NISSAN PICK-UP 2001 Repair Manual

Installation
1. Referring to the figure and the marking which were made for
installation, connect the injection tubes to all the cylinders.
2. Connect temporarily the tubes to the cylinder head side only
by screwing 2 to 3 turns. Make sure that all tubes can be
connected to the pump side also.
3. Then, tighten the flare nuts of the cylinder head side and
pump side, starting from the opposite side from you.
4. Attach the injection tube clamp in the direction shown in the
figure.
5. Insert tightening bolt of the clamp (4-tube type) from the rear
to the front of the engine.
Injection Nozzle Oil Seal
Removal
Using a tool such as a flat-bladed screwdriver, pry the flange of
the seal, then remove it.
Installation
1. After the high-pressure injection nozzle assembly is installed,
push the seal from the cylinder head side until it contacts the
flange.
2. Make sure that the garter spring of the seal on the high-
pressure injection nozzle assembly side is not falling.
+Replace the oil seal with new one when the high-pres-
sure injection nozzle assembly is removed. (It is not nec-
essary to replace the oil seal when only injection tubes
are removed.)
JEF341Y
JEC335D
JEF343Y
BASIC SERVICE PROCEDUREYD25DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-3416

Spill Tube
Removal
Loosen and remove the mounting bolts and flare nuts in the
reverse order of the numbers in the figure.
+When the flare nuts are loosened, hold the head of hexago-
nal retaining bolts (head inside) using a wrench.
Installation
1. Tighten the flare nuts and mounting bolts in the numerical
order shown in the figure.
+When the flare nuts are tightened, hold the head of the hex-
agonal retaining bolts (head inside) using a wrench.
2. To prevent interference with the rocker cover, place the spill
gasket joint within the range shown by the arrow, then tighten
the mounting bolts. (Be especially careful about No. 2 and 4
cylinders.)
+After the spill tube is installed, check the airtightness of
the spill tube.
+After the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.
High Pressure Injection Nozzle Assembly
Removal
1. Remove the nozzle support, then pull out the high-pressure
injection nozzle assembly by turning it clockwise/
counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the
copper washer inside the cylinder head.
CAUTION:
Do not disassemble the high-pressure injection nozzle.
Installation
1. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.
TEST AND ADJUSTMENT
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and
make sure your eyes are properly protected with goggles.
JEF344Y
JEF345Y
BASIC SERVICE PROCEDUREYD25DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-3417

Inspection for Spill Tube Airtightness
Before the rocker cover is installed, perform the inspection as
follows.
1. Connect the handy vacuum pump to the spill hose.
2. Check that the airtightness is maintained after the negative
pressure shown below is applied.
Standard:
þ53.3 to þ66.7 kPa (þ533 to þ667 mbar, þ400 to
þ500 mmHg, þ15.75 to þ19.69 inHg)
Air Bleeding of Fuel Piping
After the repair, bleed air in the piping by pumping the priming
pump up and down until it becomes heavy. Refer to EC-3427.
Injection Pressure Test
1. Install injection nozzle assembly to injection nozzle tester
and bleed air from flare nut.
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
New
18,500 - 20,500 kPa (185 - 205 bar, 189 - 209
kg/cm
2, 2,682 - 2,973 psi)
Limit
16,200 kPa (162 bar, 165 kg/cm
2, 2,349 psi)
+The injection nozzle assembly has a 2-stage pressure injec-
tion function. However, the judgement should be made at the
first stage of the valve opening pressure.
Always check initial injection pressure using a new nozzle.
JEF346Y
SEC943C
JEF348Y
BASIC SERVICE PROCEDUREYD25DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-3418

Spray Pattern Test
1. Check spray pattern by pumping tester handle one full stroke
per second.
NG spray pattern:
Does not inject straight and strong (B in the fig-
ure).
Fuel drips (C in the figure).
Does not inject evenly (D in the figure).
2. If the spray pattern is not correct, replace injection nozzle
assembly.
Electronic Control Fuel Injection Pump
REMOVAL AND INSTALLATION
Removal
1. Remove the parts shown below.
+Engine hood
+Engine coolant (drain)
+Engine cover
+Heater pipe under intake manifold
+Injection tubes
+Right splash cover (with undercover)
+Right front wheel
SEF434Z
JEC336D
BASIC SERVICE PROCEDUREYD25DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-3419

