engine NISSAN PICK-UP 2001 Repair Manual

Tool number
Tool nameDescription
KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate
NT617
Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
NT041
Changing valve lifter shims
ST16610001
Pilot bushing puller
NT045
Removing crankshaft pilot bushing
KV10111100
Seal cutter
NT046
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder head,
etc.
KV10109300
Pulley holder
NT628
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
PREPARATION
Special Service Tools (YD25DDTi engine)
(Cont'd)
EM-3005

Tool number
Tool nameDescription
KV11106010
Hexagon wrench
NT801
a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
KV11106020
Hexagon wrench
NT803
a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pin
NT804
a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrench
NT805
a: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrench
SBIA0224E
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
Removing and installing mounting bolts of fuel
injection pump sprocket
PREPARATION
Special Service Tools (YD25DDTi engine)
(Cont'd)
EM-3006

Commercial Service Tools (YD25DDTi
engine)
Tool name Description
Valve seat cutter set
NT048
Finishing valve seat dimensions
Piston ring compressor
NT044
Installing piston assembly into cylinder bore
Piston ring expander
NT030
Removing and installing piston ring
TORX socket
NT807
Standard Universal
NT808
PREPARATION
EM-3007

NVH Troubleshooting Ð Engine Noise
SEM862G
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTINGYD25DDTi
EM-3011

Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
Top of
engine
Rocker
cover
Cylinder
headTicking
or click-
ingCAÐABÐTappet
noiseValve clearance EM-3060
Rattle C A Ð A B CCamshaft
bearing
noiseCamshaft journal
clearance
Camshaft runoutEM-3050,
3050
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noisePiston and piston pin
clearance
Connecting rod bush-
ing clearanceEM-3071,
3080
Slap or
rapAÐÐBBAPiston slap
noisePiston-to-bore clear-
ance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-3071,
3071, 3073,
3072
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing clearance (Small
end)
Connecting rod bear-
ing clearance (Big
end)EM-3080,
3077
Knock A B Ð A B CMain bear-
ing noiseMain bearing oil clear-
ance
Crankshaft runoutEM-3075,
3075
Front of
engine
Timing
chain coverTapping
or tick-
ingAAÐBBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain ten-
sioner operationEM-3023,
3026
Front of
engineSqueak-
ing or
fizzingABÐBÐCOther drive
belts
(Sticking
or slipping)Drive belts deflectionMA section
(ªChecking
Drive Beltsº,
ªENGINE
MAINTE-
NANCEº) Creak-
ingABABABOther drive
belts (Slip-
ping)Idler pulley bearing
operation
Squall
CreakABÐBABWater
pump
noiseWater pump operationLC section
(ªWater
Pump
Inspectionº,
ENGINE
COOLING
SYSTEMº)
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTINGYD25DDTi
NVH Troubleshooting Ð Engine Noise
(Cont'd)
EM-3012

1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated
for self-diagnosis items. Refer to ªTrouble Diagnosis Ð
INDEXº in EC section.
+Do not disconnect CONSULT-II until the end of this opera-
tion; it will be used to check engine rpm and for error detec-
tion at the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT3 (20A)] from fuse box
on the right side of engine compartment.
6. Remove glow plugs from all the cylinders.
+Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
+Carefully remove glow plugs to prevent any damage or
breakage.
+Handle with care to avoid applying any shock to glow
plugs.
7. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
:18-21Nzm (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine
rpm. Repeat the above steps for each cylinder.
+Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
3,100 (31.00, 31.6,
45.0)/2002,500 (25.00, 25.5, 363)/
200490 (4.90, 5.0, 71)/200
+When engine rpm is out of the specified range, check the
specific gravity of battery liquid. Measure again under cor-
rected conditions.
+If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cyl-
inder head gaskets, piston rings, pistons, cylinder bores, cyl-
inder block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Install glow plugs.
d. Install fuel injection pump fuse [ENG CONT3 (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self- diagnosis. Refer to ªTrouble Diagnosis Ð
INDEXº in EC section.
SEM863G
SEM864G
MEASUREMENT OF COMPRESSION PRESSUREYD25DDTi
EM-3013

Removal
WARNING:
To avoid danger of being scalded, never drain engine oil
when engine is hot.
1. Raise vehicle and support it with safety stands.
2. Remove engine under cover.
3. Drain engine oil.
4. Remove lower oil pan bolts.
+Loosen bolts in the reverse order of that shown in the figure.
SEM850G
SEM851G
OIL PANYD25DDTi
EM-3016

