2005 NISSAN NAVARA height

EM-2
Components ........................................................... 42
Removal and Installation ........................................ 42
INSPECTION BEFORE REMOVAL ..................... 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
INJECTION TUBE AND FUEL INJECTOR .............. 44
Components ........................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSTALLATION .................................................... 46
INSPECTION AFTER INSTALLATION ................ 48
FUEL PUMP .............................................................. 49
Components ........................................................... 49
Removal and Installation ........................................ 49
REMOVAL ........................................................... 49
INSPECTION AFTER REMOVAL ........................ 52
INSTALLATION .................................................... 52
ROCKER COVER ..................................................... 56
Components ........................................................... 56
Removal and Installation ........................................ 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 57
INSPECTION AFTER INSTALLATION ................ 58
CAMSHAFT ............................................................... 59
Components ........................................................... 59
Removal and Installation ........................................ 59
REMOVAL ........................................................... 59
INSPECTION AFTER REMOVAL ........................ 60
INSTALLATION .................................................... 63
INSPECTION AFTER INSTALLATION ................ 65
Valve Clearance ...................................................... 66
INSPECTION ....................................................... 66
ADJUSTMENTS .................................................. 67
OIL SEAL .................................................................. 70
Removal and Installation of Valve Oil Seal ............. 70
REMOVAL ........................................................... 70
INSTALLATION .................................................... 70
Removal and Installation of Front Oil Seal ............. 71
REMOVAL ........................................................... 71
INSTALLATION .................................................... 71
Removal and Installation of Rear Oil Seal .............. 72
REMOVAL ........................................................... 72
INSTALLATION .................................................... 72
SECONDARY TIMING CHAIN .................................. 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 73
INSPECTION AFTER REMOVAL ........................ 75
INSTALLATION .................................................... 75
INSPECTION AFTER INSTALLATION ................ 77
PRIMARY TIMING CHAIN ........................................ 79
Components ........................................................... 79
Removal and Installation ........................................ 80
REMOVAL ........................................................... 80
INSPECTION AFTER REMOVAL ........................ 84
INSTALLATION .................................................... 85
INSPECTION AFTER INSTALLATION ................ 91CYLINDER HEAD ..................................................... 92
On-Vehicle Service ................................................. 92
CHECKING COMPRESSION PRESSURE ......... 92
Components ............................................................ 93
Removal and Installation ......................................... 94
REMOVAL ............................................................ 94
INSPECTION AFTER REMOVAL ........................ 94
INSTALLATION .................................................... 96
INSPECTION AFTER INSTALLATION ................ 98
Components ............................................................ 99
Disassembly and Assembly .................................... 99
DISASSEMBLY .................................................... 99
ASSEMBLY ........................................................100
INSPECTION AFTER DISASSEMBLY ..............101
ENGINE ASSEMBLY ...............................................106
Components ..........................................................106
Removal and Installation .......................................106
REMOVAL ..........................................................107
INSTALLATION ..................................................108
INSPECTION AFTER INSTALLATION ..............108
CYLINDER BLOCK .................................................110
Components ..........................................................110
Disassembly and Assembly .................................. 111
DISASSEMBLY .................................................. 111
ASSEMBLY ........................................................114
How to Select Piston and Bearing ........................121
DESCRIPTION ..................................................121
HOW TO SELECT PISTON ...............................121
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................122
HOW TO SELECT MAIN BEARING ..................123
Inspection After Disassembly ................................124
CRANKSHAFT END PLAY ................................124
CONNECTING ROD SIDE CLEARANCE .........125
PISTON TO PISTON PIN CLEARANCE ...........125
PISTON RING SIDE CLEARANCE ...................126
PISTON RING END GAP ..................................126
CONNECTING ROD BEND AND TORSION .....127
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................127
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................127
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................128
MAIN BEARING HOUSING INNER DIAMETER.128
PISTON TO CYLINDER BORE CLEARANCE ..129
CRANKSHAFT MAIN JOURNAL DIAMETER ...130
CRANKSHAFT PIN JOURNAL DIAMETER ......130
CRANKSHAFT OUT-OF-ROUND AND TAPER.130
CRANKSHAFT RUNOUT ..................................131
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................131
MAIN BEARING OIL CLEARANCE ...................132
CRUSH HEIGHT OF MAIN BEARING ..............132
CRUSH HEIGHT OF CONNECTING ROD

