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B ENGINE

                                                                                                                                                                       A




                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL
                                                                                                                               EM                                      EM



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                                                                                                                                                                       E
                                                                   CONTENTS
PRECAUTIONS ......................................................... 4  .            INSTALLATION .................................................. 16      .        F
 Precautions for Supplemental Restraint System                                       Changing Air Cleaner Filter ................................... 16       .
 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                              REMOVAL .......................................................... 16   .
 SIONER" ................................................................. 4
                                                                         .            INSTALLATION .................................................. 16      .        G
 Precautions for Drain Engine Coolant ..................... 4            .         INTAKE MANIFOLD COLLECTOR ......................... 17                     .
 Precautions for Disconnecting Fuel Piping ............. 4               .           Removal and Installation ....................................... 17      .
 Precautions for Removal and Disassembly ............ 4                  .            REMOVAL .......................................................... 18   .
                                                                                                                                                                       H
 Precautions for Inspection, Repair and Replace-                                      INSTALLATION .................................................. 19      .
 ment ........................................................................ 4
                                                                         .         INTAKE MANIFOLD ................................................ 20        .
 Precautions for Assembly and Installation .............. 4              .           Removal and Installation ....................................... 20      .
 Parts Requiring Angle Tightening ............................ 5         .            REMOVAL .......................................................... 20   .         I
 Precautions for Liquid Gasket ................................. 5       .            INSPECTION AFTER REMOVAL ...................... 20                      .
   REMOVAL OF LIQUID GASKET SEALING ......... 5                          .            INSTALLATION .................................................. 21      .
   LIQUID GASKET APPLICATION PROCEDURE 5                                 .....     EXHAUST MANIFOLD AND THREE WAY CATA-                                                J
PREPARATION .......................................................... 7 .         LYST ......................................................................... 22
                                                                                                                                                              .
 Special Service Tools .............................................. 7  .           Removal and Installation ....................................... 22      .
 Commercial Service Tools ....................................... 9      .            REMOVAL (LEFT BANK) ................................... 22              .
                                                                                                                                                                       K
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  INSPECTION AFTER REMOVAL ...................... 23                      .
TROUBLESHOOTING ..............................................11         .            INSTALLATION (LEFT BANK) ........................... 24                 .
 NVH Troubleshooting --Engine Noise ...................11                .            REMOVAL (RIGHT BANK) ................................. 25               .
 Use the Chart Below to Help You Find the Cause                                       INSPECTION AFTER REMOVAL ...................... 25                      .        L
 of the Symptom ..................................................... 12 .            INSTALLATION (RIGHT BANK) ......................... 26                  .
ENGINE ROOM COVER ......................................... 13           .         OIL PAN AND OIL STRAINER ................................ 27               .
 Removal and Installation ....................................... 13     .           Removal and Installation ....................................... 27      .        M
   REMOVAL .......................................................... 13 .            REMOVAL (LOWER) .......................................... 27           .
   INSTALLATION .................................................. 13    .            INSPECTION AFTER REMOVAL ...................... 28                      .
DRIVE BELTS .......................................................... 14.            INSTALLATION (LOWER) .................................. 28              .
 Checking Drive Belts ............................................. 14   .            INSPECTION AFTER INSTALLATION ............... 29                        .
 Tension Adjustment ............................................... 14   .            REMOVAL (UPPER) .......................................... 29           .
 Removal and Installation ....................................... 14     .            INSPECTION AFTER REMOVAL ...................... 30                      .
   DRIVE BELT ...................................................... 14  .            INSTALLATION (UPPER) ................................... 30             .
   INSTALLATION .................................................. 15    .            INSPECTION AFTER INSTALLATION ............... 31                        .
 Drive Belt Auto-Tensioner and Idler Pulley ............ 15              .         IGNITION COIL ........................................................ 32  .
   REMOVAL .......................................................... 15 .           Removal and Installation ....................................... 32      .
   INSTALLATION .................................................. 15    .            REMOVAL (LEFT BANK) ................................... 32              .
AIR CLEANER AND AIR DUCT .............................. 16               .            INSTALLATION (LEFT BANK) ........................... 32                 .
 Removal and Installation ....................................... 16     .            REMOVAL (RIGHT BANK) ................................. 32               .
   REMOVAL .......................................................... 16 .            INSTALLATION (RIGHT BANK) ......................... 32                  .
   INSPECTION AFTER REMOVAL ...................... 16                    .



