maintenance nissan cwb

MAINTENANCE

CONTENTS SERVICE DATA ......................... ................................... ................. ....... MA-1- 1

MAINTENANCE PROCEDURE ...... ......... ...... ... MA-3MA-3- 1

SERVICE DA DATA TA .................... .............................. .................... ............ .. MA-1- 1 TIGHTENI TIGHTENING NG TORQUE TORQUE ........ ............ ........ ........ ........ ........ ...... MA-1MA-1- 2 TOOLS ............................ ....................................... ..................... .................... .......... MA-2- 1

BASIC BASIC MECHANIC MECHANICAL AL SYSTEM SYSTEM ........ ............ ........ ...... MA-3MA-3- 1 FUEL SYSTEM SYSTEM ........ ............ ........ ........ ........ ........ ........ ........ ........ ....... ... MA-3MA-3- 5 INTAKE INTAKE AND EXHAUST EXHAUST SYSTEM SYSTEM ........ ............ ...... MA-3MA-3- 8

SUPPLEMENTAL OUTLINE + + + + +

Addition Addition of service service data and maintenanc maintenance e procedure due to introducti introduction on of a new vehicle vehicle model. The fuel injection injection timing timing has been changed. changed. The idle speed speed has been changed. changed. The tightening tightening torque of the injection injection pump coupling mounting mounting bolt has been changed. changed. Procedures Procedures for adjusting adjusting the valve clearance clearance have been changed (for EE brake).

SERVI CE DATA

SERVICE DATA SERVICE DATA Unit: mm (in) Item

Maintenance standard

Service limit

Intake

0.30 - 0.40 (0.012 - 0.016)

—

Exhaust

0.30 - 0.40 (0.012 - 0.016)

—

Open

20° B.T.D.C.

—

Closed

42° A.B.D.C.

—

Open

60° B.B.D.C.

—

Closed

10° A.T.D.C.

—

3,040 {31, 441}

1,961 {20, 284}

Valve clearance m e t s y s l a c i n a h c e m c i s a B

m e t s y s g n i l o o C

Intake Valve timing Exhaust

Cylinder compression pressure kPa {kgf/cm2, psi}

—

Water tank cap operating pressure kPa {kgf/cm2, psi}

49 - 69 {0.5 - 0.7, 7 - 10}

—

Fan pulley - Tension pulley

8 - 12 (0.31 - 0.47)

—

Idler (cooler compressor) pulley - Alternator pulley

15 - 18 (0.59 - 0.71)

—

Valve opening temperature °C (°F)

74.5 - 78.5 (166 - 173)

73.0 - 80.0 (163 - 176)

Valve lift/temperature mm/°C (in/°F)

More than 10/90 (0.39/194)

More than 8.5/90 (0.335/194)

5°

—

445 - 500

—

Thermostat

m e t s y s l e u F

When engine is cold

Compression pressure difference Less than 392 {4, 57} kPa {kgf/cm2, psi}

Deflection of V-belt

Fuel injection timing Idle speed

B.T.D.C. rpm

MA-1-1

Remarks

At 180 - 220 rpm (With engine warm)

Pressure side

With a force of about 98 N {10 kgf, 22 lbf} applied to the mid part

SERVI CE DATA

TIGHTENING TORQUE Unit: N·m {kgfzm, ftzlbf} Item

Tightening torque

Valve clearance adjusting screw lock nut

69 - 78 {7.0 - 8.0, 51 - 58}

Snug torque (1st) m e t s y s l a c i n a h c e m c i s a B

Cylinder head bolt Cylinder head sub bolt

Tightening angle (2nd)

88 - 98 {9.0 - 10.0, 65 - 72}

L = 147 mm (5.79 in)

85° - 95°

L = 119 mm (4.69 in)

70° - 80°

1st

34 {3.5, 25}

2nd

44 - 54 {4.5 - 5.5, 33 - 40}

Air intake manifold mounting bolt and nut

49 - 54 {5.0 - 5.5, 36 - 40}

Exhaust manifold mounting nut

29 - 44 {3.0 - 4.5, 22 - 33}

Crank damper mounting bolt

98 - 108 {10.0 - 11.0, 72 - 80}

Compression gauge bolt m e t s y s n o i t a c i r b u L

25 - 29 {2.5 - 3.0, 18 - 22}

Oil pan drain plug Full-flow type Oil filter Bypass type

98 - 127 {10.0 - 13.0, 72 - 94} Center bolt

59 - 69 {6.0 - 7.0, 43 - 51}

Drain plug

16 - 22 {1.6 - 2.2, 12 - 16}

Center bolt

59 - 69 {6.0 - 7.0, 43 - 51}

Drain plug

16 - 22 {1.6 - 2.2, 12 - 16}

Injection pump Coupling bolt and nut drive coupling Cotter bolt

m e t s y s l e u F

103 - 113 {10.5 - 11.5, 76 - 83} 147 - 167 {15.0 - 17.0, 108 - 123}

Injection nozzle retaining nut

59 - 78 {6.0 - 8.0, 43 - 58}

Nozzle holder assembly mounting bolt

25 - 29 {2.5 - 3.0, 18 - 22} Apply film of engine oil to gasket and screw on until gasket contacts engine, then tighten 3/4 turn by hand or UD genuine filter wrench

