FE series
FE6,FE6T & FE6TA
ENGINE
SERVICE MANUAL
Applicable Engine Numbers FE6-200001 —
FOREWORD
This manual describes the service, by system, of the engine of FE6A, FE6B, FE6T and FE6TA models. In order for a vehicle to perform at its best, and to extend vehicle life, maintenance should be performed properly. Also, overhaul and repair should be effected in accordance with prescribed service stan-dards.
This manual should be kept readily available in the workshop as a helpful reference for those engaged in servicing vehicles.
Nissan Diesel Motor Co., Ltd. reserves the right to make changes for improvement at any time without notice.
This manual is based on vehicles that were manufac-tured on or before April.1, 1998. Revisions, if any, will be introduced in the Technical Bulletin.
FM edition: Mar. 2005 1st edition: Jun. 1998 9904K30-14203-100-SZ1(M)
MAINTENANCE
TROUBLE DIAGNOSIS
ENGINE PROPER
MA
TD
EP
GENERAL
GE
CYLINDER HEAD AND VALVE MECHANISM HV
LUBRICATION SYSTEM
LB
COOLING SYSTEM
EC
FUEL SYSTEM
EF
AIR INTAKE AND EXHAUST SYSTEM
IE
ELECTRICAL SYSTEM
EE
AUXILIARY EQUIPMENT
EA
© 1999 NISSAN DIESEL MOTOR CO., LTD.
ENGINE DISASSEMBLY AND REASSEMBLY DR
MODEL
FE6 series
X
A quick reference index, a black tab is provided on the first page, so you can quickly find the first
page of each chapter by mating it to the chapter’s black tab.
X
The contents are listed on the first page of each chapter.
X
Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major compo-nents, items requiring adjustment after reassembling and their maintenance standards.
The number given to each part in the illustration corresponds to the number attached to each part name, and the number is determined according to the operation sequence.
No. 1, 2, 3 Disassembly sequence Reassembly sequence is in the reverse order of disassembly.
The marks “
+
” and “,
” affixed to the part name number indicate that the key points of operation (pre-cautions, technique, use of special tools, and other maintenance information) are explained in the text.+
: Key points of disassembly,
: Key points of reassemblyThe tightening torque necessary for maintenance and lubricating points are indicated by symbols in the illustration.
NOTE
z
Disassembly and reassembly sequences show general examples and in some operations it
may be possible to change sequences.
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)
Marks “
,
” and “+
” indicate that the key points of operation are explained in the text.1. Plug 4. Ball 7. Driven gear assembly , 2. Gasket 5. Cover ,+8. Pump gear assembly , 3. Spring 6. Gasket
Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated by the star marks “+” and “,” affixed to the sequence number in the exploded illustration.
NOTE
z
If there are no “
+
” and “
,
” marks affixed to the parts, general explanation is given for those
parts.
X
The following marks and abbreviations are used in this manual.
Marks:
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended multi-pur-pose grease.
: Should be lubricated with oil. : Sealing point
: Always replace after every disassembly. Abbreviations
X
Engine position:
X
Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
X
Specific terms related to the maintenance standard
z
Maintenance standard
“Maintenance standard” indicates the standard clearance when parts are assembled or the standard performances of assembly parts.
z
Service limit
“Service limit” indicates the limit value where adjustment, correction or parts replacement must be done.
X
The captions WARNING and CAUTION warn you about procedures that must be followed to
pre-vent personal injury and/or damage to some parts of the vehicle.
T.D.C.: Top dead center I.D.: Inside diameter
B.T.D.C.: Before top dead center Dia.: Diameter
A.T.D.C.: After top dead center S.T.D.: Standard
B.B.D.C.: Before bottom dead center O.S.: Oversize
A.B.D.C.: After bottom dead center U.S.: Undersize
Engine models specified for TAIWAN are different from those for general markets. Hereinafter, engine mod-els will be described by specifications for general markets. For TAIWAN specifications, use the above table to identify the engine model specification for TAIWAN when reading this service manual.
NOTE
z
Only maintenance interval information includes information for TAIWAN engine models.
Max. gross output (JIS) kW {PS}/rpm
Engine model
For general markets For TAIWAN
118 {160}/3,000 FE6A — 119 {162}/3,000 FE6B FE6 132 {180}/3,000 FE6B — 135 {183}/3,000 FE6T FE6T 151 {205}/2,800 FE6T FE6T-Z 162 {220}/2,800 FE6T — 157 {213}/2,800 FE6TA — 173 {235}/2,800 FE6TA FE6TA
GENERAL
CONTENTS
SPECIFICATIONS ...
