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ENGINE MECHANICAL Supplement 3 (Diesel)

1. Grade number Thickness T mm in Width W mm in Identification color mark 0 1 492 1 496 0 0587 0 0589 Black 22 9 23 1 1 1 496 1 500 0 0589 0 0591 0 902 0 909 Brown 2 1 500 1 504 0 0591 0 0592 Green UNDERSIZE Unit mm in Thickness Crank pin journal diameter Dp 0 08 0 0031 0 12 0 0047 0 25 0 0098 1 536 1 540 0 0605 0 0606 1 556 1 560 0 0613 0 0614 Grind so that Midi e is the specified 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 Standard 0 039 0 066 0 0015 0 0026 Main bearing clearance Limit 0 10 0 0039 Standard 0 031 0 061 0 0012 0 0024 Connecting rod bearing clearance 0 09 0 0035 EM 3097
2. Engine coolant Valve lifter a temperature sensor Thermal transmitter Ea 912 15 Elis o9 i 1 4 2 1 0 14 0 22 13 19 1 2 1 6 E 9 11 70 104 eS Camshaft sprocket Ca Glo har p w ness oN Y Glow plug 9 18 21 1 8 2 2 13 15 Gasket x e Cylinder head ue assembly Camshaft sprocket ge LH A A QQ E 138 147 eas o 14 0 15 0 102 108 Water outlet 9121 28 2 1 2 9 16 20 Select with proper thickness Lubricate with new engine oil Apply Genuine Liquid Gasket or equivalent Nem kg m ft lb Nem kg m in Ib ie OS SEM887G EM 3046 Engine front D Intake valve Exhaust valve T ENEFA i Oro oe pes peg eee SOS JEM152G JEM159G CYLINDER HEAD Components Cont d CAUTION When installing camshafts chain tensioners oil seals or other sliding parts lubricate contacting surfaces with new engine oil Apply new engine oil to threads and seat surfaces when installing cylinder head camshaft sprocket crankshaft pulley and camshaft bracket Attach tags to valve lifters so as not to mix them up Removal T 2 3 Drain engine coolant Refer to LC section Changing Engine Coolant Remove exhaust manifold Turbocharger Refer to EM 3039 Removal and Installation Remove intake manifold Refer to EM 3035 Removal and Installatio
3. 154 1 mm 6 059 6 067 in JEM204G EM 3088 SERVICE DATA AND SPECIFICATIONS SDS Valve VALVE Unit mm in T Margin thickness a D SEM188 Intake 28 0 28 3 1 102 1 114 Valve head diameter D Exhaust 26 0 26 3 1 024 1 035 Intake 106 72 4 2016 Valve length L Exhaust 106 36 4 1874 Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 945 5 960 0 2341 0 2346 Intake Valve seat angle o 45 15 45 45 Exhaust Intake 1 38 0 0543 Valve margin T Exhaust 1 48 0 0583 Valve margin T limit More than 1 0 0 039 Valve stem end surface grinding limit Less than 0 2 0 008 VALVE CLEARANCE Unit mm in Cold Hot reference data Intake 0 24 0 32 0 009 0 013 0 29 0 37 0 011 0 015 Exhaust 0 26 0 34 0 010 0 013 0 33 0 41 0 013 0 016 Approximately 80 C 176 F AVAILABLE SHIMS Thickness mm in Identification mark 2 10 0 0827 2 10 2 12 0 0835 2 12 2 14 0 0843 2 14 2 16 0 0850 2 16 2 18 0 0858 2 18 2 20 0 0866 2 20 2 22 0 0874 2 22 2 24 0 0882 2 24 2 26 0 0890 2 26 2 28 0 0898 2 28 2 30 0 0906 2 30 2 32 0 0913 2 32 2 34 0 0921 2 34 EM 3089 SERVICE DATA AND SPECIFICATIONS SDS Valve Cont d 2 36 0 0929 2 36 2 38 0 0937 2 38 2 40 0 0945 2 40 2 42 0 0953 2 42 2 44 0 0961 2 44 2 46 0
4. Inspection e Before starting the engine check levels of coolant engine oil and other operating fluids and if necessary refill them to the specified level e Start the engine and check that there is no abnormal noise or vibration e Warm up the engine to the sufficient temperature and check that there is no leakage of coolant greases fuel or exhaust gas EM 3065 CYLINDER BLOCK Components SEC 110 120 186 Oil pressure switch o 0 13 17 49 58 1 25 1 75 9 12 5 0 6 0 37 43 9 12 13 1 2 1 4 9 10 Oil level gauge guide P Cylinder block Kl 5 49 58 X N Rear oil seal FF 73 5 0 6 0 37 43 N Rear oil seal retainer Fuel injection pump bracket Coolant drain plug Top ring FY Second ring ual i 8 11 0 8 1 2 70 104 A N Piston pin Oil jet A Oil jet relief valve d Suet 40 58 4 0 6 0 29 43 CS 9 6 1 10 7 m i 0 62 1 1 54 95 Copper icd is d A 2 asher 3 3 103 112 10 5 11 5 76 83 Piston x E Thrust bearing Connecting rod 1 Main bearing Connecting rod bearing Connecting rod cap Connecting rod nut E o Refer to text c Crankshaft KO a e We eC Select with proper thickness gt We P J Jj Pilot bush B uk Sues Main bearing x E W Main bearing ca Lubricate with new engine oil i Mg cap Apply Genuine Liquid Gasket or equivalent Nem kg m in Ib Nem
5. 161 4 174 8 kPa 1 614 1 748 mbar 1 210 5 1 311 0 mmHg 47 7 51 6 inHg 4 0 mm 0 157 in EM 3043 EXHAUST MANIFOLD TURBOCHARGER Inspection Cont d Trouble Diagnosis of Turbocharger Preliminary check e Check that the engine oil level is between MIN and MAX of the dipstick When the engine oil amount is more than MAX the oil flows into the inlet duct through the blow by gas passage and the turbocharger is misjudged failure e Ask the customer if he she always runs the vehicle in idle engine speed to cool the oil down after driving e Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the table below e f no malfunction is found after the unit inspections judge that the turbocharger body has no failure Check the other parts again Symptom when each inspection item meets each inspection result Inspection item Inspection result Insufficient power Oil leakage Smoke Noise acceleration failure Oil leaks A Carbon is accumulated A O O Turbine wheel Friction with housing A O O Blades are bent or broken Inside the air inlet is seriously contaminated Bv oi i O O y oil Compressor wheel Friction with housing O O Blades are bent or broken There is resistance when the rotor shaft is A A O rotated by your fingertips After checking both turbine and compressor The rotor shaft sometimes does not rotate inspe
6. 61 9 78 5 d s 3 0 2 4 27 6 4 8 0 45 51 18 20 O Nem kg m ft lb 46 57 SEM866G SEC 140 147 164 211 Engine front Apply new engine oil 9 21 5 24 5 until it reaches 5 2 2 4 4 a height of more 18 LAF than 3 mm 0 12 in Heater pipe X Engine oil or equivalent 26 6 29 4 2 9 19 7 23 5 U 2 8 2 9 Engine front oo ri M LN JN NE S M NO a i3 Ey VUA hy 9 8 11 8 1 0 1 2 Pus agnum Ps R as 7 0 61 9 78 5 _ Gasket 3 CSS 6 4 8 0 J a Se S 0 77 98 DANNS A 7 9 9 9 S ue A S n 3 a Se 6 4 8 0 S ve 57 Gasket D 1 2 3 4 Intake manifold 5 EGR tube 8 Injection tube clamp EGR guide tube 6 Cylinder head 9 Injection tube EGR volume control valve 7 Cylinder block 10 Injection nozzle oil seal EGR spacer REMOVAL 1 Drain engine coolant Refer to LC section Changing engine coolant 2 Remove charge air cooler Refer to EM 3014 Removal and Installation 3 Remove EGR volume control valve EGR spacer and EGR guide tube 4 Remove fuel injection tubes and intake manifold EM 3035 INTAKE MANIFOLD Removal and Installation Cont d 2 y li gt IS din iin ji Sas A ANG D emova da SS S D e To prevent fuel from flowing out plug the opening of the hose A 3G W778 with a blind plug after disconnection 7 pe Se TRUE WIR e Be careful not to spill fuel in the engine compartment YAS E Ins
7. B 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 e lf necessary replace cylinder block EM 3072 Crank journal P grade No From bottom No 1 to 5 i TNCS Le Bore grade No Engine front Control code From bottom No 1 to 4 JEM208G CYLINDER BLOCK Inspection Cont d PISTON TO BORE CLEARANCE de 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 Y Limit 0 015 mm 0 0006 in Taper C A Limit 0 010 mm 0 0004 in Check for scratches and seizure If seizure is found hone it Measure piston skirt diameter Piston diameter A Standard 88 940 88 970 mm 3 5016 3 5027 in Measuring point a Distance from the top 59 0 mm 2 323 in 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 Piston diameter A Standard at room temperature 20 C 68 F 0 050 0 070 mm 0 0020 0 0028 in If the value is out of t
8. Check nozzle for deformation or damage Check oil passage for obstruction by blowing in air on nozzle side If abnormality is found clean or replace OIL JET RELIEF VALVE Using a clean resin rod press down on the check valve inside relief valve Check for appropriate bounce repulsion and smooth operation Assembly PISTON 1 With using snap ring pliers install snap rings to grooves at the rear side of the piston e Install securely to fully fit into the groove 2 Install piston to the connecting rod e Heat the piston with an industrial drier to 60 to 70 C 140 to e o 158 F so that the piston pin can be easily inserted by finger Then insert the piston pin from the front of the piston into the piston and into the connecting rod Assemble so that the front mark on the piston top surface and cylinder No stamped on connecting rod are positioned as shown in the figure Install snap ring on piston front Refer to step 1 above for notes for installation After installing check that the connecting rod moves smoothly Install piston rings using piston ring expander Commercial Service Tool Be extremely careful to avoid any damage to the piston Install top ring and second ring with the punched surface facing upward Identification mark Top ring R Second ring 2R Install rings so that three closed gap position 120 apart one another Closed gaps do not need to face in a specific directions as long as each
9. Install connecting rod cap to connecting rod Tighten bolts to the specified torque 3 Measure inner diameter C of connecting rod Inner diameter Standard 55 000 55 013 mm 2 1654 2 1659 in AEM027 EM 3077 CYLINDER BLOCK Inspection Cont d 4 Measure outer diameter Dp of each crankshaft pin journal 5 Calculate connecting rod bearing clearance Connecting rod bearing clearance C Dp Standard 0 031 0 061 mm 0 0012 0 0024 in 6 If it exceeds the standard replace bearing Upper line Journal grade No When using a new crankshaft and connecting rods PM From left No 1 to 5 e Identify the pin diameter grade No 0 1 or 2 on front sur M a face of crankshaft and select the connecting rod bearings of ugoG QUESO the same grade 700022009 ower line e There is no grading for the inner diameter of the big end of p ZN Pin grade No the connecting rod Lot No J From left No 1 to When re using the removed crankshaft and connecting N CY rods e Measure the inner diameter of the big end of the connecting rod and make sure it is within the specified range JEM215G e Measure the outer diameter of the crankshaft pin e Determine the crankshaft pin grade by comparing the mea surement with the values under the column Crankshaft pin OD of the table below Choose the bearings of the same grade Key Crankshaft front face Selective fitting for connecting rod beari
10. SUPPLEMENT III ENGINE MECHANICAL MODIFICATION NOTICE SECTION E M E e KA24DE engine information has been added for Europe For information not included here refer to information for KA24DE engine in D22 Supplement Il Service Manual SM9E D22BEOE e YD25DDTi engine has newly been added CONTENTS YD25DDTi EM 3002 SEM164F Inner side AEMO80 PRECAUTIONS Parts Requiring Angular Tightening Dg Use an angle wrench for the final tightening of the following engine parts Oylinder head bolts Main bearing cap bolts YD series Connecting rod cap nuts KA and YD series 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 Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves Also completely clean any oil from these areas 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 Apply liquid gasket around the inner side of bolt holes unless otherwise specified Assembly should be done within 5 minutes after coating Wait at least 30 minutes before refilling engine oil and engine coolant EM 3003 Tool number Too
11. bearing avoid damaging the fillet R Standard dimension R 1 5 1 7 mm 0 0591 0 0669 in Method B Using plastigage CAUTION Do not turn crankshaft or connecting rod while plasti gage is being inserted When bearing clearance exceeds the specified limit ensure that the proper bearing has been installed If incorrect bearing clearance exists use a thicker or undersized main bearing to ensure specified clearance MAIN BEARING CRUSH HEIGHT When the bearing cap is removed after being tightened to the specified torque with main bearings installed the tip end of bearing must protrude Standard There must be crush height If the standard is not met replace main bearings MAIN BEARING CAP BOLT DEFORMATION Measure the outer diameter of threaded area d1 and d2 at the points specified in the figure When the necked point is identified at a point other than where specified measure at the point as d2 Calculate the difference between d1 and d2 Limit 0 13 mm 0 0051 in EM 3079 CYLINDER BLOCK Inspection Cont d CONNECTING ROD BUSHING CLEARANCE SMALL END 1 Measure inner diameter C of bushing Inner diameter C Standard 28 026 28 038 mm 1 1034 1 1039 in 2 Measure outer diameter Dp of piston pin Outer diameter Dp Standard 27 994 28 000 mm 1 1021 1 1024 in 3 Calculate connecting rod bushing clearance Connecting rod bushing clearance C Dp Standard 0 026 0 044 mm 0 0010 0 0
