-DTInstallation of Distribution Chains

Nissan D22 Pick Up Engine Assembly Manual YD25DDTI. The Distribution Torques & Tips for Assembling the YD25DDTi 2.5 Lts Engine. (2488cc) 16 val. DOHC Nissan D22 Pick Up, Cabstar

In this type of engine the compression chamber is very small, to such a degree that the piston head reaches the highest surface of the monoblock and even protrudes and if the distribution or height of the head is altered, the valves can hit with the piston.

Cylinder Head Specifications:

The cylinder head and camshafts of the YD25DDTi engine are slightly different from known gasoline engine applications. It uses a system that generates high turbulence, this is achieved by having a cylinder head with two intake ports for each cylinder, one tangential and the other helical. Which implies that the left and right camshafts will have cams that control both intake and exhaust valves.

Head flatness check sequence

Nissan D22 Pick Up Engine Assembly Manual YD25DDTI

Max head flatness: 0.1 mm (0.004″) Head height “H” (new): 153.9-154.1 mm (6.059″ – 6.067″) Important: Before assembling your engine, consider the thickness of the head gasket to use through the following procedure.

Procedure to Correctly Designate and Install the Oversize Head Gasket:

The Head gasket to be installed must be selected according to the thickness required in the engine; Case No. 1: Only replacement of the head gasket without having performed any machining on the engine. • From OE the engine may have one of the six existing grades of Head Gaskets installed, for which it must be replaced with a new Head Gasket of the same thickness or grade.

Nissan D22 Pick Up Manual

Gasket thickness mm (in) *	Grade Number	Number of cuts
0.900 (0.0354 ″)	1	0
0.925 (0.0364 ″)	2	1
0.950 (0.0374 ″)	3	2
0.975 (0.0384 ″)	4	3
1.000 (0.0394 ″)	5	4
1.025 (0.0404 ″)	6	5

Note: Consider only those circular cuts of the same size, since there could be others of a different size and this is due to manufacturing issues of the joint.

Nissan D22 Pick Up Manual Case No. 2:

When any engine component has been repaired, rectified or replaced (Monoblock, Crankshaft, Connecting Rod, Piston).

• Bring the piston to its TDC (Top Dead Center) and place the tip of a dial indicator on its head (See Image below), and adjust the dial indicator to zero.

• Move the caliper support and ensure that the tip of the indicator contacts the monoblock and in this way we will obtain a reading (Protruding height of the piston head with respect to the monoblock).

• 2 readings should be taken on each piston and an average taken for each cylinder. The highest reading of any of the 4 cylinders is the one that will be considered for the selection of the appropriate gasket (Refer to the following table).

Piston Protrusionmm (in)	Gasket thickness mm (in) *	Number of cuts
0.230-0.255 (0.0090-0.0100″)	0.900 (0.0354 ″)	0
0.255-0.280 (0.0100-0.0110″)	0.925 (0.0364 ″)	1
0.280-0.305 (0.0110-0.0120″)	0.950 (0.0374 ″)	2
0.305-0.330 (0.0120-0.0130″)	0.975 (0.0384 ″)	3
0.330-0.355 (0.0130-0.0140″)	1.000 (0.0394 ″)	4
0.355-0.400 (0.0140-0.0157″)	1.025 (0.0404 ″)	1

Calculated and measured with torque head screws.

Note: If the dimension obtained from the protruding part of the piston head to the monoblock is greater than the tolerances in the previous table, possibly an operation in the engine repair was done poorly or one of the parts is already out of specifications and will have to be replaced.

Important!: The previous procedure is only to compensate for the protruding part of the piston in the monoblock. Regarding the height of the cylinder head, the tolerances marked for its height must be respected, and if it is below it, TF Victor will soon issue shims to recover the lost height.

Cylinder Head Sequence and Torque Specification:

Cylinder Head Screws:

1.- 39.2 nm (4 Kg-m or 29 lb-ft)
2.- 180°
3.- Loosen them completely
4.- 39.2 nm (4 Kg-m or 29 lb-ft)
5.- 90° 6.- 90°

Valve Specifications:

ADMISSION:	EXHAUST:
Head diameter mm / (in): 28.00-28.30 (1.102″-1.114″) Stem diameter mm / (in): 5.965-5.980 (0.2348″-0.2354″) Total length mm / (in): 106.72 (4.2016″) Angle seat: 45° No. of slots in stem: 1 Height of stem. Install mm / (in) : 36.53-36.98 (1.4382″-1.4559″) Valve-guide tolerance mm / (in): 0.020-0.053 (0.0008″-0.0021″) Type of seal used: POSITIVE	Head diameter mm / (in): 26.00-26.30 (1.024″-1.035″) Stem diameter mm / (in): 5.945-5.960 (0.2341″-0.2346″) Total length mm / (in): 106.36 (4.1874″) Angle seat height: 45° No. of slots in stem: 1 Height of stem. Install mm / (in): 36.53-37.01 (1.4382″-1.4571″) Valve-guide tolerance mm / (in): 0.040-0.073 (0.0016″-0.0029″) Type of seal used: POSITIVE
Spring loading pressure: 18.77-21.22 @ 32.82 (Kg @ mm)

