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EM


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B ENGINE

                                                                                                                                                                       A


                                                                                                                                                                       EM
                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL                                                            C


                                                                                                                                                                       D


                                                                                                                                                                       E
                                                                   CONTENTS
PRECAUTIONS ......................................................... 4  .         INTAKE MANIFOLD COLLECTOR ......................... 16                     .        F
 Precautions for Drain Engine Coolant ..................... 4            .           Removal and Installation ....................................... 16      .
 Precautions for Disconnecting Fuel Piping ............. 4               .            REMOVAL .......................................................... 17   .
 Precautions for Removal and Disassembly ............ 4                  .            INSTALLATION .................................................. 18      .        G
 Precautions for Inspection, Repair and Replace-                                   INTAKE MANIFOLD ................................................ 19        .
 ment ........................................................................ 4
                                                                         .           Removal and Installation ....................................... 19      .
 Precautions for Assembly and Installation .............. 4              .            REMOVAL .......................................................... 19   .
                                                                                                                                                                       H
 Parts Requiring Angle Tightening ............................ 4         .            INSPECTION AFTER REMOVAL ...................... 19                      .
 Precautions for Liquid Gasket ................................. 5       .            INSTALLATION .................................................. 20      .
   REMOVAL OF LIQUID GASKET SEALING ......... 5                          .         EXHAUST MANIFOLD AND THREE WAY CATA-
   LIQUID GASKET APPLICATION PROCEDURE 5                                 .....     LYST ......................................................................... 21
                                                                                                                                                              .         I
PREPARATION .......................................................... 6 .           Removal and Installation ....................................... 21      .
 Special Service Tools .............................................. 6  .            REMOVAL (LEFT BANK) ................................... 21              .
 Commercial Service Tools ....................................... 8      .            INSPECTION AFTER REMOVAL ...................... 22                      .        J
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  INSTALLATION (LEFT BANK) ........................... 23                 .
TROUBLESHOOTING ............................................. 10         .            REMOVAL (RIGHT BANK) ................................. 24               .
 NVH Troubleshooting --Engine Noise .................. 10                .            INSPECTION AFTER REMOVAL ...................... 24                      .
                                                                                                                                                                       K
 Use the Chart Below to Help You Find the Cause                                       INSTALLATION (RIGHT BANK) ......................... 25                  .
 of the Symptom ......................................................11 .         OIL PAN AND OIL STRAINER ................................ 26               .
ENGINE ROOM COVER ......................................... 12           .           Removal and Installation ....................................... 26      .
 Removal and Installation ....................................... 12     .            REMOVAL (LOWER) .......................................... 26           .        L
   REMOVAL .......................................................... 12 .            INSPECTION AFTER REMOVAL ...................... 27                      .
   INSTALLATION .................................................. 12    .            INSTALLATION (LOWER) .................................. 27              .
DRIVE BELTS .......................................................... 13.            INSPECTION AFTER INSTALLATION ............... 28                        .        M
 Checking Drive Belts ............................................. 13   .            REMOVAL (UPPER) .......................................... 28           .
 Tension Adjustment ............................................... 13   .            INSPECTION AFTER REMOVAL ...................... 29                      .
 Removal and Installation ....................................... 13     .            INSTALLATION (UPPER) ................................... 29             .
   DRIVE BELT ...................................................... 13  .            INSPECTION AFTER INSTALLATION ............... 30                        .
   INSTALLATION .................................................. 14    .         IGNITION COIL ........................................................ 31  .
 Drive Belt Auto-Tensioner and Idler Pulley ............ 14              .           Removal and Installation ....................................... 31      .
   REMOVAL .......................................................... 14 .            REMOVAL (LEFT BANK) ................................... 31              .
   INSTALLATION .................................................. 14    .            INSTALLATION (LEFT BANK) ........................... 31                 .
AIR CLEANER AND AIR DUCT .............................. 15               .            REMOVAL (RIGHT BANK) ................................. 31               .
 Removal and Installation ....................................... 15     .            INSTALLATION (RIGHT BANK) ......................... 31                  .
   REMOVAL .......................................................... 15 .         SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 32                          .
   INSPECTION AFTER REMOVAL ...................... 15                    .           Removal and Installation ....................................... 32      .
   INSTALLATION .................................................. 15    .            REMOVAL .......................................................... 32   .
 Changing Air Cleaner Filter ................................... 15      .            INSPECTION AFTER REMOVAL ...................... 32                      .
   REMOVAL .......................................................... 15 .            INSTALLATION .................................................. 33      .
   INSTALLATION .................................................. 15    .