12. kg m ft lb o Refer to text Main bearing cap bolt K 1 kel SS y SEM897G EM 3066 NS Ou Knock pin D Oo KV10106500 D 40 49 4 0 5 0 29 36 o N m kg m ft lb M12 bolt 98 107 10 0 11 0 73 79 JEM192G CYLINDER BLOCK Removal and Installation CAUTION When installing bearings pistons or other sliding parts lubricate contacting surfaces with new engine oil Place removed parts such as bearings and bearing caps in their proper order and direction When installing connecting rod nuts and main bearing cap bolts apply new engine oil to threads and seating surfaces Do not allow any magnetic materials to contact the sig nal plate of flywheel Do not remove the signal plate at back Do not place the signal plate side facing under Handle with care so as not to damage the signal plate especially four places on protrusions for signal of crank position sensor TDC sensor Disassembly PISTON AND CRANKSHAFT LA 2 a e Remove engine Refer to ENGINE REMOVAL EM 3063 Place engine on a work stand Remove flywheel Hold ring gear with ring gear stopper KV10105630 KV10105610 Then loosen securing bolts with TORX socket size Q8 E20 Commercial Service Tool and remove them As an alternative method hold the crankshaft pulley with a pulley holder SST to remove the flywheel Install engine sub attachment SST to rear surface of cylin der block To
13. 0969 2 46 2 48 0 0976 2 48 2 50 0 0984 2 50 2 52 0 0992 2 52 2 54 0 1000 2 54 2 56 0 1008 2 56 2 58 0 1016 2 58 2 60 0 1024 2 60 2 62 0 1031 2 62 2 64 0 1039 2 64 2 66 0 1047 2 66 2 68 0 1055 2 68 2 70 0 1063 2 70 2 72 0 1071 2 72 2 74 0 1079 2 74 Hole Less than 3 mm 0 12 in dia T 2 50 7 Indicate T 2 500 mm Shim 0 0984 in SEM512G VALVE SPRING 43 7 1 720 Free height mm in Pressure N kg Ib at height mm in Out of square mm in Outer Limit 1 9 0 075 320 360 32 6 36 7 71 9 80 9 at 24 82 0 9772 VALVE LIFTER Unit mm in Valve lifter outer diameter 29 960 29 975 1 1795 1 1801 30 000 30 021 1 1181 1 1819 0 025 0 061 0 0010 0 0024 Lifter guide inner diameter Clearance between lifter and lifter guide EM 3090 SERVICE DATA AND SPECIFICATIONS SDS 5 Valve Cont d VALVE GUIDE Unit mm in 104 106 V 10 4 10 6 0 409 0 417 0 409 0 417 O Unit mm in JEM156G Standard Service Valve guide Outer diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 Valve guide Inner diameter Finished size 6 000 6 018 0 2362 0 2369 Cylinder head valve guide hole diameter 9 975 9 996 0 3927 0 3935 10 175 10 196 0 4006 0 4014 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08
14. 1D22E0E 2WD models only 5 Install transmission with transfer assembly Refer to MT sec tion in NISSAN Service Manual Supplement Ill of SM3E00 1D22E0E 4WD models only 6 Install crankshaft position sensor Refer to EM section in NISSAN Service Manual Supplement IIl of SM3E00 1D22E0E 7 Install front final drive together with differential mounting member and front suspension member refer to PD MT and FA sections in NISSAN Service Manual First Edition of SM3E00 1D22E0E 4WD models only 8 Install left side of the tie rod end 2WD models only 3 54 0 98 0 N m 5 5 9 9 kg m 40 72 ft lb 9 Install air conditioned compressor and bracket 3 56 9 65 7 N m 5 9 6 7 kg m 42 48 ft Ib 10 Install oil strainer EM 3019 SEM857G e Inner 7 i Groove Bolt hole 4 rop Groove SEM159F Tube presser 3 5 4 5 mm 0 138 0 177 in SEM858G 2WD models Engine front SEM851G 4WD models 7 Engine front SEM852G OIL PAN Installation Cont d 11 Install lower oil pan a Deen Use a scraper to remove old liquid gasket from mating sur faces Also remove old liquid gasket from mating surface of upper oil pan Apply a continuous bead of liquid gasket to mating surface of lower oil pan Use Genuine Liquid Gasket or equivalent Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in wide Assembly should be do
15. 7 Exhaust manifold cover charger assembly EGR volume control valve 8 Oil outlet tube PREPARATIVE WORK Remove the following parts e Charge air cooler Air duct air inlet pipe Catalyst insulators Exhaust manifold cover Exhaust front tube disconnect Refer to FE section Removal and Installation EXHAUST SYSTEM Oil inlet and outlet tubes Exhaust manifold cover e Catalyst and turbocharger assembly Put aside until exhaust manifold is removed EM 3039 EXHAUST MANIFOLD TURBOCHARGER SEM872G Removal and Installation Cont d EXHAUST MANIFOLD AND TURBOCHARGER Removal e Loosen exhaust manifold mounting nuts in the reverse order specified in the figure e After removing exhaust manifold catalyst and turbocharger assembly is pulled out CAUTION Be careful not to deform each turbocharger piping when pulling out the assembly Installation e When a stud bolt is removed tighten it to the following torque 12 7 16 7 N m 1 3 1 7 kg m 10 12 ft Ib e Tighten the exhaust manifold mounting nuts in the following procedure a Tighten the nuts in the order specified in the figure b Re tighten the nuts 1 to 4 EXHAUST MANIFOLD GASKET Installation Install the gasket so that the alignment protrusion faces the No 4 port EM 3040 EXHAUST MANIFOLD TURBOCHARGER Disassembly and Assembly SEC 140 144 9 43 1 53 9 FN e 4 4 5 4 32 39 Dp O iu 9 1
16. 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 SEMS599A limit even with a new ring do the following Rebore cylinder and use oversized piston and piston rings EM 3071 CYLINDER BLOCK Inspection Cont d Refer to SDS EM 3094 e 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 SEM038F Torsion CYLINDER BLOCK DISTORTION AND WEAR e 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 e f out of specification resurface it The limit for cylinder block resurfacing is determined by cylinder head resurfacing in engine Resurfacing limit fo Amount of cylinder head resurfacing is A SEM501G Amount of cylinder block resurfacing is
17. Limit 0 4 mm 0 016 in e f the value exceeds the limit replace connecting rod and measure again If the measurement exceeds the limit again replace the crankshaft EM 3070 CYLINDER BLOCK Inspection Cont d PISTON AND PISTON PIN CLEARANCE 1 Measure inner diameter of piston pin hole dp Standard diameter dp 27 997 28 005 mm 1 1022 1 1026 in AEMO23 2 Measure outer diameter of piston pin Dp Standard diameter Dp 27 994 28 000 mm 1 1021 1 1024 in 3 Calculate interference fit of piston pin to piston Dp dp 0 002 0 006 mm 0 0001 0 0002 in If it exceeds the above value replace piston assembly with pin Micrometer V LZ AEMO24 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 Cil 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 e 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 t 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 NG Feeler gauge OK JEM205G PISTON RING END
18. Remove transmission Refer to MT section in NISSAN Ser vice Manual Supplement Ill of SM3E00 1D22E0E 2WD models only Remove transmission with transfer assembly Refer to MT section in NISSAN Service Manual Supplement III of SM3E00 1D22E0E 4WD models only Remove clutch cover and clutch disc Refer to CL section in NISSAN Service Manual Supplement of SM3E00 1D22E0E Remove flywheel and engine rear plate Refer to EM section Disassembly CYLINDER BLOCK in NISSAN Service Manual Supplement III of SM3E00 1D22E0E EM 3017 OIL PAN Removal Cont d 15 Remove upper oil pan bolts in reverse order shown 16 Remove upper oil pan a Insert an appropriate size tool into the notch of upper oil pan e Be careful not to damage aluminum mating surface e Do not insert screwdriver or oil pan flange will be deformed b Pry off upper oil pan by moving the tool up and down c Remove upper oil pan Installation 1 Install upper oil pan a Use a scraper to remove old liquid gasket from mating sur faces e Also remove old liquid gasket from mating surface of cylinder block front cover and lower oil pan e Remove old liquid gasket from the bolt hole and thread b Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan e Use Genuine Liquid Gasket or equivalent e Apply liquid gasket to areas shown in the figure e For bolt holes with A marks apply
19. aligning it with the crankshaft key on the far side Fuel injection 5 Install primary timing chain with fuel injection pump sprocket pump sprocket Ji ui J e When installing match the alignment marks on sprockets amA Cd i MENS with color coded alignment marks colored links on the chain e Install fuel injection pump sprocket washer with the surface marked F 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 e 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 MAR EN Fuel injection pump sprocket Unit mm in LAG u D Say V9 a Oe 8 Install timing chain slack guide 9 Install chain tensioner e Push the plunger of the chain tensioner While keeping IAS Lo plunger pressed down with a push pin etc install the chain x ESA tensioner OAL e After installation pull out the push pin holding the plunger e Check again that the alignment marks on the sprockets and the colored alig
20. auxiliary components A C Unit mm in 0 118 SEM898G compressor alternator to the specified torque 3 57 65 N m 5 8 6 7 kg m 42 48 ft Ib EM 3084 CYLINDER BLOCK Assembly Cont d 20 Remove engine from engine stand in the reverse order of assembly 21 Install flywheel e Holding ring gear with ring stopper SST tighten securing bolts with TORX socket size Q8 E20 Commercial Service Tool e Tighten bolts uniformly in a crisscross manner REPLACEMENT OF PILOT BUSHING 1 Remove pilot bushing using tool or suitable tool Pes aA Pilot bush N W O ul SR sT16610001 9 LC bi AN s Y SEM500G 2 Install pilot bushing as shown Crankshaft side SEM275GA EM 3085 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment VALVE Valve clearance adjustment Unit mm in Valve clearance Hot Intake 0 31 0 39 0 012 0 015 0 33 0 41 0 013 0 016 Exhaust Except for Europe 0 39 0 47 0 015 0 019 For Europe CAMSHAFT AND CAMSHAFT BEARING Ny SEM568A EM120 Unit mm in Standard Limit Intake 42 505 42 695 1 673 1 681 Cam height A Exhaust 40 905 41 095 1 610 1 618 Wear limit of cam height 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 d 10 45 28 000 28 025 1 1024 1 1033
21. gauge stand so that the tip of dial gauge can contact the cylinder block Read the difference Measure at two locations per cylinder that is eight locations for four cylinders Select gasket based on the maximum pro trusion of eight measurements ka l Gasket thickness Identification Piston protrusion mm in mm in Number of cut outs Less than 0 255 0 0100 0 900 0 0354 0 Less than 0 255 0 280 0 0100 0 0110 0 925 0 0364 1 Less than 0 280 0 305 0 0110 0 0120 dS THUS Less than 0 305 0 330 0 0120 0 0130 0 975 0 0384 3 Less than 0 330 0 355 0 0130 0 0140 ane 0 0394 More than 0 355 0 0140 1 025 0 0404 5 Measured with head bolts tightened CYLINDER HEAD BOLT DEFORMATION CHECK Measure the outer diameter of threaded area d1 and d2 at the points specified in the figure When the necked point is identified at a point other than specified points measure at the point as d1 Calculate the difference between d1 and d2 If the value exceeds the limit replace with new ones Limit 0 15 mm 0 0059 in EM 3057 Vernier caliper A el i M NON JEM172G Detail of B i passage t 332 0 102 0 142 in dia 0 14 d seg UM JEM149G KV10112100 CYLINDER HEAD Installation Cont d CYLINDER HEAD TO BLOCK DIFFERENCE CHECK e After installing cylinder head measure dimension from the front end surface of cylind
22. guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil Drive out valve guide with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or hammer and suitable tool Ream cylinder head valve guide hole Valve guide hole diameter for service parts 10 175 10 196 mm 0 4006 0 4014 in EM 3052 CYLINDER HEAD Inspection Cont d 4 Heat cylinder head to 110 to 130 C 230 to 266 F and press service valve guide onto cylinder head 10 4 10 6 10 4 10 6 Projection L 0 409 0 417 0 409 0 417 10 4 10 6 mm 0 409 0 417 in 5 Ream valve guide Finished size 6 000 6 018 mm 0 2362 0 2369 in VALVE SEATS e Before starting this check confirm that the dimensions of valve guides and valves are as specified e Apply red lead primer on contacting surfaces of valve seat and of valve face to examine the conditions of contacting surfaces e Check that the paint on contacting surfaces is continuous along the entire circumference e lf there are abnormal indications grind the valve and check the contact again If abnormal indications still persist replace valve seat NG Q JEM157G REPLACING VALVE SEAT FOR SERVICE PARTS 1 Bore out old seat until it collapses Boring should not con tinue beyond the bottom face of the seat recess in cylinder head Set the machine depth stop to ensure this 2 Ream cylinder head recess for service valve seat