Cartridge type Fuel filter Bypass type

m e t s y s t s u a h x e d n a e k a t n i r i A

Turbocharger

Center bolt

59 - 69 {6.0 - 7.0, 43 - 51}

Drain plug

16 - 22 {1.6 - 2.2, 12 - 16}

Turbine housing and center housing mounting V-band lock nut N·m {kgfzm, ftzlbf}

17.0 {1.73, 12.5} → Loosen → 13.7 {1.40, 10.1}

Compressor housing and back plate clamp mounting bolt N·m {kgfzm, ftzlbf}

9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}

Model TE45

MA-1-2

Remarks

TOOLS

TOOLS Tool name and number Feeler gauge 99541 Z5000

Description

Shape

For adjusting valve clearance Thickness mm (in) 0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4 (0.016), 0.45 (0.0177), 0.5 (0.020)

ET14-049

Feeler gauge 99541 Z0001

For adjusting valve clearance Thickness mm (in) 0.2 (0.008), 0.3 (0.012), 0.4 (0.016)

ET14049A

Timing plate 99646 Z5001

For measuring valve timing

ZMA121A ET14-053

Adapter 99808 96500

Used when measuring valve timing as a set including the timing plate (99646 Z5001)

WMA148A

Compression gauge 99640 96000

For measuring compression pressure

ET14050B

Compression gauge hose 99644 97000

Used with the compression gauge (99640 96000) when the gauge cannot be installed directly due to interference with the air duct, etc.

ET14-051

MA-2-1

TOOLS

Tool name and number Plate 157944-9520

Description

Shape

For fixing nozzle holder NOTE + Tool number designated by ZEXEL CORPORATION

WMA001A

Pin vice 99727 Z5005

For cleaning nozzle orifice

EP14-121

Nozzle cleaner 99726 Z5000

For removal of carbon from rear of nozzle orifice

ET14-072

Filter wrench 99755 00Z01

For removal of fuel filter (Only when replacing cartridge type element)

WMA027A

MA-2-2

MAINTENANCE PROCEDURE

MAINTENANCE PROCEDURE BASIC MECHANICAL SYSTEM VALVE CLEARANCE NOTE + Ensure the engine is cool when checking and adjusting the valve clearance. 1. Align the flywheel housing pointer with the stamp on the flywheel. NOTE + When turning the flywheel to align the stamp, turn it counterclockwise when viewed from behind the engine. 2. When the stamps on the injection pump housing and timer are close to each other, it indicates T.D.C. on the compression stroke. When they are located opposite to each other, it indicates T.D.C. on the exhaust stroke.

WMA003A

EP4-23

3. Turn the flywheel an additional 20°counterclockwise from the T.D.C. stamp mark ‘‘1|6’’ so that the stamp mark ‘‘A’’ on the flywheel is aligned with the pointer. Stamp mark ‘‘A’’: No. 1 (No. 6) piston at T.D.C. on compression stroke +20° NOTE + When turning the flywheel to align the stamp, turn it counterclockwise when viewed from behind the engine. WMA166A

Valve clearance adjusting sequence Cylinder No. Stamp mark on flywheel

Valve arrangement

1

2

1

2

+

+

No. 1 piston at T.D.C. on compression stroke (stamp mark ‘‘1|6’’) +20°

—

C


Flywheel turned 240°counterclockwise from stamp mark ‘‘A’’

B


Flywheel turned 240°counterclockwise from stamp mark ‘‘C’’

4

5

6

IN E X IN EX IN EX IN E X I N EX IN EX

Valve No. A

3

3

4

.

5

6

.

7

8

9

+

+

10 11 12

. m

.

m

m

m

Cylinder No. Stamp mark on flywheel

Valve arrangement Valve No.

A


—

C


Flywheel turned 240°counterclockwise from stamp mark ‘‘A’’

B


Flywheel turned 240°counterclockwise from stamp mark ‘‘C’’

MA-3-1

1

2

3

4

5

6

IN E X IN EX IN EX IN E X I N EX IN EX 1

2

3

4

5

j

7

8

9

10 11 12

j

> n

6

j

> n

> n

n

>

j


4. Refer to the ‘‘Valve clearance adjusting sequence’’ table for the stamp mark ‘‘A’’. The adjustable valve clearance locations are indicated by + or j. Push the actuator plunger in until it reaches B.D.C.

