lock NISSAN PATROL 2006 Service Manual

CAUTION:
+When installing sliding parts such as camshaft and oil
seal, be sure to apply new engine oil on their sliding sur-
faces.
+When tightening cylinder head bolts, apply new engine oil
to thread portions and seat surfaces of bolts.
Removal
1. Remove charge air cooler assembly.
2. Set No. 1 cylinder at BDC on its expansion stroke.
3. Drain engine coolant from drain plugs on cylinder block and
radiator.
4. Remove air cleaner and/or air duct.
5. Remove timing belt.
6. Remove rocker cover securing bolts/nuts in numerical order
shown in ®gure.
To install rocker cover, tighten bolts/nuts in reverse order of
removal. Tighten in two or three stages.
7. Remove camshaft sprocket, injection pump drive sprocket and
back cover.
8. Disconnect exhaust manifold from exhaust tube.
9. Remove intake and exhaust manifold.
To install manifolds, tighten bolts/nuts in reverse order of
removal. Tighten in two or three stages.
SEM786F
SEM711B
SEM431C
CYLINDER HEAD
EM-30

Inspection
CYLINDER HEAD DISTORTION
Warpage of surface:
Less than 0.1 mm (0.004 in)
If beyond the speci®ed limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the
cylinder block resurfacing in an engine.
Amount of cylinder head resurfacing is ``A''.
Amount of cylinder block resurfacing is ``B''.
The maximum limit is as follows:
A + B = 0.1 mm (0.004 in)
Nominal cylinder head height:
139.9 - 140.1 mm (5.508 - 5.516 in)
VALVE GUIDE CLEARANCE
1. Insert the valve stem into the valve guide and move it back,
forth and slide it.
If valve stem makes a clatter and moves back and forth exces-
sively out of line, or if it does not slide well, replace valve or
valve guide, or both.
2. Install valve stem into the valve guide.
3. Measure the de¯ection.
Stem to guide de¯ection limit:
0.1 mm (0.004 in)
(Half of dial gauge reading)
4. If it exceeds the limit, check valve to valve guide clearance.
(1) Measure valve stem diameter and guide inner diameter.
(2) Check that clearance is within the speci®cation.
Valve to valve guide clearance limit:
0.1 mm (0.004 in)
(3) If it exceeds the limit, replace valve or valve guide.
VALVE GUIDE REPLACEMENT
1. Heat cylinder head 150 to 160ÉC (302 to 320ÉF) in oil.
2. Remove the guide with suitable tool.
SEM718B
SEM719B
EM030
SEM871
CYLINDER HEAD
EM-32

Assembly
1. Install valve component parts.
Install valve spring with its narrow pitch side toward cylinder
head side.
a. When installing valve, apply engine oil on the valve stem
and lip of valve oil seal.
b. Check whether the valve face is free from foreign matter.
c. Install valve spring retainers on the intake side and valve
rotators on the exhaust side.
d. Valve rotators cannot be disassembled.
2. Set camshaft.
Set camshaft so that dowel pin faces up.
3. Install cam bracket caps so that front mark faces forward.
Cam bracket nut (Tighten in two or three stages):
:21-26Nzm
(2.1 - 2.7 kg-m, 15 - 20 ft-lb)
4. Apply engine oil to new oil seal and install it.
Installation
1. Install cylinder head gasket.
a. When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as
follows:
SEM202
SEM731BB
SEM732B
SEM733B
CYLINDER HEAD
EM-38

Step 1:
Measure piston projection.
1) Set dial gauge on cylinder block surface to zero.
2) Set dial gauge at measuring point of piston, being careful not
to disturb its zero setting.
3) Set each piston at its Top Dead Center. With piston held in that
position, measure its projections at four points, M1, M2, M3 and
M4, and record measured values.
Be sure to measure the projection at four points for every cyl-
inder as shown.
Step 2:
Calculate the average value of measured projections for each cyl-
inder.
Step 3:
Calculate the average value of projections for all pistons.
Step 4:
Round off the average value.
Step 5:
Determine the gasket thickness, referring to chart A.
Relation between piston projection and cylinder head gasket
(Chart A)
Unit: mm (in)
GradeAverage values
piston projectionsGasket thicknessNumber of
identi®cations
ALess than
0.79 (0.0311)1.42 0.05
(0.0559 0.0020)1
B0.79 - 0.875
(0.0311 - 0.0344)1.50 0.05
(0.0591 0.0020)2
CMore than
0.875 (0.0344)1.58 0.05
(0.0622 0.0020)3
Step 6:
Check to see if the average value of each projection in step 2 is
larger than the max. value of the standard projection (of selected
gasket) plus 0.08 mm (0.0031 in).
Step 7:
If it is, use gasket that is 1 grade thicker.
If it is not, use gasket that was selected in step 4.
SEM734B
SEM735B
SEM736B
CYLINDER HEAD
Installation (Cont'd)
EM-39