23. install align the hole on the sub attachment with the knock pin on the cylinder block The engine sub attachment has five bolts Install engine attachment SST The four sets of bolts and nuts are multi purpose products EM 3067 CYLINDER BLOCK Disassembly Cont d d Hoist up engine and install it on the engine stand SST e Another method is to set engine sub attachment and engine attachment on engine stand beforehand and then install engine Drain engine oil and coolant from engine 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 amp EGR guide tube assembly Secondary timing chain Fuel injection pump Primary timing chain Rocker cover Vacuum pump High pressure injection nozzle assembly Camshaft Oylinder head Thermostat water pipes KV10106500 eeoeo0606060C ST0501S000 JEM193G Oil cooler Auxiliary component brackets Remove fuel injection pump bracket c1e0e0000000009909 6 If the replacement of pilot bushing is necessary remove it with pilot bushing puller SST 7 Remove rear oil seal retainer e 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 e Punch out with a flat bladed screwdriver e Be careful not to damage
24. lap valve seat with abrasive compound 7 Check valve seating condition Refer to EM 3053 Valve Seats 8 Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end If the distance is shorter than specified repeat step 5 above to adjust it If it is longer replace the valve seat with a new one Valve seat resurface limit L Intake 36 53 36 98 mm 1 4382 1 4559 in Exhaust 36 53 37 01 mm 1 4382 1 4571 in EM 3054 CYLINDER HEAD YD25DDTi Inspection Cont d VALVE DIMENSIONS Check dimensions of each valve For dimensions refer to SDS EM 3089 When valve head has been worn down to 0 5 mm 0 020 in in margin thickness replace valve Grinding allowance for valve stem tip is 0 2 mm 0 008 in or less T Margin thickness Seeded VALVE SPRING Squareness 1 Measure dimension S Out of square S Limit 1 9 mm 0 075 in 2 If it exceeds the limit replace spring SEM288A Pressure Check valve spring pressure at specified spring height Standard Free height 43 7 mm 1 720 in Installation height 32 82 mm 1 2921 in Installation load 184 208 N 18 77 21 22 kg 41 4 46 8 Ib Height during valve open 24 82 mm 0 9772 in Load with valve open 320 360 N 32 65 36 73 kg 71 9 80 9 Ib If it exceeds the standard replace spring VALVE LIFTER 1 Check contact and sliding surfaces
25. liquid gasket to the outside of the holes e Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in or 4 5 to 5 5 mm 0 177 to 0 217 in wide as shown in the figure Be careful that the diameter of the silicon bead is different around the front e Assembly should be done within 5 minutes after coating EM 3018 OIL PAN Installation Cont d Unit mm in Engine front SEM204H c Install upper oil pan e Tighten bolts in numerical order e Bolt dimensions vary depending on the installation location Refer to the following and use appropriate bolts 2WD models M6 x 12 mm 0 47 in Bolt No 11 14 M6 x 30 mm 1 18 in Bolt No 15 16 M8 x 25 mm 0 98 in Bolt No 1 5 9 13 M8 x 60 mm 2 36 in Bolt No 2 3 4 6 7 8 10 2WD models C Engine front Q 12 4WD models M6 x 27 mm 1 06 in Bolt No 15 16 M8 x 30 mm 1 18 in Bolt No 1 2 4 5 8 9 M8 x 60 mm 2 36 in Bolt No 3 6 7 10 11 12 13 14 e The shank length under the bolt neck above is the length of the threaded part pilot portion not included 2 Install engine rear plate and flywheel Refer to EM section Disassembly CYLINDER BLOCK in NISSAN Service Manual Supplement IIl of SM3E00 1D22E0E 3 Install clutch disc and clutch cover Refer to CL section in NISSAN Service Manual Supplement I of SM3E00 1D22E0E 4 Install transmission Refer to MT section in NISSAN Service Manual Supplement III of SM3E00
26. rear oil seal retainer e NS BSS oor Seton AN MX s Y SEM500G o Remove piston and connecting rod assembly Set crankshaft pin of the removal location at a position close to BDC ge b Remove connecting rod cap c Push piston and connecting rod assembly toward cylinder head using a hammer handle e Before removing piston and connecting rod assembly check connecting rod side clearance Refer to EM 3070 CON NECTING ROD SIDE CLEARANCE JEM195G EM 3068 CYLINDER BLOCK Disassembly Cont d 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 e Store the removed parts in sets by the cylinder No to avoid mixing them up 11 Remove piston rings from pistons e Use piston ring expander Commercial Service Tool e Avoid scratching pistons during removal e Be careful not to damage piston rings by expanding excessively CAUTION e When piston rings are not replaced make sure that pis ton rings are mounted in their original positions Piston ring expander JEM196G 12 Remove piston from connecting rod a Remove snap rings using snap ring pliers JEM197G b With an industrial drier heat pistons to 60 to 70 C 140 to 158 F c Push out piston pin with a rod appro
27. smoothly without any resis tance when it is rotated by your fingertips e Check that the rotor shaft is not loose when it is moved ver tically or horizontally e Check that the rotor shaft does not interfere with the com pressor housing Rotor shaft SEM875G Rotor Shaft End Play Place a dial gauge at the rotor shaft end in the axial direction to measure the end play e Check that the rotor shaft does not interfere with the com pressor housing Dial gauge SEM876G EM 3042 EXHAUST MANIFOLD TURBOCHARGER Turbine SEM877G Compressor SEM879G Inspection Cont d Turbine Wheel e Check that there is no oil adhesion e Check that there is no carbon accumulation e Check that blades of the turbine wheel are not bent or bro ken e Check that the turbine wheel does not interfere with the tur bine housing Compressor Wheel e Check that there is no oil adhesion inside the air inlet e Check that the compressor wheel does not interfere with the compressor housing e Check that the wheel is not bent or broken Wastegate Valve Actuator e Connect the handy pump to the actuator and check that the rod strokes smoothly in compliance with the following pres sure e Pressure to be applied at actuator part to move rod end as follows Standard Pressure rod stroke amount 143 7 152 9 kPa 1 437 1 529 mbar 1 077 8 1 146 8 mmHg 42 4 45 1 inHg 2 0 mm 0 0787 in
28. 0 0031 Stem to guide clearance Exhaust 0 040 0 073 0 0016 0 0029 0 1 0 004 Valve deflection limit 0 15 0 0059 Projection length 10 4 10 6 0 409 0 417 EM 3091 SERVICE DATA AND SPECIFICATIONS SDS Valve Seat Unit mm in Cylinder head Exhaust Exhaust valve seat 44 22 30 45 7 30 Intake valve seat 4 4 22 30 45 7 30 Standard original Standard original 25 3 25 7 0 996 1 012 23 3 23 7 0 917 0 933 2 32 2 34 0 0913 0 0921 25 9 1 020 27 6 27 8 1 087 1 094 Oversize 0 5 0 020 255 ar E 0 996 1 012 25 4 25 6 1 000 1 008 2 85 2 87 0 1122 0 1130 Oversize 0 5 0 020 23 3 23 7 0 917 0 933 2 32 2 34 0 0913 0 0921 25 4 25 6 1 000 1 008 2 85 2 87 0 1122 0 1130 27 6 27 8 1 087 1 094 d Unit mm in SEM546G JEM253G Standard Service Intake 30 000 30 016 1 1181 1 1817 30 500 30 516 1 2008 1 2014 Cylinder head seat recess diameter D Exhaust 29 000 29 016 1 1417 1 1424 29 500 29 516 1 1614 1 1620 Intake 0 064 0 100 0 0025 0 0039 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Intake 30 080 30 100 1 1842 1 1850 30 580 30 600 1 2039 1 2047 Valve seat outer diameter d Exhaust 29 080 29 096 1 1449 1 1455 29 5
29. 017 in Limit 0 057 mm 0 0022 in If it exceeds the limit replace connecting rod assembly and or piston set with pin CONNECTING ROD BOLT DEFORMATION e Install nuts to connecting rod bolts Check that the nut can be screwed smoothly on bolt threads by hand to the last thread on the bolt e f the nut does not screw in smoothly measure the outer diameter of the bolt thread at the point specified in the figure s e f a necked point is identified measure at that point x Standard 8 90 9 00 mm 0 3504 0 3543 in dia 19 mm 0 75 in Limit 8 75 mm 0 3445 in dia e Ifthe measurement exceeds the limit replace connecting rod JEM220G bolts and nuts FLYWHEEL RUNOUT Runout Total indicator reading Less than 0 15 mm 0 0059 in CAUTION e The signal plate is built into the flywheel assembly Be careful not to damage the signal plate especially the teeth e Check the signal plate for deformation or cracks e Never place the flywheel assembly with the signal plate facing down e Keep any magnetized objects away from the signal plate e Do not allow any magnetic materials to contact the sig nal plate teeth Connecting rod bolt EM 3080 P 5 Nozzle JEM221G JEM222G Engine front Cylinder No JEM227G zu Punched mark md B e Oil ring JN Top ring zie Second rin JEM2280 CYLINDER BLOCK Inspection Cont d OIL JET
30. 070 CRANK SHAFT END PLAY Check the outer diameter of connecting rod bolts Refer to EM 3080 CONNECTING ROD BOLT DEFORMATION Install piston to connecting rod Install connecting rod bearing to connecting rod and connect ing rod cap Before installing apply engine oil on the front inner surface of bearing Do not apply oil to the back surface but thor oughly clean it Align stopper notches on connecting rod and protrusions on bearing and install Install piston and connecting rod assembly to crankshaft Set crankshaft pin of the installation location at BDC Match the cylinder No of connecting rod to the location of cylinder Using piston ring compressor Commercial Service Tool install so that the front mark on the piston top surface faces in the direction of engine front Install connecting rod caps Match the cylinder No punched on connecting rod and that on cap Make sure that the front mark on connecting rod cap faces towards the front of the engine EM 3083 CYLINDER BLOCK Assembly Cont d 14 Tighten connecting rod nuts according to the following pro KV10112100 cedure Apply engine oil on bolt threads and seat surface of nuts Tighten to 29 to 30 N m 2 9 to 3 1 kg m 21 to 22 ft lb Loosen completely to 0 N m 0 kg m O in Ib Tighten to 19 to 20 N m 1 9 to 2 1 kg m 14 to 15 ft lb Tighten 120 to 125 target 120 angular tightening Always use either an angle wrenc
31. 2 Set dial gauge perpendicularly at camshaft No 3 journal 3 Turn camshaft by hand in one direction and read runout on dial gauge Runout Total indicator reading Limit 0 02 mm 0 0008 in 4 lf it exceeds the limit replace camshaft Dial gauge JEM161G CAMSHAFT CAM HEIGHT 1 Measure camshaft cam height Standard cam height Intake 39 505 39 695 mm 1 5553 1 5628 Exhaust 39 905 40 095 1 5711 1 5785 Cam wear limit 0 15 mm 0 0059 in 2 If wear is beyond the limit replace camshaft SEM549A CAMSHAFT JOURNAL CLEARANCE e e parom eter 1 Install camshaft bracket and tighten bolts to the specified torque 2 Measure inner diameter of camshaft bearing Standard inner diameter No 1 30 500 30 521 mm 1 2008 1 2016 in No 2 3 4 5 24 000 24 021 mm 0 9449 0 9457 in rom ol JEM162G EM 3050 CYLINDER HEAD Inspection Cont d 3 Measure outer diameter of camshaft journal Standard outer diameter No 1 30 435 30 455 mm 1 1982 1 1990 in No 2 3 4 5 23 935 23 955 mm 0 9423 0 9431 in 4 f clearance exceeds the limit replace camshaft and or cyl inder head Camshaft journal clearance Standard No 1 5 0 045 0 086 mm 0 0018 0 0034 in Limit 0 045 0 086 mm 0 0018 0 0034 in CAMSHAFT END PLAY 1 Install camshaft in cylinder head 2 Measure camshaft end play Camshaft end play Standard 0 070 0 148 mm 0 0028 0 0058 in
32. 2 2 15 0 p 1 3 1 5 9 11 e c Qj 8 2 9 51 0 84 0 97 73 84 9 17 21 1 8 2 1 13 15 i N m kg m in ib 9 Nem kg m ft lb SEM873G 1 Exhaust manifold 3 Turbocharger 4 Oil inlet tube 2 Gasket TURBOCHARGER Disassembly After applying penetration lubricant Lucen etc to the mounting nuts check for the penetration of the lubricant and then loosen the nuts to remove CAUTION Do not disassemble or adjust the turbocharger body Assembly When a stud bolt is removed tighten it to the following torque 0 24 27 N m 2 4 2 8 kg m 18 20 ft Ib Inspection Exhaust Manifold Check the distortion on the mounting surface in the six directions using a straightedge and a feeler gauge Limit 0 3 mm 0 012 in Straightedge JEM267G EM 3041 EXHAUST MANIFOLD TURBOCHARGER Inspection Cont d TURBOCHARGER Actuator assembly Check for leaks Check for leaks o c Compressor housing by Compressor wheel Turbine housing Turbine wheel amp turbine wheel Check for leaks SEM874G CAUTION When the compressor wheel turbine wheel or rotor shaft is damaged remove all the fragments and foreign matter left in the following passages in order to prevent a secondary failure Suction side Between turbocharger and air cleaner Exhaust side Between turbocharger and catalyst Rotor Shaft e Check that the rotor shaft rotates
