2001 NISSAN PICK-UP Repair Manual

KA24DE ENGINE MODEL
SFE777A
FUEL SYSTEM
FE-3003

YD25DDTi ENGINE MODEL
SFE763A
FUEL SYSTEM
FE-3004

KA24DE ENGINE (2WD) MODEL
KA24DE ENGINE (4WD) MODEL
SFE778A
SFE779A
EXHAUST SYSTEM
FE-3005

YD25DDTi ENGINE (2WD) MODEL
YD25DDTi ENIGNE (4WD APPEARANCE 2WD) MODEL
SFE781A
SFE782A
EXHAUST SYSTEM
FE-3006

YD25DDTi (4WD) ENGINE MODEL
SFE764A
EXHAUST SYSTEM
FE-3007

ENGINE MECHANICAL
SECTION
EM
MODIFICATION NOTICE:
+KA24DE engine information has been added for Europe.
For information not included here, refer to information for KA24DE engine in D22 Supplement-II Service
Manual (SM9E-D22BE0E).
+YD25DDTi engine has newly been added.
CONTENTS
PRECAUTIONS................................................... 3003
Parts Requiring Angular Tightening................. 3003
Liquid Gasket Application Procedure .............. 3003
PREPARATION................................................... 3004
Special Service Tools (YD25DDTi engine) ..... 3004
Commercial Service Tools
(YD25DDTi engine).......................................... 3007
KA24DE
OUTER COMPONENT PARTS........................... 3008
YD25DDTi
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING......................................... 3011
NVH Troubleshooting - Engine Noise ............. 3011
MEASUREMENT OF COMPRESSION
PRESSURE.......................................................... 3013
CHARGE AIR COOLER...................................... 3014
Removal and Installation ................................. 3014
Inspection ......................................................... 3014
OIL PAN............................................................... 3015
Components ..................................................... 3015
Removal ........................................................... 3016
Installation ........................................................ 3018
TIMING CHAIN.................................................... 3021
Secondary Timing Chain ................................. 3021
Primary Timing Chain ...................................... 3026
INTAKE MANIFOLD............................................ 3035
Removal and Installation ................................. 3035
Inspection ......................................................... 3036
CATALYST.......................................................... 3037Removal and Installation ................................. 3037
EXHAUST MANIFOLD, TURBOCHARGER....... 3039
Removal and Installation ................................. 3039
Disassembly and Assembly ............................. 3041
Inspection ......................................................... 3041
ROCKER COVER................................................ 3045
Removal and Installation ................................. 3045
CYLINDER HEAD................................................ 3046
Components ..................................................... 3046
Removal ........................................................... 3047
Disassembly ..................................................... 3048
Inspection ......................................................... 3049
Assembly.......................................................... 3056
Installation ........................................................ 3056
Valve Clearance............................................... 3060
ENGINE REMOVAL............................................. 3063
Removal ........................................................... 3064
Installation ........................................................ 3065
Inspection ......................................................... 3065
CYLINDER BLOCK............................................. 3066
Components ..................................................... 3066
Removal and Installation ................................. 3067
Disassembly ..................................................... 3067
Inspection ......................................................... 3070
Assembly.......................................................... 3081
KA24DE
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3086
Inspection and Adjustment .............................. 3086

EM

YD25DDTi
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3088
General Specifications ..................................... 3088
Compression Pressure .................................... 3088
Cylinder Head .................................................. 3088
Valve ................................................................ 3089
Valve Seat........................................................ 3092Camshaft and Camshaft Bearing .................... 3093
Cylinder Block .................................................. 3094
Piston, Piston Ring and Piston Pin.................. 3094
Connecting Rod ............................................... 3095
Crankshaft ........................................................ 3096
Available Main Bearing .................................... 3096
Available Connecting Rod Bearing .................. 3097
Miscellaneous Components ............................. 3097
EM-3002

Parts Requiring Angular Tightening
+Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts (YD series)
c) Connecting rod cap nuts (KA and YD series)
d) Crankshaft pulley bolt (YD series)
+Do not use a torque value for final tightening.
+The torque value for these parts are for a preliminary step.
+Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure
1.Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely
clean any oil from these areas.
2.Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+Be sure liquid gasket diameter is as specified in this manual.
3.Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.Assembly should be done within 5 minutes after coating.
5.Wait at least 30 minutes before refilling engine oil and
engine coolant.
SEM164F
AEM080
PRECAUTIONS
EM-3003