2. Install cylinder head.
(1) Make sure that No. 1 cylinder is at Bottom Dead Center.
(2) Make sure that No. 1 cam of camshaft is at BDC on its expan-
sion stroke.
(3) Tighten cylinder head bolts to the speci®ed torque in the
sequence as follows:
+Tightening procedure.
M12 bolt
1st Tighten all bolts to 29 Nzm (3.0 kg-m, 22 ft-lb).
2nd Tighten all bolts to 113 Nzm (11.5 kg-m, 83 ft-lb).
3rd Loosen all bolts completely.
4th Tighten all bolts to 29 Nzm (3.0 kg-m, 22 ft-lb).
5th Tighten all bolts to 108 to 118 Nzm (11 to 12 kg-m, 80 to
87 ft-lb) or if you have an angle wrench, turn all bolts 89
to 92 degrees clockwise.
M8 bolt
16-21Nzm (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
3. Install front back cover and camshaft pulley.
Front back cover:
:3-5Nzm
(0.3 - 0.5 kg-m, 26 - 43 in-lb)
Camshaft pulley:
: 123 - 132 Nzm
(12.5 - 13.5 kg-m, 90 - 98 ft-lb)
4. Install timing belt. Refer to ``Replacing Timing Belt'' in section
MA.
5. Install rocker cover. Refer to EM-30.
Apply sealant to rocker cover gasket as shown.
Do not apply too much sealant.
6. Install intake and exhaust manifold. Refer to EM-30.
SEM732B
SEM737BA
SEM711B
SEM738B
CYLINDER HEAD
Installation (Cont'd)
EM-40

SEM788F
CYLINDER BLOCK
EM-46

CAUTION:
+When installing sliding parts such as bearings and
pistons, apply engine oil to the sliding surfaces.
+Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
+When installing connecting rod bolts and main bearing cap
bolts, apply new engine oil to threads and seating surfaces
of nuts.
+Do not allow any magnetic materials to contact the ring
gear teeth of drive plate.
Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Remove timing belt and injection pump.
3. Drain coolant and remove water pump.
4. Remove front cover.
5. Drain oil.
6. Remove oil pan and oil pump.
7. Remove cylinder head.
8. Remove pistons with connecting rod.
+To disassemble piston and connecting rod, remove snap ring
®rst. Then heat piston to 60 to 70ÉC (140 to 158ÉF) and use
piston pin press to remove pin.
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+When replacing piston rings, if there is no punchmark,
install with either side up.
9. Remove bearing cap bolts and main bearing caps in the order
shown, then remove crankshaft.
+Loosen bolts in two or three steps.
Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ``dp''.
Standard diameter ``dp'':
26.995 - 27.005 mm (1.0628 - 1.0632 in)
SEM750B
SEM877B
SEM801F
SEM672E
CYLINDER BLOCK
EM-47

2. Measure outer diameter of piston pin ``Dp''.
Standard diameter ``Dp'':
26.994 - 27.000 mm (1.0628 - 1.0630 in)
3. Calculate piston pin clearance.
dp þ Dp = þ0.004 to 0 mm (þ0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.060 - 0.093 mm (0.0024 - 0.0037 in)
2nd ring
0.040 - 0.073 mm (0.0016 - 0.0029 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of speci®cation, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
PISTON RING END GAP
End gap:
Top ring
0.20 - 0.28 mm (0.0079 - 0.0110 in)
2nd ring
0.20 - 0.46 mm (0.0079 - 0.0181 in)
Oil ring
0.30 - 0.56 mm (0.0118 - 0.0220 in)
Max. limit of ring gap:
0.4 mm (0.016 in)
If out of speci®cation, replace piston ring. If gap still exceeds maxi-
mum limit with new ring, rebore cylinder and use oversized piston
and piston rings. Refer to SDS, EM-62.
+When replacing the piston, check cylinder block surface
for scratches or seizure. If scratches or seizure are found,
hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.025 mm (0.0010 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.025 mm (0.0010 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM024AA
SEM822B
SEM038F
CYLINDER BLOCK
Inspection (Cont'd)
EM-48

CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper surface of cylinder block. Using a reliable straight-
edge and feeler gauge, check the ¯atness of cylinder block
surface.
+Check along six positions as shown in ®gure.
Limit:
0.10 mm (0.0039 in)
2. If out of speci®cation, resurface it.
The limit for cylinder block resurfacing is determined by the
amount of cylinder head resurfacing.
Amount of cylinder head resurfacing is ``A''.
Amount of cylinder block resurfacing is ``B''.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
227.40 - 227.50 mm (8.9527 - 8.9567 in)
3. If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Standard inner diameter ``Db'':
85.000 - 85.030 mm (3.3465 - 3.3476 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X þ Y):
Less than 0.015 mm (0.0006 in)
Taper (A þ B or A þ C):
Less than 0.010 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block if
necessary.
2. Check for scratches and seizure. If seizure is found, hone it.
SEM907A
SEM908A
SEM909A
CYLINDER BLOCK
Inspection (Cont'd)
EM-49

3. Measure piston skirt diameter.
Piston diameter ``A'':
Refer to SDS, EM-61.
Measuring point ``a'' (Distance from the bottom):
18 mm (0.71 in)
4. Check that piston-to-bore clearance is within speci®cation.
Piston-to-bore clearance ``B'' = Bore measurement
``C'' þ Piston diameter ``A'':
0.025 - 0.045 mm (0.0010 - 0.0018 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS,
EM-61.
6. Cylinder bore size is determined by adding piston-to-bore clear-
ance to piston diameter ``A''.
Rebored size calculation:
D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing cap and tighten bolts to 90 to 100 Nzm (9.2
to 10.2 kg-m, 67 to 74 ft-lb). This will prevent distortion of cyl-
inder bores.
8. Cut cylinder bores.
+When any cylinder needs boring, all other cylinders must
also be bored.
+Do not cut too much out of cylinder bore at a time. Cut only
0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain speci®ed piston-to-bore clearance.
10. Measure ®nished cylinder bore for out-of-round and taper.
+Measurement should be done after cylinder bore cools
down.
SEM181B
SEM755B
CYLINDER BLOCK
Inspection (Cont'd)
EM-50