NISSAN PICK-UP 2001 Repair Manual

When re-using a removed cylinder block:
+Measure the inner diameter of the cylinder block bore.
+Determine the bore grade by comparing the measurement
with the values under ªCylinder bore IDº of the table below.
Choose a piston of the same grade.
Selective fitting for piston:
Unit: mm (in)
Grade (punched) 1 2 3
Cylinder bore ID89.000 - 89.010
(3.5039 - 3.5043)89.010 - 89.020
(3.5043 - 3.5047)89.020 - 89.030
(3.5047 - 3.5051)
Piston OD88.940 - 88.950
(3.5016 - 3.5020)88.950 - 88.960
(3.5020 - 3.5024)88.960 - 88.970
(3.5024 - 3.5027)
5. Determine piston oversize according to amount of cylinder
wear.
+For oversize pistons, 0.25 and 0.5 OS [0.25 mm (0.0098
in), 0.5 mm (0.0197 in) oversize] are available as service
parts. Refer to SDS, EM-3094. When using an oversize
piston, hone cylinder so that the clearance between pis-
ton and cylinder becomes the specified value. Be sure to
use appropriate oversize piston ring for the oversize pis-
ton.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation:D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Cut cylinder bores.
+When any cylinder needs boring, all other cylinders
must also be bored.
+Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so in diameter at a time.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper.
+Measurement should be done after cylinder bore cools
down.
SEM508GB
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3074

CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
Taper (A þ B):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
3. Measure crankshaft runout at No. 3 (center) journal.
Runout (Total indicator reading):
Standard 0.05 mm (0.0020 in)
Limit 0.10 mm (0.0039 in)
MAIN BEARING HOUSING INNER DIAMETER
+Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque.
+Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
+If the measurement is out of the specified range, replace
cylinder block and main bearing caps.
BEARING CLEARANCE
+Use either of the following two methods, however, method
ªAº gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing
1. Install main bearings to the cylinder block and bearing cap,
and tighten the bolts to the specified torque. Then, measure
the inner diameter of the main bearings.
Oil clearance = Bearing ID þ Crankshaft journal OD
Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
SEM316A
JEM212G
JEM214G
JEM213G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3075

2. If the value is out of the specified range, select main bear-
ings to obtain the specified oil clearance, based on the mea-
surements of the main bearing housing inner diameter and
crankshaft journal outer diameter.
When using a new cylinder block and crankshaft:
1) Identify the bearing housing grade (No. 0, 1, or 2) on LH
surface at the rear of the cylinder block, and locate the appli-
cable grade on the ªGradeº row in the table below.
2) Identify the journal grade (No. 0, 1, or 2) on the front surface
of the crankshaft, and locate the applicable grade under the
ªGradeº column on the table.
3) The main bearing to be used (STD 0 to STD 4) can be
located in the cell where the row and column cross.
When re-using removed cylinder block and crankshaft:
1) Measure the inner diameter of cylinder block main bearing
housing.
2) Locate the applicable cell where the measurement falls, on
ªCylinder block main bearing housing IDº row on the table.
3) Measure the outer diameter of the crankshaft journal.
4) Locate the applicable cell where the measurement falls,
under ªCrankshaft journal ODº column on the table.
5) The main bearing to be used (STD 0 to STD 4) can be
located in the cell where the row and column cross.
JEM208G
JEM215G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3076

Selective fitting for main bearing
Unit: mm (in)
Cylinder block main bearing housing ID66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft journal
ODGrade (punched) 0 1 2
62.967 - 62.975
(2.4790 - 2.4793)0+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
62.959 - 62.967
(2.4787 - 2.4790)1+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
62.951 - 62.959
(2.4784 - 2.4787)2+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
3. When the specified oil clearance is not obtained with stan-
dard size main bearings, use undersized bearings.
+When an undersized bearing is used, measure the inner
diameter of the bearing while the bearing is installed. Grind
crankshaft journal so that the specified oil clearance is
obtained.
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
Connecting Rod Bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter ªCº of connecting rod.
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
JEM216G
AEM027
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3077