Camshaft Specifications:

Description

Trunnion Diameter

Case Diameter

Support No. 1st 2nd 3rd 4th 5th

30.435-30.455 mm (1.1982″-1.1990″)

23.935-23-955 mm (0.9423″-0.9431″)

30.500-30.521 mm (1.2008″-1.2016″)

24.000-24.021 mm (0.9449″-0.9457″)

Description	Metal Lubrication Light	Game. Axial

Support No.1°2°3° 4° 5°	0.045-0.086mm (0.0018″- 0.0034″)	0.070-0.148 mm (0.0028″- 0.0058″)
Aim Type: Direct Action Mechanical C/Coins

Nissan D22 Pick Up Manual

Camshaft Caps Torque:

Tighten the camshaft cover bolts in the following steps, maintaining the numerical order indicated in the figure on the right.

1) 2Nm

Connecting Rods Specifications

Description	Trunnion Diameter	Case Diameter

Part: STD connecting rod mm	51-954-51.974 mm(2.0454″-2.0462″)	55.000-55.013mm(2.1654″-2.1659″)

Description	Metal Lubrication Light	Game. Axial

Part: STD connecting rod mm	0.047-0.077mm(0.0019″-0.0030″)	0.100-0.250mm(0.0039″-0.0098″)

Torque / Crank Nuts:

1. 22 lb-ft

2. Loosen the nuts completely

3. 14 lb-ft

4. 120°

Crankshaft Specifications

Description	Trunnion Diameter	Case Diameter

Part: Crankshaft STD mm	62.951-62.975 mm (2.4784″-2.4793″)	66.654-66.681 mm (2.6242″-2.6252″)

Description	Metal Lubrication Light	Game. Axial

Part: Crankshaft STD mm	0.047-0.077 mm (0.0019″-0.0030″)	0.100-0.250 mm (0.0039″-0.0098″)

Bench Screw Torque: 1.- 20 Lb-ft2.- 90°

Table of Contents

Nissan D22 Pick Up Manual

Installation of Distribution Chains

Main components of the front timing of the Nissan YD25DDTi engine

Secondary Chain Tensioner
Secondary Chain Guide Tensioner
Fuel Pump Gear
Primary Chain Guide
Primary Chain
Vacuum Pump Gear
Primary Chain Guide Tensioner
Primary Chain Tensioner
Crankshaft Gear
Crankshaft Gear Wedge
Primary Chain Guide Tensioner
Primary Chain Guide Tensioner
Secondary Chain Guide Tensioner
Camshaft Gears

Secondary Chain

Alignment mark on Chains (“Darker” silver links)
Alignment mark on camshaft gears and fuel pump (dotted)
Alignment mark on crankshaft gear (longitudinal groove)
Alignment Mark on Chains (Yellow Links)

Steps to follow Nissan D22 Pick Up Manual:

First you will have to identify the primary and secondary Chains perfectly well.

• Primary Chain: Synchronizes the crankshaft gear with the fuel pump gear.

• Number of Links: 47 Links.

• Links with Marks: 1 Yellow Link 1 “Dark” Silver Link

• Location of Links:

a) Yellow; Link #1

b) Silver; Link #19

• Secondary Chain: Synchronizes the front gear of the fuel pump with the gears of the camshafts.

• Number of Links: 46 Links

• Links with Marks:

1 Yellow Link

2 “Dark” Silver Links

• Location of Links:

a) Yellow; Link #1

b) Silver; 1st Link #22

c) Silver; 2nd Link # 27

Nissan D22 Pick Up Manual

• Having the crankshaft wedge pointing at 12:00 hrs. Clockwise, position the primary chain, taking care to align all the timing marks on both the chains and the gears. Subsequently install all its corresponding guides and tensioners.

Use of the goniometer

Important Manual Nissan D22 Pick Up

If you need to tighten in degrees and you do not have the special tool (angular torque dial or goniometer), use the diagram shown.

Which is based on the face of a watch; As you can see, when it is 12:00 am or 0˚, this will be the starting point of the tightening tool (common way).

For example, if you want to tighten at 90˚ you must turn from 12:00 am to 3:00 and so on depending on the required tightening.

Remember that tightening degrees is not the same as lb.ft or Nm and verify the torques recommended by the manufacturers, for optimal operation of the engine components.

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NISSAN D22 Pick Up Engine Assembly Manual YD25DDTI

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