2001 NISSAN PICK-UP Repair Manual

d. Hoist up engine and install it on the engine stand (SST).
+Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
+Exhaust manifold
+Turbocharger assembly
+Injection tube
+Intake manifold
+Water pump
+Oil pan (upper and lower)
+EGR volume control valve and EGR tube & EGR guide tube
assembly
+Secondary timing chain
+Fuel injection pump
+Primary timing chain
+Rocker cover
+Vacuum pump
+High pressure injection nozzle assembly
+Camshaft
+Cylinder head
+Thermostat, water pipes
+Oil cooler
+Auxiliary component brackets
5. Remove fuel injection pump bracket.
6. If the replacement of pilot bushing is necessary, remove it
with pilot bushing puller (SST).
7. Remove rear oil seal retainer.
+Insert a flat-bladed screwdriver between main bearing cap
and rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
+Punch out with a flat-bladed screwdriver.
+Be careful not to damage rear oil seal retainer.
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
+Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-3070, ªCON-
NECTING ROD SIDE CLEARANCEº.
JEM193G
SEM500G
JEM195G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3068

CAUTION:
When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.
10. Remove connecting rod bearings from connecting rod and
connecting rod cap.
+Store the removed parts in sets by the cylinder No. to avoid
mixing them up.
11. Remove piston rings from pistons.
+Use piston ring expander (Commercial Service Tool).
+Avoid scratching pistons during removal.
+Be careful not to damage piston rings by expanding
excessively.
CAUTION:
+When piston rings are not replaced, make sure that pis-
ton rings are mounted in their original positions.
12. Remove piston from connecting rod.
a. Remove snap rings using snap ring pliers.
b. With an industrial drier, heat pistons to 60 to 70ÉC (140 to
158ÉF).
c. Push out piston pin with a rod approx. 26 mm (1.02 in) in
diameter.
FEM086
JEM196G
JEM197G
JEM198G
JEM199G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3069

13. Remove main bearing cap bolts.
+With a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the
reverse order of that shown in the figure and remove them.
+Before loosening main bearing cap bolts, measure crank-
shaft end play. Refer to EM-3070, ªCRANKSHAFT END
PLAYº.
14. Remove main bearing caps.
+Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder
block and main bearing caps.
+Check the correct installation locations of removed
parts. Store them so they do not get mixed up.
17. Remove oil jet.
18. Remove oil jet check valve.
Inspection
CRANKSHAFT END PLAY
+Measure the moving distance of the crankshaft with the dial
gauge when the crankshaft is moved fully forward or back-
ward.
Standard: 0.085 - 0.25 mm (0.0033 - 0.0098 in)
Limit: 0.30 mm (0.0118 in)
+If the value exceeds the limit, replace thrust bearings with
new ones and measure again. If the measurement exceeds
the limit again, replace crankshaft with a new one.
CONNECTING ROD SIDE CLEARANCE
+Measure the side clearance between connecting rod and
crank arm with feeler gauge.
Standard: 0.200 - 0.350 mm (0.0079 - 0.0138 in)
Limit: 0.4 mm (0.016 in)
+If the value exceeds the limit, replace connecting rod and
measure again. If the measurement exceeds the limit again,
replace the crankshaft.
JEM200G
JEM201G
JEM202G
JEM203G
CYLINDER BLOCKYD25DDTi
Disassembly (Cont'd)
EM-3070

PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
27.997 - 28.005 mm (1.1022 - 1.1026 in)
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate interference fit of piston pin to piston.
Dp þ dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
2nd ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
Top ring 0.1 mm (0.004 in)
2nd ring 0.1 mm (0.004 in)
+To measure top ring side clearance, align the outer circum-
ferences of the ring and piston while pressing ring upward
against the upper surface of the ring groove. Under this
condition, measure the clearance between ring and bottom
surface of the ring groove.
+If out of specification, replace piston ring. If clearance
exceeds maximum limit with new ring, replace piston.
PISTON RING END GAP
End gap:
Top ring 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring 0.37 - 0.52 mm (0.0146 - 0.0205 in)
Oil ring 0.30 - 0.55 mm (0.0118 - 0.0217 in)
Max. limit of ring gap:
Top ring 1.0 mm (0.039 in)
2nd ring 1.0 mm (0.039 in)
Oil ring 1.0 mm (0.039 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
AEM023
AEM024
SEM024AA
JEM205G
SEM599A
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3071

