NISSAN PICK-UP 2001 Repair Manual

Removal and Installation
1. Charge air cooler cover
2. Charge air cooler
3. Air inlet hose4. Intake manifold
5. Bracket6. Air inlet pipe
7. Bracket
Inspection
Check air passages of charge air cooler core and fins for
clogging, leaks or deformation. Clean or replace charge air
cooler if necessary.
+Be careful not to deform core fins.
+For cleaning procedure of charge air cooler core, refer to
ªCHECKING RADIATORº in LC section.
SEM848G
CHARGE AIR COOLERYD25DDTi
EM-3014

Components
SEM849G
OIL PANYD25DDTi
EM-3015

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

15. Remove upper oil pan bolts in reverse order shown.
16. Remove upper oil pan.
a. Insert an appropriate size tool into the notch of upper oil pan.
+Be careful not to damage aluminum mating surface.
+ Do not insert screwdriver, or oil pan flange will be
deformed.
b. Pry off upper oil pan by moving the tool up and down.
c. Remove upper oil pan.
Installation
1. Install upper oil pan.
a. Use a scraper to remove old liquid gasket from mating sur- faces.
+ Also remove old liquid gasket from mating surface of
cylinder block, front cover and lower oil pan.
+ Remove old liquid gasket from the bolt hole and thread.
b. Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan.
+ Use Genuine Liquid Gasket or equivalent.
+ Apply liquid gasket to areas shown in the figure.
+ For bolt holes with smarks, apply liquid gasket to the
outside of the holes.
+ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide as shown in the
figure. (Be careful that the diameter of the silicon bead
is different around the front.)
+ Assembly should be done within 5 minutes after coating.
SEM853G
SEM854G
SEM855G
SEM159F
SEM205H
OILPAN YD25DDTi
Removal (Cont'd)
EM-3018

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

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

9. Remove timing chain slack guide.
+Using a hexagon-head wrench [face to face: 6 mm (0.24 in),
SST], remove bolt to remove timing chain slack guide.
10. Remove timing chain tension guide.
11. Remove secondary timing chain.
+Timing chain alone can be removed without removing
sprockets.
INSPECTION
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Install secondary timing chain.
+When installing, match the alignment marks on sprockets
with color coded alignment marks (colored links) on the
chain.
2. Install timing chain tension guide.
+The upper bolt has a longer shank than the lower bolt.
SBIA0228E
JEM127G
SEM984C
JEM128G
TIMING CHAINYD25DDTi
Secondary Timing Chain (Cont'd)
EM-3023