2001 NISSAN PICK-UP Repair Manual

Valve Seat
Unit: mm (in)
SEM546G
JEM253G
Standard Service
Cylinder head seat recess diameter (D)Intake 30.000 - 30.016 (1.1181 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620)
Valve seat interference fitIntake 0.064 - 0.100 (0.0025 - 0.0039)
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat outer diameter (d)Intake 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Exhaust 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
Height (h)Intake 7.0 - 7.1 (0.276 - 0.280) 6.60 - 6.70 (0.2598 - 0.2638)
Exhaust 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
EM-3092

Depth (H)Intake 8.83 - 9.13 (0.3476 - 0.3594)
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Depth (L)Intake 36.53 - 36.98 (1.4382 - 1.4559)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
Camshaft and Camshaft Bearing
Unit: mm (in)
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.045 - 0.086 (0.0018 - 0.0034)
Inner diameter of camshaft bearingNo. 1
30.500 - 30.521 (1.2008 - 1.2016)
No. 2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)Ð
Outer diameter of camshaft journalNo. 1
30.435 - 30.455 (1.1982 - 1.1990)
No. 2, 3, 4, 5
23.935 - 23.955 (0.9423 - 0.9431)Ð
Camshaft runout [TIR*] Ð 0.02 (0.0008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) Ð
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
*: Total indicator reading
EM671
Cam height ªAºIntake 39.505 - 39.695 (1.5553 - 1.5628)
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
Wear limit of cam height0.15 (0.0059)
Valve timing
PBIC0187E
Unit: degree
abcde f
224 212 2 30 þ2 46
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
Valve Seat (Cont'd)
EM-3093

Cylinder Block
Unit: mm (in)
SEM899G
Surface flatnessStandard
Less than 0.03 (0.0012)
Limit 0.1 (0.004)
Cylinder bore Inner diameter StandardGrade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028)
Out-of-round (X þ Y) Less than 0.015 (0.0006)
Taper (C þ A) Less than 0.010 (0.0004)
Main journal inner
diameter grade
(Without bearing) Grade No. 0
Grade No. 1
Grade No. 2 66.654 - 66.663 (2.6242 - 2.6245)
66.663 - 66.672 (2.6245 - 2.6249)
66.672 - 66.681 (2.6249 - 2.6252)
Difference in inner
diameter between
cylinders Limit
Less than 0.05 (0.0020)
Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
Unit: mm (in)
SEM882E
Piston skirt diameter ªAº StandardGrade No. 1 88.940 - 88.950 (3.5016 - 3.5020)
Grade No. 2 88.950 - 88.960 (3.5020 - 3.5024)
Grade No. 3 88.960 - 88.970 (3.5024 - 3.5027)
0.25 (0.0098) oversize (Service) 89.190 - 89.220 (3.5114 - 3.5126)
0.50 (0.0197) oversize (Service) 89.440 - 89.470 (3.5213 - 3.5224)
ªaº dimension 59.0 (2.323)
Piston pin hole diameter 27.997 - 28.005 (1.1022 - 1.1026)
Piston clearance to cylinder block 0.050 - 0.070 (0.0020 - 0.0028)
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
EM-3094

PISTON RING
Unit: mm (in)
Standard Limit
Side clearanceTop 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
2nd 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) Ð
End gapTop 0.21 - 0.31 (0.0083 - 0.0122) 1.0 (0.039)
2nd 0.37 - 0.52 (0.0146 - 0.0205) 1.0 (0.039)
Oil (rail ring) 0.30 - 0.55 (0.0118 - 0.0217) 1.0 (0.039)
PISTON PIN
Unit: mm (in)
Piston pin outer diameter27.994 - 28.000 (1.1021 - 1.1024)
Interference fit of piston pin to piston0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing clearanceStandard 0.026 - 0.044 (0.0010 - 0.0017)
Limit 0.057 (0.0022)
*: Values measured at ambient temperature of 20ÉC (68ÉF)
Connecting Rod
Unit: mm (in)
Center distance154.47 - 154.53 (6.0815 - 6.0838)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod small end inner diameter 30.080 - 31.000 (1.1842 - 1.2205)
Piston pin bushing inner diameter*28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Side clearanceStandard 0.200 - 0.350 (0.0079 - 0.0138)
Limit 0.4 (0.016)
*: After installing in connecting rod
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
Piston, Piston Ring and Piston Pin (Cont'd)
EM-3095