33. 66 0 039 0 066 Identification color 0 0015 0 0026 0 0015 0 0026 0 0015 0 0026 Black Brown Green STD 1 STD 2 STD 3 Bearing grade No 1 820 1 824 1 824 1 828 1 828 1 832 62 959 62 967 Bearing thickness 0 0717 0 0718 0 0718 0 0720 0 0720 0 0721 2 4787 2 4790 Oil clearance 0 039 0 066 0 039 0 066 0 039 0 066 Identification color 0 0015 0 0026 0 0015 0 0026 0 0015 0 0026 Brown Green Yellow STD2 STD 3 STD 4 Bearing grade No 1 824 1 828 1 828 1 832 1 832 1 836 62 951 62 959 Bearing thickness 0 0718 0 0720 0 0720 0 0721 0 0721 0 0723 2 4784 2 4787 Oil clearance 0 039 0 066 0 039 0 066 0 039 0 066 Identification color 0 0015 0 0026 0 0015 0 0026 0 0015 0 0026 Green Yellow Blue 3 When the specified oil clearance is not obtained with stan dard size main bearings use undersized bearings e When an undersized bearing is used measure the inner diameter of the bearing while the bearing is installed Grind crankshaft journal so that the specified oil clearance is obtained Undersize bearing Pin area SE Unit mm in Journal area Size Thickness US 0 25 0 0098 1 949 1 953 0 0767 0 0769 CAUTION When grinding the crankshaft journal to use an undersize bearing avoid damaging the fillet R JEM216G Connecting Rod Bearing Big end Inside micrometer 1 Install connecting rod bearing to connecting rod and cap 2
34. 80 29 596 1 1646 1 1652 Intake 7 0 7 1 0 276 0 280 6 60 6 70 0 2598 0 2638 Height h Exhaust 6 7 6 8 0 264 0 268 6 3 6 4 0 248 0 252 EM 3092 SERVICE DATA AND SPECIFICATIONS SDS Valve Seat Cont d Intake 8 83 9 13 0 3476 0 3594 Depth H Exhaust 9 06 9 36 0 3567 0 3685 Intake 36 53 36 98 1 4382 1 4559 Depth L 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 No 1 30 500 30 521 1 2008 1 2016 Inner diameter of camshaft bearing No 2 3 4 5 24 000 24 021 0 9449 0 9457 No 1 30 435 30 455 1 1982 1 1990 Outer diameter of camshaft journal No 2 3 4 5 23 935 23 955 0 9423 0 9431 Camshaft runout TIR 0 02 0 0008 Camshaft sprocket runout TIR Less than 0 15 0 0059 Camshaft end play 0 070 0 148 0 0028 0 0058 0 24 0 0094 Total indicator reading A EM671 Intake 39 505 39 695 1 5553 1 5628 Cam height A Exhaust 39 905 40 095 1 5711 1 5785 Wear limit of cam height 0 15 0 0059 Valve timing BDC PBICO187E Unit degree a b c d e f 224 212 2 30 2 46 EM 3093 SERVICE DATA AND SPECIFICATIONS SDS YD25DDTi Cylinder Block io pu e 9 ceo x 10 0 39 Unit m
35. 9 0 37 0 011 0 015 Exhaust 0 26 0 34 0 010 0 013 0 33 0 41 0 013 0 016 Approximately 80 C 176 F EM 3062 ENGINE REMOVAL Front engine mounting SEC 112 2 52 4 0 41 52 4 2 5 3 30 38 0 41 52 O Nem kg m ft Ib Rear engine g mounting Sub member 3 68 87 CN 0 59 74 7 0 8 8 P 6 1 7 5 51 64 44 54 Insulator Vehicle n front o 41 52 B b 4 2 5 3 O Nem kg m ft lb 31 38 4 2 5 3 30 38 41 52 3 xS 4 2 5 3 30 38 Tw c lt j ZO aS 41 52 L 4 2 5 3 30 38 x i SEM892G WARNING e Situate vehicle on a flat and solid surface Place chocks at front and back of rear wheels Do not remove engine until exhaust system has com pletely cooled off Otherwise you may burn yourself and or fire may break out in fuel line Be sure to hoist engine and transmission in a safe man ner e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATA LOG CAUTION When lifting engine be careful not to strike adjacent parts especially the following Accelerator wire casing brake lines and brake master cylinder In hoisting the engine always use engine slingers in a safe manner For 4WD models apply sealant between engine and transmission Refer to MT section Removal and Instal lation For tightening torque r
36. 9G Disassembly SEC 111 130 Adjusting shim Nene es a shim x ZJ l Q Valve lifter E vane ief 8 y Valve collet alve colle amp Q i i Valve spring retainer fb g 2 eee Valve gering B e e d MAU _y i alve oil seal Valve oil seal El 6g i oa Bund e n Valve spring seat a Valve duide Valve guide fj n E D g es Cylinder head Valve seat Valve INT me amp o amp vave EXH E Select with proper thickness A Lubricate with new engine oil JEM150G 1 Remove adjusting shims and valve lifters Confirm the cor rect location of each part removed Store them in order to avoid mixing them up EM 3048 JEM151G Q Intake valve Exhaust valve JEM152G KV10107902 KV10116100 JEM153G SEM496G CYLINDER HEAD YD25DDTi Disassembly Cont d 2 Remove valve collets e Compress valve spring with a valve spring compressor and remove valve collet with a magnet hand 3 Remove valve spring retainers and valve springs 4 Push valve stem toward combustion chamber and remove valve e Before removing valves check valve guide clearance Refer to EM 3052 VALVE GUIDE CLEARANCE e Confirm the correct location of each valve Store them so they do not get mixed up e For the locations and arrangement of intake and exhaust valves refer to the figure 5 Remove valve oil seals e Use a valve oil seal pul
37. ALLATION 1 Install secondary timing chain e When installing match the alignment marks on sprockets with color coded alignment marks colored links on the chain Install timing chain tension guide e The upper bolt has a longer shank than the lower bolt m EM 3023 TIMING CHAIN Secondary Timing Chain Cont d 3 Using a hexagon head wrench face to face 6 mm 0 24 in SST install timing chain slack guide Face to face 6 mm 0 24 in KV11106020 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 Face to face c Pull out the push pin etc holding the plunger 5mm 20mm REZ e Check again that the alignment marks on the sprockets 0 20 in 0 79 in Ly ZK A and the colored alignment marks on the timing chain are er EN aligned KV11106010 5 Install front chain case a Install tension guide on the back surface of front chain case e Hold front chain case vertically when installing Tension guide may come off if front chain case is tilted 5 0 20 b Apply specified liquid gasket Refer to EM 3003 Liquid Gas Apply in ket mo Application Procedure 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 A d In
38. ION e To avoid damage glow plugs should be removed only when required e Handle with care to avoid applying shock When dropped from approx 100 mm 3 94 in or higher always replace with a new one e Before installing remove carbon depositing on mount ing hole of glow plug with a reamer EM 3058 No screw holes Camshaft RH A Camshaft LH Screw holes exist JEM173G Approximately 4 Up oy Y No S RH A NH LH oy WW LN Journal No Front mark aD re front JEM175G JEM160G CYLINDER HEAD Installation Cont d CAMSHAFT INSTALLATION le 2 o ep eecoc Install valve lifters and adjusting shims Install in the correct locations the same places as before removal Install camshafts Identify camshafts by the paint position and screw hole at the rear end Camshaft RH Paint is at position A without screw hole Camshaft LH Paint is at position B with screw hole Install so that knock pins are positioned in the directions shown in the figure Install camshaft brackets Install correctly identifying brackets by the journal No and front mark on top surface Tighten bolts in the order shown in the figure according to the following procedure Tighten to 2 0 N m 0 2 kg m 17 in Ib Make sure camshaft thrusting parts on rear side securely fit in their mating parts on the cylinder head Tighten to 6 N m 0 6 kg m 52 in Ib Tighten to 12 t
39. Limit 0 24 mm 0 0094 in e Ifthe value exceeds the limit replace camshaft and measure again e If the measurement exceeds the limit again replace cylinder head Dial gauge JEM163G CAMSHAFT SPROCKET RUNOUT 1 Install sprocket on camshaft 2 Measure camshaft sprocket runout Runout Total indicator reading Less than 0 15 mm 0 0059 in 3 If it exceeds the limit replace camshaft sprocket JEM164G EM 3051 CYLINDER HEAD Inspection Cont d JEM155G Dial gauge 2 js po VALVE GUIDE CLEARANCE Check that valve stem diameter is within the specified range Push out valve approx 25 mm 0 98 in toward combustion chamber Swing valve in the direction of the dial gauge to measure the runout This inspection should be performed before removing valve guides Half of the runout reading on the dial gauge is the valve guide clearance Standard Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 040 0 073 mm 0 0016 0 0029 in If it exceeds the limit check valve to valve guide clearance Measure valve stem diameter and valve guide inner diam eter Check that clearance is within specification Valve to valve guide clearance limit Intake 0 08 mm 0 0031 in Exhaust 0 1 mm 0 004 in If it exceeds the limit replace valve or valve guide VALVE GUIDE REPLACEMENT e When a valve guide is removed replace with an oversized 0 2 mm 0 008 in valve guide To remove valve
40. NT046 WS39930000 Pressing the tube of liquid gasket Tube presser NT052 KV10112100 Tightening bolts for bearing cap cylinder head Angle wrench etc NT014 KV10109300 a 68 mm 2 68 in Pulley holder b 8 mm 0 31 in dia NT628 EM 3005 PREPARATION Special Service Tools YD25DDTi engine Cont d Tool number Tool name Description KV11106010 a a 5 mm 0 20 in Face to face Hexagon wrench N b 20 mm 0 79 in Ur NT801 KV11106020 a a 6 mm 0 24 in Face to face Hexagon wrench b 20 mm 0 79 in b NT803 KV11106030 a 6 mm 0 24 in dia Positioning stopper pin a b 80 mm 3 15 in b NT804 KV11106040 a a T70 TORX wrench b 26 mm 1 02 in b NT805 KV11106050 a 6 mm 0 24 in Face to face Hexagonal wrench b 42 mm 1 65 in Removing and installing mounting bolts of fuel injection pump sprocket b SBIA0224E EM 3006 PREPARATION Commercial Service Tools YD25DDTi engine Tool name Description Valve seat cutter set Finishing valve seat dimensions NT048 Piston ring compressor Installing piston assembly into cylinder bore NT044 Piston ring expander Removing and installing piston ring NT030 TORX socket NT807 Standard Universal NT808 EM 3007 OUTER COMPONENT PARTS SEC 120 140 150 163 164 210 220 221 230 231 For Europe 9 16 19 9 16 19 1 6 1 9 12 14 1 6 1 9 12 14 el 2 9 3 8 0 30 0 39 26 0 33 9 Intake manifold sta
41. Oversize 0 5 mm 0 020 in Intake 30 500 30 516 mm 1 2008 1 2014 in Exhaust 29 500 29 516 mm 1 1614 1 1620 in Be sure to ream in circles concentric to the valve guide center SEM795A This will enable valve seat to fit correctly b Recess diameter EM 3053 Intake Unit mm in 7 0 7 1 0 276 0 280 2 32 2 34 0 0913 0 0921 27 6 27 8 1 087 1 094 dia 88 45 90 15 30 080 30 100 1 1842 1 1850 dia SEM888G Exhaust Unit mm in 6 7 6 8 0 264 0 268 2 85 2 87 0 1122 0 1130 25 4 25 6 1 000 1 008 dia 88 45 90 15 29 080 29 096 1 1449 1 1455 dia SEM889G JEM253G CYLINDER HEAD Inspection Cont d 3 Heat cylinder head to 110 to 120 C 230 to 248 F by soak ing in heated oil 4 Sufficiently cool valve seat with dry ice Force fit valve seat into cylinder head WARNING Do not touch cold valve seat with your bare hands 5 Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS EM 3092 CAUTION Use the valve seat cutter properly Securely gripping the cutter handle with both hands press the cutter down onto the entire circumference of the contacting surface and fin ish cutting at one time Improper pressing of the cutter or cutting in several steps may result in staged surface on the valve seat 6 After cutting
42. P d as 0 19 6 23 5 V e 2 0 2 3 15 17 Pre m 19 6 23 5 2 0 2 3 15 17 M Ci gl 1 0 1 3 0 11 0 13 9 11 I N m kg m in ib 9 19 6 23 5 9 Nem kg m ft Ib 2 0 2 3 15 17 SEM848G 1 Charge air cooler cover 4 Intake manifold 6 Air inlet pipe 2 Charge air cooler 5 Bracket 7 Bracket 3 Air inlet hose Inspection Check air passages of charge air cooler core and fins for clogging leaks or deformation Clean or replace charge air cooler if necessary e Be careful not to deform core fins e Forcleaning procedure of charge air cooler core refer to CHECKING RADIATOR in LC section EM 3014 OIL PAN YD25DDTi Components SEC 110 2WD models 9 15 7 18 6 1 6 19 8 Oil strainer 12 13 9 8 43 10 8 fo 6 26 0 9 1 1 75 95 0 20 6 26 5 9 30 39 2 1 2 7 16 19 ST 3 0 4 0 22 28 Copper washer 1 e Drain plug 1 Oil pan side Apply Genuine Liquid Oil pan lower Gasket or equivalent Nem kg m in Ib 9 Nem kg m ft Ib ig 8 43 10 8 0 9 1 1 75 95 SEM849G EM 3015 OIL PAN SEC 110 4WD models 9 15 7 18 6 1 6 1 9 Oil strainer 12 13 si 8 43 10 8 0 9 1 1 75 95 0 20 6 26 5 2 1 2 7 16 19 N U 20 6 26 5 2 1 2 7 0 30 39 3 0 4 0 22 28 Drain plug a Co
43. are positioned 120 apart EM 3081 CYLINDER BLOCK Assembly Cont d CRANKSHAFT 1 Blow air sufficiently into the coolant passage oil passage in the cylinder block inside of crankshaft case and inside of cylinder bores to remove any foreign materials 2 Install oil jet relief valves 3 Install oil jets 4 Install main bearings and thrust bearings a Remove debris dust and oil from the locations on the cylin der block and main bearing caps where bearings are installed b Install thrust bearing on each side of cylinder block No 3 housing e Install thrust bearings with oil groove facing in the direction of the crankshaft arm outside Engine front Thrust bearing installation area Face oil groove outside JEM224G c Be sure to install main bearings in the correct direction e Make sure those with oil holes or oil grooves are mounted on n i gig Gyiindsr plock side te AN the cylinder block side and those without oil holes or oil D grooves are on the main cap side Q j Oll groove e Before installing apply engine oil on the front inner surfaces of bearings Do not apply oil to the back surfaces but thor Re V7 oughly clean them Sal n e Align stopper notches on bearings and install c Cap side e Check the oil holes on cylinder block and those on bearings Engine tront are aligned JEM213G Install crankshaft to cylinder block Make sure crankshaft rotates s
