engine NISSAN NAVARA 2005 Repair Workshop Manual

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

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

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

EM-98
CYLINDER HEAD
lBefore installing, remove carbon depositing on mounting hole of glow plug with a reamer.
6. Install engine coolant temperature sensor.
7. 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.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-100
CYLINDER HEAD
NOTE:
Refer to the figure for intake and exhaust valve positions.
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.
5. Remove valve oil seals using the valve oil seal puller [SST].
6. Remove valve spring seats.
7. Before removing valve seats, perform valve seat contact check.
Refer toEM-103, "
Va l v e S e a t C o n t a c t".
8. Before removing valve guides, perform valve guide clearance
check. Refer toEM-101, "
Valve Guide Clearance".
ASSEMBLY
1. Install valve guides. Refer toEM-102, "Valve Guide Replacement".
2. Install valve seats. Refer toEM-103, "
Valve Seat Replacement".
3. Using the valve oil seal drift [SST], install valve oil seals referring
to the dimension shown in the figure.
4. Install valve spring seats.
5. Install valves.
lInstall the valves with bigger outer diameter to intake valve
side.
lNote that valve layout here is different from that of conven-
tional engine.
6. Install valve spring.
7. Install valve spring retainers.
SBIA0196E
JEM153G
JEM165G
SBIA0196E

EM-106
ENGINE ASSEMBLY
ENGINE ASSEMBLY
PFP:10001
ComponentsEBS01EV6
Removal and InstallationEBS01E6D
WARNING:
lSituate vehicle on a flat and solid surface.
lPlace chocks at front and back of rear wheels.
lFor engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
lAlways be careful to work safely, avoid forceful or uninstructed operations.
lDo not start working until exhaust system and engine coolant are cool enough.
lIf items or work required are not covered by the engine main body section, refer to the applicable
sections.
lAlways use the support point specified for lifting.
lUse either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
1. RH engine mounting insulator 2. RH engine mounting bracket 3. LH engine mounting bracket
4. Heat insulator 5. LH engine mounting insulator 6. Transmission cross member
7.Engine mounting insulator (rear)
(4WD models)8.Engine mounting insulator (rear)
(2WD M/T models)9.Dynamic damper (2WD M/T mod-
els)
10.Engine mounting insulator (rear)
(2WD A/T models)11. Dynamic damper (2WD A/T models)
PBIC4096E

ENGINE ASSEMBLY
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lFor supporting points for lifting and jacking point at rear axle, refer toGI-52, "Pantograph Jack,
Garage Jack and Safety Stand".
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer toSC-5, "BATTERY".
2. Drain engine coolant from radiator drain plug. Refer toCO-7, "
Changing Engine Coolant".
3. Remove the following parts.
lEngine undercover front, engine undercover middle, engine undercover rear; Refer toEI-15, "FRONT
BUMPER".
lHood assembly; Refer toBL-12, "HOOD".
lEngine cover; Refer toEM-20, "INTAKE MANIFOLD".
lDrive belts; Refer toEM-12, "DRIVE BELTS".
lCooling fan, fan coupling and water pump pulley; Refer toCO-19, "COOLING FAN".
lAir duct and air cleaner case; Refer toEM-15, "AIR CLEANER AND AIR DUCT".
lAir inlet tube and air inlet hose; Refer toEM-18, "CHARGE AIR COOLER".
lAlternator; Refer toSC-23, "Removal and Installation".
lRadiator, radiator shroud (upper and lower) and cooling fan assembly; Refer toCO-11, "RADIATOR"
andCO-19, "COOLING FAN".
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room RH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer toEM-44,
"INJECTION TUBE AND FUEL INJECTOR".
2. Remove fuel filter. Refer toFL-4, "
FUEL FILTER".
3. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer toCO-23,
"THERMOSTAT AND WATER PIPING".
Engine room LH
1. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer toATC-142, "
Removal and Installation for Compressor"(automatic A/C
models) orMTC-122, "
Removal and Installation for Compressor"(manual A/C models).
Vehicle underbody
1. Remove exhaust front tube. Refer toEX-3, "Removal and Installation".
2. Remove front propeller shaft (4WD models) and rear propeller shaft. Refer toPR-3, "
FRONT PROPEL-
LER SHAFT"(4WD models) andPR-7, "REAR PROPELLER SHAFT".
3. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer toMT-16,
"TRANSMISSION ASSEMBLY"andCL-11, "OPERATING CYLINDER".
4. Disconnect power steering fluid piping at a point between body and engine. Refer toPS-30, "
HYDRAULIC
LINE".
5. Remove starter motor. Refer toSC-31, "
Removal and Installation".
6. Remove transmission assembly. Refer toMT-16, "
TRANSMISSION ASSEMBLY"(M/T models) orAT-
247, "TRANSMISSION ASSEMBLY"(A/T models).

EM-108
ENGINE ASSEMBLY
Removal
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).
2. Lift with hoist and secure engine in position.
3. Loosen LH and RH engine mounting insulator mounting nuts.
4. Remove engine.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
INSTALLATION
Install in the reverse order of removal.
lDo not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer toEM-106, "
ENGINE ASSEMBLY".
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
lInsert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stop-
per is provided at vacuum gallery.
lInsert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
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.
–Before starting engine, 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.
1 : Engine slinger (front)
2 : Engine slinger (rear)
: Engine front
Engine slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
PBIC3480E
SEM896G