2. Disconnect the fuel hoses from the fuel injection pump.
3. Disconnect the harness connector from the fuel injection
pump.
+Disconnect the connector by pulling the connector stopper
fully.
+When the stopper is fully pulled, the connector will be dis-
connected together. For installation, push the connector half
way first, then press the stopper until it locks, so that the
connector is connected together.
4. Remove the fuel injection pump rear bracket.
5. Remove the front chain case.
+Move the power steering fluid reservoir tank from the bracket.
+Loosen and remove the mounting bolts in the reverse order
of the numbers shown in the figure.
+As for bolts 6, 10, and 11, remove with rubber washer
because there is not enough space for removing only the
bolts.
CAUTION:
To prevent foreign objects from getting in the engine, cover
the opening during the removal of the front chain case.
6. Adjust the No. 1 cylinder to the top dead center position.
+Turn the crankshaft pulley clockwise, then align the align-
ment mark (punched mark) of the camshaft sprocket to the
position shown in the figure.
+There is no indicator on the crankshaft pulley.
+It is not necessary to mark the secondary timing chain for
removal because it can be matched by the link color for
installation. However, the alignment mark on the fuel injec-
tion pump sprocket is difficult to see; mark it if necessary.
7. Remove the chain tensioner.
a. Push the plunger of the chain tensioner, then fix it with a tool
such as a push pin.
b. Using the hexagon wrench (face to face: 5 mm) (SST),
remove the mounting bolts, then remove the chain tensioner.
+A multi-purpose tool may also be used.
JEF351Y
JEF352Y
JEF353Y
JEF354Y
JEF355Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3420

8. Remove the timing chain slack guide.
+Using the hexagon wrench (face to face: 6 mm, short-type)
(SST), remove the mounting bolts, then remove the timing
chain slack guide.
9. Remove the timing chain tension guide.
10. Remove the secondary timing chain.
+Only the timing chain can be removed without removing the
sprockets.
11. Fix the fuel injection pump sprocket.
a. Insert the positioning stopper pin (SST) in the 6 mm (0.24 in)
dia. hole of the fuel injection pump sprocket.
b. Using the torx wrench (SST), turn the pump shaft gradually
to adjust the hole position of the fuel injection pump sprocket.
c. Insert the positioning stopper pin through the fuel injection
pump body to fix the sprocket.
+Insert the positioning stopper pin until its flange contacts the
fuel injection pump sprocket.
d. Remove the torx wrench (SST).
JEF356Y
JEF357Y
JEF358Y
JEF359Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3421

12. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), remove the mounting bolts of the fuel injection pump
sprocket.
+It is not necessary to remove the washer of the fuel injection
pump sprocket.
13. Using the sprocket holder (SST), hold the fuel injection pump
sprocket to prevent falling.
+When the sprocket holder is installed, if the positioning stop-
per pin interferes, pull out the stopper pin approximately 10
mm (0.39 in), then install it.
+After the sprocket holder is installed temporarily, insert the
extension bar (SST) and Torx socket in the three holes A.
After positioning the holes, tighten the holder mounting bolts.
(Refer to the step 14 about the tool.)
+The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
+Make sure that the a- and b-faces of the sprocket holder
contact the bottom side of the sprocket 15 mm (0.59 in)
(small diameter side).
CAUTION:
Do not remove the sprocket holder until the fuel injection
pump is installed.
+After the sprocket holder is installed, pull out the positioning
stopper pin (SST) from the fuel injection pump sprocket.
14. Using the extension bar [SST: whole length 43 mm (1.69 in)]
and the Torx socket (Q6-E12: commercially available),
remove the mounting bolts, them remove the fuel injection
pump toward the rear of the engine.
+Even after all the mounting bolts are removed, the fuel injec-
tion pump is still held by a dowel pin.
CAUTION:
Do not disassemble or adjust the fuel injection pump.
JEF360Y
JEF361Y
JEF362Y
JEF363Y
JEF364Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3422