44. ation They will be used later to determine the required replacement adjusting shim Valve clearance for checking Cold Intake 0 24 0 32 mm 0 009 0 013 in Exhaust 0 26 0 34 mm 0 010 0 013 in JEM179G No 4 cylinder compression at TDC 4 Rotate crankshaft clockwise by one turn to set the No 4 pis ton to TDC on the compression stroke 5 Check only those valves shown in the figure Valve Crank position No 1 No 2 No 3 No 4 INT No 4 TDC Compression stroke JEM180G EM 3060 E S C Il Facing straight above NM Lr N CS Bu Drm CIE E So E EN DL S 5 NCR lt 0 SEM497G Tool B X kv10115120 I NM e ae 2e MEE JEM555G CYLINDER HEAD Valve Clearance Cont d ADJUSTING Adjust valve clearance while engine is cold jl 2 Turn crankshaft to position cam lobe on camshaft of valve that must be adjusted upward Place Tool A around camshaft as shown in figure Before placing Tool A SST rotate notch toward cen ter of cylinder head See figure to simplify shim removal later CAUTION Be careful not to damage cam surface with Tool A 3 4 Rotate Tool A See figure so that valve lifter is pushed down Place Tool B SST between camshaft and the edge of the valve lifter to retain valve lifter CAUTION B Tool B must be placed as close to camshaft bracket as poss
45. ct rotor shaft end play i oO by your fingertips There is too much play in the bearing A A O A 7 Carbon or sludge is accumulated in the Oil return port waste oil hole A A A Large possibility Medium possibility A Small possibility EM 3044 ROCKER COVER Removal and Installation SEC 111 118 Kg 6 9 8 8 N m 9 0 7 0 9 kg m 61 78 in Ib Washer 9 Apply Genuine Liquid Gasket or equivalent SS SEM880G 1 Oil filler cap 2 Rocker cover 3 Gasket PREPARATIVE WORK Remove the engine following parts e Charge air cooler e Charge air cooler bracket ROCKER COVER Removal Loosen bolts in the reverse order of that shown in the figure and remove Installation e Tighten bolts in the numerical order shown in the figure e Re tighten to the same torque in the same order as above K Engine front SEM884G Engine front lt e Apply 3 0 mm 0 118 in dia of specified liquid gasket Refer Cylinder head rear cover to EM 3003 Liquid Gasket Application Procedure on loca JI tions shown in the figure as 0 20 S e Install in the reverse order of removal o Same length for RH and LH Liquid gasket application area Unit mm in JEM248G EM 3045 CYLINDER HEAD Components SEC 111 210 220 253 Camshaft bracket EF Camshaft RH E n Camshaft LH Cylinder head bolt KE 3 Refer to text Copper washer e Adjusting shim
46. d install cylinder head gasket with appropriate thick rasa O x ness according to the following procedure Gasket thickness 1 025 mm 0 0404 in pa When replacing gasket alone pO 60V LI Se O1 e Install a gasket with the same thickness as that of the one removed e identify the thickness of gasket by the number of cut outs and holes on the rear RH side SEM890G EM 3056 Z cz Intak ifol o Gna e manitord O iun Engine front Position for measuring amount of protrusion Front ma di d2 11 0 43 65 2 56 Unit mm in JEM171G CYLINDER HEAD YD25DDTi Installation Cont d Gasket thickness Number of cut outs mm in Number of grade 0 900 0 0354 0 925 0 0364 1 0 0 950 0 0374 0 975 0 0384 1 000 0 0394 1 025 0 0404 Measured with head bolts tightened Gasket thickness can be identified at the location shown in the figure by the numbers of cut outs before removal QO oo Rl Ww Pp o AJOJN When the following parts have been repaired replaced With cylinder block upper surface and or crankshaft pin jour nal ground With cylinder block pistons connecting rods and or crank shaft replaced Set piston at a point close to TDC Set a dial gauge at the location as shown in the figure Turn ing crankshaft gradually set the gauge scale to O where the piston protrusion is maximized Move the dial
47. e tube Remove radiator shroud and radiator Refer to LC section REMOVAL AND INSTALLATION Radiator Remove idler pulley idler pulley bracket and drive belts Remove upper and lower oil pans Refer to EM 3015 Removal and Installation OlL PAN Remove injection tube Refer to EC section Injection Tube and Injection Nozzle Remove secondary timing chain and associated parts Refer to EM 3021 Secondary Timing Chain When removing rear chain case remove camshaft sprock ets Refer to EM 3047 CAMSHAFT Remove crankshaft pulley Hold crankshaft pulley with the pulley holder SST Loosen crankshaft pulley fixing bolt and pull out the bolt approximately 10 mm 0 39 in 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 EM 3027 oN ZNN ON Slack E Y 5 kj E Chain tensioner Push pin JEM134G NS bos j amp M AY Fuel injection pump mS PNE Unit mm in KV11106030 Fuel injection ump sprocket bi JEF359Y Face to face 6 Ju 0 24 in i 42 mm 1 65 in KV11106050 TIMING CHAIN Primary Timing Chain Cont d 11 Remove oil pump e 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 t
48. efer to EC section Electronic control fuel injection pump e To prepare for removing installing secondary timing chain to remove install camshaft refer to EM 3047 CAMSHAFT 1 Drain engine oil 2 Drain coolant by removing cylinder block drain plugs Refer to LC section Changing Engine Coolant Remove EGR guide tube Remove radiator upper and lower hoses Remove radiator shroud and radiator Refer to LC section REMOVAL AND INSTALLATION Radiator EM 3021 QUE p TIMING CHAIN Secondary Timing Chain Cont d 6 Remove front chain case e Move power steering fluid reservoir tank from the bracket e Loosen fixing bolts in the reverse order of that shown in the figure and remove them e Remove all bolts with the rubber washer as space is limited for pulling them out JEM121G CAUTION e While front chain case is removed cover openings to prevent entry of foreign material into engine e Do not remove two mass dampers on the back of cover SBIAO189E 7 Setthe No 1 piston to TDC on its compression stroke e Turn crankshaft pulley clockwise so that the alignment mark punched mark on each camshaft sprocket is positioned as shown in the figure e No position indicator is provided on the crankshaft pul ley 2 KA YX e When installing color coded links on the secondary tim Alignment mark Alignment mark ing chain can be used as alignment marks Marking may punched mark
49. efer to M T and PD sections Before separating engine and transmission remove the crankshaft position sensor TDC sensor from the assembly Always pay extra attention not to damage edge of crank shaft position sensor TDC sensor or ring gear teeth EM 3063 ENGINE REMOVAL Removal Preparation Drain coolant from radiator drain plugs Remove the following parts Engine hood Charge air cooler Under protector Battery Radiator shroud Radiator Accessory belt Cooling fan Exhaust front tube ngine room Left Remove air duct and air cleaner case Disconnect harness connectors from alternator and air con ditioner compressor Remove alternator 6 Remove installation bolts Relocate air conditioner compres sor Use a rope to temporarily anchor it to vehicle side 7 Disconnect and relocate heating hose install blank cap to hose to prevent coolant from leaking 8 Remove heat insulator Engine room Right 9 Remove fuel feed and return hoses CAUTION Install blank caps immediately to avoid fuel leakage 10 Remove all harness connectors on the engine and move harnesses to the side of the vehicle Vehicle underfloor 11 Remove starter motor 12 Remove front propeller shaft 13 Remove front final drive together with differential mounting member Refer to PD section Removal and Installation Front final drive 4WD models only omeeeeeeeeem P 14 Remove mounting bolts to secure the engi
50. elts deflection Checking fizzing or Spend Drive Belts E ENGINE Creak Other drive laler pulley bearing MAINTE in A B belts Slip obarati n NANCE Front of ping P Sogns LC section Water Pump Vive A B Water pump operation Inspection ENGINE COOLING SYSTEM A Closely related B Related C Sometimes related Not related EM 3012 MEASUREMENT OF COMPRESSION PRESSURE Front edge I C SEM864G Warm up engine Turn ignition switch OFF Using CONSULT II make sure no error codes are indicated for self diagnosis items Refer to Trouble Diagnosis INDEX in EC section Do not disconnect CONSULT II until the end of this opera tion it will be used to check engine rpm and for error detec tion at the end of this operation Disconnect the negative battery terminal To prevent fuel from being injected during inspection remove fuel injection pump fuse ENG CONTS 20A from fuse box on the right side of engine compartment Remove glow plugs from all the cylinders Before removal clean the surrounding area to prevent entry of any foreign materials into the engine Carefully remove glow plugs to prevent any damage or breakage Handle with care to avoid applying any shock to glow plugs Install adapter SST to installation holes of glow plugs and connect compression gauge for diesel engine 3 18 21 N m 1 8 2 2 kg m 13 15 ft Ib Con
51. er block to that of cylinder head Standard 23 53 24 07 mm 0 9264 0 9476 in e If the difference is out of the range check fitting of dowel pins and cylinder head LIQUID GASKET APPLICATION ON REAR CHAIN CASE Apply a continuous bead of specified liquid gasket Refer to EM 3003 Liquid Gasket Application Procedure on the surface shown in the figure A Apply bead so that it does not protrude into oil passage B Minimize the overlapping area of the bead with start and end areas of bead as shown in the figure Apply so that the portion marked comes at an external location but cannot be viewed externally after engine is assembled CYLINDER HEAD INSTALLATION e Tighten bolts in numerical order as shown in the figure according to the following procedure 1 Apply engine oil to bolt threads and seat surfaces 2 Tighten bolts to 35 to 44 N m 3 5 to 4 5 kg m 26 to 32 ft Ib 3 Tighten 180 to 185 target 180 angular tightening 4 Loosen completely to 0 N m 0 kg m O0 in Ib in the reverse order of that shown in the figure 5 Tighten bolts to 35 to 44 N m 3 5 to 4 5 kg m 26 to 32 ft Ib 6 Tighten 90 to 95 target 90 angular tightening 7 Tighten another 90 to 95 target 90 angular tightening e When an angle wrench is not used paint an alignment mark on the head of cylinder head bolt and cylinder head surface before tightening Check the angle with a pro tractor GLOW PLUG INSTALLAT
52. ersize piston ring for the oversize pis ton Cylinder bore size is determined by adding piston to bore clearance to piston diameter A Rebored size calculation D A B C where D Bored diameter A Piston diameter as measured B Piston to bore clearance C Honing allowance 0 02 mm 0 0008 in 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 Hone cylinders to obtain specified piston to bore clearance Measure finished cylinder bore for out of round and taper Measurement should be done after cylinder bore cools down EM 3074 CYLINDER BLOCK Inspection Cont d A B 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 Y Standard 0 003 mm 0 0001 in Taper A B Limit Out of round X Y 0 005 mm 0 0002 in SEM316A Taper A B Standard 0 003 mm 0 0001 in Limit 0 005 mm 0 0002 in 3 Measure crankshaft runout at No 3 center journal Dial gauge Runout Total indicator reading Standard 0 05 mm 0 0020 in Limit 0 10 mm 0 0039 in MAIN BEARING HOUSING INNER DIAMETER e Without installing main bearings install main bearing caps and tighten bolts to the specified torque e Measure the inner diameter of main bearing hou
53. for wear or scratches SEM960E 2 Check diameter of valve lifter and valve lifter guide bore Valve lifter outer diameter 29 960 29 975 mm 1 1795 1 1801 in SEM961E EM 3055 CYLINDER HEAD Inspection Cont d Lifter guide bore diameter 30 000 30 021 mm 1 1811 1 1819 in Clearance between lifter and lifter guide Standard 0 025 0 061 mm 0 0010 0 0024 in e lf the value is out of the range replace valve lifter and or cylinder head referring to the specified values for the outer diameter and bore diameter 12 1 12 7 mm Assembly 0 476 0 500 in 1 Install valve oil seal e Using valve oil seal drift SST install so that the dimension shown in the figure is obtained The dimension in the figure shows the dimension before the valve spring seat is installed e Different parts should be used depending on the valve oil seal location Identify by the rubber color KV10115600 For intake Black For exhaust Brown e Always use new valve oil seal e Before installing valve oil seal install valve spring seat 2 Install other valve component parts Refer to Disassembly EM 3048 e After installing valve collets tap valve stem tip with plastic hammer to assure a proper fit JEM165G Installation e Before installation remove old liquid gasket from mating surface of all liquid gasket applied parts CYLINDER HEAD GASKET SELECTION Identification e Select an