GE-1-1ENGINE SPECIFICATIONS... GE-1-1 ENGINE NUMBERS... GE-1-9
LUBRICATION...
GE-2-1PRECAUTIONS ...
GE-3-1PREPARATION ... GE-3-1 GENERAL REMARKS REGARDING
IN DISASSEMBLY OPERATIONS ... GE-3-1 CLEANING AND INSPECTION ... GE-3-2
SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine models FE6A and FE6B
Engine model
Item FE6A FE6B
Max. gross output (JIS) kW {PS}/rpm 118 {160}/3,000 119 {162}/3,000 132 {180}/3,000
Type Diesel
Cooling method Water cooled
Number of cylinders and cylinder arrangement 6, in-line
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead valve
Cylinder liner Dry
Bore x stroke mm (in) 108 x 126 (4.25 x 4.96)
Compression ratio 18.0
Cylinder compression kPa {kgf/cm2, psi}/rpm 2,942 {30, 427}/200
Idling speed 600 Valve timing Intake Open (B.T.D.C.) 15º Closed (A.B.D.C.) 40º Exhaust Open (B.B.D.C.) 53º Closed (A.T.D.C.) 9º
Valve clearance mm (in) Intake 0.3 - 0.4 (0.012 - 0.016)
Exhaust 0.3 - 0.4 (0.012 - 0.016)
Lubrication system
Lubrication system Forced-circulation type
Oil pump Gear pump
Oil filter Cartridge type
Oil cooler Water cooled flat tube type
Regulator valve opening pressure kPa {kgf/cm2, psi} 422 - 461 {4.3 - 4.7, 61 - 67}
C
ooling system
Cooling system Forced-circulation type
Radiator type Corrugated fin
Cooling fan Outside diameter - Number of fins
mm (in) 480 (18.90) - 6 485 (19.09) - 8 510 (20.08) - 6 485 (19.09) - 8 510 (20.08) - 7 530 (20.87) - 6 530 (20.87) - 6
Water pump Centrifugal, belt-driven type
Engine model
Item FE6A FE6B
Fuel system
Ignition system Compression ignition
Fuel injection timing (B.T.D.C.) 14º 15º 12º
Ignition order 1-4-2-6-3-5
Fuel feed pump Plunger type
Fuel filter Cartridge type and primary fuel filter
Fuel injection pump
Type Bosch
Plunger diameter mm (in) 9.5 (0.374) 9.0 (0.354) 9.5 (0.374)
Plunger lead Right lead
Cam lift mm (in) Injection pump 8.0 (0.315) 9.0 (0.354)
Feed pump 6.0 (0.236)
Governor Type Centrifugal
Type name RAD/RLD/RFD RLD RAD/RLD/RFD
Timer
Type Centrifugal
Type name SA SA (RAD, RLD)/SAG (RFD)
Fuel injection nozzle
Type Conventional type
Nozzle holder Flange type
Nozzle Multi-jet
Identification mark Z D2 Z
Number of nozzle holes 5
Injection pressure kPa {kgf/cm2, psi} 19,614 {200, 2,844}
Overflow valve opening pressure
kPa {kgf/cm2, psi}
Injection pump outlet 157 {1.6, 23}
Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}
Air int
ake and exhaust system
Air cleaner Paper element (Dry: Single or dual type)
Turbocharger
Model —
External dimensions
(Length x Width x Height) mm (in) —
Maximum permissible continuous
speed —
Direction of rotation —
Air volume kg (lb)/min —
Compression ratio —
Exhaust brake Type Chamber type Cylinder type
Engine model
Item FE6A FE6B
Electrical sys
te
m
Starting motor
Type Shift type
Model 0350 502 0310/0350 502 0321
Output V-kW 24-4.5
Alternator
Type AC, diode-rectified
Model 0202 152 0310 0201 152 0420/0201 152 0421
0202 152 0311
Output V-A 24-50
Regulator IC-transistor type
Air heater Type Ribbon
Voltage x Current - Number V-A 22 x 85 - 1
Auxiliary equipment
Air compressor
Type Reciprocating type
Bore x stroke - Number of cylinders
mm (in) 85 x 40 - 1 (3.35 x 1.57 - 1)
Cooling system Water cooled
Engine rear PTO
Allowable maximum torque
N·m {kgf·m, ft·lbf} 343 {35, 253}
Direction of rotation Clockwise (as viewed from the rear)
Gear ratio (PTO gear : crankshaft gear) 1.264 (67 : 53)
