engine NISSAN PICK-UP 1998 Owner's Manual

REMOVAL AND INSTALLATION
Separate type
lRemove release bearing.
lInstall release bearing with suitable drift.
lInstall retainer spring and holder spring.
SCL747-A
.(TD25 engine only)
CL145
SCL705
SCL217
CLUTCH RELEASE MECHANISM
CL-9

Clutch Disc and Flywheel
INSPECTION
lCheck clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.
lCheck clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
lCheck clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):
240 1.0 mm (0.039 in)
250 1.0 mm (0.039 in)
Runout limit:
0.7 mm (0.028 in) TD25 engine
1.0 mm (0.039 in) Except TD25 engine
Distance of runout check point (from hub center):
240 115 mm (4.53 in)
250 120 mm (4.72 in)
lCheck flywheel and clutch disc contact surface for slight
burns or discoloration. Repair flywheel with emery paper.
lCheck flywheel runout.
Maximum allowable runout:
Refer to EM section (``Inspection'', ``CYLINDER
BLOCK'').
SCL206
SCL229-A
SCL221-A
SEM929A
CLUTCH DISC AND CLUTCH COVER
CL-12

INSTALLATION
lApply recommended grease to contact surface of spline por-
tion.
Too much lubricant might cause clutch disc facing damage.
Clutch Cover
INSPECTION
lAdjust unevenness of diaphragm spring with Tool.
Uneven limit:
250 0.5 mm (0.020 in)
240 0.5 mm (0.020 in) Except TD25 engine
0.7 mm (0.028 in) TD25 engine
lSet Tool and check height and unevenness of diaphragm
spring.
Set 0.2 mm (0.008 in) feeler gauges on distance pieces
(ST20050100) when checking 240 or 250.
Diaphragm spring height ``A'':
240 37.5 - 39.5 mm (1.476 - 1.555 in)
250 37.0 - 39.0 mm (1.457 - 1.535 in)
lCheck thrust rings for wear or damage by shaking cover
assembly up and down to listen for chattering noise, or lightly
hammering on rivets for a slightly cracked noise. Replace
clutch cover assembly if necessary.
lCheck pressure plate and clutch disc contact surface for
slight burns or discoloration. Repair pressure plate with
emery paper.
lCheck pressure plate and clutch disc contact surface for
deformation or damage. Replace if necessary.
INSTALLATION
lInsert Tool into clutch disc hub while installing clutch cover
and disc.
lBe careful not to allow grease to contaminate clutch facing.
lTighten bolts in numerical order, in two steps.
First step:
:10-20Nzm (1.0 - 2.0 kg-m,7-14ft-lb)
Final step:
:22-29Nzm (2.2 - 3.0 kg-m, 16 - 22 ft-lb)
SCL466-A
SCL219-A
SCL749
CLUTCH DISC AND CLUTCH COVER
Clutch Disc and Flywheel (Cont'd)
CL-13

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER (All models)
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Unit: mm (in)
Inner
diameterLHD model 17.46 (11/16)
RHD model 19.05 (3/4)
CLUTCH DISC
Destination Europe
Model 240
Engine KA24E TD25
Facing size
mm (in)
(Outer dia. x inner
dia. x thickness)240 x 150 x 3.5
(9.45 x 5.91 x 0.138)240 x 160 x 3.5
(9.45 x 6.30 x 0.138)
Thickness of disc
assembly
With load
mm (in)7.8 - 8.2
(0.307 - 0.323)
With 4,904 N
(500 kg, 1,103 lb)7.5 - 7.9
(0.295 - 0.311)
With 3,923 N
(400 kg, 882 lb)
CLUTCH COVER
Model 240
Engine TD25 KA24E
Full load
N (kg, lb)3,923
(400, 882)4,413
(450, 992)
Inspection and Adjustment
CLUTCH PEDALUnit: mm (in)
Pedal height ``H*''
LHD model
TD25 and KA24E engine models 221 - 231 (8.70 - 9.09)
RHD model
TD25 andKA24E engine models 195 - 205 (7.68 - 8.07)
Pedal free play (at clevis pin) 1 - 1.5 (0.039 - 0.059)
*: Measured from surface of melt sheet to pedal pad
CLUTCH DISCUnit: mm (in)
Model 240
Engine model KA24E TD25
Wear limit of facing surface to rivet
head0.3 (0.012) or more
Runout limit of facing 1.0 (0.039) 0.7 (0.028)
Unit: mm (in)
Model 240
Distance of runout check point
(from the hub center)115 (4.53)
Maximum backlash of spline
(at outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Model 240
Engine model KA24E TD25
Diaphragm spring
height37.5 - 39.5
(1.476 - 1.555)
Uneven limit of dia-
phragm spring toe
height0.5 (0.020) 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14