54. gt punched mark not be necessary for removal however make alignment JJ d Whe Il marks as required because the alignment mark on fuel We O SEM515G injection pump sprocket may not be easy to see 8 Remove chain tensioner a Push the plunger of chain tensioner and keep it pressed with a push pin b Using a hexagon head wrench face to face 5 mm 0 20 in SST remove bolts to remove chain tensioner Face to face 5mm 20 mm 0 20 in 0 79 in KV11106010 Ve Is seal 77 KV11106010 o Ne b Sey SBIA0227E EM 3022 Face to face 6 mm 0 24 in KV11106020 Secondary timing chain Alignment mark Alignment mark dark blue link dark blue link Alignment mark Secondary punched mark timing chain JK LL A fy pA Chain tensioner 7777 bv He a Slack guide Tension guide d lt Alignment mark punched mark Fuel injection pump sprocket Alignment mark yellow link JEM128G TIMING CHAIN Secondary Timing Chain Cont d 9 Remove timing chain slack guide e Using a hexagon head wrench face to face 6 mm 0 24 in SST remove bolt to remove timing chain slack guide 10 Remove timing chain tension guide 11 Remove secondary timing chain e Timing chain alone can be removed without removing sprockets INSPECTION Check for cracks and excessive wear at roller links Replace chain if necessary INST
55. h SST or protractor during angular tightening Avoid tightening based on visual checks alone JEM231G e After tightening nuts check that crankshaft rotates smoothly e Check connecting rod side clearance Refer to EM 3070 CONNECTING ROD SIDE CLEARANCE 15 Force fit rear oil seal into rear oil seal retainer e Using a drift 105 mm 4 13 in dia force fit so that the dimension is as specified in the figure e Avoid inclined fitting Force fit perpendicularly eoococp 0 0 020 in Oil seal 16 Install rear oil seal retainer Apply a continuous bead of specified liquid gasket Refer to EM 3003 Liquid Gasket Application Procedure on loca tions shown in the figure 2 0 3 0 mm 0 079 0 118 in 17 Install pilot bushing e Force fit with the drift approx 19 mm 0 75 in dia JEM234G 18 Install fuel injection pump bracket 3s Dowelpin Fuel injection e Align the bracket with the dowel pins on the block to install Bp SS pump bracket e Thetwo bolts used for dowel pins have a longer shanks than A il NS PRS kd the other two E MS Loss 1 38 e Check the protruding distance of the dowel pin for fuel injec f EN gt tion pump Dowel pin for fuel s SL Standard 13 0 15 0 mm 0 512 0 591 in injection pump v Ni QA 19 parts to the engine in the reverse order of disassem Not installed Attaching bolt ys on some models dpessc is 30 e Tighten bolts securing brackets of
56. he seal off from the back surface of the oil pump using a flat bladed screwdriver e Becareful 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 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 e 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 e It is not necessary to remove the washer of the fuel injection pump sprocket EM 3028 TIMING CHAIN Primary Timing Chain Cont d Fuel injection f Fuel injection pump pump sprocket KV11106030 KV11106050 Mounting bolt JEF361Y Fuel injection 17 Remove primary timing chain with fuel injection pump pump sprocket Ji _ ae J sprocket and crankshaft sprocket 18 Remove chain guide and tension guides 19 Remove vacuum pum
57. he 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 EM 3073 Front OO j Piston grade Control code SEM508GB CYLINDER BLOCK Inspection Cont d 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 Cylinder bore ID of the table below Choose a piston of the same grade Selective fitting for piston Grade punched 1 2 Cylinder bore ID Unit mm in 89 000 89 010 89 010 89 020 3 5039 3 5043 3 5043 3 5047 89 020 89 030 3 5047 3 5051 Piston OD 88 940 88 950 88 950 88 960 3 5016 3 5020 3 5020 3 5024 88 960 88 970 3 5024 3 5027 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 ov
58. ible Be careful not to damage cam surface with Tool B Remove Tool A Blow air into the hole to separate adjusting shim from valve lifter To avoid engine oil spills wipe off oil fully beforehand Wear safety goggles etc during work if necessary EM 3061 CYLINDER HEAD YD25DDTi Valve Clearance Cont d 7 8 e e e Thickness is stamped 2 50 mm 0 0984 in JEM184G 3 9 Tool DE 9 ZA a s SEM552G 10 11 12 13 Remove adjusting shim using a small screwdriver and a magnetic finger Determine replacement adjusting shim size following for mula Using a micrometer determine thickness of removed shim Calculate thickness of new adjusting shim so valve clearance comes within specified values R Thickness of removed shim N Thickness of new shim M Measured valve clearance Intake N R M 0 28 mm 0 0110 in Exhaust N R M 0 30 mm 0 0118 in Shims are available in 33 sizes from 2 10 mm 0 0827 in to 2 74 mm 0 1079 in in steps of 0 02 mm 0 0008 in Select new shim with thickness as close as possible to cal culated value Install new shim using a suitable tool Install with the surface on which the thickness is stamped facing down Place Tool A as mentioned in steps 2 and 3 Remove Tool B Remove Tool A Recheck valve clearance Valve clearance Unit mm in Cold Hot reference data Intake 0 24 0 32 0 009 0 013 0 2
59. journals Outer diameter of camshaft journal D E 27 935 27 955 1 0998 1 1006 Camshaft runout Less than 0 02 0 0008 0 04 0 0016 Camshaft end play 0 070 0 148 0 0028 0 0058 0 2 0 008 Except for Europe For Europe a 216 224 a b 232 224 Valve timing Degree on crankshaft c 1 1 d 53 45 m e 4 JT f 32 37 x Total indicator reading EM 3086 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d PISTON PISTON RING AND PISTON PIN Standard Limit 1 0 0016 0 0031 90004 ane 2ng 001 i ons 0 1 0 004 0 0026 0 0083 9 0004 Top m l 0205 1 0 0 039 cR lene Bots m 1 0 0 039 ai ring ocr RN 1 0 0 039 EM 3087 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Cylinder arrangement In line 4 Displacement cm cu in 2 488 151 82 Bore and stroke mm in 89 0 x 100 3 504 x 3 937 Valve arrangement DOHC Firing order 1 3 4 2 Compression 2 Number of piston rings Oil 1 Number of main bearings 5 Compression ratio 18 0 Compression Pressure Unit kPa bar kg cm psi 200 rpm Standard 3 100 31 00 31 6 45 0 Compression pressure Minimum 2 500 25 00 25 5 363 Differential limit between cylinders 490 4 90 5 0 71 Cylinder Head Unit mm in Standard Limit Head surface distortion Less than 0 03 0 0012 0 1 0 004 Nominal cylinder head height H 153 9
60. k and crankshaft Identify the bearing housing grade No 0 1 or 2 on LH surface at the rear of the cylinder block and locate the appli cable grade on the Grade row in the table below Identify the journal grade No 0 1 or 2 on the front surface of the crankshaft and locate the applicable grade under the Grade column on the table The main bearing to be used STD 0 to STD 4 can be located in the cell where the row and column cross When re using removed cylinder block and crankshaft Measure the inner diameter of cylinder block main bearing housing Locate the applicable cell where the measurement falls on Cylinder block main bearing housing ID row on the table Measure the outer diameter of the crankshaft journal Locate the applicable cell where the measurement falls under Crankshaft journal OD column on the table The main bearing to be used STD 0 to STD 4 can be located in the cell where the row and column cross EM 3076 CYLINDER BLOCK Inspection Cont d Selective fitting for main bearing Unit mm in Cylinder block main bearing housing ID 66 654 66 663 66 663 66 672 66 672 66 681 2 6242 2 6245 2 6245 2 6249 2 6249 2 6252 Journal Grade punched 0 1 2 STD 0 STD 1 STD 2 Bearing grade No 1 816 1 820 1 820 1 824 1 824 1 828 62 967 62 975 Bearing thickness 0 0715 0 0717 0 0717 0 0718 0 0718 0 0720 2 4790 2 4793 Oil clearance 0 039 0 066 0 039 0 0
61. l name ST0501S000 Engine stand assembly 1 ST05011000 Engine stand 2 ST05012000 Base KV10106500 Engine stand shaft Description NT042 NT028 PREPARATION Special Service Tools YD25DDTi engine Disassembling and assembling KV11105900 Engine sub attachment KV10115600 Valve oil seal drift NT799 KV10115900 has been replaced with KV10106500 Installing valve oil seal Use side A Side A a 20 0 79 dia b 13 0 51 dia c 10 3 0 406 dia d 8 0 31 dia e f e 10 7 0 421 f 5 0 20 NT603 Unit mm in KV10107902 Removing valve oil seal Valve oil seal puller 1 KV10116100 Valve oil seal puller adapter NT605 KV11103000 Removing crankshaft pulley Injection pump drive gear puller NT676 EM 3004 Tool number Tool name KV101056S0 Ring gear stopper 1 KV10105630 Adapter 2 KV10105610 Plate Description PREPARATION Special Service Tools YD25DDTi engine Cont d Preventing crankshaft from rotating a 3 0 12 b 6 4 0 252 c 2 8 0 110 d 6 6 0 260 e 107 4 21 f 14 0 55 g 20 0 79 h 14 0 55 dia Unit mm in KV101151S0 Lifter stopper set 1 KV10115110 Camshaft pliers 2 KV10115120 Lifter stopper Changing valve lifter shims NT041 ST16610001 Removing crankshaft pilot bushing Pilot bushing puller NT045 KV10111100 Removing steel oil pan and rear timing chain Seal cutter case
62. ler SST for removal 6 Remove valve spring seats 7 When removing valve seats check valve seat contact Refer to EM 3053 8 Before removing valve guides check valve guide clearance Refer to EM 3052 VALVE GUIDE CLEARANCE 9 Remove glow plugs e To avoid damage glow plugs should be removed only when required e Handle with care to avoid applying shock When dropped from approx 100 mm 3 94 in or higher always replace with a new one Inspection CYLINDER HEAD DISTORTION Clean surface of cylinder head Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface Check along six positions shown in the figure Head surface flatness Limit 0 1 mm 0 004 in If beyond the specified limit resurface or replace it The limit for cylinder head resurfacing is determined by the cylinder block resurfacing Resurfacing limit Amount of cylinder head resurfacing is A EM 3049 CYLINDER HEAD Inspection Cont d Amount of cylinder block resurfacing is B The maximum limit A B 0 07 mm 0 0028 in After resurfacing cylinder head check that camshaft rotates freely by hand If resistance is felt cylinder head must be replaced Nominal cylinder head height 153 9 154 1 mm 6 059 6 067 in CAMSHAFT VISUAL CHECK Check camshaft for scratches seizure and wear CAMSHAFT RUNOUT 1 Place V blocks on a work bench and support camshaft at No 1 and No 5 journal
63. m grade Grade No 1 62 959 62 967 2 4787 2 4790 Grade No 2 62 951 62 959 2 4784 2 4787 Grade No 0 51 968 51 974 2 0460 2 0462 Pin journal dia Dp Grade No 1 51 961 51 968 2 0457 2 0460 Grade No 2 51 954 51 961 2 0454 2 0457 Center distance r 49 97 50 03 1 9673 1 9697 Out of round X Y Standard Limit Less than 0 003 0 0001 Less than 0 005 0 0002 Taper A B Standard Limit Less than 0 003 0 0001 Less than 0 005 0 0002 Standard Less than 0 05 0 0020 Runout TIR Limit Less than 0 10 0 0039 Standard 0 085 0 25 0 0033 0 0098 Free end play Limit 0 30 0 0118 Out of round Y Taper l SEM645 EM715 Total indicator reading Available Main Bearing Oil hole Thrust bearing N groove AONE M Front Ohh oF Ur Ur No 1 No 2 No 3 No 4 No 5 SEM255G Grade number Thickness T mm in Width W mm in Identification color 0 1 816 1 820 0 0715 0 0717 Black 1 1 820 1 824 0 0717 0 0718 Brown 2 1 824 1 828 0 0718 0 0720 19 9 20 1 0 783 0 791 Green 3 1 828 1 832 0 0720 0 0721 Yellow 4 1 832 1 836 0 0721 0 0723 Blue EM 3096 SERVICE DATA AND SPECIFICATIONS SDS Available Main Bearing Cont d UNDERSIZE Unit mm in Main journal diameter Dm 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
64. m in 160 6 30 Unit mm in SEM899G Less than 0 03 0 0012 0 1 0 004 89 000 89 010 3 5039 3 5043 89 010 89 020 3 5043 3 5047 89 020 89 030 3 5047 3 5051 Standard Surface flatness Limit Grade No 1 Standard Grade No 2 Oylinder bore Inner diameter Grade No 3 Wear limit 0 07 0 0028 Out of round X Y Less than 0 015 0 0006 Taper C A Less than 0 010 0 0004 Main journal inner Grade No 0 66 654 66 663 2 6242 2 6245 diameter grade Grade No 1 66 663 66 672 2 6245 2 6249 Without bearing Grade No 2 66 672 66 681 2 6249 2 6252 Difference in inner diameter between Limit Less than 0 05 0 0020 cylinders Piston Piston Ring and Piston Pin AVAILABLE PISTON Unit mm in Grade No 1 SEM882E 88 940 88 950 3 5016 3 5020 Grade No 2 Grade No 3 Standard Piston skirt diameter A 3 5020 3 5024 3 5024 3 5027 88 950 88 960 88 960 88 970 0 25 0 0098 oversize Service 89 190 89 220 3 5114 3 5126 0 50 0 0197 oversize Service a dimension Sle yroyoel ya 89 440 89 470 3 5213 3 5224 59 0 2 323 Piston pin hole diameter 27 997 28 005 1 1022 1 1026 Piston clearance to cylinder block EM 3094 0 050 0 070 0 0020 0 0028 SERVICE DATA AND SPECIFICATIONS SDS PISTON RING Piston Piston Ring and Pis