Revision: February 2006                                                      EM-1                                                                  2005 Xterra
FUEL INJECTOR AND FUEL TUBE ....................... 34                 .           ASSEMBLY .........................................................98   .
  Removal and Installation ....................................... 34  .         Inspection After Disassembly .................................99         .
    REMOVAL .......................................................... 34
                                                                       .           VALVE DIMENSIONS .........................................99           .
    INSTALLATION ................................................... 37.           VALVE GUIDE CLEARANCE .............................99                  .
    INSPECTION AFTER INSTALLATION ............... 39                   .           VALVE GUIDE REPLACEMENT ...................... 100                     .
ROCKER COVER .................................................... 40   .           VALVE SEAT CONTACT ................................... 101             .
  Removal and Installation ....................................... 40  .           VALVE SEAT REPLACEMENT ......................... 101                   .
    REMOVAL (LEFT BANK) ................................... 40         .           VALVE SPRING SQUARENESS ...................... 102                     .
    INSTALLATION (LEFT BANK) ............................ 41           .           VALVE SPRING DIMENSIONS AND VALVE
    REMOVAL (RIGHT BANK) ................................. 42          .           SPRING PRESSURE LOAD ............................. 103                 .
    INSTALLATION (RIGHT BANK) ......................... 43             .        ENGINE ASSEMBLY .............................................. 104        .
FRONT TIMING CHAIN CASE ................................ 45            .         Removal and Installation ...................................... 104      .
  Removal and Installation ....................................... 45  .           REMOVAL ......................................................... 105  .
    REMOVAL .......................................................... 45
                                                                       .           INSTALLATION ................................................. 106     .
    INSTALLATION ................................................... 49.           INSPECTION AFTER INSTALLATION ............. 106                        .
    INSPECTION AFTER INSTALLATION ............... 52                   .        CYLINDER BLOCK ................................................ 107       .
TIMING CHAIN ......................................................... 54
                                                                       .         Disassembly and Assembly ................................. 107           .
  Removal and Installation ....................................... 54  .           DISASSEMBLY ................................................. 108      .
    REMOVAL .......................................................... 55
                                                                       .           ASSEMBLY ....................................................... 112   .
    INSPECTION AFTER REMOVAL ....................... 62                .         How to Select Piston and Bearing ....................... 118             .
    INSTALLATION ................................................... 63.           DESCRIPTION ................................................. 118      .
    INSPECTION AFTER INSTALLATION ............... 73                   .           HOW TO SELECT PISTON .............................. 118                .
CAMSHAFT .............................................................. 74
                                                                       .           HOW TO SELECT CONNECTING ROD BEAR-
  Removal and Installation ....................................... 74  .           ING .................................................................... 119
                                                                                                                                                          .
    REMOVAL .......................................................... 75
                                                                       .           HOW TO SELECT MAIN BEARING ................. 120                       .
    INSPECTION AFTER REMOVAL ....................... 76                .         Inspection After Disassembly ............................... 123         .
    INSTALLATION ................................................... 79.           CRANKSHAFT END PLAY ............................... 123                .
    INSPECTION AFTER INSTALLATION ............... 82                   .           CONNECTING ROD SIDE CLEARANCE ........ 123                             .
  Valve Clearance ..................................................... 83
                                                                       .           PISTON TO PISTON PIN OIL CLEARANCE .... 123                            .
    INSPECTION ...................................................... 83
                                                                       .           PISTON RING SIDE CLEARANCE .................. 124                      .
    ADJUSTMENT ................................................... 86  .           PISTON RING END GAP ................................. 124              .
OIL SEAL ................................................................. 88
                                                                       .           CONNECTING ROD BEND AND TORSION .... 125                               .
  Removal and Installation of Valve Oil Seal ............ 88           .           CONNECTING ROD BIG END DIAMETER ..... 125                              .
    REMOVAL .......................................................... 88
                                                                       .           CONNECTING ROD BUSHING OIL CLEAR-
    INSTALLATION ................................................... 88.           ANCE ................................................................ 125
                                                                                                                                                          .
  Removal and Installation of Front Oil Seal ............ 89           .           CYLINDER BLOCK DISTORTION ................... 126                      .
    REMOVAL .......................................................... 89
                                                                       .           MAIN BEARING HOUSING INNER DIAMETER.127
    INSTALLATION ................................................... 89.           PISTON TO CYLINDER BORE CLEARANCE . 127
  Removal and Installation of Rear Oil Seal ............. 90           .           CRANKSHAFT MAIN JOURNAL DIAMETER .. 128                                .
    REMOVAL .......................................................... 90
                                                                       .           CRANKSHAFT PIN JOURNAL DIAMETER ..... 129                              .
    INSTALLATION ................................................... 90.           CRANKSHAFT OUT-OF-ROUND AND TAPER.129
CYLINDER HEAD .................................................... 92  .           CRANKSHAFT RUNOUT ................................. 129                .
  On-Vehicle Service ................................................ 92
                                                                       .           CONNECTING ROD BEARING OIL CLEAR-
    CHECKING COMPRESSION PRESSURE ........ 92                          .           ANCE ................................................................ 129
                                                                                                                                                          .
  Removal and Installation ....................................... 93  .           MAIN BEARING OIL CLEARANCE .................. 130                      .
    REMOVAL .......................................................... 93
                                                                       .           CRUSH HEIGHT OF MAIN BEARING ............. 131                         .
    INSPECTION AFTER REMOVAL ....................... 94                .           CRUSH HEIGHT OF CONNECTING ROD
    INSTALLATION ................................................... 95.           BEARING .......................................................... 131 .
    INSPECTION AFTER INSTALLATION ............... 96                   .           LOWER CYLINDER BLOCK BOLT OUTER
  Disassembly and Assembly ................................... 97      .           DIAMETER ....................................................... 131   .
    DISASSEMBLY .................................................. 97  .           CONNECTING ROD BOLT OUTER DIAMETER.132
                                                                                   FLYWHEEL DEFLECTION (M/T MODELS) ..... 132                             .
                                                                                   MOVEMENT AMOUNT OF FLYWHEEL (M/T
                                                                                   MODELS) .......................................................... 132 .
                                                                                   DRIVE PLATE ................................................... 133    .
                                                                                   OIL JET ............................................................. 133
                                                                                                                                                          .
                                                                                   OIL JET RELIEF VALVE ................................... 133           .



