NISSAN PICK-UP 2001 Repair Manual

3. Using a hexagon-head wrench [face to face: 6 mm (0.24 in),
SST], install timing chain slack guide.
4. Install chain tensioner.
a. Push the plunger of the chain tensioner. While holding it with
a push pin, install the chain tensioner.
b. Using a hexagon-head wrench [face to face: 5 mm (0.20 in),
SST], tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
+Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.
5. Install front chain case.
a. Install tension guide on the back surface of front chain case.
+Hold front chain case vertically when installing. Tension
guide may come off if front chain case is tilted.
b. Apply specified liquid gasket (Refer to EM-3003, ªLiquid Gas-
ket
Application Procedureº.) on both ends of arched area (loca-
tions where rear chain case is adjoined) as shown in the fig-
ure.
c. Install new chain case gasket to chain case groove.
d. Install front chain case.
+When installing, align dowel pin on oil pump case with the pin
hole.
+Install all bolts with the rubber washer to the front chain case.
e. Tighten fixing bolts in the numerical order shown in the fig-
ure.
f. After tightening all the bolts, re-tighten in the No. 1, 2, and 6
bolts.
SBIA0228E
SBIA0227E
SBIA0189E
JEM129G
JEM121G
TIMING CHAINYD25DDTi
Secondary Timing Chain (Cont'd)
EM-3024

6. Hereafter, install in the reverse order of removal.
TIMING CHAINYD25DDTi
Secondary Timing Chain (Cont'd)
EM-3025

Primary Timing Chain
SEM860G
TIMING CHAINYD25DDTi
EM-3026

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

11. Remove oil pump.
+Loosen bolts in the reverse order of that shown in the figure
and remove them.
+Use seal cutter (SST) etc. for removal.
12. Remove front oil seal from oil pump.
+Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
+Be careful not to damage the oil pump.
13. Remove chain tensioner.
+When removing chain tensioner, push the sleeve of chain
tensioner and keep it pressed with a push pin, etc.
14. Remove timing chain slack guide.
15. Hold fuel injection pump sprocket.
a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel injection pump sprocket.
b. Using a TORX wrench (SST), turn pump shaft little by little
to adjust the position of fuel injection pump sprocket so that
the holes align.
c. Insert the positioning stopper pin through fuel injection pump
sprocket to 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).
16. Using the hexagon wrench [face to face: 6 mm (0.24 in),
long-type] (SST), remove the mounting bolts of the fuel injec-
tion pump sprocket.
+It is not necessary to remove the washer of the fuel
injection pump sprocket.
JEM133G
JEM134G
JEM135G
JEF359Y
JEM903G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3028

17. Remove primary timing chain with fuel injection pump
sprocket and crankshaft sprocket.
18. Remove chain guide and tension guides.
19. Remove vacuum pump.
20. Remove camshaft sprockets.
+Loosen the camshaft sprockets installation bolts by fixing the
hexagon portion of the camshaft.
JEF361Y
JEM136G
JEM885G
JEM159G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3029

21. Remove rear chain case.
+Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
+Use seal cutter (SST) for removal.
INSPECTION
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
EMR0084D
SEM984C
JEM886G
TIMING CHAINYD25DDTi
Primary Timing Chain (Cont'd)
EM-3030

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