NISSAN PICK-UP 2001 Repair Manual

Removal
Preparation
1. Drain coolant from radiator drain plugs.
2. Remove the following parts.
+Engine hood
+Charge air cooler
+Under protector
+Battery
+Radiator shroud
+Radiator
+Accessory belt
+Cooling fan
+Exhaust front tube
Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect harness connectors from alternator and air con-
ditioner compressor.
5. Remove alternator.
6. Remove installation bolts. Relocate air conditioner compres-
sor. Use a rope to temporarily anchor it to vehicle side.
7. Disconnect and relocate heating hose, install blank cap to
hose to prevent coolant from leaking.
8. Remove heat insulator.
Engine room (Right)
9. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
10. Remove all harness connectors on the engine, and move
harnesses to the side of the vehicle.
Vehicle underfloor
11. Remove starter motor.
12. Remove front propeller shaft.
13. Remove front final drive together with differential mounting
member. Refer to PD section (ªRemoval and Installationº,
ªFront final driveº) Ð 4WD models only.
14. Remove mounting bolts to secure the engine to transmission.
1) Lift transmission with the jack, and reinstall rear mount mem-
bers to the vehicle.
2) Position the jack to the front side of transmission.
3) Remove remaining mounting bolts securing the engine to
transmission.
SEM600F
ENGINE REMOVALYD25DDTi
EM-3064

Removal operation
15. Install the engine slingers (standard service part) to front-left
and rear-right.
: 29.5 - 37.3 Nzm (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
16. Hook hoists to slingers to secure the position.
17. Remove installation nuts for left and right engine mount insu-
lators.
18. Remove crankshaft position sensor (TDC sensor) from trans-
mission.
19. Separate engine and transmission, remove the engine.
CAUTION:
+While performing operation, check that all necessary
wires and pipes are disconnected.
+Avoid interference with parts on the vehicle.
Installation
Install the engine in the reverse order of the removal procedure.
+Keep each mount insulator from oil adherence and damage.
+As for a location with positioning pin, insert the pin correctly
to the hole of mating part.
+While keeping each mount insulator free from twisting,
tighten mounting bolts and nuts for the engine mount.
Inspection
+Before starting the engine, check levels of coolant, engine oil,
and other operating fluids, and if necessary, refill them to the
specified level.
+Start the engine, and check that there is no abnormal noise
or vibration.
+Warm up the engine to the sufficient temperature, and check
that there is no leakage of coolant, greases, fuel, or exhaust
gas.
SEM893G
SEM896G
ENGINE REMOVALYD25DDTi
Removal (Cont'd)
EM-3065

Components
SEM897G
CYLINDER BLOCKYD25DDTi
EM-3066

Removal and Installation
CAUTION:
+When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
+Place removed parts such as bearings and bearing caps
in their proper order and direction.
+When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
+Do not allow any magnetic materials to contact the sig-
nal plate of flywheel.
+Do not remove the signal plate at back.
+Do not place the signal plate side facing under.
+Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
Disassembly
PISTON AND CRANKSHAFT
1. Remove engine. Refer to ªENGINE REMOVALº, EM-3063.
2. Place engine on a work stand.
a. Remove flywheel.
+Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX
socket (size: Q8 E20, Commercial Service Tool) and remove
them. As an alternative method, hold the crankshaft pulley
with a pulley holder (SST) to remove the flywheel.
b. Install engine sub-attachment (SST) to rear surface of cylin-
der block.
+To install, align the hole on the sub-attachment with the
knock pin on the cylinder block.
+The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
+The four sets of bolts and nuts are multi-purpose products.
JEM192G
CYLINDER BLOCKYD25DDTi
EM-3067

d. Hoist up engine and install it on the engine stand (SST).
+Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
+Exhaust manifold
+Turbocharger assembly
+Injection tube
+Intake manifold
+Water pump
+Oil pan (upper and lower)
+EGR volume control valve and EGR tube & EGR guide tube
assembly
+Secondary timing chain
+Fuel injection pump
+Primary timing chain
+Rocker cover
+Vacuum pump
+High pressure injection nozzle assembly
+Camshaft
+Cylinder head
+Thermostat, water pipes
+Oil cooler
+Auxiliary component brackets
5. Remove fuel injection pump bracket.
6. If the replacement of pilot bushing is necessary, remove it
with pilot bushing puller (SST).
7. Remove rear oil seal retainer.
+Insert a flat-bladed screwdriver between main bearing cap
and rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
+Punch out with a flat-bladed screwdriver.
+Be careful not to damage rear oil seal retainer.
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
+Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-3070, ªCON-
NECTING ROD SIDE CLEARANCEº.
JEM193G
SEM500G
JEM195G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3068