15. Remove the fuel injection pump mounting bolts.
+The seal washer of the mounting bolts cannot be reused.
CAUTION:
For removal, be careful not to drop the seal washer into the
engine.
Installation
+It is not necessary to adjust the injection timing by changing
the installation angle which used to be performed with con-
ventional fuel injection pumps. The installation position can
be simply decided by the dowel pin and the mounting bolts.
1. Before the fuel injection pump is installed, check that the
notch of its flange and the 6 mm (0.24 in) dia. hole on the
body are aligned.
2. Insert the fuel injection pump to the mounting position from
the rear of the engine.
+Adjust the fuel injection pump bracket position to the dowel
pin, then install it.
3. Using the extension bar (SST) and the Torx socket, tighten
the mounting bolts of the fuel injection pump.
4. Remove the sprocket holder (SST).
5. Using the torx wrench (SST), turn the pump shaft gradually
to adjust the position of the flange. Then, insert the position-
ing stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the
fuel injection pump sprocket through the pump flange and the
pump body.
6. Remove the torx wrench (SST).
JEF365Y
JEF366Y
JEF367Y
JEF364Y
JEF358Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3423

7. Using the hexagon wrench (face to face: 6 mm, long-type)
(SST), tighten the sprocket mounting bolt.
+When the washer of the fuel injection pump sprocket is
removed, install it with the marking ªFº (front) facing the front
of the engine.
8. Pull out the positioning stopper pin (SST).
9. Install the secondary timing chain.
+Align the alignment marks of the sprockets and those of the
chain, then install it.
+The figure shows the installation state and names of the
secondary timing chain and other related parts.
10. Install timing chain tension guide.
+The upper installation bolt is longer than the lower.
11. Using a hexagon wrench (face to face: 6 mm, short-type)
(SST), install the timing chain slack guide.
12. Install the chain tensioner.
a. Push the plunger of the chain tensioner, then hold it with a
tool such as a push pin, and install it.
b. Using a hexagon wrench (face to face: 5 mm) (SST), tighten
the mounting bolts.
+Installation is possible by a multi-purpose tool also.
c. Pull out the tool such as a push pin which holds the plunger.
+Make sure that the alignment marks of the sprockets and
timing chain are aligned.
JEF360Y
JEF368Y
JEF356Y
JEF355Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3424

13. Install the front chain case.
a. Install the tension guide to the back side of the front chain
case.
+If the front chain case is tilted, the tension guide may fall off.
Therefore, when installing the front chain case, hold it verti-
cally.
b. Apply Three Bond 1207C (KP510 00150) to both ends of the
arch area of the oil pump (contact surface of rear chain case)
as shown in the figure.
c. Install the front chain case.
+Align the dowel pin of the oil pump case to the pin hole, then
install it.
+Install bolts 6, 10, and 11 (shown in the figure) with the rub-
ber washer to the front chain case.
d. Tighten the mounting bolts in the numerical order shown in
the figure.
e. After all bolts are tightened, tighten the mounting bolts in the
numerical order shown in the figure again.
14. Install the fuel injection pump rear bracket.
+Tighten all the bolts temporarily, then tighten them securely
with the mounting face securely contacting the fuel injection
pump and the pump bracket.
15. Connect the fuel injection pump harness connector.
+Insert the harness connector securely until the stopper locks.
+Push the connector half way first, then press the stopper until
it locks, so that the connector is connected together.
16. Connect the fuel hoses.
+When the hoses are disconnected at the fuel gallery side,
insert until the hoses contact the valve, then install the clamp
securely.
17. Install other parts in the reverse order of removal.
JEF369Y
JEF370Y
JEF352Y
JEF351Y
BASIC SERVICE PROCEDUREYD25DDTi
Electronic Control Fuel Injection Pump
(Cont'd)
EC-3425