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ENGINE SECTION EM ENGINE MECHANICAL A EM C D E CONTENTS QR Components 18 Removal and Installation 18 SERVICE INFORMATION PRECAUTIONS Precaution for Procedure without Cowl Top Cover Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" Precaution for Drain Engine Coolant Precaution for Disconnecting Fuel Piping Precaution for Removal and Disassembly Precaution for Inspection, Repair and Replacement Precaution for Assembly and Installation Parts Requiring Angle Tightening Precaution for Liquid Gasket EXHAUST MANIFOLD AND THREE WAY CATALYST 21 Components 21 Removal and Installation 21 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 11 NVH Troubleshooting - Engine Noise 11 Use the Chart Below to Help You Find the Cause of the Symptom 11 DRIVE BELTS 13 Components 13 Checking Drive Belts 13 Tension Adjustment 13 Removal and Installation 13 Removal and Installation of Drive Belt Auto Tensioner 14 Components 24 Removal and Installation 24 H I IGNITION COIL 27 Components 27 Removal and Installation 27 J SPARK PLUG 28 Components 28 Removal and Installation 28 K FUEL INJECTOR AND FUEL TUBE 30 Components 30 Removal and Installation 30 ROCKER COVER 35 Components 35 Removal and Installation 35 TIMING CHAIN 37 L M N Components 37 Removal and Installation 37 CAMSHAFT 47 O Components 47 Removal and Installation 47 Valve Clearance 55 P AIR CLEANER AND AIR DUCT 16 OIL SEAL 59 Components 16 Removal and Installation 16 Changing Air Cleaner Filter 16 Removal and Installation of Valve Oil Seal 59 Removal and Installation of Front Oil Seal 59 Removal and Installation of Rear Oil Seal .60 INTAKE MANIFOLD 18 CYLINDER HEAD 62 Revision: 2007 September G OIL PAN AND OIL STRAINER 24 PREPARATION Special Service Tool Commercial Service Tool F EM-1 D40 On-Vehicle Service 62 Components 63 Removal and Installation 63 Components 66 Disassembly and Assembly 66 Inspection After Disassembly 68 ENGINE ASSEMBLY 73 Components 73 Removal and Installation 73 CYLINDER BLOCK 76 Components 76 Disassembly and Assembly 77 How to Select Piston and Bearing 86 Inspection After Disassembly 93 SERVICE DATA AND SPECIFICATIONS (SDS) 104 Standard and Limit 104 YD SERVICE INFORMATION 115 APPLICATION NOTICE 115 TURBO CHARGER 137 Components 137 Removal and Installation 138 EXHAUST MANIFOLD 139 Components 139 Removal and Installation 140 OIL PAN AND OIL STRAINER 141 2WD 141 2WD : Components 141 2WD : Removal and Installation 141 4WD 142 4WD : Components 143 4WD : Removal and Installation 143 GLOW PLUG 145 Components 145 Removal and Installation 145 VACUUM PUMP 146 Components 146 Removal and Installation 146 How to Check Engine Type 115 INJECTION TUBE AND FUEL INJECTOR 147 PRECAUTIONS 116 Components 147 Removal and Installation 147 Inspection after installation 151 Precaution for Procedure without Cowl Top Cover 116 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 116 Precaution for Draining Engine Coolant 116 Precaution for Disconnecting Fuel Piping 116 Precaution for Removal and Disassembly .116 Precaution for Inspection, Repair and Replacement .116 Precaution for Assembly and Installation 116 Parts Requiring Angle Tightening 117 Precaution for Liquid Gasket 117 PREPARATION 119 Special Service Tool 119 Commercial Service Tool 121 AIR CLEANER AND AIR DUCT 124 Components 124 Removal and Installation .124 CHARGE AIR COOLER 126 Components 126 Removal and Installation .126 INTAKE MANIFOLD 127 Components (TYPE 1) 127 Components (TYPE 2) 131 Removal and Installation .132 CATALYST 136 Components 136 Removal and Installation .136 Revision: 2007 September FUEL PUMP 152 Components 152 Removal and Installation 152 ROCKER COVER 159 Components 159 Removal and Installation 159 CAMSHAFT 162 Components 162 SECONDARY TIMING CHAIN 163 Components 163 Removal and Installation 163 