1998 NISSAN PICK-UP Repair Manual

VALVE GUIDE
SEM401E
Unit: mm (in)
Standard Service Limit
Intake Exhaust Intake Exhaust Ð
Length (L) 52.6 (2.071) 56.0 (2.205) 52.6 (2.071) 56.0 (2.205) Ð
Outer diameter (D)11.023 - 11.034
(0.4340 - 0.4344)12.023 - 12.034
(0.4733 - 0.4738)11.223 - 11.234
(0.4418 - 0.4423)12.223 - 12.234
(0.4812 - 0.4817)Ð
Inner diameter (d)
(Finished size)7.000 - 7.018
(0.2756 - 0.2763)8.000 - 8.018
(0.3150 - 0.3157)7.000 - 7.018
(0.2756 - 0.2763)8.000 - 8.018
(0.3150 - 0.3157)Ð
Cylinder head hole diameter10.975 - 10.996
(0.4321 - 0.4329)11.975 - 11.996
(0.4715 - 0.4723)11.175 - 11.196
(0.4400 - 0.4408)12.175 - 12.196
(0.4793 - 0.4802)Ð
Interference fit 0.027 - 0.059 (0.0011 - 0.0023) Ð
Stem to guide clearance0.020 - 0.053
(0.0008 - 0.0021)0.040 - 0.070
(0.0016 - 0.0028)0.020 - 0.053
(0.0008 - 0.0021)0.040 - 0.070
(0.0016 - 0.0028)0.1 (0.004)
Tapping length (,) 14.9 - 15.1 (0.587 - 0.594)
VALVE SEAT
SEM402E
Unit: mm (in)
Standard Service
Intake Exhaust Intake Exhaust
Cylinder head seat recess
diameter36.000 - 36.016
(1.4173 - 1.4179)42.000 - 42.016
(1.6535 - 1.6542)36.500 - 36.516
(1.4370 - 1.4376)42.500 - 42.516
(1.6732 - 1.6739)
Valve seat outer diameter
(D
1)36.080 - 36.096
(1.4205 - 1.4211)42.080 - 42.096
(1.6567 - 1.6573)36.580 - 36.596
(1.4402 - 1.4408)42.580 - 42.596
(1.6764 - 1.6770)
Face angle (a) 45É 45É 45É 45É
Contacting width (W) 1.6 - 1.7 (0.063 - 0.067) 1.7 - 2.1 (0.067 - 0.083) 1.6 - 1.7 (0.063 - 0.067) 1.7 - 2.1 (0.067 - 0.083)
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-92

VALVE
SEM188A
Unit: mm (in)
Standard Limit
Valve head diameter (D)In.34.0 - 34.2
(1.339 - 1.346)Ð
Ex.40.0 - 40.2
(1.575 - 1.583)Ð
Valve length (L)In.121.05 - 121.65
(4.7657 - 4.7894)Ð
Ex.122.02 - 122.62
(4.8039 - 4.8275)Ð
Valve stem diameter (d)In.6.965 - 6.980
(0.2742 - 0.2748)Ð
Ex.7.948 - 7.960
(0.3129 - 0.3134)Ð
Valve face angle (a)In. 45É15¢- 45É45¢Ð
Ex. 45É15¢- 45É45¢Ð
Valve head margin (T)In.1.15 - 1.45
(0.0453 - 0.0571)
0.5 (0.020)
Ex.1.35 - 1.65
(0.0531 - 0.0650)
Valve clearance 0 (0)
VALVE SPRING
Unit: mm (in)
Standard Limit
Intake Exhaust Intake Exhaust
Free height (H)Outer 57.44 (2.2614) 53.21 (2.0949) Ð Ð
Inner 53.34 (2.1000) 47.95 (1.8878) Ð Ð
Pressure
N (kg, lb) at heightOuter604.1 (61.6, 135.8)
at 37.6 (1.480)640.4 (65.3, 144.0)
at 34.1 (1.343)567.8 (57.9, 127.7)
at 37.6 (1.480)620.8 (63.3, 139.6)
at 34.1 (1.343)
Inner284.4 (29.0, 63.9)
at 32.6 (1.283)328.5 (33.5, 73.9)
at 29.1 (1.146)266.8 (27.2, 60.0)
at 32.6 (1.283)318.7 (32.5, 71.7)
at 29.1 (1.146)
Out-of-squareOuter Ð Ð 2.5 (0.098) 2.3 (0.091)
Inner Ð Ð 2.3 (0.091) 2.1 (0.083)
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-93