65. moothly by hand Install main bearing caps Identify main bearing caps by the punched mark Install correctly matching the journal No on the bearing cap and the journal with the front mark facing forward e Main bearing caps are commonly processed with the cylin der block Therefore caps and cylinder block should be replaced as a set eoec Front mark JEM225G EM 3082 JEM200G JEM226G Oil hole Cut out area Cylinder No e Cylinder No e JEM229G Piston ring compressor JEM230G Front mark Oil hole Cylinder No Engine front JEM227G CYLI As T NDER BLOCK sembly Con d Check the main bearing cap bolts for deformation Refer to EM 3079 MAIN BEARING CAP BOLT DEFORMA TION Tighten the main bearing cap bolts according to the follow ing procedure Apply engine oil to the threaded part and seat surface of each bolt Tighten to 25 to 30 N m 2 5 to 3 1 kg m 18 to 22 ft lb in the numerical order shown in the figure Put alignment marks with paint on each bolt and the main bearing cap all in the same direction when using a protrac tor Then tighten 90 to 95 target 907 Always use either an angle wrench SST or protractor during angular tightening Avoid tightening based on visual checks alone After tightening bolts to specified torque make sure that crankshaft rotates smoothly Check crankshaft end play Refer to EM 3
66. n Apply paint to camshaft sprockets for alignment during installation CAMSHAFT i m Remove the following parts referring to appropriate part in this section Charge air cooler cover Charge air cooler and charge air cooler bracket EGR guide tube and EGR spacer Rocker cover Spill tube Injection tube Injection nozzle oil seal High pressure injection nozzle assembly Secondary timing chain and associated parts Remove camshaft sprockets Holding the hexagonal part of the camshaft with a wrench having 21 mm 0 83 in width between facing flats loosen the bolt of the camshaft sprocket EM 3047 CYLINDER HEAD Removal Cont d 3 Remove camshafts lt 2 Engine front Loosen bolts of the camshaft bracket in several stages in the reverse order of that shown in the figure and remove them 4 Remove adjusting shims and valve lifters e Confirm the correct location of each part removed Store them so they do not get mixed up e For re installation be sure to put mark on camshaft bracket before removal JEM160G CYLINDER HEAD e Loosen bolts in the reverse order of that shown in the figure and remove them e Becareful not to damage the tips of glow plugs project ing out of the bottom surface of the cylinder head To avoid damage to glow plugs either remove them beforehand or support cylinder head with wooden blocks to create a space below the bottom surface JEM14
67. ne to transmission 1 Lift transmission with the jack and reinstall rear mount mem bers to the vehicle 2 Position the jack to the front side of transmission 3 Remove remaining mounting bolts securing the engine to transmission Front suspension member SEM600F EM 3064 ENGINE REMOVAL Removal Cont d Wes Removal operation a A Engine slinger Engine slinger Rear x 15 Install the engine slingers standard service part to front left and rear right 3 29 5 37 3 N m 3 0 3 8 kg m 22 27 ft lb WARNING For engines without engine slingers attach proper slingers and bolts described in the PARTS CATALOG 16 Hook hoists to slingers to secure the position 17 Remove installation nuts for left and right engine mount insu VI AN SEM893G lators 18 Remove crankshaft position sensor TDC sensor from trans mission E gt 19 Separate engine and transmission remove the engine CAUTION e While performing operation check that all necessary wires and pipes are disconnected e Avoid interference with parts on the vehicle Installation Install the engine in the reverse order of the removal procedure e Keep each mount insulator from oil adherence and damage e As for a location with positioning pin insert the pin correctly to the hole of mating part e While keeping each mount insulator free from twisting tighten mounting bolts and nuts for the engine mount
68. ne within 5 minutes after coating Install lower oil pan Tighten in numerical order shown in the figure Wait at least 30 minutes before refilling engine oil Install in the reverse order of removal EM 3020 TIMING CHAIN Secondary Timing Chain CAUTION e After removing timing chain do not turn crankshaft and camshaft separately or valves will strike piston heads e When installing camshafts chain tensioners oil seals or other sliding parts lubricate contacting surfaces with new engine oil e Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets crankshaft pulley and camshaft brackets e Do not spill engine coolant on drive belts Chain tensioner ko 8 5 10 7 0 86 1 1 75 95 go _ A Spring 2 Plunger a Caen sprocket BY 9 21 26 2 1 2 7 16 19 f M rr lt Slack guide hy 6 9 8 8 0 7 0 9 61 78 See text for loosening and tightening order Front chain case m fa Oil pump side oe 9 138 147 14 0 15 0 102 108 P d Secondary timing chain ss Washer 23 Gasket 9 Tension guide I 0 21 26 2 1 2 7 16 19 Lubricate with new engine oil Apply Genuine Liquid Gasket Tension guide or equivalent Nem kg m ft Ib Nem kg m in Ib JEM859G p 7 v REMOVAL e Forpreparative work for removing installing secondary timing chain to remove install fuel injection pump r
69. nect battery negative terminal Set the ignition switch to START and crank When gauge pointer stabilizes read compression pressure and engine rpm Repeat the above steps for each cylinder Always use a fully charged battery to obtain specified engine speed Unit kPa bar kg cm psi rpm Difference limit between Standard Minimum A cylinders moapgp z 3 100 31 00 31 6 2 500 25 00 25 5 363 490 4 90 5 0 71 2 45 0 200 200 90 4 90 5 0 71 200 When engine rpm is out of the specified range check the specific gravity of battery liquid Measure again under cor rected conditions If engine rpm exceeds the limit check valve clearance and combustion chamber components valves valve seats cyl inder head gaskets piston rings pistons cylinder bores cyl inder block upper and lower surfaces and measure again Complete this operation as follows Turn the ignition switch to OFF Disconnect battery negative terminal Install glow plugs Install fuel injection pump fuse ENG CONTS3 20A Connect battery negative terminal Using CONSULT II make sure no error code is indicated for items of self diagnosis Refer to Trouble Diagnosis INDEX in EC section EM 3013 CHARGE AIR COOLER Removal and Installation SEC 144 fy 6 4 7 5 0 66 0 76 57 66 hy 6 4 7 5 NS 0 66 0 76 57 66 ig 9 3 10 8 1 0 1 1 83 95 fy 9 3 10 8 1 0 1 1 83 95
70. ng Unit mm in 55 000 55 013 Connecting rod big end ID 2 1654 2 1659 Crankshaft pin OD Grade punched 0 no punching STD 0 Bearing grade No 1 492 1 496 51 968 51 974 Bearing thickness 0 0587 0 0589 2 0460 2 0462 Oil clearance 0 031 0 061 Identification color 0 0012 0 0024 Black STD 1 Bearing grade No 1 496 1 500 51 961 51 968 1 Bearing thickness 0 0589 0 0591 2 0457 2 0460 Oil clearance 0 031 0 061 Identification color 0 0012 0 0024 Brown STD2 Bearing grade No 1 500 1 504 51 954 51 961 2 Bearing thickness 0 0591 0 0592 2 0454 2 0457 Oil clearance 0 031 0 061 Identification color 0 0012 0 0024 Green 7 f clearance cannot be adjusted within the standard of any bearing grind crankshaft journal and use undersized bear ing e When an undersized bearing is used measure the inner diameter of the bearing while the bearing is installed Grind the pins so that the specified oil clearance is obtained EM 3078 Pin area ae JEM216G Crush height SEM502G d2 di 5 0 20 35 1 38 Unit mm in JEM219G CYLINDER BLOCK Inspection Cont d Undersize bearing Unit mm in Size Thickness US 0 08 0 0031 1 536 1 540 0 0605 0 0606 US 0 12 0 0047 1 556 1 560 0 0613 0 0614 US 0 25 0 0098 1 621 1 625 0 0638 0 0640 CAUTION When grinding the crankshaft journal to use an undersize
71. ng 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 Tighten fixing bolts in the numerical order shown in the fig ure After tightening all the bolts re tighten in the same order 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 0 14 to 0 14 mm 0 0055 to 0 0055 in Rear chain case and cylinder block 0 25 to 0 13 mm 0 0098 to 0 0051 in If the measured value is out of the above range install again EM 3033 TIMING CHAIN Primary Timing Chain Cont d 14 Install crankshaft pulley Install crankshaft pulley to crankshaft Hold crankshaft pulley with the pulley holder SST Tighten bolt to 20 to 29 N m 2 0 to 3 0 kg m 15 to 21 ft lb Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt Tighten fixing bolt another 60 66 target 60 turn by one notch 15 Install secondary timing chain and the associated parts Alignment mark Refer to EM 3023 Secondary Timing Chain INSTALLA Punched mark TION JEM147G i 16 Install in the reverse order of removal hereafter 2pop P EM 3034 Removal and Installation KE Apply new engine oil 7 9 9 9 ie m 59 8 69 6 23 6 27 4 f Nem kg m in tb 57 72
72. nment 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 e Do not touch lips of oil seal Make sure seal surfaces are free of foreign materials Drift JEM142G EM 3032 PAN Oil pump 2 6 3 6 mm dad 0 142 in dia All locations JEM144G Front mark Oil pump drive spacer JEM145G JEM133G Cylinde Rear chain case AWS Stai r block N x Feeler gauge NRI TIMING CHAIN Primary Timing Chain Cont d 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 Liquid Gasket Application Procedure as shown in the figure Apply liquid gasket on oil pump side surface Install oil pump a Apply a continuous bead of specified liquid gasket Refer to EM 3003 Liquid Gasket Application Procedure 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 Install oil pump drive spacer to crankshaft Install with the front mark punched mark facing the front of the engine Install O ring into the groove of rear chain case Install oil pump When installi
73. o 13 N m 1 2 to 1 4 kg m 9 to 10 ft lb Install camshaft sprockets Camshaft sprockets are commonly used for RH and LH Align camshaft sprocket and dowel pin on camshaft and install Holding the hexagonal part of camshaft with a wrench tighten bolt securing camshaft sprocket Before installing spill tube after installing secondary timing chain check and adjust valve clearance Refer to EM 3060 Valve Clearance Hereafter install in the reverse order of removal EM 3059 CYLINDER HEAD n Valve Clearance Engine x WEE iG CHECKING pu Check valve clearance while engine is cold and not running a 1 Set the No 1 piston to TDC on its compression stroke e Turn crankshaft pulley clockwise so that the knock pin on camshaft LH faces straight above No position indicator etc qi Co DS Knock pin is provided on the crankshaft pulley CL Pa aff LH 7 Cl ns ern JEM176G 2 Putan alignment mark with paint etc on the crankshaft pul ley and on the oil pump as an angle indicator CNN 1 Alignment j 2 mark X JEM177G No 1 cylinder compression at TDC 3 Check only those valves shown in the figure Valve Crank position No 1 No 2 No 3 No 4 No 1 TDC Compression stroke Engine front c JEM178G e Using a feeler gauge measure clearance between valve lifter and camshaft e Record any valve clearance measurements which are out of specific
74. ontinuous bead of specified liquid gasket Refer to EM 3003 Liquid Gasket Application Procedure 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 Install four O rings to the grooves of the cylinder block and fuel injection pump bracket Install rear chain case When installing align the dowel pin with the pin hole 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 After tightening all the bolts re tighten in the same order EM 3031 TIMING CHAIN Primary Timing Chain Cont d 2 Install vacuum pump e 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
75. p 20 Remove camshaft sprockets e Loosen the camshaft sprockets installation bolts by fixing the hexagon portion of the camshaft JEM159G EM 3029 TIMING CHAIN Primary Timing Chain Cont d 21 Remove rear chain case e Loosen fixing bolts in the reverse order of that shown in the figure and remove them e Use seal cutter SST for removal EMR0084D INSPECTION Check for cracks and excessive wear at roller links Replace chain if necessary INSTALLATION Alignment mark dark blue link Secondary timing chain Chain tensioner Slack guide Alignment mark dark blue link Alignment mark punched mark E Cam ahari sprocket N Tension guide Alignment mark punched mark fF OS Alignment mark yellow link Tension guide Alignment mark punched mark Ss Crankshaft key Oil pump drive spacer Primary timing chain OSL cman sprocket ANY C Vacuum pump sprocket Y D gt m A A NY Alignment mark yellow link Slack guide h Chain tensioner Alignment mark cut out area Fuel injection pump ar Chain guide s M JEM886G EM 3030 Oil passage Detail of start and end areas 1 for B and C 0 142 in dia All locations Detail of D SEM861G JEM141G EMR0084D TIMING CHAIN YD25DDTi Primary Timing Chain Cont d a b e200 Install rear chain case Apply a c