PRIMARY TIMING CHAIN 164 Components 164 Removal and Installation 165 CYLINDER HEAD 177 On-Vehicle Service 177 Components 178 Components 179 Disassembly and Assembly 179 ENGINE ASSEMBLY 180 Components 180 Removal and Installation 180 CYLINDER BLOCK 181 Components 181 EM-2 D40 SERVICE DATA AND SPECIFICATIONS (SDS) 183 Standard and Limit 183 Tightening Torque 192 A EM C D E F G H I J K L M N O P Revision: 2007 September EM-3 D40 PRECAUTIONS [QR] < SERVICE INFORMATION > SERVICE INFORMATION PRECAUTIONS Precaution for Procedure without Cowl Top Cover INFOID:0000000003292975 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc PIIB3706J Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000003292976 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision Information necessary to service the system safely is included in the “SUPPLEMENTAL RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual WARNING: • To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer • Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM” • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors Precaution for Drain Engine Coolant INFOID:0000000003291989 Drain engine coolant when engine is cooled Precaution for Disconnecting Fuel Piping INFOID:0000000003291990 • Before starting work, check no fire or spark producing items are in the work area • Release fuel pressure before disassembly • After disconnecting pipes, plug openings to stop fuel leakage Precaution for Removal and Disassembly INFOID:0000000003291991 • When instructed to use special service tools, use the specified tools Always be careful to work safely, avoid forceful or uninstructed operations • Exercise maximum care to avoid damage to mating or sliding surfaces • Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials • Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly • When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on If the order of loosening is specified, exactly as specified Precaution for Inspection, Repair and Replacement INFOID:0000000003291992 Before repairing or replacing, thoroughly inspect parts Inspect new replacement parts in the same way, and replace if necessary Revision: 2007 September EM-4 D40 PRECAUTIONS [QR] < SERVICE INFORMATION > Precaution for Assembly and Installation INFOID:0000000003291993 A • Use torque wrench to tighten bolts or nuts to specification • When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order If the order of tightening is specified, EM exactly as specified • Replace with new gasket, packing, oil seal or O-ring • Dowel pins are used for several parts alignment When replacing and reassembling with dowel pins, check C that dowel pins are installed in the original portion • Thoroughly wash, clean, and air-blow each part Carefully check oil or coolant passages for any restriction and blockage • Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust D Before assembly, oil sliding surfaces well • Release air within route when refilling after draining coolant • Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine E stopped) Then check there are no leaks at fuel line connections • After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust systems for leakage F Parts Requiring Angle Tightening INFOID:0000000003291994 • • • • Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle tightening) Balancer unit 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 Precaution for Liquid Gasket INFOID:0000000003291995 G H I J REMOVAL OF LIQUID GASKET • After removing the mounting bolts and nuts, separate the mating surface using a seal cutter (SST) and remove the old liquid gasket sealing CAUTION: Be careful not to damage the mating surfaces • Tap seal cutter to insert it (1), and then slide it (2) by tapping on the side as shown in the figure • In areas where seal cutter is