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Nissan Frontier D40. Manual - part 589

EM-88

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

ENGINE UNIT

14. Install flywheel (M/T Models), or drive plate (A/T Models).

• Install drive plate, reinforcement plate and pilot converter as

shown.

• Using a drift with 33 mm (1.30 in) diameter, push pilot con-

verter into the end of the crankshaft.

• Press fit pilot bushing into the crankshaft as shown; using a

suitable drift of 19 mm (0.75 in)

15. Install the cylinder block heater.

16. Install the knock sensor.

• Make sure that there is no foreign material on the cylinder

block mating surface and the back surface of the knock sen-
sor.

• Install the knock sensor with the connector facing lower left by

as shown.

• Do not tighten the knock sensor bolt while holding the connec-

tor.

• Make sure that the knock sensor does not interfere with other

components.

CAUTION:

If the knock sensor is dropped, replace it with new one.

17. Install the crankshaft position sensor (POS).

18. Installation of remaining components is in reverse order of removal.

Inspection After Disassembly

INFOID:0000000005274299

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with a dial
indicator.

• If the measured value exceeds the limit, replace thrust bearings,

and measure again. If it still exceeds the limit, replace crankshaft
also.

CONNECTING ROD SIDE CLEARANCE

KBIA0075E

Cylinder block heater

: 73.5 N·m (7.5 kg-m, 54 ft-lb)

Knock sensor bolt

: 21.1 N·m (2.2 kg-m, 16 ft-lb)

Crankshaft position
sensor bolt

: 7.0 N·m (0.71 kg-m, 62 in-lb)

PBIC3020E

Standard

: 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit

: 0.30 mm (0.0118 in)

PBIC2377E

ENGINE UNIT

EM-89

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

• Measure the side clearance between connecting rod and crank-

shaft arm with a feeler gauge.

• If the measured value exceeds the limit, replace connecting rod,

and measure again. If it still exceeds the limit, replace crankshaft
also.

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with an inside
micrometer.

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer.

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to

EM-106, "Standard and Limit"

NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no

grades can be selected. (Only grade “0” is available.)

PISTON RING SIDE CLEARANCE

Standard

: 0.20 - 0.35 mm (0.0079 - 0.138 in)

Limit

: 0.50 mm (0.0197 in)

KBIA0071E

Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)

PBIC0116E

Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)

PBIC0117E

Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

EM-90

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

ENGINE UNIT

• Measure the side clearance of piston ring and piston ring groove

with a feeler gauge.

• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,

replace piston also.

PISTON RING END GAP

• Make sure that cylinder bore inner diameter is within the specifica-

tion. Refer to

EM-106, "Standard and Limit"

• Lubricate with new engine oil to piston and piston ring, and then

insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with a feeler gauge.

• If the measured value exceeds the limit, replace piston ring, and measure again.

CONNECTING ROD BEND AND TORSION

Standard:

Top ring

: 0.045 - 0.080 mm (0.0018 - 0.0031 in)

2nd ring

: 0.030 - 0.070 mm (0.0012 - 0.0028 in)

Oil ring

: 0.065 - 0.135 mm (0.0026 - 0.0053 in)

Limit:

Top ring

: 0.11 mm (0.0043 in)

2nd ring

: 0.10 mm (0.0039 in)

SEM024AA

Standard:

Top ring

: 0.21 - 0.31 mm (0.0083 - 0.0122 in)

2nd ring

: 0.32 - 0.47 mm (0.0126 - 0.0185 in)

Oil ring (rail ring)

: 0.20 - 0.60 mm (0.0079 - 0.0236 in)

Limit:

Top ring

: 0.54 mm (0.0213 in)

2nd ring

: 0.65 mm (0.0256 in)

Oil ring (rail ring)

: 0.95 mm (0.0374 in)

SEM822B

ENGINE UNIT

EM-91

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

• Check with a connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without connecting rod bearing installed, and tightening connecting rod

bolts to the specified torque. Refer to

EM-79, "Disassembly and Assembly"

for the tightening procedure.

• Measure the inner diameter of connecting rod big end with an

inside micrometer.

• If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside
micrometer.

Piston Pin Outer Diameter

Bend:

Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

Torsion:

Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

PBIC2077E

Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)

PBIC1641E

Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)

PBIC0120E

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