Revision: February 2006                                                   EM-2                                                                 2005 Xterra
SERVICE DATA AND SPECIFICATIONS (SDS) ... 134                    .        MANIFOLD AND EXHAUST MANIFOLD ......... 135                  .
 Standard and Limit .............................................. 134
                                                                 .        SPARK PLUG ................................................... 135
                                                                                                                                       .       A
   GENERAL SPECIFICATIONS ......................... 134          .        CAMSHAFT AND CAMSHAFT BEARING ....... 136                    .
   DRIVE BELT .................................................... 135
                                                                 .        CYLINDER HEAD ............................................ 138
                                                                                                                                       .
   INTAKE MANIFOLD COLLECTOR, INTAKE                                      CYLINDER BLOCK .......................................... 141.       EM
                                                                          PISTON, PISTON RING AND PISTON PIN ..... 142                 .
                                                                          CONNECTING ROD ........................................ 143  .
                                                                          CRANKSHAFT ................................................. 144
                                                                                                                                       .
                                                                          MAIN BEARING ............................................... 145
                                                                                                                                       .       C
                                                                          CONNECTING ROD BEARING ....................... 146           .

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Revision: February 2006                                            EM-3                                                      2005 Xterra
                                              PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001

Precautions for Drain Engine Coolant                                                                        EBS00NKD


Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping                                                                   EBS00NKE


G   Before starting work, make sure no fire or spark producing items are in the work area.
G   Release fuel pressure before disconnecting and disassembly.
G   After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly                                                                     EBS00NKF


G   When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
    structed operations.
G   Exercise maximum care to avoid damage to mating or sliding surfaces.
G   Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
G   Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
G   When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
    opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
    used in the step.
Precautions for Inspection, Repair and Replacement                                                          EBS00NKG


Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation                                                                   EBS00NKH


G   Use torque wrench to tighten bolts or nuts to specification.
G   When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
    ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
    fied, do exactly as specified.
G   Replace with new gasket, packing, oil seal or O-ring.
G   Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
    any restriction and blockage.
G   Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
    Before assembly, oil sliding surfaces well.
G   Release air within route when refilling after draining engine coolant.
G   After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
    exhaust gasses for leakage.
Parts Requiring Angle Tightening                                                                            EBS00NKI


G   For the final tightening of the following engine parts use Tool:
       Tool number        : KV10112100 (BT-8653-A)



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