4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing.
When using a new crankshaft and connecting rods:
+Identify the pin diameter grade (No. 0, 1, or 2) on front sur-
face of crankshaft and select the connecting rod bearings of
the same grade.
+There is no grading for the inner diameter of the big end of
the connecting rod.
When re-using the removed crankshaft and connecting
rods:
+Measure the inner diameter of the big end of the connecting
rod and make sure it is within the specified range.
+Measure the outer diameter of the crankshaft pin.
+Determine the crankshaft pin grade by comparing the mea-
surement with the values under the column ªCrankshaft pin
ODº of the table below. Choose the bearings of the same
grade.
Selective fitting for connecting rod bearing
Unit: mm (in)
Connecting rod big end ID55.000 - 55.013
(2.1654 - 2.1659)
Crankshaft pin OD Grade (punched) 0 (no punching)
51.968 - 51.974
(2.0460 - 2.0462)0+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 0
1.492 - 1.496
(0.0587 - 0.0589)
0.031 - 0.061
(0.0012 - 0.0024)
Black
51.961 - 51.968
(2.0457 - 2.0460)1+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 1
1.496 - 1.500
(0.0589 - 0.0591)
0.031 - 0.061
(0.0012 - 0.0024)
Brown
51.954 - 51.961
(2.0454 - 2.0457)2+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 2
1.500 - 1.504
(0.0591 - 0.0592)
0.031 - 0.061
(0.0012 - 0.0024)
Green
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing.
+When an undersized bearing is used, measure the inner
diameter of the bearing while the bearing is installed. Grind
the pins so that the specified oil clearance is obtained.
AEM034
JEM215G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3078

Undersize bearing
Unit: mm (in)
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
Standard dimension R:
1.5 - 1.7 mm (0.0591 - 0.0669 in)
Method B (Using plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while plasti-
gage is being inserted.
+When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If
incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.
MAIN BEARING CRUSH HEIGHT
+When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of
bearing must protrude.
Standard: There must be crush height.
+If the standard is not met, replace main bearings.
MAIN BEARING CAP BOLT DEFORMATION
+Measure the outer diameter of threaded area, d1 and d2, at
the points specified in the figure.
+When the necked point is identified at a point other than
where specified, measure at the point as d2.
+Calculate the difference between d1 and d2.
Limit: 0.13 mm (0.0051 in)
JEM216G
EM142
SEM502G
JEM219G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3079

CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
1. Measure inner diameter ªCº of bushing.
Inner diameter ªCº:
Standard 28.026 - 28.038 mm (1.1034 - 1.1039 in)
2. Measure outer diameter ªDpº of piston pin.
Outer diameter ªDpº:
Standard 27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard: 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit: 0.057 mm (0.0022 in)
If it exceeds the limit, replace connecting rod assembly
and/or piston set with pin.
CONNECTING ROD BOLT DEFORMATION
+Install nuts to connecting rod bolts. Check that the nut can
be screwed smoothly on bolt threads by hand to the last
thread on the bolt.
+If the nut does not screw in smoothly, measure the outer
diameter of the bolt thread at the point specified in the figure.
+If a necked point is identified, measure at that point.
Standard: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit: 8.75 mm (0. 3445 in) dia.
+If the measurement exceeds the limit, replace connecting rod
bolts and nuts.
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
CAUTION:
+The signal plate is built into the flywheel assembly. Be
careful not to damage the signal plate, especially the
teeth.
+Check the signal plate for deformation or cracks.
+Never place the flywheel assembly with the signal plate
facing down.
+Keep any magnetized objects away from the signal plate.
+Do not allow any magnetic materials to contact the sig-
nal plate teeth.
SEM673E
JEM220G
AEM100
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3080