CAMSHAFT AND CAMSHAFT BEARING
SEM568A
EM120
Unit: mm (in)
Standard Limit
Cam height (A) 44.43 - 44.58 (1.7492 - 1.7551) Ð
Valve lift (h) 9.7 (0.382) Ð
Wear limit of cam height Ð 0.2 (0.008)
Camshaft journal to bearing clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.12 (0.0047)
Inner diameter of camshaft bearing 33.000 - 33.025 (1.2992 - 1.3002) Ð
Outer diameter of camshaft journal (D) 32.935 - 32.955 (1.2967 - 1.2974) Ð
Camshaft runout 0 - 0.02 (0 - 0.0008) Ð
Camshaft end play 0.07 - 0.15 (0.0028 - 0.0059) 0.2 (0.008)
Valve timing (Degree on crankshaft)a 232 Ð
b 232 Ð
cþ5 Ð
d57 Ð
e11 Ð
f41 Ð
ROCKER ARM AND ROCKER SHAFT
Unit: mm (in)
Rocker arm to shaft clearance 0.012 - 0.050 (0.0005 - 0.0020)
Rocker shaft diameter21.979 - 22.000
(0.8653 - 0.8661)
Rocker arm rocker shaft hole
diameter22.012 - 22.029
(0.8666 - 0.8673)
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-94

PISTON, PISTON RING AND PISTON PIN
Piston
SEM444C
Unit: mm (in)
Piston skirt
diameter (A)StandardGrade No. 188.970 - 88.980
(3.5027 - 3.5031)
Grade No. 288.980 - 88.990
(3.5031 - 3.5035)
Grade No. 388.990 - 89.000
(3.5035 - 3.5039)
Service
(Oversize)0.5 (0.020)89.470 - 89.500
(3.5224 - 3.5236)
1.0 (0.039)89.970 - 90.000
(3.5421 - 3.5433)
Dimension (a) Approximately 52 (2.05)
Piston pin hole diameter (d)21.002 - 21.008
(0.8268 - 0.8271)
Piston-to-cylinder bore clearance 0.020 - 0.040 (0.0008 - 0.0016)
Piston pin
Unit: mm (in)
Standard
Piston pin outer diameter20.993 - 20.998
(0.8265 - 0.8267)
Pin to piston pin hole clearance0.008 - 0.012
(0.0003 - 0.0005)
Piston pin to connecting rod
clearanceþ0.015 to þ0.033
(þ0.0006 to þ0.0013)
Piston ring
Unit: mm (in)
Standard Limit
Side clear-
anceTop0.010 - 0.030
(0.0004 - 0.0012)0.1 (0.004)
2nd0.030 - 0.070
(0.0012 - 0.0028)0.1 (0.004)
Oil0.085 - 0.115
(0.0033 - 0.0045)*0.1 (0.004)
Ring gapTop0.28 - 0.43
(0.0110 - 0.0169)0.5 (0.020)
2nd0.45 - 0.60
(0.0177 - 0.0236)0.5 (0.020)
Oil
(rail ring)0.20 - 0.60
(0.0079 - 0.0236)0.5 (0.020)
*: Riken-make
CONNECTING ROD
SEM216E
Unit: mm (in)
Standard Limit
Center distance (S)164.95 - 165.05
(6.4941 - 6.4980)Ð
Bend
[per 100 mm (3.94 in)]Ð 0.15 (0.0059)
Torsion
[per 100 mm (3.94 in)]Ð 0.3 (0.012)
Small end inner diameter (d)20.965 - 20.978
(0.8254 - 0.8259)Ð
Connecting rod big end inner
diameter (D)53.000 - 53.013
(2.0866 - 2.0871)Ð
Side clearance0.2 - 0.4
(0.008 - 0.016)0.6 (0.024)
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-95