WMA167A

5. Place a 0.4 mm (0.016 in) thick feeler gauge between the valve stem and rocker arm. The valve clearance is correct if the feeler gauge is neither too tight nor too loose.

EKO-003

6. If the valve clearance is not within maintenance standards, loosen the adjusting screw lock nut and turn the adjusting screw in or out until the valve clearance is correct. Unit: mm (in) Item

Valve clearance (While cold)


Service limit

Intake valve

0.30 - 0.40 (0.012 - 0.016)

—

Exhaust valve

0.30 - 0.40 (0.012 - 0.016)

—

7. After adjusting the valve clearance, hold the adjusting screw and tighten the lock nut. : 69 - 78 N·m {7.0 - 8.0 kgf zm, 51 - 58 ftzlbf}

8. Turn the flywheel 240° in the direction of standard engine rotation until the T.D.C. stamp mark ‘‘2|5’’ position is reached. From that position, turn the flywheel an additional 20°until the stamp mark ‘‘C’’ is aligned with the pointer. Stamp mark ‘‘C’’: No. 2 (No. 5) piston at T.D.C. on compression stroke +20° 9. Refer to the ‘‘Valve clearance adjusting sequence’’ table for the stamp mark ‘‘C’’. The adjustable valve clearance locations are indicated by . or >. Push the actuator plunger in until it reaches B.D.C. If the valve clearance is not within maintenance standards, adjust it in a manner similar to steps 5 through 7 above. MA-3-2

EKO-004

WMA168A


10. Turn the flywheel 240° in the direction of standard engine rotation so that the T.D.C. stamp mark ‘‘4|3’’ is aligned with the pointer. From that position, turn the flywheel an additional 20° rotation until the stamp mark ‘‘B’’ is aligned with the pointer. Stamp mark ‘‘B’’: No. 3 (No. 4) piston at T.D.C. on compression stroke +20° 11. Refer to the ‘‘Valve clearance adjusting sequence’’ table for the stamp mark ‘‘B’’. The adjustable valve clearance locations are indicated by m or n. Push the actuator plunger in until it reaches B.D.C. If the valve clearance is not within maintenance standards, adjust it in a manner similar to steps 5 through 7 above.

WMA169A

12. Check the valve clearances and adjust if necessary. If the engine vibrates after the valve clearances have been adjusted, check and correct valve timing as required.

Procedure for checking valve timing 1. Remove the V-belt, cooling fan and crank pulley assembly. 2. Turn the flywheel in the normal direction until the No. 1 piston is at the T.D.C. on the compression stroke. NOTE + If the flywheel has been rotated excessively, rotate it backwards beyond the desired position then gradually rotate it back in the normal direction until it is set in the proper position.

3. Attach the timing plate (99646 Z5001) and adapter (99808 96500) to the end of the crankshaft. Also attach a needle pointer utilizing the front cover mounting bolt, and align the needle to ‘‘0’’. 4. Set a dial gauge so that the contact arm is in contact with the upper valve spring seats of the intake valve and exhaust valve.

JMA578A

MA-3-3


WMA149A

5. If the needle of the dial gauge begins to move, it means that the valve is beginning to open; the movement of the needle will stop as the valve closes. Read the needle position on the timing plate on each occasion. Item Intake valve

Exhaust valve

Valve timing

Remarks

Open

20° B.T.D.C.

j 1

Closed

42° A.B.D.C.

j 2

Open

60° B.B.D.C.

j 3

Closed

10° A.T.D.C.

j 4

WMA004A

CRANK DAMPER Check the crank damper for cracks or flaking, and the mounting bolts for looseness. Replace faulty parts if necessary. Crank damper : 98 - 108 N·m {10.0 - 11.0 kgfzm, 72 - 80 ftzlbf} NOTE Be careful not to confuse peeling paint for cracks. +

WMA170A

MA-3-4


FUEL SYSTEM INJECTION TIMING 1. Remove the pointer cover. Secure the pointer to the flywheel housing using bolts. 2. Crank the engine in the standard direction by turning the flywheel with a lever until the pointer is aligned with the timing mark. NOTE + If the mark goes past the pointer, move it back past the pointer and turn again in the standard direction until alignment is made. Item Fuel injection timing (B.T.D.C.)