difficult to use, use plastic hammer to lightly tap the areas where the liquid gasket is applied CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces K L M PBIC0275E N LIQUID GASKET APPLICATION PROCEDURE Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface • Remove the liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts and bolt holes Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials O P PBIC0003E Revision: 2007 September EM-5 D40 PRECAUTIONS < SERVICE INFORMATION > Attach liquid gasket tube to the tube presser (commercial service tool) Use Genuine Liquid Gasket or equivalent Apply the liquid gasket without breaks to the specified location with the specified dimensions • If there is a groove for the liquid gasket application, apply the liquid gasket to the groove [QR] EMA0622D • As for the bolt holes, normally apply the liquid gasket inside the holes Occasionally, it should be applied outside the holes Check to read the text of service manual • Within five minutes of liquid gasket application, install the mating component • If the liquid gasket protrudes, wipe it off immediately • Do not retighten mounting bolts or nut after the installation • Wait 30 minutes or more after installation before refilling engine oil and engine coolant CAUTION: If there are instructions in this manual, observe them Revision: 2007 September EM-6 SEM159F D40 PREPARATION [QR] < SERVICE INFORMATION > PREPARATION A Special Service Tool INFOID:0000000003291996 EM Tool number Tool name Description KV10111100 Seal cutter Removing oil pan and timing chain case C D S-NT046 E Disassembling and assembling valve mechanism Part (1) is a component of KV10116200, but Part (2) is not so KV10116200 Valve spring compressor KV10115900 Attachment KV10109220 Adapter F G PBIC1650E KV10112100 Angle wrench Tightening bolts for bearing cap, cylinder head, etc H I S-NT014 KV10117100 Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor with 22 mm (0.87 in) hexagon nut J K L NT379 Removing valve oil seal KV10107902 Valve oil seal puller KV10116100 Valve oil seal puller adapter M N S-NT605 KV10115600 Valve oil seal drift Installing valve oil seal O P NT024 Revision: 2007 September EM-7 D40 PREPARATION [QR] < SERVICE INFORMATION > Tool number Tool name Description EM03470000 Piston ring compressor Installing piston assembly into cylinder bore S-NT044 ST16610001 Pilot bushing puller Removing pilot converter S-NT045 Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC 164 of PARTS CATALOG: Part No 16441 6N210) PBIC0198E KV11103000 Pulley puller Removing crankshaft pulley NT676 Commercial Service Tool INFOID:0000000003291997 Tool name Description Spark plug wrench Removing and installing spark plug PBIC2982E Pulley holder Crankshaft pulley removing and installing ZZA1010D Revision: 2007 September EM-8 D40 PREPARATION [QR] < SERVICE INFORMATION > Tool name Description Valve seat cutter set Finishing valve seat dimensions A EM C S-NT048 TORX socket Removing and installing flywheel Size: T55 D E PBIC1113E Piston ring expander Removing and installing piston ring F G H S-NT030 Valve guide drift Removing and installing valve guide Intake & Exhaust: a: 9.5 mm (0.374 in) dia b: 5.5 mm (0.217 in) dia I J S-NT015 Valve guide reamer 1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide Intake & Exhaust: d1: 6.0 mm (0.236 in) dia d2: 10.2 mm (0.402 in) dia K L S-NT016 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) a = 18 mm (0.71 in) dia for zirconia heated oxygen sensor and air fuel ratio sensor b = 12 mm (0.47 in) dia for titania heated oxygen sensor AEM488 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A-907) EM-9 N O P AEM489 Revision: 2007 September M D40 PREPARATION [QR] < SERVICE INFORMATION > Tool name Description Tube presser Pressing the tube of liquid gasket S-NT052 Power tool