Revision: September 2005                                                     EM-1                                                                  2006 Xterra
SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 33                      .           ASSEMBLY .........................................................99   .
  Changing Spark Plugs (Platinum - Tipped Type) ... 33                           Inspection After Disassembly ............................... 100         .
    REMOVAL .......................................................... 33
                                                                       .           VALVE DIMENSIONS ....................................... 100           .
    INSPECTION AFTER REMOVAL ....................... 33                .           VALVE GUIDE CLEARANCE ........................... 100                  .
    INSTALLATION ................................................... 34.           VALVE GUIDE REPLACEMENT ...................... 101                     .
FUEL INJECTOR AND FUEL TUBE ....................... 35                 .           VALVE SEAT CONTACT ................................... 102             .
  Removal and Installation ....................................... 35  .           VALVE SEAT REPLACEMENT ......................... 102                   .
    REMOVAL .......................................................... 35
                                                                       .           VALVE SPRING SQUARENESS ...................... 103                     .
    INSTALLATION ................................................... 38.           VALVE SPRING DIMENSIONS AND VALVE
    INSPECTION AFTER INSTALLATION ............... 40                   .           SPRING PRESSURE LOAD ............................. 104                 .
ROCKER COVER .................................................... 41   .        ENGINE ASSEMBLY .............................................. 105        .
  Removal and Installation ....................................... 41  .         Removal and Installation ...................................... 105      .
    REMOVAL (LEFT BANK) ................................... 41         .           REMOVAL ......................................................... 106  .
    INSTALLATION (LEFT BANK) ............................ 42           .           INSTALLATION ................................................. 107     .
    REMOVAL (RIGHT BANK) ................................. 43          .           INSPECTION AFTER INSTALLATION ............. 107                        .
    INSTALLATION (RIGHT BANK) ......................... 44             .        CYLINDER BLOCK ................................................ 108       .
FRONT TIMING CHAIN CASE ................................ 46            .         Disassembly and Assembly ................................. 108           .
  Removal and Installation ....................................... 46  .           DISASSEMBLY ................................................. 109      .
    REMOVAL .......................................................... 46
                                                                       .           ASSEMBLY ....................................................... 113   .
    INSTALLATION ................................................... 50.         How to Select Piston and Bearing ....................... 119             .
    INSPECTION AFTER INSTALLATION ............... 53                   .           DESCRIPTION ................................................. 119      .
TIMING CHAIN ......................................................... 55
                                                                       .           HOW TO SELECT PISTON .............................. 119                .
  Removal and Installation ....................................... 55  .           HOW TO SELECT CONNECTING ROD BEAR-
    REMOVAL .......................................................... 56
                                                                       .           ING .................................................................... 120
                                                                                                                                                          .
    INSPECTION AFTER REMOVAL ....................... 63                .           HOW TO SELECT MAIN BEARING ................. 121                       .
    INSTALLATION ................................................... 64.         Inspection After Disassembly ............................... 124         .
    INSPECTION AFTER INSTALLATION ............... 74                   .           CRANKSHAFT END PLAY ............................... 124                .
CAMSHAFT .............................................................. 75
                                                                       .           CONNECTING ROD SIDE CLEARANCE ........ 124                             .
  Removal and Installation ....................................... 75  .           PISTON TO PISTON PIN OIL CLEARANCE .... 124                            .
    REMOVAL .......................................................... 76
                                                                       .           PISTON RING SIDE CLEARANCE .................. 125                      .
    INSPECTION AFTER REMOVAL ....................... 77                .           PISTON RING END GAP ................................. 125              .
    INSTALLATION ................................................... 80.           CONNECTING ROD BEND AND TORSION .... 126                               .
    INSPECTION AFTER INSTALLATION ............... 83                   .           CONNECTING ROD BIG END DIAMETER ..... 126                              .
  Valve Clearance ..................................................... 84
                                                                       .           CONNECTING ROD BUSHING OIL CLEAR-
    INSPECTION ...................................................... 84
                                                                       .           ANCE ................................................................ 126
                                                                                                                                                          .
    ADJUSTMENT ................................................... 87  .           CYLINDER BLOCK DISTORTION ................... 127                      .
OIL SEAL ................................................................. 89
                                                                       .           MAIN BEARING HOUSING INNER DIAMETER.128
  Removal and Installation of Valve Oil Seal ............ 89           .           PISTON TO CYLINDER BORE CLEARANCE . 128
    REMOVAL .......................................................... 89
                                                                       .           CRANKSHAFT MAIN JOURNAL DIAMETER .. 129                                .
    INSTALLATION ................................................... 89.           CRANKSHAFT PIN JOURNAL DIAMETER ..... 130                              .
  Removal and Installation of Front Oil Seal ............ 90           .           CRANKSHAFT OUT-OF-ROUND AND TAPER.130
    REMOVAL .......................................................... 90
                                                                       .           CRANKSHAFT RUNOUT ................................. 130                .
    INSTALLATION ................................................... 90.           CONNECTING ROD BEARING OIL CLEAR-
  Removal and Installation of Rear Oil Seal ............. 91           .           ANCE ................................................................ 130
                                                                                                                                                          .
    REMOVAL .......................................................... 91
                                                                       .           MAIN BEARING OIL CLEARANCE .................. 131                      .
    INSTALLATION ................................................... 91.           CRUSH HEIGHT OF MAIN BEARING ............. 132                         .
CYLINDER HEAD .................................................... 93  .           CRUSH HEIGHT OF CONNECTING ROD
  On-Vehicle Service ................................................ 93
                                                                       .           BEARING .......................................................... 132 .
    CHECKING COMPRESSION PRESSURE ........ 93                          .           LOWER CYLINDER BLOCK BOLT OUTER
  Removal and Installation ....................................... 94  .           DIAMETER ....................................................... 132   .
    REMOVAL .......................................................... 94
                                                                       .           CONNECTING ROD BOLT OUTER DIAMETER.133
    INSPECTION AFTER REMOVAL ....................... 95                .           FLYWHEEL DEFLECTION (M/T MODELS) ..... 133                             .
    INSTALLATION ................................................... 96.           MOVEMENT AMOUNT OF FLYWHEEL (M/T
    INSPECTION AFTER INSTALLATION ............... 97                   .           MODELS) .......................................................... 133 .
  Disassembly and Assembly ................................... 98      .           DRIVE PLATE ................................................... 134    .
    DISASSEMBLY .................................................. 98  .           OIL JET ............................................................. 134
                                                                                                                                                          .
                                                                                   OIL JET RELIEF VALVE ................................... 134           .



