Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Rogue 2008-2009 Approved Nissan Navara 2005 EM
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 4 . INTAKE MANIFOLD ................................................ 20 . F
Precautions for Draining Engine Coolant ................ 4 . Components .......................................................... 20
.
Precautions for Disconnecting Fuel Piping ............. 4 . Removal and Installation ....................................... 21.
Precautions for Removal and Disassembly ............ 4 . REMOVAL .......................................................... 21
. G
Precautions for Inspection, Repair and Replace- INSPECTION AFTER REMOVAL ...................... 22 .
ment ........................................................................ 4
. INSTALLATION .................................................. 22.
Precautions for Assembly and Installation .............. 4 . INSPECTION AFTER INSTALLATION ............... 25 .
H
Parts Requiring Angle Tightening ............................ 4 . CATALYST ............................................................... 26
.
Precautions For Liquid Gasket ................................ 5 . Components .......................................................... 26
.
REMOVAL OF LIQUID GASKET ......................... 5 . Removal and Installation ....................................... 26.
LIQUID GASKET APPLICATION PROCEDURE 5 ..... REMOVAL .......................................................... 26
. I
PREPARATION .......................................................... 6 . INSTALLATION .................................................. 27.
Special Service Tools .............................................. 6 . TURBO CHARGER .................................................. 28 .
Commercial Service Tools ....................................... 8 . Components .......................................................... 28
. J
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 29.
TROUBLESHOOTING ............................................. 10 . REMOVAL .......................................................... 29
.
NVH Troubleshooting -- Engine Noise ................. 10 . INSPECTION AFTER REMOVAL ...................... 30 .
K
Use the Chart Below to Help You Find the Cause TROUBLE DIAGNOSIS OF TURBOCHARGER 32 ...
of the Symptom. .....................................................11 . INSTALLATION .................................................. 33.
DRIVE BELTS .......................................................... 12. EXHAUST MANIFOLD ............................................ 34 .
Checking Drive Belts ............................................. 12 . Components .......................................................... 34
. L
Deflection Adjustment ........................................... 13 . Removal and Installation ....................................... 34.
POWER STEERING OIL PUMP BELT .............. 13 . REMOVAL .......................................................... 34
.
A/C COMPRESSOR, ALTERNATOR AND INSPECTION AFTER REMOVAL ...................... 35 . M
WATER PUMP BELT ......................................... 14 . INSTALLATION .................................................. 35.
Removal and Installation ....................................... 14 . INSPECTION AFTER INSTALLATION ............... 35 .
REMOVAL .......................................................... 14 . OIL PAN AND OIL STRAINER ................................ 36 .
INSTALLATION .................................................. 14 . Components .......................................................... 36
.
AIR CLEANER AND AIR DUCT .............................. 15 . Removal and Installation ....................................... 36.
Components .......................................................... 15. REMOVAL .......................................................... 36
.
Removal and Installation ....................................... 15 . INSPECTION AFTER REMOVAL ...................... 38 .
REMOVAL .......................................................... 15 . INSTALLATION .................................................. 38.
INSTALLATION .................................................. 16 . INSPECTION AFTER INSTALLATION ............... 40 .
CHANGING AIR CLEANER FILTER .................. 17 . GLOW PLUG ........................................................... 41
.
CHARGE AIR COOLER .......................................... 18 . Components .......................................................... 41
.
Components .......................................................... 18. Removal and Installation ....................................... 41.
Removal and Installation ....................................... 18 . REMOVAL .......................................................... 41
.
REMOVAL .......................................................... 18 . INSTALLATION .................................................. 41.
INSPECTION AFTER REMOVAL ...................... 19 . VACUUM PUMP ....................................................... 42
.
INSTALLATION .................................................. 19 .
EM-1
Components .......................................................... 42
. CYLINDER HEAD ....................................................92 .
Removal and Installation ....................................... 42 . On-Vehicle Service ................................................92 .
INSPECTION BEFORE REMOVAL .................... 42 . CHECKING COMPRESSION PRESSURE ........92 .
REMOVAL .......................................................... 42
. Components ...........................................................93 .
INSTALLATION ................................................... 43 . Removal and Installation ...................................... ..94 .
INJECTION TUBE AND FUEL INJECTOR ............. 44 . REMOVAL ...........................................................94 .
Components .......................................................... 44
. INSPECTION AFTER REMOVAL .......................94 .
Removal and Installation ....................................... 44 . INSTALLATION ...................................................96 .
REMOVAL .......................................................... 44
. INSPECTION AFTER INSTALLATION ...............98 .
INSTALLATION ................................................... 46 . Components ...........................................................99 .
INSPECTION AFTER INSTALLATION ............... 48 . Disassembly and Assembly ...................................99 .
FUEL PUMP ............................................................. 49
. DISASSEMBLY ...................................................99 .
Components .......................................................... 49
. ASSEMBLY ....................................................... 100 .
Removal and Installation ....................................... 49 . INSPECTION AFTER DISASSEMBLY ............. 101 .
REMOVAL .......................................................... 49
. ENGINE ASSEMBLY .............................................. 106 .
INSPECTION AFTER REMOVAL ....................... 52 . Components ......................................................... 106 .
INSTALLATION ................................................... 52 . Removal and Installation ...................................... 106 .
ROCKER COVER .................................................... 56 . REMOVAL ......................................................... 107 .
Components .......................................................... 56
. INSTALLATION ................................................. 108 .
Removal and Installation ....................................... 56 . INSPECTION AFTER INSTALLATION ............. 108 .
REMOVAL .......................................................... 56
. CYLINDER BLOCK ................................................ 110 .