76. pper washer 1 e Apply Genuine Liquid Gasket or equivalent lel Nem kg m in Ib 8 43 10 8 i O Nem kg m ft Ib pls 1 1 75 95 SEM850G Removal WARNING To avoid danger of being scalded never drain engine oil when engine is hot 1 Raise vehicle and support it with safety stands 2 Remove engine under cover 3 Drain engine oil 4 Remove lower oil pan bolts 2WD e Loosen bolts in the reverse order of that shown in the figure models S Engine front SEM851G EM 3016 4WD models 7 NO o LGA Front suspension member SEM600F OIL PAN Removal Cont d eepo go Doro er 10 11 12 13 14 Remove lower oil pan Insert Tool between upper oil pan and lower oil pan Be careful not to damage aluminum mating surface Do not insert screwdriver or oil pan flange will be deformed Slide Tool by tapping on the side of the Tool with a hammer Remove lower oil pan Remove oil strainer Remove air conditioner compressor and bracket Remove left side of the tie rod end 2WD models only Remove front final drive together with differential mounting member and front suspension member Refer to PD MT and FA sections in NISSAN Service Manual First Edition of SM3E00 1D22E0E 4WD models only Remove crankshaft position sensor Refer to EM section in NISSAN Service Manual Supplement IIl of SM3E00 1D22E0E
77. rope 0 20 29 2 0 3 0 14 22 i 9 3 10 8 0 95 1 1 82 5 95 5 Engine front 5 1 6 4 0 52 0 66 45 1 57 3 pe Apply Genuine Liquid Gasket or p 35 44 equivalent 3 6 4 4 26 32 I Nem kg m in ib 29 4 34 3 9 Nem kg m ft lb 3 0 3 5 22 25 SEM882G Spark plug Heated oxygen sensor 1 front Water drain plug Ignition wire Exhaust manifold 8 TWC manifold Camshaft position sensor built Exhaust manifold cover into distributor EM 3009 OUTER COMPONENT PARTS For Europe Intake manifold Engine front gt Rocker cover Tighten in numerical order Loosen in reverse order 9 15 7 18 6 1 6 1 9 11 6 13 7 Exhaust manifold Throttle body m lt gt Tighten in numerical order f Loosen in reverse order U 0 37 3 48 0 3 8 4 9 27 5 35 4 O Nem kg m ft lb Tighten in numerical order Loosen in reverse order tst 7 9 11 0 9 1 1 6 5 8 0 2nd 0 18 22 1 8 2 2 13 16 SEM883G EM 3010 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise Piston pin noise Camshaft bearing noise Timing chain and chain tensioner noise SEM862G EM 3011 NOISE VIBRATION AND HARSHNESS NVH Operating condition of engine TROUBLESHOOTING NVH Troubleshooting Engine Noise Cont d YD25DDTi Use the char
78. sing with a bore gauge Standard 66 654 66 681 mm 2 6242 2 6252 in dia e f the measurement is out of the specified range replace cylinder block and main bearing caps Bore gauge JEM214G BEARING CLEARANCE Cylinder block side A e Use either of the following two methods however method Q A gives more reliable results and is preferable SAN Y N Method A Using bore gauge amp micrometer S gi T Main bearing Oil groove Nr oe 1 Install main bearings to the cylinder block and bearing cap Oil hole V and tighten the bolts to the specified torque Then measure t S Cap side the inner diameter of the main bearings Engine front Oil clearance Bearing ID Crankshaft journal OD Standard 0 039 0 066 mm 0 0015 0 0026 in JEM213G EM 3075 Crank journal grade No Prem bottom No 1 to 5 Bore grade No From bottom No 1 to 4 Engine front Control code JEM208G Upper line Journal grade No From left No 1 to 5 Identification poo ER C e c M ooo0o bs Lower line Pin grade No Lot No 2 gt sed From left No 1 to 4 Key Crankshaft front face JEM215G CYLINDER BLOCK YD25DDTi Inspection Cont d 2 If the value is out of the specified range select main bear ings to obtain the specified oil clearance based on the mea surements of the main bearing housing inner diameter and crankshaft journal outer diameter When using a new cylinder bloc
79. stall front chain case X e When installing align dowel pin on oil pump case with the pin Same length for RH and LH Rear chain case hole m N Oil pump am gasket applica Unit mm in t tion area JEM129G e 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 JEM121G EM 3024 TIMING CHAIN Secondary Timing Chain Cont d 6 Hereafter install in the reverse order of removal EM 3025 TIMING CHAIN Primary Timing Chain SEC 120 130 135 186 Chain tensioner g WE Tct 10 Electronic fuel 8 5 10 7 i lel 0 86 1 1 T ud KY 7 46 55 4 7 5 7 34 41 injection pump 75 95 d Seal washer e Slack guide O ring e A K1 721 26 Spring d 2 1 2 7 16 19 Plunger i O ring e 2 71 A 1 gu 2 9 12 13 Cee a ee ae KY 138 147 ri 14 0 15 0 C8 mshaft sprocket 102 108 Gp xc Vacuum pump A O ri 3 38 41 O ring 3 ring 3 A 3 8 4 2 S N U 20 6 26 5 2 1 2 28 30 g e n Fuel injection ket pump sprocke o ring m NE ai Ari ln al NS e J 12 13 E ge i 1 2 1 4 9 10 AUS bw zd Tension guide i Chain guide Tension guide Spacer n a a E NS 571 9 1 J S J 21 26 2 1 2 7 16 19 Spring iw Ts i f kj Chain
80. t air inlet pipe Catalyst insulators Exhaust manifold cover Exhaust front tube disconnect Refer to FE section Removal and Installation EXHAUST SYSTEM Oil inlet tube e Exhaust manifold e Catalyst converter and turbocharger assembly CATALYST Removal CAUTION Do not disassemble Installation Install two locking pins into both sides of the catalyst Be careful not to confuse locking pins with insulator mounting bolts Catalyst locking pin Flange bolt black EM 3037 CATALYST Removal and Installation Cont d Insulator mounting bolt Washer bolt silver or yellow GUSSET Installation Pushing gussets against the oil pan and the catalyst temporarily tighten the mounting bolt And then tighten it to the specified torque EM 3038 EXHAUST MANIFOLD TURBOCHARGER Removal and Installation SEC 140 144 147 165 O 61 9 705 Fi 9 77 98 ee 90 Alignment protrusion 7 9 9 9 6557 ToEGR 97772 P ms iS Oo uide tube q1 e e d LaF p e gss T Pa No 3 No 4 A ee Fi 0 28 5 33 3 m ae l ges l 2 9 3 3 e NAi 21 24 0 83 4 93 2 o 9 19 6 X g z ek 9l 5 1 6 5 e MV l 8 5 9 5 17 0 52 0 66 46 57 Fa Clamp p e 62 68 i N m kg m in ib Se a i 9 Nem kg m ft lb SEM871G RON Gasket 5 Air inlet pipe 9 Oil return hose EGR tube 6 Air inlet 10 Exhaust manifold and turbo EGR spacer
81. t below to help you find the cause of the symptom 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace these parts Location of Type of f Source of Check item Reference noise noise Before After i When While noise page warm up warm up starting racing driving Top of Ticking engine or click C A B Ha E Valve clearance EM 3060 Rocker ing cover Camshaft Camshaft journal Cylinder Rattle C A bearing clearance us is head noise Camshaft runout Piston and piston pin Slap or m A Piston pin clearance EM 3071 knock noise Connecting rod bush 3080 ing clearance Piston to bore clear ance Slap or Piston slap Piston ring side clear EM 3071 Crankshaft rap A nois ance 3071 3073 pulley Piston ring end gap 3072 Cylinder Connecting rod bend block Side and torsion of engine Connecting rod bush Oil pan Connect ing clearance Small ing rod end EM 3080 Knack A B bearing Connecting rod bear 3077 noise ing clearance Big end Main bear Main bearing oil clear EM 3075 moe ing noise 92779 3075 9 Crankshaft runout Front of Tappin Iu M Timing chain cracks engine pP g and wear EM 3023 tae or tick A A chain ten ie f Timing in sioner Timing chain ten 3026 chain cover 9 Heise sioner operation Other drive j Squeak belts MA section ing or A B Stickin Drive b
82. tallation 7 WN pr p UN After repairing bleed air in pipes by shifting priming pump up and 9717 i UK LZ VY down until the touch is heavy Yel f For further air bleeding crank engine while operating priming pump up and down Do not crank engine more than 10 seconds at a time INTAKE MANIFOLD c Engine front Removal e Loosen bolts and nuts in the reverse order of that shown in the figure Installation e When stud bolts come off install with the following torque W 10 11 N m 1 0 1 2 kg m 87 104 in Ib e Tighten fixing bolts in the numerical order shown in the fig ure SEMPER EGR VOLUME CONTROL VALVE e Handle with care avoiding any shocks e Do not disassemble or adjust Inspection Straightedge INTAKE MANIFOLD N Check distortion on the mounting surface with a straightedge and feeler gauge Limit 0 1 mm 0 004 in Feeler gauge SEM869G EM 3036 CATALYST Removal and Installation SEC 208 Wles 23 0 65 0 85 0 44 2 52 0 56 73 4 5 5 3 33 wa vA eu 2 29 5 37 3 3 0 3 8 22 27 U 43 1 53 9 4 4 5 4 32 39 fy 6 3 8 3 lel 6 3 8 3 0 65 0 84 56 73 lel Nem kg m in Ib 0 65 0 84 DN m ft 56 73 9 Nem kg m ft lb SEM870G 1 Gasket 4 Insulator 6 Gasket cap 2 Exhaust outlet 5 Catalyst 7 Locking pin 3 Gusset PREPARATIVE WORK Remove the following parts e Charge air cooler Air duc
83. tensioner N S Slack guide 955 107 E 12 18 1 2 1 4 9 10 so 0 86 1 1 2 3 2 7 75 95 17 19 Gasket e Front chain case Fa Oil pump side Washer e Pd c I Secondary timing chain Crankshaft sprocket Oil pump drive spacer Primary timing chain hy 6 9 8 8 0 7 0 9 oil pump 61 78 L See text for loosening el 8 2 9 5 and tightening order 0 83 0 97 Crankshaft pulley 72 84 9 12 13 1 2 1 4 9 10 F Lubricate with p a K C7 Refer to text new engine oil ension guide Apply Genuine Liquid Vacuum Gasket or equivalent pump cover for el Nem kg m in Ib assemble disassemble qa Oil pump side Nem kg m ft Ib SEM860G EM 3026 KV10109300 KV11103000 JEM132G TIMING CHAIN Primary Timing Chain Cont d 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 2 om Remove charge air cooler and bracket Remove rocker cover Refer to EM 3045 Removal and Installation ROCKER COVER Remove EGR guid
84. ton Pin Cont d Unit mm in Top 0 050 0 090 0 0020 0 0035 0 1 0 004 Side clearance 2nd 0 050 0 090 0 0020 0 0035 0 1 0 004 Oil ring 0 030 0 070 0 0012 0 0028 Top 0 21 0 31 0 0083 0 0122 1 0 0 039 End gap 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 diameter 27 994 28 000 1 1021 1 1024 Interference fit of piston pin to piston 0 002 0 006 0 0001 0 0002 Piston pin to connecting rod bushing clearance Standard 0 026 0 044 0 0010 0 0017 0 057 0 0022 Values measured at ambient temperature of 20 C 68 F Center distance Connecting Rod Unit mm in 154 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 clearance After installing in connecting rod Standard 0 200 0 350 0 0079 0 0138 0 4 0 016 EM 3095 SERVICE DATA AND SPECIFICATIONS SDS YD25DDTi Crankshaft Unit mm in Grade No 0 62 967 62 975 2 4790 2 4793 Main journal dia D
85. x 26 mm 1 02 in in diameter ie JEM199G EM 3069 CYLINDER BLOCK Disassembly Cont d 13 Remove main bearing cap bolts Engine front m e 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 e Before loosening main bearing cap bolts measure crank shaft end play Refer to EM 3070 CRANKSHAFT END PLAY 14 Remove main bearing caps e Using main bearing cap bolts remove by rocking bearing cap back and forth JEM201G 15 Remove crankshaft 16 Remove main bearings and thrust bearings from cylinder block and main bearing caps e 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 e 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 e lf the value exceeds the limit replace thrust bearings with new ones and measure again If the measurement exceeds JEM202G the limit again replace crankshaft with a new one CONNECTING ROD SIDE CLEARANCE Feeler gauge e Measure the side clearance between connecting rod and vL crank arm with feeler gauge RI Standard 0 200 0 350 mm 0 0079 0 0138 in JR
86. y 9 16 18 1 6 1 9 12 13 3 N gt 120 29 Noy 31 36 d 2 0 3 0 14 22 3 1 3 7 Pa 23 26 a 9 21 26 2 1 2 7 15 Big m N Knock sensor 9 16 19 1 6 1 9 12 14 Oil filter bracket Ai D Oil filter n Oil pressure switch U 12 25 17 15 1 3 1 7 9 12 6 3 8 3 0 64 0 85 55 6 73 8 9 16 21 1 6 2 1 12 15 Water pump pulley kole 10 0 6 1 0 Lf 52 c 9 16 19 1 6 1 9 Alternator bracket 12 14 45 60 4 6 6 1 33 44 owes djvsting Bar 9 16 21 1 6 2 1 12 15 Nem kg m in Ib Nem kg m ft lb Apply Genuine Liquid Gasket or equivalent Lubricate with new engine oil Fl p kl P lt 1 Ne N 30 37 Crankshaft pulley x 9 1st 9 11 0 9 1 1 6 5 8 0 0 2nd 18 22 1 8 2 2 13 16 Oil level gauge us E 3 Exhaust manifold uu e 3 37 3 48 0 3 8 4 9 28 35 fy 5 1 6 5 0 52 0 66 45 1 57 3 C 78 8 0 58 Heated oxygen sensor 1 front ii 9 40 50 4 1 5 1 0 29 4 34 3 manifold 3 0 3 5 cover 22 25 gs es 0 52 0 66 46 57 X fy 9 3 10 8 RAN 0 95 1 1 os ES 82 5 95 5 Ignition E1 7 142 152 WISS 14 5 15 5 105 112 Camshaft position sensor built into distributor SEM881G EM 3008 OUTER COMPONENT PARTS SEC 140 220 221 226 For Eu

ENGINE MECHANICAL Supplement 3 (Diesel)

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