engine NISSAN PICK-UP 2001 Repair Manual

Secondary Timing Chain
CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing camshafts, chain tensioners, oil seals,
or other sliding parts, lubricate contacting surfaces with
new engine oil.
+Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
+Do not spill engine coolant on drive belts.
REMOVAL
+For preparative work for removing/installing secondary timing
chain to remove/install fuel injection pump, refer to EC
section, ªElectronic control fuel injection pumpº.
+To prepare for removing/installing secondary timing chain to
remove/install camshaft, refer to EM-3047, ªCAMSHAFTº.
1. Drain engine oil.
2. Drain coolant by removing cylinder block drain plugs. Refer
to LC section, ªChanging Engine Coolantº.
3. Remove EGR guide tube.
4. Remove radiator upper and lower hoses.
5. Remove radiator shroud and radiator. Refer to LC section,
ªREMOVAL AND INSTALLATIONº, ªRadiatorº.
JEM859G
TIMING CHAINYD25DDTi
EM-3021

6. Remove front chain case.
+Move power steering fluid reservoir tank from the bracket.
+Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
+Remove all bolts with the rubber washer as space is limited
for pulling them out.
CAUTION:
+While front chain case is removed, cover openings to
prevent entry of foreign material into engine.
+Do not remove two mass dampers on the back of cover.
7. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
+No position indicator is provided on the crankshaft pul-
ley.
+When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
8. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
b. Using a hexagon-head wrench [face to face: 5 mm (0.20 in),
SST], remove bolts to remove chain tensioner.
JEM121G
SBIA0189E
SEM515G
JEM124G
SBIA0227E
TIMING CHAINYD25DDTi
Secondary Timing Chain (Cont'd)
EM-3022

CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing camshafts, chain tensioners, oil seals,
or other sliding parts, lubricate contacting surfaces with
new engine oil.
+Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
+Do not spill engine coolant on drive belts.
REMOVAL
1. Remove charge air cooler and bracket.
2. Remove rocker cover. Refer to EM-3045, ªRemoval and
Installationº, ªROCKER COVERº.
3. Remove EGR guide tube.
4. Remove radiator shroud and radiator. Refer to LC section,
ªREMOVAL AND INSTALLATIONº, ªRadiatorº.
5. Remove idler pulley, idler pulley bracket and drive belts.
6. Remove upper and lower oil pans. Refer to EM-3015,
ªRemoval
and Installationº, ªOIL PANº.
7. Remove injection tube.
Refer to EC section, ªInjection Tube and Injection Nozzleº.
8. Remove secondary timing chain and associated parts.
Refer to EM-3021, ªSecondary Timing Chainº.
9. When removing rear chain case, remove camshaft sprock-
ets.
Refer to EM-3047, ªCAMSHAFTº.
10. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
c. Using pulley puller (SST), remove crankshaft pulley.
+Use two M6 (0.24 in) bolts with approx. 60 mm (2.36 in)
shank length for securing crankshaft pulley.
JEM131G
JEM132G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3027

1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3003, ªLiquid Gasket Application Procedureº.) on loca-
tions shown in the figure.
A: Apply bead so that it does not protrude into the oil pas-
sage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the por-
tion marked * comes at an external location but cannot be
viewed externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
b. Install four O-rings to the grooves of the cylinder block and
fuel injection pump bracket.
c. Install rear chain case.
+When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
+Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21,
22
20 mm (0.79 in): Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
+The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
SEM861G
JEM141G
EMR0084D
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3031

2. Install vacuum pump.
+Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
3. Install chain guide and tension guides.
4. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
5. Install primary timing chain with fuel injection pump sprocket.
+When installing, match the alignment marks on sprockets
with color coded alignment marks (colored links) on the
chain.
+Install fuel injection pump sprocket washer with the surface
marked ªFº (front mark) facing the front of the engine.
6. Install timing chain onto vacuum pump sprocket and through
chain guide.
7. Use the positioning stopper pin (SST) to hold the fuel injec-
tion pump sprocket and install the bolt for mounting the
sprocket.
+Using a TORX wrench (SST), turn the pump shaft little by
little to adjust the position of the pump flange. Insert position-
ing stopper pin (SST) into the hole 6 mm (0.24 in) in diam-
eter on the fuel injection pump sprocket so that the stopper
pin goes through the pump flange to the pump body. While
the stopper pin is in place, install the bolt.
8. Install timing chain slack guide.
9. Install chain tensioner.
+Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install the chain
tensioner.
+After installation, pull out the push pin holding the plunger.
+Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
10. Install front oil seal to oil pump.
+Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
+Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
JEM885G
JEM136G
JEM135G
JEM134G
JEM142G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3032