Loosening nuts and bolts PBIC0190E Compression tester Adaptor Checking compression pressure ZZA0008D TORX socket Loosening and tightening drive plate mounting bolt Size: E20 NT807 Revision: 2007 September EM-10 D40 DTC P2147, P2148 FUEL INJECTOR CIRCUIT [YD TYPE 2] < SERVICE INFORMATION > DTC P2147, P2148 FUEL INJECTOR CIRCUIT Component Description INFOID:0000000003288524 The fuel injector is a small, precise solenoid valve When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized The energized coil pulls the needle valve back and allows fuel to flow through the fuel injector into the cylinder The amount of fuel injected depends upon the injection pulse duration Pulse duration is the length of time the fuel injector remains open The ECM controls the injection pulse duration based on engine fuel needs PBIB0465E On Board Diagnosis Logic DTC No INFOID:0000000003288526 Trouble diagnosis name DTC detecting condition P2147 2147 Fuel injector circuit low input ECM detects the fuel injector circuit is shorted to ground P2148 2148 Fuel injector circuit high input ECM detects the fuel injector circuit is shorted to power DTC Confirmation Procedure Possible cause • Harness or connectors (The fuel injector circuit is shorted.) INFOID:0000000003288527 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test Start engine and let it idle for at least seconds Check 1st trip DTC If 1st trip DTC is detected, check possible cause items Revision: 2007 September EC-490 D40 DTC P2147, P2148 FUEL INJECTOR CIRCUIT [YD TYPE 2] < SERVICE INFORMATION > Wiring Diagram INFOID:0000000003288528 A EC C D E F G H I J K L M N O P MBWA2135E Revision: 2007 September EC-491 D40 DTC P2228, P2229 BARO SENSOR [YD TYPE 2] < SERVICE INFORMATION > DTC P2228, P2229 BARO SENSOR Description INFOID:0000000003288533 The barometric pressure sensor is built into ECM The sensor detects ambient barometric pressure and sends the voltage signal to the microcomputer MBIB0625E On Board Diagnosis Logic DTC No INFOID:0000000003288534 Trouble diagnosis name DTC detecting condition P2228 2228 Barometric pressure sensor circuit low input An excessively low voltage from the barometric pressure sensor (built-into ECM) is sent to ECM P2229 2229 Barometric pressure sensor circuit high input An excessively high voltage from the barometric pressure sensor (built-into ECM) is sent to ECM DTC Confirmation Procedure Possible cause • ECM INFOID:0000000003288535 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test Turn ignition switch ON Wait at least seconds Check 1st trip DTC If 1st trip DTC is detected, check possible cause items Revision: 2007 September EC-492 D40 DTC P2621, P2622 TP SENSOR [YD TYPE 2] < SERVICE INFORMATION > DTC P2621, P2622 TP SENSOR A Description INFOID:0000000003288542 Electric throttle control actuator consists of the following two components, throttle control motor with gear which operates throttle valve, throttle position sensor which detects throttle position sensor Throttle valve is fully opened when regeneration is not performed The valve is closed only to perform regeneration Throttle position sensor detects the opening angle of throttle valve and converts the angle into a voltage signal Based on the signal, ECM judges whether throttle control actuator operates throttle valve properly or not EC C D PBIB3184E On Board Diagnosis Logic INFOID:0000000003288544 NOTE: If DTC P2621 or P2622 is displayed with DTC P0642 or P0643, first perform trouble diagnosis for DTC P0642 or P0643 Refer to EC-462 DTC No E Trouble diagnosis name DTC detecting condition P2621 2621 Throttle position sensor circuit low input An excessively low voltage from the sensor is sent to ECM P2622 2622 Throttle position sensor circuit high input An excessively high voltage from the sensor is sent to ECM DTC Confirmation Procedure F