CRANKSHAFT
SEM394EM715
Unit: mm (in)
Main journal diameter (Dm) GradeNo. 0 59.967 - 59.975 (2.3609 - 2.3612)
No. 1 59.959 - 59.967 (2.3606 - 2.3609)
No. 2 59.951 - 59.959 (2.3603 - 2.3606)
Pin journal diameter (Dp) GradeNo. 0 49.968 - 49.974 (1.9672 - 1.9675)
No. 1 49.962 - 49.968 (1.9670 - 1.9672)
No. 2 49.956 - 49.962 (1.9668 - 1.9670)
Center distance (r) 47.95 - 48.05 (1.8878 - 1.8917)
Standard Limit
Taper of journal and pin [
VA±VB]Journal Ð 0.01 (0.0004)
Pin Ð 0.005 (0.0002)
Out-of-round of journal and pin
[
VX±VY]Journal Ð 0.01 (0.0004)
Pin Ð 0.005 (0.0002)
Runout [TIR]* Ð 0.10 (0.0039)
Free end play 0.05 - 0.18 (0.0020 - 0.0071) 0.3 (0.012)
Fillet roilMore than 0.1 (0.004)
* Total indicator reading
BEARING CLEARANCE
Unit: mm (in)
Standard Limit
Main bearing clearance0.020 - 0.047
(0.0008 - 0.0019)0.1 (0.004)
Connecting rod bearing
clearance0.010 - 0.035
(0.0004 - 0.0014)0.09 (0.0035)
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-96

AVAILABLE MAIN BEARING
Standard
Grade
numberThickness
mm (in)Identification
color
01.821 - 1.825
(0.0717 - 0.0719)Black
11.825 - 1.829
(0.0719 - 0.0720)Brown
21.829 - 1.833
(0.0720 - 0.0722)Green
31.833 - 1.837
(0.0722 - 0.0723)Yellow
41.837 - 1.841
(0.0723 - 0.0725)Blue
Undersize (service)
Unit: mm (in)
ThicknessMain journal
diameter ``Dm''
0.25
(0.0098)1.952 - 1.960
(0.0769 - 0.0772)Grind so that bearing
clearance is the
specified value.
AVAILABLE CONNECTING ROD BEARING
Standard
Grade
numberThickness
mm (in)Identification
color
01.505 - 1.508
(0.0593 - 0.0594)Ð
11.508 - 1.511
(0.0594 - 0.0595)Brown
21.511 - 1.514
(0.0595 - 0.0596)Green
Undersize (service)
Unit: mm (in)
ThicknessCrank pin journal
diameter ``Dp''
0.08 (0.0031)1.540 - 1.548
(0.0606 - 0.0609)
Grind so that bearing
clearance is the
specified value. 0.12 (0.0047)1.560 - 1.568
(0.0614 - 0.0617)
0.25 (0.0098)1.625 - 1.633
(0.0640 - 0.0643)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Camshaft sprocket runout
[TIR]*Less than 0.12 (0.0047)
Flywheel runout [TIR]* Less than 0.1 (0.004)
* Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)KA
Inspection and Adjustment (Cont'd)
EM-97