11. Install vacuum pump cover (for vacuum pump removal/
installation opening) to oil pump if cover is removed.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-3003, ªLiquid Gasket Application Procedureº.) as shown
in the figure.
+Apply liquid gasket on oil pump-side surface.
12. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3003, ªLiquid Gasket Application Procedureº.) on loca-
tions shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
b. Install oil pump drive spacer to crankshaft.
+Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
d. Install oil pump.
+When installing, align the inner rotor in the direction of the
two facing flats of the oil pump drive spacer.
+When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the fig-
ure.
f. After tightening all the bolts, re-tighten in the same order.
13. Check gaps on upper oil pan mounting surface.
+Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
þ0.14 to 0.14 mm (þ0.0055 to 0.0055 in)
Rear chain case and cylinder block
þ0.25 to 0.13 mm (þ0.0098 to 0.0051 in)
+If the measured value is out of the above range, install again.
JEM143G
JEM144G
JEM145G
JEM133G
JEM146G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3033

Removal and Installation
1. Intake manifold
2. EGR guide tube
3. EGR volume control valve
4. EGR spacer5. EGR tube
6. Cylinder head
7. Cylinder block8. Injection tube clamp
9. Injection tube
10 Injection nozzle oil seal
REMOVAL
1. Drain engine coolant. Refer to LC section, ªChanging engine
coolantº.
2. Remove charge air cooler. Refer to EM-3014, ªRemoval and-
Installationº.
3. Remove EGR volume control valve, EGR spacer and EGR
guide tube.
4. Remove fuel injection tubes and intake manifold.
SEM866G
INTAKE MANIFOLDYD25DDTi
EM-3035

FUEL PIPING
Removal
+To prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
+Be careful not to spill fuel in the engine compartment.
Installation
After repairing, bleed air in pipes by shifting priming pump up and
down until the touch is heavy.
For further air bleeding, crank engine while operating priming
pump up and down. Do not crank engine more than 10 seconds
at a time.
INTAKE MANIFOLD
Removal
+Loosen bolts and nuts in the reverse order of that shown in
the figure.
Installation
+When stud bolts come off, install with the following torque:
:10-11Nzm (1.0 - 1.2 kg-m, 87 - 104 in-lb)
+Tighten fixing bolts in the numerical order shown in the fig-
ure.
EGR VOLUME CONTROL VALVE
+Handle with care avoiding any shocks.
+Do not disassemble or adjust.
Inspection
INTAKE MANIFOLD
Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
SEM867G
SEM868G
SEM869G
INTAKE MANIFOLDYD25DDTi
Removal and Installation (Cont'd)
EM-3036

Trouble Diagnosis of Turbocharger
Preliminary check:
+Check that the engine oil level is between MIN and MAX of
the dipstick. (When the engine oil amount is more than MAX,
the oil flows into the inlet duct through the blow-by gas
passage, and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item meets each
inspection result)
Oil leakage Smoke NoiseInsufficient
power/
acceleration
failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contaminated
by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor shaft is
rotated by your fingertips.nnj
The rotor shaft sometimes does not rotate
by your fingertips.
There is too much play in the bearing.nnjn
Oil return portCarbon or sludge is accumulated in the
waste oil hole.n
nn
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD25DDTi
Inspection (Cont'd)
EM-3044

Removal and Installation
1. Oil filler cap 2. Rocker cover 3. Gasket
PREPARATIVE WORK
Remove the engine following parts.
+Charge air cooler
+Charge air cooler bracket
ROCKER COVER
Removal
Loosen bolts in the reverse order of that shown in the figure and
remove.
Installation
+Tighten bolts in the numerical order shown in the figure.
+Re-tighten to the same torque in the same order as above.
+Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-3003, ªLiquid Gasket Application Procedureº.) on loca-
tions shown in the figure.
+Install in the reverse order of removal.
SEM880G
SEM884G
JEM248G
ROCKER COVERYD25DDTi
EM-3045