G Possible cause • Harness or connectors (The TP sensor circuit is open or shorted.) • Throttle position sensor INFOID:0000000003288545 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test Turn ignition switch ON Wait at least second Check 1st trip DTC If 1st trip DTC is detected, check possible cause items H I J K L M N O P Revision: 2007 September EC-493 D40 DTC P2621, P2622 TP SENSOR [YD TYPE 2] < SERVICE INFORMATION > Wiring Diagram INFOID:0000000003288546 MBWA2159E Revision: 2007 September EC-494 D40 GLOW CONTROL SYSTEM [YD TYPE 2] < SERVICE INFORMATION > GLOW CONTROL SYSTEM A Wiring Diagram INFOID:0000000003288551 EC C D E F G H I J K L M N O P MBWA2160E Revision: 2007 September EC-495 D40 TC BOOST CONTROL SOLENOID VALVE [YD TYPE 2] < SERVICE INFORMATION > TC BOOST CONTROL SOLENOID VALVE Wiring Diagram INFOID:0000000003288557 MBWA2161E Revision: 2007 September EC-496 D40 REFRIGERANT PRESSURE SENSOR [YD TYPE 2] < SERVICE INFORMATION > REFRIGERANT PRESSURE SENSOR Wiring Diagram A INFOID:0000000003288572 EC C D E F G H I J K L M N O P MBWA2162E Revision: 2007 September EC-497 D40 BRAKE SWITCH [YD TYPE 2] < SERVICE INFORMATION > BRAKE SWITCH Wiring Diagram INFOID:0000000003288577 MBWA2163E Revision: 2007 September EC-498 D40 PNP SWITCH [YD TYPE 2] < SERVICE INFORMATION > PNP SWITCH A Wiring Diagram INFOID:0000000003288582 EC C D E F G H I J K L M N O P MBWA2164E Revision: 2007 September EC-499 D40 START SIGNAL [YD TYPE 2] < SERVICE INFORMATION > START SIGNAL Wiring Diagram INFOID:0000000003288584 MBWA2165E Revision: 2007 September EC-500 D40 ASCD INDICATOR [YD TYPE 2] < SERVICE INFORMATION > ASCD INDICATOR A Wiring Diagram INFOID:0000000003288588 EC C D E F G H I J K L M N O P MBWA2166E Revision: 2007 September EC-501 D40 MIL AND DATA LINK CONNECTOR [YD TYPE 2] < SERVICE INFORMATION > MIL AND DATA LINK CONNECTOR Wiring Diagram INFOID:0000000003288595 MBWA2167E Revision: 2007 September EC-502 D40 SERVICE DATA AND SPECIFICATIONS (SDS) [YD TYPE 2] < SERVICE INFORMATION > SERVICE DATA AND SPECIFICATIONS (SDS) A General Specification INFOID:0000000003288599 EC Target idle speed Air conditioner: ON A/T No load* (in P or N position) M/T No load* (in Neutral position) A/T In P or N position 750 rpm or more M/T In Neutral position 800 rpm or more 750±25 rpm Maximum engine speed C 4,900 rpm D *: Under the following conditions: • Heat up switch: OFF • Air conditioner switch: OFF E • Electric load: OFF (Lights, heater fan & rear window defogger) • Steering wheel: Kept in straight-ahead position Mass Air Flow Sensor INFOID:0000000003288600 Supply voltage Battery voltage (11 - 14V) Ignition switch ON (Engine stopped.) F G Approx 0.4V Idle (Engine is warmed up to normal operating temperature.) 1.4 - 1.8V* H *: Engine is warmed up to normal operating temperature and running under no load Intake Air Temperature Sensor INFOID:0000000003288601 I Temperature °C (°F) Resistance kΩ 25 (77) 1.800 - 2.200 80 (176) 0.283 - 0.359 Engine Coolant Temperature Sensor J INFOID:0000000003288602 K Temperature °C (°F) Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 Fuel Rail Pressure Sensor L M INFOID:0000000003288604 N Supply voltage Approximately 5V Idle (Engine is warmed up to normal operating temperature.) 1.7 - 2.0V 2,000 rpm (Engine is warmed up to normal operating temperature.) 2.0 - 2.3V Fuel Injector INFOID:0000000003288605 Resistance [at 10 - 60°C (50 - 140°F)] 0.3 - 0.6Ω Glow Plug INFOID:0000000003288608 Resistance [at 25°C (77°F)] Revision: 2007 September O Approximately 0.8Ω EC-503 D40 P SERVICE DATA AND SPECIFICATIONS (SDS) [YD TYPE 2] < SERVICE INFORMATION > Fuel Pump INFOID:0000000003288611 Resistance [at 10 - 60°C (50 - 140°F)] 1.5 - 3.0Ω Throttle Control Motor INFOID:0000000003288613 Resistance [at 25°C (77°F)] Revision: 2007 September Approximately 0.3 - 100Ω EC-504 D40