OIL JET
+Check nozzle for deformation or damage.
+Check oil passage for obstruction by blowing in air on nozzle
side.
+If abnormality is found, clean or replace.
OIL JET RELIEF VALVE
Using a clean resin rod, press down on the check valve inside
relief valve. Check for appropriate bounce/repulsion and smooth
operation.
Assembly
PISTON
1. With using snap ring pliers, install snap rings to grooves at
the rear side of the piston.
+Install securely to fully fit into the groove.
2. Install piston to the connecting rod.
+Heat the piston with an industrial drier to 60 to 70ÉC (140 to
158ÉF) so that the piston pin can be easily inserted by finger.
Then, insert the piston pin from the front of the piston into the
piston and into the connecting rod.
+Assemble so that the front mark on the piston top surface
and cylinder No. stamped on connecting rod are positioned
as shown in the figure.
3. Install snap ring on piston front.
+Refer to step 1. above for notes for installation.
+After installing, check that the connecting rod moves
smoothly.
4. Install piston rings using piston ring expander (Commercial
Service Tool).
+Be extremely careful to avoid any damage to the piston.
+Install top ring and second ring with the punched surface
facing upward.
Identification mark:
Top ring R
Second ring 2R
+Install rings so that three closed gap position 120É apart one
another.
+Closed gaps do not need to face in a specific directions, as
long as each are positioned 120É apart.
JEM221G
JEM222G
JEM227G
JEM228G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3081

CRANKSHAFT
1. Blow air sufficiently into the coolant passage, oil passage in
the cylinder block, inside of crankshaft case, and inside of
cylinder bores to remove any foreign materials.
2. Install oil jet relief valves.
3. Install oil jets.
4. Install main bearings and thrust bearings.
a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are
installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
+Install thrust bearings with oil groove facing in the direction
of the crankshaft arm (outside).
c. Be sure to install main bearings in the correct direction.
+Make sure those with oil holes or oil grooves are mounted on
the cylinder block side, and those without oil holes or oil
grooves are on the main cap side.
+Before installing, apply engine oil on the front (inner) surfaces
of bearings. Do not apply oil to the back surfaces, but thor-
oughly clean them.
+Align stopper notches on bearings and install.
+Check the oil holes on cylinder block and those on bearings
are aligned.
5. Install crankshaft to cylinder block.
+Make sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
+Identify main bearing caps by the punched mark. Install
correctly, matching the journal No. on the bearing cap and
the journal, with the front mark facing forward.
+Main bearing caps are commonly processed with the cylin-
der block. Therefore, caps and cylinder block should be
replaced as a set.
JEM223G
JEM224G
JEM213G
JEM225G
CYLINDER BLOCKYD25DDTi
Assembly (Cont'd)
EM-3082

7. Check the main bearing cap bolts for deformation.
Refer to EM-3079, ªMAIN BEARING CAP BOLT DEFORMA-
TIONº.
8. Tighten the main bearing cap bolts according to the follow-
ing procedure:
a. Apply engine oil to the threaded part and seat surface of
each bolt.
b. Tighten to 25 to 30 Nzm (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (when using a protrac-
tor)
d. Then, tighten 90É to 95É [target: 90É].
+Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
+After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
+Check crankshaft end play. Refer to EM-3070, ªCRANK-
SHAFT END PLAYº.
9. Check the outer diameter of connecting rod bolts. Refer to
EM-3080, ªCONNECTING ROD BOLT DEFORMATIONº.
10. Install piston to connecting rod.
11. Install connecting rod bearing to connecting rod and connect-
ing rod cap.
+Before installing, apply engine oil on the front (inner) surface
of bearing. Do not apply oil to the back surface, but thor-
oughly clean it.
+Align stopper notches on connecting rod and protrusions on
bearing and install.
12. Install piston and connecting rod assembly to crankshaft.
+Set crankshaft pin of the installation location at BDC.
+Match the cylinder No. of connecting rod to the location of
cylinder.
+Using piston ring compressor (Commercial Service Tool),
install so that the front mark on the piston top surface faces
in the direction of engine front.
13. Install connecting rod caps.
+Match the cylinder No. punched on connecting rod and that
on cap.
+Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
JEM200G
JEM226G
JEM229G
JEM230G
JEM227G
CYLINDER BLOCKYD25DDTi
Assembly (Cont'd)
EM-3083