Vacuum pump Type Vane —
Engine model FE6T
Engine model
Item FE6T
Max. gross output (JIS) kW {PS}/rpm 135 {183/3,000} 151 {205/2,800} 162 {220/2,800}
Type Diesel
Cooling method Water cooled
Number of cylinders and cylinder arrangement 6, in-line
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead valve
Cylinder liner Dry
Bore x stroke mm (in) 108 x 126 (4.25 x 4.96)
Compression ratio 18.0 17.5
Cylinder compression kPa {kgf/cm2, psi}/rpm 2,942 {30, 427}/200
Idling speed 600 Valve timing Intake Open (B.T.D.C.) 15º Closed (A.B.D.C.) 30º Exhaust Open (B.B.D.C.) 53º Closed (A.T.D.C.) 9º
Valve clearance mm (in) Intake 0.3 - 0.4 (0.012 - 0.016)
Exhaust 0.3 - 0.4 (0.012 - 0.016)
Lubric
at
ion
system
Lubrication system Forced-circulation type
Oil pump Gear pump
Oil filter Cartridge type
Oil cooler Water cooled flat tube type
Regulator valve opening pressure kPa {kgf/cm2, psi} 422 - 461 {4.3 - 4.7, 61 - 67}
Cooling system
Cooling system Forced-circulation type
Radiator type Corrugated fin
Cooling fan Outside diameter - Number of fins
mm (in) 510 (20.08) - 7
510 (20.08) - 7
580 (22.83) - 7 580 (22.83) - 6
580 (22.83) - 7
Water pump Centrifugal, belt-driven type
Engine model
Item FE6T
Fuel system
Ignition system Compression ignition
Fuel injection timing (B.T.D.C.) 12º 10º 9º
Ignition order 1-4-2-6-3-5
Fuel feed pump Plunger type
Fuel filter Cartridge type and primary fuel filter
Fuel injection pump
Type Bosch
Plunger diameter mm (in) 9.0 (0.354)
Plunger lead Right lead
Cam lift mm (in) Injection pump 9.0 (0.354) 10.0 (0.394)
Feed pump 6.0 (0.236)
Governor Type Centrifugal
Type name RLD
Timer Type Centrifugal
Type name SA SAG
Fuel injection nozzle
Type Conventional type
Nozzle holder Flange type
Nozzle Multi-jet
Identification mark D3 A5 A6
Number of nozzle holes 5
Injection pressure kPa {kgf/cm2, psi} {200, 2,844}19,614 {220, 3,128}21,575 {200, 2,844}19,614
Overflow valve opening pressure
kPa {kgf/cm2, psi}
Injection pump outlet 157 {1.6, 23}
Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21} Air int ak e a nd exhaust sys tem
Air cleaner Paper element (Dry: Single or dual type)
Turbocharger
Model T04B RHC62E
External dimensions
(Length x Width x Height) mm (in)
220 x 190 x 160 (8.66 x 7.48 x
6.30)
218 x 238 x 145 (8.58 x 9.37 x 5.71) Maximum permissible continuous
speed 138,000 150,000
Direction of rotation Counterclockwise as viewed from the exhaust
tur-bine side
Air volume kg (lb)/min 21 (46) 18.8 (41.5)
Compression ratio 3.2
Exhaust brake Type Cylinder type
Engine model Item FE6T Electrical sys te m Starting motor
Type Shift type
Model 0350 502 0310/0350 502 0321 0350 502 0321
Output V-kW 24-4.5
Alternator
Type AC, diode-rectified
Model 0201 152 0420/0201 152 0421 0201 152 0421 0201 222 0273 Output V-A 0201 152 0420 0201 152 0421 24-50 0201 222 0273 — 24-80
Regulator IC-transistor type
Air heater Type Ribbon
Voltage x Current - Number V-A 22 x 85 - 1
Auxiliary equipment
Air compressor
Type Reciprocating type
Bore x stroke - Number of cylin-ders mm (in) 408738-5600 85 x 40 - 1 (3.35 x 1.57 - 1) — 408738-5601 85 x 40 - 1 (3.35 x 1.57 - 1) 408738-5611 — — 408738-5741 — 85 x 60 - 1 (3.35 x 2.36 - 1)
Cooling system Water cooled
Engine rear PTO
Allowable maximum torque
N·m {kgf·m, ft·lbf} 343 {35, 253}
Direction of rotation Clockwise (as viewed from the rear)
Engine model FE6TA
