NISSAN PICK-UP 2001 Repair Manual

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION
FE
MODIFICATION NOTICE:
+KA24DE engine model information has been added for Europe. For information not included here, refer
to the KA24E engine model.
+YD25DDTi engine model has been added.
CONTENTS
ACCELERATOR CONTROL SYSTEM............... 3002
Removal and Installation ................................. 3002FUEL SYSTEM.................................................... 3003
EXHAUST SYSTEM............................................ 3005
<SUPPLEMENT-III>
FE

Removal and Installation
YD25DDTi ENGINE MODEL
REMOVAL
1.Remove harness connector.
2. Loosen nuts, and remove accelerator pedal assembly.
CAUTION:
+Do not disassemble the accelerator pedal assembly. Do not remove the sensors and the switches
from the assembly.
+Avoid impact from dropping etc. during handling.
+Be careful to keep the assembly away from water.
+Do not adjust the adjusting screw (painted white) of the accelerator work unit.
+When the harness connector of the accelerator sensor is disconnected, perform ªAccelerator
Pedal Released Position Learningº. Refer to ªBasic Service Procedureº in EC section.
INSTALLATION
Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
+Check that the accelerator pedal moves smoothly within the whole operation range.
+Check that the accelerator pedal securely returns to the original position.
+For the electrical inspection of the accelerator work unit, refer to EC section, ªDTC 0403 ACCELERA-
TOR PEDAL POSITION SENSORº.
+Check that the drum of the accelerator work unit can be fully opened.
SFE780A
ACCELERATOR CONTROL SYSTEM
FE-3002

KA24DE ENGINE MODEL
SFE777A
FUEL SYSTEM
FE-3003

YD25DDTi ENGINE MODEL
SFE763A
FUEL SYSTEM
FE-3004

KA24DE ENGINE (2WD) MODEL
KA24DE ENGINE (4WD) MODEL
SFE778A
SFE779A
EXHAUST SYSTEM
FE-3005

YD25DDTi ENGINE (2WD) MODEL
YD25DDTi ENIGNE (4WD APPEARANCE 2WD) MODEL
SFE781A
SFE782A
EXHAUST SYSTEM
FE-3006

YD25DDTi (4WD) ENGINE MODEL
SFE764A
EXHAUST SYSTEM
FE-3007

ENGINE MECHANICAL
SECTION
EM
MODIFICATION NOTICE:
+KA24DE engine information has been added for Europe.
For information not included here, refer to information for KA24DE engine in D22 Supplement-II Service
Manual (SM9E-D22BE0E).
+YD25DDTi engine has newly been added.
CONTENTS
PRECAUTIONS................................................... 3003
Parts Requiring Angular Tightening................. 3003
Liquid Gasket Application Procedure .............. 3003
PREPARATION................................................... 3004
Special Service Tools (YD25DDTi engine) ..... 3004
Commercial Service Tools
(YD25DDTi engine).......................................... 3007
KA24DE
OUTER COMPONENT PARTS........................... 3008
YD25DDTi
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING......................................... 3011
NVH Troubleshooting - Engine Noise ............. 3011
MEASUREMENT OF COMPRESSION
PRESSURE.......................................................... 3013
CHARGE AIR COOLER...................................... 3014
Removal and Installation ................................. 3014
Inspection ......................................................... 3014
OIL PAN............................................................... 3015
Components ..................................................... 3015
Removal ........................................................... 3016
Installation ........................................................ 3018
TIMING CHAIN.................................................... 3021
Secondary Timing Chain ................................. 3021
Primary Timing Chain ...................................... 3026
INTAKE MANIFOLD............................................ 3035
Removal and Installation ................................. 3035
Inspection ......................................................... 3036
CATALYST.......................................................... 3037Removal and Installation ................................. 3037
EXHAUST MANIFOLD, TURBOCHARGER....... 3039
Removal and Installation ................................. 3039
Disassembly and Assembly ............................. 3041
Inspection ......................................................... 3041
ROCKER COVER................................................ 3045
Removal and Installation ................................. 3045
CYLINDER HEAD................................................ 3046
Components ..................................................... 3046
Removal ........................................................... 3047
Disassembly ..................................................... 3048
Inspection ......................................................... 3049
Assembly.......................................................... 3056
Installation ........................................................ 3056
Valve Clearance............................................... 3060
ENGINE REMOVAL............................................. 3063
Removal ........................................................... 3064
Installation ........................................................ 3065
Inspection ......................................................... 3065
CYLINDER BLOCK............................................. 3066
Components ..................................................... 3066
Removal and Installation ................................. 3067
Disassembly ..................................................... 3067
Inspection ......................................................... 3070
Assembly.......................................................... 3081
KA24DE
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3086
Inspection and Adjustment .............................. 3086
<SUPPLEMENT-III>
EM

YD25DDTi
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3088
General Specifications ..................................... 3088
Compression Pressure .................................... 3088
Cylinder Head .................................................. 3088
Valve ................................................................ 3089
Valve Seat........................................................ 3092Camshaft and Camshaft Bearing .................... 3093
Cylinder Block .................................................. 3094
Piston, Piston Ring and Piston Pin.................. 3094
Connecting Rod ............................................... 3095
Crankshaft ........................................................ 3096
Available Main Bearing .................................... 3096
Available Connecting Rod Bearing .................. 3097
Miscellaneous Components ............................. 3097
EM-3002

Parts Requiring Angular Tightening
+Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts (YD series)
c) Connecting rod cap nuts (KA and YD series)
d) Crankshaft pulley bolt (YD series)
+Do not use a torque value for final tightening.
+The torque value for these parts are for a preliminary step.
+Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure
1.Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely
clean any oil from these areas.
2.Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+Be sure liquid gasket diameter is as specified in this manual.
3.Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.Assembly should be done within 5 minutes after coating.
5.Wait at least 30 minutes before refilling engine oil and
engine coolant.
SEM164F
AEM080
PRECAUTIONS
EM-3003