Service limit

5°

—

WMA165A

3. If the timer marks are not aligned as shown in the figure, adjust as follows:

EP4-23

Adjustment of fuel injection timing 1. Make sure the pointer points to the specified injection timing graduation on the outer periphery of the flywheel and loosen the coupling bolts (2 places). 2. Back the timer off a little in the reverse direction of the normal timer direction. Turn the timer in the normal direction to adjust the pointer to the mark. 3. Tighten the coupling bolts and cotter bolt. Coupling bolt and nut : 103 - 113 N·m {10.5 - 11.5 kgfzm, 76 - 83 ftzlbf} Cotter bolt : 147 - 167 N·m {15.0 - 17.0 kgfzm, 108 - 123 ftzlbf}

MA-3-5

EMA1002E


IDLE SPEED NOTE + When checking engine idle speed ensure that the engine idle control knob inside the cab is set to the low-speed position. 1. Start the engine and warm it up to the normal operating temperature. 2. Allow the engine to idle and observe the engine speed on the tachometer. 3. If idle speed is not within specified range, adjust as follows: NOTE + If equipped with an air conditioner, the air conditioner switch must be turned off when checking idle speed. Unit: rpm Item


Service limit

445 - 500

—

Idle speed

Idle speed adjustment 1. Loosen the lock nut on the idle adjusting bolt. 2. Turn the idle adjusting bolt to obtain the correct idle speed. 3. Tighten the lock nut on the idle adjusting bolt. NOTE + Accelerate the engine two or three times. Allow the engine to return to idle speed and observe the tachometer reading. If the idle speed is not within the specified range, check the accelerator linkage for binding and repeat idle adjustment.

NOZZLE (INJECTOR PRESSURE AND PATTERN) Cleaning nozzle 1. Remove the nozzle holder assembly from the engine. Refer to the ‘‘ENGINE DISASSEMBLY AND REASSEMBLY’’ section for details. 2. Clamp the nozzle holder in a vise with a holder plate (1579449520).

3. Loosen the retaining nut, and then remove the nozzle from the nozzle holder. Do not drop the nozzle needle.

WEF292A

MA-3-6


4. Pull the nozzle needle from the nozzle body. NOTE + Do not use the nozzle needle in another nozzle body. 5. Remove carbon from around the openings by using the corner of a hard piece of wood. Do not use waste or any other material to push carbon into the openings.

WMA017A

6. Removing carbon in openings Use the pin vice (99727 Z5005) and wire to clean the openings. Unit: mm (in) Nozzle identification mark

Number of injection nozzle holes

Injection nozzle hole diameter

Wire diameter

K5

6

0.31 (0.0122)

0.29 (0.0114)

+

+

Allowing too much wire to protrude at the tip of the holder will permit the wire to bend inside the nozzle, in which case withdrawal proves difficult. The wire should protrude no more than 2.0 to 2.5 mm (0.079 to 0.098 in). Carefully push the carbon into the nozzle. Too much force will bend the wire. Proceed slowly.

WMA018A

Remove carbon at the inside end of the openings with the nozzle cleaner (99726 Z5000). Exercise care to avoid damaging the surface which the nozzle needle contacts. The use of compressed air may clog the openings with foreign particles. 7. Tighten the retaining nut. : 59 - 78 N·m {6.0 - 8.0 kgf zm, 43 - 58 ftzlbf} +

WMA019A

MA-3-7


INTAKE AND EXHAUST SYSTEM TURBOCHARGER NOTE + Before attempting any servicing of the turbocharger, clean its entire exterior surface. + Never use a caustic solution. Caustic solutions attack aluminum.

To clean the compressor side 1. Remove the turbocharger from the engine. 2. Remove the compressor housing and check the condition of the impeller (compressor wheel). If it is not excessively dirty, clean the impeller and the inner surface of the housing with a brush and a cloth dampened with diesel fuel. CAUTION + Do not use a wire brush or scraper. 3. If the impeller is excessively dirty, overhaul and clean. Refer to the ENGINE ‘‘IE’’ section for cleaning instructions. 4. When the impeller is wet with cleaning solvent, dry with compressed air. CAUTION + Hold the impeller by hand to prevent it from turning while drying. 5. Install the compressor housing in its original position. : Model TE45 9.0 - 11.3 N·m {0.92 - 1.15 kgfzm, 6.7 - 8.3 ftzlbf}

To clean the turbine side 1. Remove the turbine housing and check the condition of the turbine. If the turbine is not excessively dirty, clean the turbine and the inner surface of the turbine housing in a manner similar to that outlined under ‘‘To clean the compressor side’’. 2. If the turbine is excessively dirty, overhaul and clean. 3. When the impeller is wet with cleaning solvent, dry with compressed air. CAUTION + Hold the impeller with your hand to prevent it from turning while cleaning. 4. Install the turbine housing in its original position. : Model TE45 17.0 N·m {1.73 kgfzm, 12.5 ftzlbf} → Loosen → 13.7 N·m {1.40 kgfzm, 10.1 ftzlbf} 5. Check that the turbine wheel rotates smoothly by your hand. Install the turbocharger on the engine and check for gas or air leakage.

MA-3-8

maintenance nissan cwb

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