2005 NISSAN NAVARA engine

CYLINDER BLOCK
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lIf corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer toEM-132, "
MAIN BEARING OIL CLEARANCE"and/orEM-
131, "CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
lPlace V-block onto surface plate to support journals at both ends
of crankshaft.
lPosition dial gauge vertically onto No. 3 journal.
lRotate crankshaft to read needle movement on dial gauge.
(Total indicator reading)
lIf it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement
lInstall connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer toEM-114,
"ASSEMBLY". Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter)-
(Crankshaft pin outer diameter)
lIf clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin outer diameter to obtain specified bearing oil
clearance. Refer toEM-122, "
HOW TO SELECT CONNECTING
ROD BEARING".
Method of Using Plastigage
lRemove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.
lCut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
lInstall connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft.
lRemove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.039 - 0.070 mm (0.0015 - 0.0028 in)
PBIC1642E
EM142

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

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-135
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS01E6H
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3(cu in)2,488 (151.82)
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.5
Compression pressure
Unit: kPa (bar, kg/cm
2, psi)/200 rpmStandard 3,100 (31, 31.6, 450)
Minimum 2,500 (25, 25.5, 363)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
226 210 2 28 -2 48
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
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)

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTIONEX
A
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EXHAUST SYSTEM
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2Components ............................................................. 2
Removal and Installation .......................................... 3
REMOVAL ............................................................. 3
INSTALLATION ..................................................... 3
INSPECTION AFTER INSTALLATION .................. 3

EXHAUST SYSTEM
EX-3
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Removal and InstallationEBS01E7B
CAUTION:
lBe sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
lPerform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
lBe careful not to cut your hand on the insulator edge.
REMOVAL
Separate each connection as necessary.
CAUTION:
Do not disassemble main muffler at the portion “A” shown in the figure.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
lAlways replace exhaust gaskets and seal bearings with new ones when reassembling.
lIf insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.
lWhen installing insulator avoid large gaps or interference between insulator and each exhaust
pipe.
lRemove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.
lTemporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
cle side. Check each part for unusual interference, and then tighten them to the specified torque.
lWhen installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
lInstall tail tube to main muffler as follows.
Ta i l t u b e
Install tail tube (3) to main muffler (1) as shown in the figure.
CAUTION:
The emboss (B) of tail tube (3) shall be properly fitted to the slit
(A) of main muffler (1).
INSPECTION AFTER INSTALLATION
lWith the engine running, check exhaust tube joints for gas leakage and unusual noises.
lCheck to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
2:Band
PBIC3362E

FAX-14
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Wheel BearingEDS003IB
Drive ShaftEDS003IC
Wheel bearing axial end play 0.05 mm (0.002 in) or less
Wheel Side Final Drive Side
Applied modelEngine YD25, VQ40
Transaxle MT AT
Drive shaft joint type Final drive side AAR3300I AAR3300I
Wheel side UF3700I AC3300I
GreaseQuality Nissan genuine grease or equivalent
Capacity g (oz)Final drive side 134 - 144 (4.73 - 5.08) 134 - 144 (4.73 - 5.08)
Wheel side 226 - 246 (7.97 - 8.68) 110 - 130 (3.88 - 4.59)
Boot length “L” mm (in)Final drive side 176 - 178 (6.93 - 7.01) 176 - 178 (6.93 - 7.01)
Wheel side 154 (6.06) 150.4 (5.92)
MDIB9038EMDIB9037E

FFD-8
DIFFERENTIAL GEAR OIL
DIFFERENTIAL GEAR OIL
PFP:KLD30
Changing Differential Gear OilEDS00351
DRAINING
1. Stop the engine.
2. Remove the drain plug and gasket. Drain the gear oil.
3. Install the drain plug with a new gasket to the final drive assem-
bly. Tighten to the specified torque. Refer toFFD-17, "
COMPO-
NENTS".
CAUTION:
Do not reuse gasket.
FILLING
1. Remove the filler plug and gasket. Fill with new gear oil until the
oil level reaches the specified level near the filler plug hole.
2. After refilling oil, check the oil level. Install the filler plug with a
new gasket on it to the final drive assembly. Tighten to the spec-
ified torque. Refer toFFD-17, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilEDS00352
OIL LEAKAGE AND OIL LEVEL
lMake sure that oil is not leaking from the final drive assembly or around it.
lCheck oil level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
lInstall the filler plug with a new gasket on it to the final drive
assembly. Tighten to the specified torque. Refer toFFD-17,
"COMPONENTS".
CAUTION:
Do not reuse gasket.
LDIA0175E
Oil grade and Viscosity:
Refer toMA-14, "
Fluids and Lubricants".
Oil capacity:
Approx. 0.85 (1-1/2 Imp pt)
LDIA0176E
LDIA0176E

FFD-10
FRONT OIL SEAL
CAUTION:
Do not pull on the ABS sensor harness.
6. Support the lower link using a suitable jack.
7. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using a jack.
8. Remove the engine under cover rear using power tool.
9. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
10. Remove the front propeller shaft. Refer toPR-4, "
Removal and
Installation".
11. Measure the total preload with the preload gauge.
NOTE:
Record the preload measurement.
12. Remove the drive pinion lock nut using flange wrench.
13. Put a matching mark on the end of the drive pinion in line with
the matching mark B on the companion flange.
CAUTION:
Use paint to make the matching mark on the drive pinion.
Do not damage the companion flange or drive pinion.
NOTE:
The matching mark B on the final drive companion flange indi-
cates the maximum vertical runout position.Tool number : ST29020001
Tool number A: ST3127S000WEIA0119E
PDIA1002E
PDIA1004E
SDIA0270E