BODY & TRIM
SECTIONBT
CONTENTS
PRECAUTIONS......................................................... 1
Service Notice ........................................................ 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
GENERAL SERVICING............................................. 2
Clip and Fastener .................................................. 2
BODY END................................................................ 5
Body Front End ...................................................... 5
Body Rear End ...................................................... 8
DOOR....................................................................... 10
Front Door ............................................................ 10
Rear Door ............................................................ 11
INSTRUMENT PANEL............................................. 12
INTERIOR TRIM...................................................... 15
Side and Floor Trim ............................................. 15
Door Trim ............................................................. 18
Roof Trim ............................................................. 21EXTERIOR............................................................... 24
SEAT........................................................................ 30
Front Seat ............................................................ 30
Heated Seat ......................................................... 32
Rear Seat ............................................................. 33
Jump Seat ............................................................ 34
SUNROOF................................................................ 35
WINDSHIELD AND WINDOWS.............................. 36
Windshield............................................................ 37
Side Window ........................................................ 38
MIRROR................................................................... 39
Door Mirror ........................................................... 39
CAB AND REAR BODY.......................................... 40
Removal ............................................................... 40
Body Mounting ..................................................... 41
BODY ALIGNMENT................................................. 43
Engine Compartment ........................................... 44
Underbody............................................................ 46
.For seat belt, refer to MA and RS section.
.For wiring diagrams of body electrical systems, refer to EL section.BT

Removal
CAB BODY
lRemove the following parts in engine compartment at least.
(1) Main harness and other wiring harnesses
lDisconnect brake and clutch line in engine compartment.
lRemove the following parts from underbody at least.
(1) Transmission and transfer control levers
(2) Parking brake control lever and cables
(3) Main harness and other wiring harnesses
REAR BODY
lRemove the following parts at least.
(1) Rear combination lamp and license plate lamp harness
(2) Fuel filler tube fixing screws
SBF348C
ABT189
CAB AND REAR BODY
BT-40

Engine Compartment
MEASUREMENT
SBT459
BODY ALIGNMENT
BT-44

MEASUREMENT POINTS
SBT460
BODY ALIGNMENT
Engine Compartment (Cont'd)
BT-45

ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
DIAGNOSTIC TROUBLE CODE INDEX................... 1
Alphabetical & Numerical Index for DTC
(KA engine) ............................................................ 1
PRECAUTIONS AND PREPARATION..................... 2
Special Service Tools ............................................ 2
Commercial Service Tool....................................... 4
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 4
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 4
KA
PRECAUTIONS AND PREPARATION..................... 5
Engine Fuel & Emission Control System .............. 5
Precautions ............................................................ 6
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM..................................................................... 8
Circuit Diagram ...................................................... 8
System Diagram .................................................... 9
ECCS Component Parts Location ....................... 10
Vacuum Hose Drawing ........................................ 12
System Chart ....................................................... 13
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION..................................... 14
Multiport Fuel Injection (MFI) System.................. 14
Distributor Ignition (DI) System............................ 17
Air Conditioning Cut Control ................................ 18
Fuel Cut Control (at no load & high engine
speed) .................................................................. 18
EVAPORATIVE EMISSION SYSTEM..................... 19
Description ........................................................... 19
Inspection ............................................................. 19POSITIVE CRANKCASE VENTILATION................ 21
Description ........................................................... 21
Inspection ............................................................. 21
BASIC SERVICE PROCEDURE............................. 22
Fuel Pressure Release ........................................ 22
Fuel Pressure Check ........................................... 22
Injector Removal and Installation ........................ 23
Fast Idle Cam (FIC) Inspection and
Adjustment ........................................................... 24
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment ........................................................... 25
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION......................................................... 36
Introduction .......................................................... 36
Diagnostic Trouble Code (DTC) .......................... 36
Malfunction Indicator Lamp (MIL) ........................ 38
CONSULT ............................................................ 45
TROUBLE DIAGNOSIS - Introduction.................. 54
Introduction .......................................................... 54
Diagnostic Worksheet .......................................... 54
TROUBLE DIAGNOSIS - Work Flow..................... 56
Work Flow ............................................................ 56
Description for Work Flow ................................... 57
TROUBLE DIAGNOSIS - Basic Inspection.......... 58
Basic Inspection ................................................... 58
TROUBLE DIAGNOSIS - General Description..... 61
Fail-Safe Chart ..................................................... 61
Symptom Matrix Chart ......................................... 62
CONSULT Reference Value in Data Monitor
Mode .................................................................... 64
Major Sensor Reference Graph in Data
Monitor Mode ....................................................... 66
ECM Terminals and Reference Value ................. 68
EC

TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 75
Main Power Supply and Ground Circuit .............. 75
TROUBLE DIAGNOSIS FOR ``CAMSHAFT
POSI SEN'' (DTC 11).............................................. 82
Camshaft Position Sensor (CMPS) ..................... 82
TROUBLE DIAGNOSIS FOR ``MASS AIR
FLOW SEN'' (DTC 12)............................................ 89
Mass Air Flow Sensor (MAFS) ............................ 89
TROUBLE DIAGNOSIS FOR ``COOLANT TEMP
SEN'' (DTC 13)........................................................ 95
Engine Coolant Temperature Sensor (ECTS) ..... 95
TROUBLE DIAGNOSIS FOR ``IGN SIGNAL-
PRIMARY'' (DTC 21)............................................... 99
Ignition Signal ...................................................... 99
TROUBLE DIAGNOSIS FOR ``OVER HEAT''
(DTC 28)................................................................. 106
Overheat ............................................................ 106
TROUBLE DIAGNOSIS FOR ``INT AIR TEMP
SEN'' (DTC 41)...................................................... 109
Intake Air Temperature Sensor ......................... 109
TROUBLE DIAGNOSIS FOR ``THROTTLE POSI
SEN'' (DTC 43)...................................................... 113
Throttle Position Sensor .................................... 113
TROUBLE DIAGNOSIS FOR
NON-DETECTABLE ITEMS.................................. 118
Vehicle Speed Sensor (VSS) ............................ 118
Heated Oxygen Sensor (HO2S)
- LHD Models - .................................................. 123
Heated Oxygen Sensor Heater
- LHD Models - .................................................. 127
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve .......................................... 131
Neutral Position Switch ...................................... 136
EVAP Canister Purge Control Solenoid Valve .. 140
Injector ............................................................... 144
Start Signal ........................................................ 149
Fuel Pump.......................................................... 151
Power Steering Oil Pressure Switch ................. 157
Swirl Control Valve Control Solenoid Valve ...... 161
IACV-FICD Solenoid Valve ................................ 168
MIL & Data Link Connectors ............................. 173
TD
INJECTION SYSTEM............................................ 176
Fuel System ....................................................... 176
INJECTION PUMP................................................. 178
Inspection ........................................................... 178
Removal ............................................................. 178
Installation and Adjustment................................ 180
Disassembly ....................................................... 183
Load Timer Adjustment...................................... 183
Start Q Adjustment Lever .................................. 184
INJECTION NOZZLE............................................. 186Removal and Installation ................................... 186
Disassembly ....................................................... 186
Inspection ........................................................... 187
Cleaning ............................................................. 187
Assembly............................................................ 189
Test and Adjustment .......................................... 189
FUEL SYSTEM CHECK........................................ 191
Bleeding Fuel System ........................................ 191
Bleeding Fuel Filter ............................................ 192
Checking Priming Pump .................................... 192
Checking Fuel Filter Switch ............................... 192
POSITIVE CRANKCASE VENTILATION.............. 193
Description ......................................................... 193
Inspection ........................................................... 193
QUICK-GLOW SYSTEM........................................ 194
Component Parts Location ................................ 194
Circuit Diagram .................................................. 195
Description ......................................................... 196
Wiring Diagram .................................................. 197
Glow Control Unit Circuit Inspection (For Cold
Areas)................................................................. 203
Glow Control Unit Circuit Inspection (Except
for Cold Areas)................................................... 206
Component Inspection ....................................... 208
EGR SYSTEM........................................................ 210
Component Parts Location ................................ 210
Description ......................................................... 211
Operation ........................................................... 212
Wiring Diagram .................................................. 213
System Inspection.............................................. 217
Component Inspection ....................................... 218
SOLENOID TIMER................................................ 220
Description ......................................................... 220
Operation ........................................................... 220
Wiring Diagram .................................................. 222
Inspection ........................................................... 224
FUEL CUT SYSTEM.............................................. 225
Wiring Diagram .................................................. 225
FUEL HEATER SYSTEM...................................... 226
Description ......................................................... 226
Wiring Diagram .................................................. 227
System Inspection.............................................. 228
Component Inspection ....................................... 228
FAST IDLE CONTROL CIRCUIT.......................... 230
Wiring Diagram .................................................. 230
Electrical Components Inspection ..................... 231
KA
SERVICE DATA AND SPECIFICATIONS (SDS). 232
General Specifications ....................................... 232
Inspection and Adjustment ................................ 232