2005 NISSAN NAVARA engine

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

ENGINE ASSEMBLY
EM-109
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Summary of the inspection items:
*1: Transmission/transaxle/AT 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 —

CYLINDER BLOCK
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lRefer toGI-10, "Components"for symbol marks in the figure.
Disassembly and AssemblyEBS01E6E
DISASSEMBLY
1. Remove engine from the vehicle. Refer toEM-106, "ENGINE ASSEMBLY".
2. Remove clutch cover and disk. (M/T models) Refer toCL-17,
"CLUTCH DISC, CLUTCH COVER AND FLYWHEEL".
3. If they need to be replaced, replace pilot bush (M/T models) or
pilot converter (A/T models).
lUsing the pilot bushing puller [SST], remove the pilot bush (M/
T models) or pilot converter (A/T models) from rear end of
crankshaft.
4. Install engine to engine stand as follows.
a. Remove flywheel (M/T models) or drive plate (A/T models).
lSecure ring gear with the ring gear stopper (A) [SST], then
loosen mounting bolts with TORX socket (B) (commercial ser-
vice tool) and remove them. As an alternative method hold
crankshaft pulley with the pulley holder (commercial service
tool) to remove flywheel (M/T models) or drive plate (A/T
models).
CAUTION:
lDo not disassemble flywheel (M/T models) or drive plate (A/T models).
lDo not place flywheel (M/T models) or drive plate (A/T models) with signal plate facing down.
lWhen handling signal plate, take care not to damage or scratch it.
lHandle signal plate in a manner that prevents it from becoming magnetized.
1. Fuel pump bracket 2. Oil pressure switch 3. Cylinder block
4. Rear oil seal retainer 5. Rear oil seal 6. Top ring
7. Second ring 8. Oil ring 9. Piston pin
10. Snap ring 11. Piston 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Connecting rod nut
16. A/C compressor bracket 17. Oil jet 18. Copper washer
19. Oil jet relief valve 20. Drain plug 21. Thrust bearing
22. Main bearing upper 23. Key 24. Crankshaft
25. Main bearing lower 26. Main bearing cap bolt 27. Main bearing cap
28. Flywheel (M/T models) 29. Pilot bushing (M/T models) 30. Rear plate
31. Pilot converter (A/T models) 32. Drive plate (A/T models) 33. Reinforcement plate (A/T models)
A. Refer toEM-114
.
SEM500G
1 : Flywheel (M/T models) or drive plate (A/T models)
A : KV10105630
B: TORX bit (size: T55)(M/T models) or TORX socket (size: E20)(A/T
models)
PBIC3482E

EM-112
CYLINDER BLOCK
b. Hoist engine and install it to the engine stand (commercial ser-
vice tool).
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
5. Drain engine oil and engine coolant from inside engine. Refer toLU-6, "
Changing Engine Oil".
6. Drain engine coolant by removing drain plug from inside of
engine.
7. Remove the following parts and related parts. (Only major parts are listed.)
lIntake manifold (Refer toEM-20, "INTAKE MANIFOLD".)
lTurbocharger (Refer toEM-28, "TURBO CHARGER".)
lExhaust manifold (Refer toEM-34, "EXHAUST MANIFOLD".)
lRocker cover (Refer toEM-56, "ROCKER COVER".)
lFuel injector (Refer toEM-44, "INJECTION TUBE AND FUEL INJECTOR".)
lOil pan and oil strainer (Refer toEM-36, "OIL PAN AND OIL STRAINER".)
lWater pump (Refer toCO-21, "WATER PUMP".)
lThermostat and water piping (Refer toCO-23, "THERMOSTAT AND WATER PIPING".)
lSecondary timing chain (Refer toEM-73, "SECONDARY TIMING CHAIN".)
lPrimary timing chain (Refer toEM-79, "PRIMARY TIMING CHAIN".)
lFuel pump (Refer toEM-49, "FUEL PUMP".)
lVacuum pump (Refer toEM-42, "VACUUM PUMP".)
lCamshaft (Refer toEM-59, "CAMSHAFT".)
lCylinder head (Refer toEM-92, "CYLINDER HEAD".)
lOil cooler (Refer toLU-11, "OIL COOLER".)
lAccessory, accessory bracket and mount brackets
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.
lInsert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer. Refer toEM-70, "
OIL SEAL".
lPunch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
PBIC0085E
1 : Cylinder block
2 : Drain plug
PBIC3483E

EM-114
CYLINDER BLOCK
b. Using the industrial use dryer, heat pistons up to 60 to 70°C(140
to 158°F).
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
15. Remove main bearing cap bolts.
lWith a TORX socket (size: E14, commercial service tool),
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.
lBefore loosening main bearing cap bolts, measure crankshaft
end play. Refer toEM-124, "
CRANKSHAFT END PLAY".
16. Remove main bearing caps.
lUsing main bearing cap bolts, remove by rocking bearing cap
back and forth.
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block
andmainbearingcaps.
CAUTION:
Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
19. Remove oil jet.
20. Remove oil jet relief valve.
ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
PBIC0089E
EMM0072D
JEM200G
JEM201G