Refer to SDS (EM-3094).
+When replacing the piston, check the cylinder block surface
for scratches or seizure. If scratches or seizure is found,
hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
CYLINDER BLOCK DISTORTION AND WEAR
+Clean upper surface of cylinder block. Use a reliable straight-
edge and feeler gauge to check the flatness of cylinder block
surface. Check along six positions shown in the figure.
Distortion limit: 0.04 mm (0.0016 in)
+If out of specification, resurface it. The limit for cylinder block
resurfacing is determined by cylinder head resurfacing in
engine.
Resurfacing limit:
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A+B=0.07mm (0.0028 in)
Nominal cylinder block height from crankshaft center:
252.95 - 253.05 mm (9.9586 - 9.9626 in)
+If necessary, replace cylinder block.
SEM038F
SEM003F
SEM501G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3072

PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore in X and Y direc-
tions at A, B and C for wear, out-of-round and taper.
Cylinder bore inner diameter:
Standard
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit
0.07 mm (0.0028 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X þ Y):
Limit 0.015 mm (0.0006 in)
Taper (C þ A):
Limit 0.010 mm (0.0004 in)
2. Check for scratches and seizure. If seizure is found, hone it.
3. Measure piston skirt diameter.
Piston diameter ªAº:
Standard
88.940 - 88.970 mm (3.5016 - 3.5027 in)
Measuring point ªaº (Distance from the top):
59.0 mm (2.323 in)
4. Check that piston-to-bore clearance is within specification.
+Calculate the clearance by using outer diameter at piston
skirt and inner diameter of cylinder (direction of X, point B):
Piston-to-bore clearance = Cylinder bore þ Piston
diameter ªAº
Standard [at room temperature 20ÉC (68ÉF)]:
0.050 - 0.070 mm (0.0020 - 0.0028 in)
+If the value is out of the specified range, replace piston and
piston pin assembly.
+If cylinder block or pistons are replaced with new ones, select
piston as follows:
When using a new cylinder block:
+Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface
at the rear of cylinder block and select a piston of the same
grade.
+The part No. of piston is specified together with the piston pin
as an assembly.
JEM206G
SEM899G
SEM258C
JEM208G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3073

When re-using a removed cylinder block:
+Measure the inner diameter of the cylinder block bore.
+Determine the bore grade by comparing the measurement
with the values under ªCylinder bore IDº of the table below.
Choose a piston of the same grade.
Selective fitting for piston:
Unit: mm (in)
Grade (punched) 1 2 3
Cylinder bore ID89.000 - 89.010
(3.5039 - 3.5043)89.010 - 89.020
(3.5043 - 3.5047)89.020 - 89.030
(3.5047 - 3.5051)
Piston OD88.940 - 88.950
(3.5016 - 3.5020)88.950 - 88.960
(3.5020 - 3.5024)88.960 - 88.970
(3.5024 - 3.5027)
5. Determine piston oversize according to amount of cylinder
wear.
+For oversize pistons, 0.25 and 0.5 OS [0.25 mm (0.0098
in), 0.5 mm (0.0197 in) oversize] are available as service
parts. Refer to SDS, EM-3094. When using an oversize
piston, hone cylinder so that the clearance between pis-
ton and cylinder becomes the specified value. Be sure to
use appropriate oversize piston ring for the oversize pis-
ton.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation:D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Cut cylinder bores.
+When any cylinder needs boring, all other cylinders
must also be bored.
+Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so in diameter at a time.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper.
+Measurement should be done after cylinder bore cools
down.
SEM508GB
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3074

CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
Taper (A þ B):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
3. Measure crankshaft runout at No. 3 (center) journal.
Runout (Total indicator reading):
Standard 0.05 mm (0.0020 in)
Limit 0.10 mm (0.0039 in)
MAIN BEARING HOUSING INNER DIAMETER
+Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque.
+Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
+If the measurement is out of the specified range, replace
cylinder block and main bearing caps.
BEARING CLEARANCE
+Use either of the following two methods, however, method
ªAº gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing
1. Install main bearings to the cylinder block and bearing cap,
and tighten the bolts to the specified torque. Then, measure
the inner diameter of the main bearings.
Oil clearance = Bearing ID þ Crankshaft journal OD
Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
SEM316A
JEM212G
JEM214G
JEM213G
CYLINDER BLOCKYD25DDTi
Inspection (Cont'd)
EM-3075