INSTALLATION ................................................... 57 . Components ......................................................... 110 .
INSPECTION AFTER INSTALLATION ............... 58 . Disassembly and Assembly ................................. 111 .
CAMSHAFT .............................................................. 59
. DISASSEMBLY ................................................. 111 .
Components .......................................................... 59
. ASSEMBLY ....................................................... 114 .
Removal and Installation ....................................... 59 . How to Select Piston and Bearing ....................... 121 .
REMOVAL .......................................................... 59
. DESCRIPTION ................................................. 121 .
INSPECTION AFTER REMOVAL ....................... 60 . HOW TO SELECT PISTON .............................. 121 .
INSTALLATION ................................................... 63 . HOW TO SELECT CONNECTING ROD BEAR-
INSPECTION AFTER INSTALLATION ............... 65 . ING .................................................................... 122
.
Valve Clearance ..................................................... 66
. HOW TO SELECT MAIN BEARING ................. 123 .
INSPECTION ...................................................... 66. Inspection After Disassembly ............................... 124 .
ADJUSTMENTS ................................................. 67 . CRANKSHAFT END PLAY ............................... 124 .
OIL SEAL ................................................................. 70
. CONNECTING ROD SIDE CLEARANCE ........ 125 .
Removal and Installation of Valve Oil Seal ............ 70 . PISTON TO PISTON PIN CLEARANCE .......... 125 .
REMOVAL .......................................................... 70
. PISTON RING SIDE CLEARANCE .................. 126 .
INSTALLATION ................................................... 70 . PISTON RING END GAP ................................. 126 .
Removal and Installation of Front Oil Seal ............ 71 . CONNECTING ROD BEND AND TORSION .... 127 .
REMOVAL .......................................................... 71
. CONNECTING ROD BIG END INNER DIAME-
INSTALLATION ................................................... 71 . TER ................................................................... 127
.
Removal and Installation of Rear Oil Seal ............. 72 . CONNECTING ROD BUSHING OIL CLEAR-
REMOVAL .......................................................... 72
. ANCE ................................................................ 127
.
INSTALLATION ................................................... 72 . CYLINDER BLOCK TOP SURFACE DISTOR-
SECONDARY TIMING CHAIN ................................. 73 . TION ................................................................. 128
.
Components .......................................................... 73
. MAIN BEARING HOUSING INNER DIAMETER.128
Removal and Installation ....................................... 73 . PISTON TO CYLINDER BORE CLEARANCE . 129
REMOVAL .......................................................... 73
. CRANKSHAFT MAIN JOURNAL DIAMETER .. 130 .
INSPECTION AFTER REMOVAL ....................... 75 . CRANKSHAFT PIN JOURNAL DIAMETER ..... 130 .
INSTALLATION ................................................... 75 . CRANKSHAFT OUT-OF-ROUND AND TAPER.130
INSPECTION AFTER INSTALLATION ............... 77 . CRANKSHAFT RUNOUT ................................. 131 .
PRIMARY TIMING CHAIN ....................................... 79 . CONNECTING ROD BEARING OIL CLEAR-
Components .......................................................... 79
. ANCE ................................................................ 131
.
Removal and Installation ....................................... 80 . MAIN BEARING OIL CLEARANCE .................. 132 .
REMOVAL .......................................................... 80
. CRUSH HEIGHT OF MAIN BEARING ............. 132 .
INSPECTION AFTER REMOVAL ....................... 84 . CRUSH HEIGHT OF CONNECTING ROD
INSTALLATION ................................................... 85 .
INSPECTION AFTER INSTALLATION ............... 91 .
EM-2
BEARING ......................................................... 132
. FOLD ................................................................ 135
.
MAIN BEARING CAP BOLT DEFORMATION . 133 DRIVE BELTS .................................................. 135 . A
CONNECTING ROD BOLT DEFORMATION ... 133 . CYLINDER HEAD ............................................ 136 .
OIL JET ............................................................ 133
. VALVE .............................................................. 136
.
OIL JET RELIEF VALVE .................................. 133 . CAMSHAFT ...................................................... 140 . EM
FLYWHEEL DEFLECTION .............................. 134 . CYLINDER BLOCK .......................................... 141 .
MOVEMENT AMOUNT OF FLYWHEEL .......... 134 . PISTON, PISTON RING AND PISTON PIN ..... 141 .
DRIVE PLATE .................................................. 134 . CONNECTING ROD ........................................ 144 .
SERVICE DATA AND SPECIFICATIONS (SDS) ... 135 . CRANKSHAFT ................................................. 144 . C
Standard and Limit .............................................. 135. AVAILABLE MAIN BEARING ........................... 145 .
GENERAL SPECIFICATIONS ......................... 135 . AVAILABLE CONNECTING ROD BEARING ... 145 .
INTAKE MANIFOLD AND EXHAUST MANI- MISCELLANEOUS COMPONENTS ................ 145 . D
E
F
G
H
I
J
K
L
M
EM-3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Draining Engine Coolant EBS01E5H
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping EBS01E5I
q Before starting work, make sure no fire or spark producing items are in the work area.
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS01E5J
q When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or
uninstructed operations.
q Exercise maximum care to avoid damage to mating or sliding surfaces.
q Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
q 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.
Precautions for Inspection, Repair and Replacement EBS01E5K
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation EBS01E5L
q Use torque wrench to tighten bolts or nuts to specification.
q 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.
q Replace with new liquid gasket, packing, oil seal or O-ring.
q Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
q Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
q Release air within route when refilling after draining engine coolant.
q After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle Tightening EBS01E5M
q Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
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