GLOW PLUG
EM-41
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GLOW PLUGPFP:22401
ComponentsEBS01EJL
Removal and InstallationEBS01E60
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect glow harness from glow plate.
2. Remove glow nut to remove glow plate.
3. Remove glow plug.
CAUTION:
lWhen removing or installing, do not use such tools as an air impact wrench.
lHandle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install remaining parts in the reverse order of removal.
1. Glow plate 2. Glow harness 3. Glow nut
4. Cap 5. Glow plug
PBIC2436E

CAMSHAFT
EM-61
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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-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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Valve Spring Dimensions and Valve Spring Pressure Load
lUsing valve spring tester, check the following.
lIf out of the standard, replace the valve spring.Standard:
Free height : 44.74 mm (1.76 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during
valve open: 24.82 mm (0.9772 in)
Load with valve
open:320-360N
(32.65 - 36.73 kg, 71.9 - 80.9 lb)
SEM113

EM-132
CYLINDER BLOCK
MAIN BEARING OIL CLEARANCE
Method by Measurement
lInstall main bearings to cylinder block and bearing cap, and
tighten the bolts to the specified torque. Refer toEM-114,
"ASSEMBLY". Then, measure the inner diameter of main bear-
ings.
(Bearing clearance) = (Bearing inner diameter)-(Crankshaft
journal outer diameter)
lIf out of the standard, check main bearing housing inner diame-
ter and crankshaft journal outer diameter, and select appropriate
main bearing to adjust clearance to specifications. Refer toEM-
123, "HOW TO SELECT MAIN BEARING".
Method of Using Plastigage
lRemove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.
lCut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.
lInstall main bearings and bearing cap and tighten to the speci-
fied torque. Refer toEM-114, "
ASSEMBLY"for the tightening
procedure.
CAUTION:
Do not rotate crankshaft.
lRemove main bearings and bearing caps, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.
CRUSH HEIGHT OF MAIN BEARING
lWhen bearing cap is removed after being tightened to the speci-
fied torque with main bearings installed, the tip end of bearing
must protrude. Refer toEM-114, "
ASSEMBLY".
lIf out of the standard, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING
lWhen connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer toEM-114,
"ASSEMBLY".
lIf out of the standard, replace connecting rod bearings.Standard : 0.047 - 0.077 mm (0.0019 - 0.0030 in)
PBIC1644E
EM142
Standard : There must be crush height.
SEM502G
Standard : There must be crush height.
PBIC1646E

EM-138
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Spring
Valve Lifter
Unit: mm (in)
Valve Guide
Unit: mm (in) Valve spring square mm (in) 1.9 (0.075)
Free height mm (in) 44.74 (1.761)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Height during valve open mm (in) 24.82 (0.9772)
Load with valve open N (kg, lb) 320 - 360 (32.65 - 36.73, 71.9 - 80.9)
Item Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
Item Standard Service
Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Item Standard Limit
Valve guide clearanceIntake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0039)
Projection length 10.4 - 10.6 (0.409 - 0.417)
JEM156G

EM-140
SERVICE DATA AND SPECIFICATIONS (SDS)
CAMSHAFT
Unit: mm (in)
*: Total indicator readingDiameter “d2”Intake (A) 26.00 - 26.50 (1.0236 - 1.0433) —
Exhaust (B) —
Diameter “d3”Intake (A) 25.3 - 25.7(0.996 - 1.012)
Exhaust (B) 23.3 - 23.7 (0.917 - 0.933)
Angle “a”43°30¢-46°30¢
Height “h1”Intake (A) 7.0 - 7.1 (0.276 - 0.280) 6.6 - 6.7 (0.260 - 0.264)
Exhaust (B) 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
Height “h2”Intake (A) 2.23 - 2.43 (0.0878 - 0.0957) 2.13 - 2.53 (0.0839 - 0.0996)
Exhaust (B) 2.76 - 2.96 (0.1087 - 0.1165) 2.66 - 3.06 (0.1047 - 0.1205)
Depth “H”Intake 8.83 - 9.13 (0.3476 - 0.3594)
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Projection (L)Intake 36.53 - 36.98 (1.4382 - 1.4559)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
Item Standard Limit
Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
— Camshaft bracket inner diameterNo.1 30.500 - 30.521 (1.2008 - 1.2016)
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457)
Camshaft journal outer diameterNo. 1 30.435 - 30.455 (1.1982 - 1.1990)
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
Cam height “A”Intake 39.505 - 39.695 (1.5553 - 1.5628)
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
SEM671