journal diameter.
lIf out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer toEM-131,
"CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT OUT-OF-ROUND AND TAPER
lUsing micrometer, measure each journal and pin at four points
showninthefigure.
lOut-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
lTaper value is indicated by difference in dimensions between
points A and B in directions X and Y.
lIf the measured value exceeds the limit, correct or replace crankshaft.A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
FEM114
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
PBIC0127E
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E