Revision: September 2005                                                   EM-2                                                                2006 Xterra
SERVICE DATA AND SPECIFICATIONS (SDS) ... 135                    .        MANIFOLD AND EXHAUST MANIFOLD ......... 136                  .
 Standard and Limit .............................................. 135
                                                                 .        SPARK PLUG ................................................... 136
                                                                                                                                       .       A
   GENERAL SPECIFICATIONS ......................... 135          .        CAMSHAFT AND CAMSHAFT BEARING ....... 137                    .
   DRIVE BELT .................................................... 136
                                                                 .        CYLINDER HEAD ............................................ 139
                                                                                                                                       .
   INTAKE MANIFOLD COLLECTOR, INTAKE                                      CYLINDER BLOCK .......................................... 142.       EM
                                                                          PISTON, PISTON RING AND PISTON PIN ..... 143                 .
                                                                          CONNECTING ROD ........................................ 144  .
                                                                          CRANKSHAFT ................................................. 145
                                                                                                                                       .
                                                                          MAIN BEARING ............................................... 146
                                                                                                                                       .       C
                                                                          CONNECTING ROD BEARING ....................... 147           .

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Revision: September 2005                                           EM-3                                                      2006 Xterra
                                              PRECAUTIONS

PRECAUTIONS                                                         PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER"                                                                                           EBS00T56


The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
G    To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
     in the event of a collision which would result in air bag inflation, all maintenance must be per-
     formed by an authorized NISSAN/INFINITI dealer.
G    Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
     sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
     Bag Module, see the SRS section.
G    Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
     Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
     harness connectors.
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.



Revision: September 2005                              EM-4                                              2006 Xterra
                                              PRECAUTIONS

Parts Requiring Angle Tightening                                                                          EBS00NKI

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



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