belt NISSAN NAVARA 2005 Repair Repair Manual

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTIONEM
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ENGINE MECHANICAL
PRECAUTIONS .......................................................... 4
Precautions for Draining Engine Coolant ................. 4
Precautions for Disconnecting Fuel Piping .............. 4
Precautions for Removal and Disassembly ............. 4
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 4
Precautions for Assembly and Installation ............... 4
Parts Requiring Angle Tightening ............................. 4
Precautions For Liquid Gasket ................................. 5
REMOVAL OF LIQUID GASKET .......................... 5
LIQUID GASKET APPLICATION PROCEDURE..... 5
PREPARATION ........................................................... 6
Special Service Tools ............................................... 6
Commercial Service Tools ........................................ 8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 10
NVH Troubleshooting — Engine Noise .................. 10
Use the Chart Below to Help You Find the Cause
of the Symptom. ...................................................... 11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Deflection Adjustment ............................................ 13
POWER STEERING OIL PUMP BELT ............... 13
A/C COMPRESSOR, ALTERNATOR AND
WATER PUMP BELT .......................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Components ........................................................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
CHANGING AIR CLEANER FILTER ................... 17
CHARGE AIR COOLER ........................................... 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19INTAKE MANIFOLD ................................................. 20
Components ........................................................... 20
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 25
CATALYST ................................................................ 26
Components ........................................................... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 27
TURBO CHARGER ................................................... 28
Components ........................................................... 28
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSPECTION AFTER REMOVAL ....................... 30
TROUBLE DIAGNOSIS OF TURBOCHARGER... 32
INSTALLATION ................................................... 33
EXHAUST MANIFOLD ............................................. 34
Components ........................................................... 34
Removal and Installation ........................................ 34
REMOVAL ........................................................... 34
INSPECTION AFTER REMOVAL ....................... 35
INSTALLATION ................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
OIL PAN AND OIL STRAINER ................................. 36
Components ........................................................... 36
Removal and Installation ........................................ 36
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ....................... 38
INSTALLATION ................................................... 38
INSPECTION AFTER INSTALLATION ................ 40
GLOW PLUG ............................................................ 41
Components ........................................................... 41
Removal and Installation ........................................ 41
REMOVAL ........................................................... 41
INSTALLATION ................................................... 41
VACUUM PUMP ........................................................ 42

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EMA BEARING .......................................................... 132
MAIN BEARING CAP BOLT DEFORMATION .. 133
CONNECTING ROD BOLT DEFORMATION .... 133
OIL JET ............................................................. 133
OIL JET RELIEF VALVE ................................... 133
FLYWHEEL DEFLECTION ............................... 134
MOVEMENT AMOUNT OF FLYWHEEL ........... 134
DRIVE PLATE ................................................... 134
SERVICE DATA AND SPECIFICATIONS (SDS) .... 135
Standard and Limit ............................................... 135
GENERAL SPECIFICATIONS .......................... 135
INTAKE MANIFOLD AND EXHAUST MANI-FOLD .................................................................135
DRIVE BELTS ...................................................135
CYLINDER HEAD .............................................136
VALVE ...............................................................136
CAMSHAFT .......................................................140
CYLINDER BLOCK ...........................................141
PISTON, PISTON RING AND PISTON PIN ......141
CONNECTING ROD .........................................144
CRANKSHAFT ..................................................144
AVAILABLE MAIN BEARING ............................145
AVAILABLE CONNECTING ROD BEARING ....145
MISCELLANEOUS COMPONENTS .................145

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)

OIL PAN AND OIL STRAINER
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3. Remove oil pan lower bolts, loosen bolts in the reverse order of
that shown in the figure.
4. Remove oil pan lower.
a. Insert the seal cutter [SST] between oil pan upper and oil pan
lower.
CAUTION:
lBe careful not to damage aluminum mating surface.
lDo not insert screwdriver, or oil pan flange will be
deformed.
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
c. Remove oil pan lower.
5. Remove oil strainer.
6. Remove power steering oil pump belt. Refer toEM-12, "
DRIVE BELTS".
7. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con-
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer toPS-25,
"POWER STEERING OIL PUMP".
8. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer toEM-42, "
VACUUM PUMP".
9. Remove A/C compressor bracket mounting bolts (A).
10. Remove crankshaft position sensor and oil level sensor.
CAUTION:
lAvoid impacts such as a dropping.
lDo not disassemble.
lKeep it away from metal particles.
lDo not place sensor close to magnetic materials.
11. Remove front propeller shaft (4WD models). Refer toPR-3, "
FRONT PROPELLER SHAFT".
12. Remove RH and LH front drive shaft (4WD models). Refer toFAX-7, "
DRIVE SHAFT".
13. Remove front final drive assembly (4WD models). Refer toFFD-15, "
FRONT FINAL DRIVE ASSEMBLY".
14. Remove rear plate cover and transmission joint bolts.
: Vehicle front
PBIC3425E
SEM365EA
1 : Oil pan upper
2 : A/C compressor bracket
: Vehicle front
PBIC3426E

OIL SEAL
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Removal and Installation of Front Oil SealEBS01EK8
REMOVAL
1. Remove the following parts.
lUndercover
lDrive belt; Refer toEM-12, "DRIVE BELTS".
lCrankshaft pulley; Refer toEM-79, "PRIMARY TIMING CHAIN".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
lUsing the suitable drift [60 mm (2.36 in) dia.] (A), press fit the
oil seal (2) so that the dimension is as specified in the figure.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
3. Install in the reverse order of removal.
PBIC4050E
SEM715A
1 : Oil pump
PBIC4051E

SECONDARY TIMING CHAIN
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SECONDARY TIMING CHAINPFP:13028
ComponentsEBS01EKA
Removal and InstallationEBS01E68
CAUTION:
lAfter removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
lWhen installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
lFor preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to
EM-49, "
FUEL PUMP".
lTo prepare for removing/installing secondary timing chain to remove/install camshaft, refer toEM-59,
"Removal and Installation".
1. Remove radiator shroud (upper and lower) and cooling fan (crankshaft driven type). Refer toCO-11,
"RADIATOR"andCO-19, "COOLING FAN".
2. Remove EGR cooler (A/T models) and related water hoses, or EGR tube (M/T models).
CAUTION:
lPerform this step when engine is cold.
lDo not spill engine coolant on drive belts.
3. Remove front chain case.
1. Chain tensioner 2. Spring 3. Plunger
4. Slack guide 5. Front chain case 6. Rubber washer
7. Tension guide 8. Gasket 9. Secondary timing chain
PBIC2326E

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).