2005 NISSAN NAVARA engine

CYLINDER BLOCK
EM-115
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2. Install drain plug to cylinder block.
lApply liquid gasket to drain plug.
Use Genuine Liquid Gasket or equivalent
3. Install oil jet relief valve.
4. Install oil jet.
lAlign knock pin on back of oil jet with hole on block when
installing oil jet.
5. Install main bearings and thrust bearings.
a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
lInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
c. Being careful with the direction, install main bearings.
lInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
lWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
lAlign stopper notches on bearings to install them.
lMake sure that the oil holes on the cylinder block body are
mated with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block.
lMake sure crankshaft rotates smoothly by hand.
1 : Cylinder block
2 : Drain plug
PBIC3483E
PBIC0389E
JEM224G
JEM213G

EM-116
CYLINDER BLOCK
7. Install main bearing caps.
lIdentify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
lMain bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer toEM-
133, "MAIN BEARING CAP BOLT DEFORMATION".
9. With the TORX socket (size: E14, commercial service tool),
tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees. (angle tightening)
CAUTION:
Always use either the angle wrench [SST] or protractor dur-
ing angular tightening. Avoid tightening based on visual
checks alone.
lAfter tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
lCheck crankshaft end play. Refer toEM-124, "CRANKSHAFT
END PLAY".
10. Check the outer diameter of connecting rod bolts. Refer toEM-
133, "CONNECTING ROD BOLT DEFORMATION".
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.
lFit snap ring correctly into grooves.
b. Install pistons to connecting rods.
lUsing the industrial use dryer, heat pistons up to approx. 60 to
70°C(140to158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
JEM225G
: 27.0 N·m (2.8 kg-m, 20 ft-lb)
JEM200G
JEM226G
PBIC0089E

CYLINDER BLOCK
EM-117
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lAssemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.
lRefer to above step a for precaution on snap ring installation.
lAfter installation, check connecting rods for smooth move-
ment.
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
lInstall top ring and second ring with punched mark surfaces
facing upward.
lInstall rings so that three closed gap position 120 degrees
apart one another.
lClosed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
13. Install connecting rod bearing to connecting rod and cap.
lWhile installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
lAlign protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
14. Install piston and connecting rod assembly to crankshaft.
lMove crankshaft pin to be assembled to BDC.
lAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
lUsing the piston ring compressor [SST] or suitable tool, install
piston and connecting rod assembly with front mark on piston
head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet.
MBIA0024E
Punched mark:
To p r i n g : R TO P
Second ring : R2ND
JEM228G
JEM229G
PBIC1619E

EM-118
CYLINDER BLOCK
15. Install connecting rod caps and mounting nuts.
lAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
lMake sure that the front mark on connecting rod cap faces
towards the front of the engine.
16. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
c. Loosen completely.
d. Tighten bolts.
e. Tighten 120 degrees. (angle tightening)
lAlways use either the angle wrench [SST] or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening nuts, make sure that crankshaft rotates
smoothly.
lCheck connecting rod side clearance. Refer toEM-125,
"CONNECTING ROD SIDE CLEARANCE".
17. Press fit rear oil seal into rear oil seal retainer.
lUsing the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
lAvoid inclined fitting. Force fit perpendicularly.
MBIA0024E
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
:0N·m(0kg-m,0in-lb)
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
JEM231G
JEM232G

CYLINDER BLOCK
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18. Install rear oil seal retainer to cylinder block.
lApply new engine oil to the oil and dust seal lips.
lApply liquid gasket to rear oil seal retainer using the tube
presser [SST: WS39930000] as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
19. Press fit pilot bushing into crankshaft (M/T models).
lUsing the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
20. Press fit pilot converter into crankshaft (A/T models).
lUsing the drift with outer diameter of 33 mm (1.30 in), press fit pilot converter until it stops.
lPress fit pilot converter with its chamfer facing crankshaft as
showninthefigure.
21. Install fuel pump bracket.
lAlign the bracket with the dowel pins on cylinder block to
install.
lThe two bolts used for dowel pins have a longer shanks than
the other two.
22. Install parts to engine in the reverse order of disassembly.
23. Remove engine from engine stand in the reverse order of assembly.
24. Install flywheel (M/T models).
JEM233G
JEM234G
SEM537E
PBIC2329E

EM-120
CYLINDER BLOCK
lWhen installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin
hole.
CAUTION:
If these are not aligned correctly, engine runs roughly
and “MI” turns on.
lThere is a mating mark on the clutch cover side of flywheel.
Refer it during installation.
lHolding ring gear with ring gear stopper [SST], tighten secur-
ing bolts with TORX socket (size: T55, commercial service
tool).
lTighten bolts uniformly in a crisscross manner.
–If these are not aligned correctly, engine runs roughly and “MI” turns on.
25. Install drive plate (A/T models).
lWhen installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive
plate side dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and “MI” turns on.
lInstall drive plate and reinforcement plate as shown in the fig-
ure.
lHolding ring gear with ring gear stopper [SST: KV10105630],
tighten securing bolts with TORX socket (size: E20) (commer-
cial service tool).
lTighten bolts uniformly in a crisscross manner.
26. Install in the reverse order of removal.
PBIC2538E
PBIC1112E
PBIC2406E
PBIC0910E

EM-126
CYLINDER BLOCK
PISTON RING SIDE CLEARANCE
lUsing feeler gauge, measure the side clearance between piston
ringandpistonringgroove.
Unit: mm (in)
lAlign top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.
lIf side clearance exceeds the limit, replace piston ring.
lCheck clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP
lMake sure that cylinder bore diameter is within the specifica-
tions. Refer toEM-129, "
PISTON TO CYLINDER BORE
CLEARANCE".
lLubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure piston ring end gap with feeler gauge.
Unit: mm (in)
lIf out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder
and use oversized piston and piston ring. Refer toEM-129, "
PISTON TO CYLINDER BORE CLEAR-
ANCE".
Item Standard Limit
Top ring 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
FEM100
Item Standard Limit
Top ring 0.21 - 0.28 (0.0083 - 0.0110)
1.0 (0.039) 2nd ring 0.32 - 0.47 (0.0126 - 0.0185)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)
FEM101

EM-128
CYLINDER BLOCK
Piston Pin Outer Diameter
Use micrometer to measure piston pin outer diameter.
Calculation of Connecting Rod Bushing Clearance
(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter)-(Piston pin outer diameter)
lIf it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer toEM-122,
"HOW TO SELECT CONNECTING ROD BEARING"and/orEM-121, "HOW TO SELECT PISTON".
CYLINDER BLOCK TOP SURFACE DISTORTION
lUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as engine oil, scale, and car-
bon.
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.
lUse straightedge and feeler gauge to check block upper surface
for six distortion.
lIf it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
lWithout installing main bearings, install main bearing caps, and
tighten bolts to the specified torque. Refer toEM-114, "
ASSEM-
BLY"EM-114, "ASSEMBLY".
lMeasure the inner diameter of main bearing housing with a bore
gauge.
lIf the measurement is out of the standard, replace cylinder block
andmainbearingcaps.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.026 - 0.043 mm (0.0010 - 0.0017 in)
Limit : 0.057 mm (0.0022 in)
Limit : 0.1 mm (0.004 in)
SEM501G
Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in)
PBIC1643E