General Specifications
Engine model TD25
Cylinder arrangementIn-line
Number of cylinders 4
Valve arrangement OHV
Bore x stroke mm (in)92.9 x 92.0
(3.657 x 3.622)
Displacement cm
3(cu in) 2,494 (152.18)
Firing order 1-3-4-2
Number of
piston ringsCompression 2
Oil 1
Number of main bearings 5
Inspection and Adjustment
COMPRESSION PRESSURE
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard 2,942 (29.4, 30, 427)/200
Minimum 2,452 (24.5, 25, 356)/200
Differential limit between cylinders 294 (2.9, 3, 43)/200
CYLINDER HEAD
Unit: mm (in)
Standard Limit
Head surface distortionLess than
0.07 (0.0028)0.2 (0.008)
Nominal cylinder head height 89.9 - 90.1 (3.539 - 3.547)
VALVE
Unit: mm (in)
SEM188
Engine TD25
Valve head diameter ``D''
Intake41.4 - 41.6
(1.630 - 1.638)
Exhaust36.9 - 37.1
(1.453 - 1.461)
Valve length ``L''
Intake
117 (4.61)
Exhaust
Valve stem diameter ``d''
Intake 7.962 - 7.977 (0.3135 - 0.3141)
Exhaust 7.945 - 7.960 (0.3128 - 0.3134)
Valve seat angle ``a''
Intake
45É - 45É30¢
Exhaust
Valve margin ``T'' limit 0.5 (0.020)
Valve stem end surface
grinding limit0.2 (0.008)
Valve clearance (Hot)
Intake
0.35 (0.0138)
Exhaust
SERVICE DATA AND SPECIFICATIONS (SDS)TD
EM-98

Valve guide
Unit: mm (in)
Standard Service
Valve guide outside diameter12.033 - 12.044
(0.4737 - 0.4742)Ð
Valve guide inner diameter
(Finished size)8.000 - 8.015
(0.3150 - 0.3156)
Cylinder head valve guide
hole diameter12.00 - 12.011
(0.4724 - 0.4729)Ð
Interference fit of valve guide0.022 - 0.044
(0.0009 - 0.0017)
Standard Max. tolerance
Stem to guide clearance
Intake0.023 - 0.053
(0.0009 - 0.0021)0.15 (0.0059)
Exhaust0.04 - 0.07
(0.0016 - 0.0028)0.20 (0.0079)
Valve deflection limit
Intake 0.30 (0.0118)
Exhaust 0.40 (0.0157)
Valve spring
Free length mm (in)
Painted red 53.4 (2.102)
Pressure height
mm/N (mm/kg, in/lb)
Painted red31.8/713.9 - 788.5
(31.8/72.8 - 80.4,
1.252/160.5 - 177.3)
Assembled height
mm/N (mm/kg, in/lb)
Standard42.3/314.8 - 361.9
(42.3/32.1 - 36.9,
1.665/70.8 - 81.4)
Limit42.3/270.7
(42.3/27.6, 1.665/60.9)
Out-of-square mm (in) 2.3 (0.091)
VALVE LIFTER AND PUSH ROD
Unit: mm (in)
Standard Limit
Valve lifter outer diameter25.960 - 25.970
(1.0220 - 1.0224)Ð
Cylinder block valve lifter
hole diameter26.000 - 26.033
(1.0236 - 1.0249)Ð
Valve lifter to lifter hole clear-
ance0.030 - 0.073
(0.0012 - 0.0029)0.20 (0.0079)
Push rod bend (TIR)*Less than
0.3 (0.012)0.5 (0.020)
*: Total indicator reading
Rocker shaft and rocker arm
Unit: mm (in)
Standard Limit
Rocker shaft
Outer diameter19.979 - 20.00
(0.7866 - 0.7874)Ð
Rocker shaft bend (TIR)0 - 0.15
(0 - 0.0059)Less than
0.30 (0.0118)
Rocker arm
Inner diameter20.014 - 20.035
(0.7880 - 0.7888)Ð
Clearance between rocker
arm and rocker shaft0.014 - 0.056
(0.0006 - 0.0022)0.15 (0.0059)
CYLINDER HEAD TO VALVE DISTANCE
Unit: mm (in)
SEM724C
Standard Limit
Intake0.7 - 1.3
(0.028 - 0.051)1.70 (0.067)
Exhaust0.7 - 1.3
(0.028 - 0.051)1.70 (0.067)
SERVICE DATA AND SPECIFICATIONS (SDS)TD
Inspection and Adjustment (Cont'd)
EM-99