5. Remove lower oil pan.
a. Insert Tool between upper oil pan and lower oil pan.
+Be careful not to damage aluminum mating surface.
+ Do not insert screwdriver, or oil pan flange will be
deformed.
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove lower oil pan.
6. Remove oil strainer.
7. Remove air conditioner compressor and bracket.
8. Remove left side of the tie rod end Ð 2WD models only.
9. Remove front final drive together with differential mounting member and front suspension member. Refer to PD, MT and
FAsectionsinNISSANServiceManual(First Edition of
SM3E00-1D22E0E) Ð 4WD models only.
10.Removecrankshaftpositionsensor.RefertoEM sectionin NISSANServiceManual(Supplement III of SM3E00-
1D22E0E).
11. Remove transmission. Refer to MT section in NISSAN Ser- viceManual(Supplement III of SM3E00-1D22E0E)Ð2WD
models only.
12. Remove transmission with transfer assembly. Refer to MT sectioninNISSANServiceManual(Supplement III of
SM3E00-1D22E0E) Ð 4WD models only.
13. Remove clutch cover and clutch disc. Refer to CL section in NISSANServiceManual(Supplement I of SM3E00-
1D22E0E).
14. Remove flywheel and engine rear plate. Refer to EM section (``Disassembly'', ``CYLINDER BLOCK'') in NISSAN Service
Manual(Supplement III of SM3E00-1D22E0E).
SEM852G
SEM865G
SEM600F
OILPAN YD25DDTi
Removal (Cont'd)
EM-3017

c. Install upper oil pan.
+Tighten bolts in numerical order.
+ Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.
2WD models: M6 x 12 mm (0.47 in): Bolt No. 11, 14
M6 x 30 mm (1.18 in): Bolt No. 15, 16
M8 x 25 mm (0.98 in): Bolt No. 1, 5, 9, 13
M8 x 60 mm (2.36 in): Bolt No. 2, 3, 4, 6, 7, 8, 10,
12
4WD models: M6 x 27 mm (1.06 in): Bolt No. 15, 16
M8 x 30 mm (1.18 in): Bolt No. 1, 2, 4, 5, 8, 9
M8 x 60 mm (2.36 in): Bolt No. 3, 6, 7, 10, 11, 12,
13, 14
+ The shank length under the bolt neck above is the length of
the threaded part (pilot portion not included).
2. Install engine rear plate and flywheel. Refer to EM section (``Disassembly'', ``CYLINDER BLOCK'') in NISSAN Service
Manual(Supplement III of SM3E00-1D22E0E).
3. Install clutch disc and clutch cover. Refer to CL section in NISSANServiceManual(Supplement I of SM3E00-
1D22E0E).
4. Install transmission. Refer to MT section in NISSAN Service Manual(Supplement III of SM3E00-1D22E0E)Ð2WDmodels
only.
5. Install transmission with transfer assembly. Refer to MT sec- tioninNISSANServiceManual(Supplement III of SM3E00-
1D22E0E) Ð 4WD models only.
6.Installcrankshaftpositionsensor.RefertoEM sectionin NISSANServiceManual(Supplement III of SM3E00-
1D22E0E).
7. Install front final drive together with differential mounting member and front suspension member. refer to PD, MT and
FAsectionsinNISSANServiceManual(First Edition of
SM3E00-1D22E0E). Ð 4WD models only.
8. Install left side of the tie rod end Ð 2WD models only.
: 54.0 - 98.0 N zm (5.5 - 9.9 kg-m, 40 - 72 ft-lb)
9 Install air conditioned compressor and bracket.
: 56.9 - 65.7 N zm (5.9 - 6.7 kg-m, 42 - 48 ft-lb)
10. Install oil strainer.
SEM204H
SEM853G
SEM854G
OILPAN YD25DDTi
Installation (Cont'd)
EM-3019

11. Install lower oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-faces.
+ Also remove old liquid gasket from mating surface of
upper oil pan.
b. Apply a continuous bead of liquid gasket to mating surface of lower oil pan.
+ Use Genuine Liquid Gasket or equivalent.
+ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
+ Assembly should be done within 5 minutes after coating.
c. Install lower oil pan.
+ Tighten in numerical order shown in the figure.
+ Wait at least 30 minutes before refilling engine oil.
6. Install in the reverse order of removal.
SEM857G
SEM159F
SEM858G
SEM851G
SEM852G
OILPAN YD25DDTi
Installation (Cont'd)
EM-3020