CAUTION:
When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.
10. Remove connecting rod bearings from connecting rod and
connecting rod cap.
+Store the removed parts in sets by the cylinder No. to avoid
mixing them up.
11. Remove piston rings from pistons.
+Use piston ring expander (Commercial Service Tool).
+Avoid scratching pistons during removal.
+Be careful not to damage piston rings by expanding
excessively.
CAUTION:
+When piston rings are not replaced, make sure that pis-
ton rings are mounted in their original positions.
12. Remove piston from connecting rod.
a. Remove snap rings using snap ring pliers.
b. With an industrial drier, heat pistons to 60 to 70ÉC (140 to
158ÉF).
c. Push out piston pin with a rod approx. 26 mm (1.02 in) in
diameter.
FEM086
JEM196G
JEM197G
JEM198G
JEM199G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3069

13. Remove main bearing cap bolts.
+With a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the
reverse order of that shown in the figure and remove them.
+Before loosening main bearing cap bolts, measure crank-
shaft end play. Refer to EM-3070, ªCRANKSHAFT END
PLAYº.
14. Remove main bearing caps.
+Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder
block and main bearing caps.
+Check the correct installation locations of removed
parts. Store them so they do not get mixed up.
17. Remove oil jet.
18. Remove oil jet check valve.
Inspection
CRANKSHAFT END PLAY
+Measure the moving distance of the crankshaft with the dial
gauge when the crankshaft is moved fully forward or back-
ward.
Standard: 0.085 - 0.25 mm (0.0033 - 0.0098 in)
Limit: 0.30 mm (0.0118 in)
+If the value exceeds the limit, replace thrust bearings with
new ones and measure again. If the measurement exceeds
the limit again, replace crankshaft with a new one.
CONNECTING ROD SIDE CLEARANCE
+Measure the side clearance between connecting rod and
crank arm with feeler gauge.
Standard: 0.200 - 0.350 mm (0.0079 - 0.0138 in)
Limit: 0.4 mm (0.016 in)
+If the value exceeds the limit, replace connecting rod and
measure again. If the measurement exceeds the limit again,
replace the crankshaft.
JEM200G
JEM201G
JEM202G
JEM203G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3070

PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
27.997 - 28.005 mm (1.1022 - 1.1026 in)
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate interference fit of piston pin to piston.
Dp þ dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
2nd ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
Top ring 0.1 mm (0.004 in)
2nd ring 0.1 mm (0.004 in)
+To measure top ring side clearance, align the outer circum-
ferences of the ring and piston while pressing ring upward
against the upper surface of the ring groove. Under this
condition, measure the clearance between ring and bottom
surface of the ring groove.
+If out of specification, replace piston ring. If clearance
exceeds maximum limit with new ring, replace piston.
PISTON RING END GAP
End gap:
Top ring 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring 0.37 - 0.52 mm (0.0146 - 0.0205 in)
Oil ring 0.30 - 0.55 mm (0.0118 - 0.0217 in)
Max. limit of ring gap:
Top ring 1.0 mm (0.039 in)
2nd ring 1.0 mm (0.039 in)
Oil ring 1.0 mm (0.039 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
AEM023
AEM024
SEM024AA
JEM205G
SEM599A
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3071

Refer to SDS (EM-3094).
+When replacing the piston, check the cylinder block surface
for scratches or seizure. If scratches or seizure is found,
hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
CYLINDER BLOCK DISTORTION AND WEAR
+Clean upper surface of cylinder block. Use a reliable straight-
edge and feeler gauge to check the flatness of cylinder block
surface. Check along six positions shown in the figure.
Distortion limit: 0.04 mm (0.0016 in)
+If out of specification, resurface it. The limit for cylinder block
resurfacing is determined by cylinder head resurfacing in
engine.
Resurfacing limit:
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A+B=0.07mm (0.0028 in)
Nominal cylinder block height from crankshaft center:
252.95 - 253.05 mm (9.9586 - 9.9626 in)
+If necessary, replace cylinder block.
SEM038F
SEM003F
SEM501G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3072

PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore in X and Y direc-
tions at A, B and C for wear, out-of-round and taper.
Cylinder bore inner diameter:
Standard
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit
0.07 mm (0.0028 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X þ Y):
Limit 0.015 mm (0.0006 in)
Taper (C þ A):
Limit 0.010 mm (0.0004 in)
2. Check for scratches and seizure. If seizure is found, hone it.
3. Measure piston skirt diameter.
Piston diameter ªAº:
Standard
88.940 - 88.970 mm (3.5016 - 3.5027 in)
Measuring point ªaº (Distance from the top):
59.0 mm (2.323 in)
4. Check that piston-to-bore clearance is within specification.
+Calculate the clearance by using outer diameter at piston
skirt and inner diameter of cylinder (direction of X, point B):
Piston-to-bore clearance = Cylinder bore þ Piston
diameter ªAº
Standard [at room temperature 20ÉC (68ÉF)]:
0.050 - 0.070 mm (0.0020 - 0.0028 in)
+If the value is out of the specified range, replace piston and
piston pin assembly.
+If cylinder block or pistons are replaced with new ones, select
piston as follows:
When using a new cylinder block:
+Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface
at the rear of cylinder block and select a piston of the same
grade.
+The part No. of piston is specified together with the piston pin
as an assembly.
JEM206G
SEM899G
SEM258C
JEM208G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3073