engine NISSAN PICK-UP 2001 Repair Manual

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

14. Tighten connecting rod nuts according to the following pro-
cedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 Nzm (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 Nzm (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 Nzm (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120É to 125É [target: 120É]. (angular tightening)
+Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
+After tightening nuts, check that crankshaft rotates smoothly.
+Check connecting rod side clearance. Refer to EM-3070,
ªCONNECTING ROD SIDE CLEARANCEº.
15. Force fit rear oil seal into rear oil seal retainer.
+Using a drift [105 mm (4.13 in) dia.], force fit so that the
dimension is as specified in the figure.
+Avoid inclined fitting. Force fit perpendicularly.
16. Install rear oil seal retainer.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-3003, ªLiquid Gasket Application Procedureº.) on loca-
tions shown in the figure.
17. Install pilot bushing.
+Force fit with the drift [approx. 19 mm (0.75 in) dia.].
18. Install fuel injection pump bracket.
+Align the bracket with the dowel pins on the block to install.
+The two bolts used for dowel pins have a longer shanks than
the other two.
+Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
19. Install parts to the engine in the reverse order of disassem-
bly.
+Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque.
:57-65Nzm (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
JEM231G
JEM232G
JEM233G
JEM234G
SEM898G
CYLINDER BLOCKYD25DDTi
Assembly (Cont'd)
EM-3084

20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel.
+Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
+Tighten bolts uniformly in a crisscross manner.
REPLACEMENT OF PILOT BUSHING
1. Remove pilot bushing using tool or suitable tool.
2. Install pilot bushing as shown.
SEM500G
SEM275GA
CYLINDER BLOCKYD25DDTi
Assembly (Cont'd)
EM-3085

HEATER &
AIR CONDITIONER
SECTION
HA
MODIFICATION NOTICE:
+Wiring Diagrams have been changed.
+Thermo switch has been abolished.
+A/C cycle for YD engine has been added.
CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION............... 3002
Precautions for Refrigerant Connection .......... 3002
MANUAL
TROUBLE DIAGNOSES..................................... 3004
Wiring Diagram - HEATER -............................ 3004
Circuit Diagram - A/C, M - ............................... 3005
Wiring Diagram - A/C, M -/LHD Models with
KA, YD Engine ................................................. 3006
Wiring Diagram - A/C, M -/RHD Models with
KA, YD Engine ................................................. 3009
Magnet Clutch .................................................. 3012
AUTO
TROUBLE DIAGNOSES..................................... 3020
Circuit Diagram - A/C, A -................................ 3020
Wiring Diagram - A/C, A -................................ 3021
Magnet Clutch .................................................. 3026
SERVICE PROCEDURES................................... 3030
Refrigerant Lines.............................................. 3030
MANUAL AND AUTO
SERVICE PROCEDURES................................... 3031
Checking Refrigerant Leaks ............................ 3031
SERVICE PROCEDURES................................... 3032
Compressor Mounting...................................... 3032
MANUAL AND AUTO
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3033
General Specifications ..................................... 3033
Inspection and Adjustment .............................. 3033

HA

O-RING AND REFRIGERANT CONNECTION
YD engine
NOTE:
This illustration is for LHD models. For RHD models, cooling unit location and routing of A/C piping
are different.
RHA174I
PRECAUTIONS AND PREPARATIONMANUAL AND AUTO
Precautions for Refrigerant Connection
(Cont'd)
HA-3003

Wiring Diagram Ð A/C, M Ð/LHD Models
with KA, YD Engine
GHA023A
TROUBLE DIAGNOSESMANUAL
HA-3006

GHA040A
TROUBLE DIAGNOSESMANUAL
Wiring Diagram Ð A/C, M Ð/LHD Models
with KA, YD Engine (Cont'd)
HA-3007

GHA041A
TROUBLE DIAGNOSESMANUAL
Wiring Diagram Ð A/C, M Ð/LHD Models
with KA, YD Engine (Cont'd)
HA-3008

Wiring Diagram Ð A/C, M Ð/RHD Models
with KA, YD Engine
GHA042A
TROUBLE DIAGNOSESMANUAL
HA-3009