Crankshaft
Unit: mm (in)
Main journal dia. ªDmº gradeGrade No. 0
Grade No. 1
Grade No. 262.967 - 62.975 (2.4790 - 2.4793)
62.959 - 62.967 (2.4787 - 2.4790)
62.951 - 62.959 (2.4784 - 2.4787)
Pin journal dia. ªDpºGrade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Grade No. 1 51.961 - 51.968 (2.0457 - 2.0460)
Grade No. 2 51.954 - 51.961 (2.0454 - 2.0457)
Center distance ªrº49.97 - 50.03 (1.9673 - 1.9697)
Out-of-round (X þ Y) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Taper (A þ B) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Runout [TIR*]Standard Less than 0.05 (0.0020)
Limit Less than 0.10 (0.0039)
Free end playStandard 0.085 - 0.25 (0.0033 - 0.0098)
Limit 0.30 (0.0118)
SEM645EM715
*: Total indicator reading
Available Main Bearing
SEM255G
Grade number Thickness ªTº mm (in) Width ªWº mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717)
19.9 - 20.1 (0.783 - 0.791)Black
1 1.820 - 1.824 (0.0717 - 0.0718) Brown
2 1.824 - 1.828 (0.0718 - 0.0720) Green
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
EM-3096

UNDERSIZE
Unit: mm (in)
Thickness Main journal diameter ªDmº
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)Grind so that bearing clearance is the specified
value.
Available Connecting Rod Bearing
CONNECTING ROD BEARING
Grade number Thickness ªTº mm (in) Width ªWº mm (in) Identification color (mark)
0 1.492 - 1.496 (0.0587 - 0.0589)
22.9 - 23.1
(0.902 - 0.909)Black
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.504 (0.0591 - 0.0592) Green
UNDERSIZE
Unit: mm (in)
Thickness Crank pin journal diameter ªDpº
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the specified
value. 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous Components
Unit: mm (in)
Flywheel runout [TIR]*Less than 0.15 (0.0059)
*: Total indicator reading
BEARING CLEARANCE
Unit: mm (in)
Main bearing clearanceStandard 0.039 - 0.066 (0.0015 - 0.0026)
Limit 0.10 (0.0039)
Connecting rod bearing clearanceStandard 0.031 - 0.061 (0.0012 - 0.0024)
Limit 0.09 (0.0035)
SERVICE DATA AND SPECIFICATIONS (SDS)YD25DDTi
Available Main Bearing (Cont'd)
EM-3097

HEATER &
AIR CONDITIONER
SECTION
HA
MODIFICATION NOTICE:
+Wiring Diagrams have been changed.
+Thermo switch has been abolished.
+A/C cycle for YD engine has been added.
CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION............... 3002
Precautions for Refrigerant Connection .......... 3002
MANUAL
TROUBLE DIAGNOSES..................................... 3004
Wiring Diagram - HEATER -............................ 3004
Circuit Diagram - A/C, M - ............................... 3005
Wiring Diagram - A/C, M -/LHD Models with
KA, YD Engine ................................................. 3006
Wiring Diagram - A/C, M -/RHD Models with
KA, YD Engine ................................................. 3009
Magnet Clutch .................................................. 3012
AUTO
TROUBLE DIAGNOSES..................................... 3020
Circuit Diagram - A/C, A -................................ 3020
Wiring Diagram - A/C, A -................................ 3021
Magnet Clutch .................................................. 3026
SERVICE PROCEDURES................................... 3030
Refrigerant Lines.............................................. 3030
MANUAL AND AUTO
SERVICE PROCEDURES................................... 3031
Checking Refrigerant Leaks ............................ 3031
SERVICE PROCEDURES................................... 3032
Compressor Mounting...................................... 3032
MANUAL AND AUTO
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3033
General Specifications ..................................... 3033
Inspection and Adjustment .............................. 3033

HA

Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
+Expansion valve to cooling unit
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
+The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the
O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing char-
acteristics.
+The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse
O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-ring part numbers and specifications
Connection
typeO-ring
sizePart number D mm (in) W mm (in)
New
892471 N8210 6.8 (0.268) 1.87 (0.0736)
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
New
1292472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
1692473 N8210 13.6 (0.535) 2.43 (0.0957)
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
1992474 N8210 16.5 (0.650) 2.43 (0.0957)
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
SHA815E
SHA814E
PRECAUTIONS AND PREPARATIONMANUAL AND AUTO
HA-3002