Engine model
Item FE6TA
Max. gross output (JIS) kW {PS}/rpm 157 {213}/2,800 173 {235}/2,800
Type Diesel
Cooling method Water cooled
Number of cylinders and cylinder arrangement 6, in-line
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead valve
Cylinder liner Dry
Bore x stroke mm (in) 108 x 126 (4.25 x 4.96)
Compression ratio 17.5
Cylinder compression kPa {kgf/cm2, psi}/rpm 2,942 {30, 427}/200
Idling speed 600 Valve timing Intake Open (B.T.D.C.) 15º Closed (A.B.D.C.) 30º 40º Exhaust Open (B.B.D.C.) 53º Closed (A.T.D.C.) 9º
Valve clearance mm (in) Intake 0.3 - 0.4 (0.012 - 0.016)
Exhaust 0.3 - 0.4 (0.012 - 0.016)
Lubric
at
ion
system
Lubrication system Forced-circulation type
Oil pump Gear pump
Oil filter Cartridge type
Oil cooler Water cooled flat tube type
Regulator valve opening pressure kPa {kgf/cm2, psi} 422 - 461 {4.3 - 4.7, 61 - 67}
Cooling sys
te
m
Cooling system Forced-circulation type
Radiator type Corrugated fin
Cooling fan Outside diameter - Number of fins
mm (in)
510 (20.08) - 7 580 (22.83) - 6
580 (22.83) - 7 580 (22.83) - 7
Water pump Centrifugal, belt-driven type
Engine model
Item FE6TA
Fu
el
system
Ignition system Compression ignition
Fuel injection timing (B.T.D.C.) 3º 12º
Ignition order 1-4-2-6-3-5
Fuel feed pump Plunger type
Fuel filter Cartridge type and primary fuel filter
Fuel injection pump
Type TC-MD Bosch
Plunger diameter mm (in) 11.0 (0.433) 9.0 (0.354)
Plunger lead Right lead
Cam lift mm (in) Injection pump 10.0 (0.394)
Feed pump 6.0 (0.236)
Governor Type Centrifugal
Type name RLD
Timer Type — Centrifugal
Type name — SAG
Injection timing control Electronic (MD-TICS) —
Fuel injection nozzle
Type Conventional type
Nozzle holder Flange type
Nozzle Multi-jet
Identification mark F4 or C1 A3
Number of nozzle holes 5
Injection pressure kPa {kgf/cm2, psi} 19,614 {200, 2,844} 1st: 16,672 {170, 2,417} 2nd: 21,575 {220, 3,128} Overflow valve opening pressure kPa {kgf/cm2, psi}
Injection pump outlet 255 {2.6, 37} 157 {1.6, 23}
Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}
Air int
ake and exhaust system
Air cleaner Paper element (Dry: Single or dual type)
Turbocharger
Model T04E RHC6V
External dimensions
(Length x Width x Height) mm (in)
230 x 195 x 265 (9.06 x 7.68 x 10.43)
246 x 214 x 196 (9.69 x 8.43 x 7.72) Maximum permissible continuous
speed 125,000 150,000
Direction of rotation Counterclockwise as viewed from the exhaust tur-bine side
Air volume kg (lb)/min 20 (44) 19.4 (42.8)
Compression ratio 3.2
Exhaust brake Type Cylinder type
ENGINE NUMBERS
The engine serial number is stamped on the right side of the cylin-der block.
*Engine specification
A: Natural aspirated engine B: Natural aspirated engine C: Turbocharged engine
D: Turbocharged engine with intercooler
Engine model
Item FE6TA
Electrical system
Starting motor
Type Shift type
Model 0350 502 0321 0350 502 0310/0350 502 0321
Output V-kW 24-4.5
Alternator
Type AC, diode-rectified
Model 0201 152 0421 0202 152 0220/0202 152 0221
Output V-A 24-50
Regulator IC-transistor type
Air heater Type Ribbon
Voltage x Current - Number V-A 22 x 85 - 1
Auxiliary equipment
Air compressor
Type Reciprocating type
Bore x stroke - Number of cylin-ders mm (in) 408738-5610 408738-5611 — 85 x 40 - 1 (3.35 x 1.57 - 1) 408738-5780 (3.35 x 1.57 - 1)85 x 40 - 1 — F8040 80 x 40 - 1 (3.15 x 1.57 - 1) —
Cooling system Water cooled
Engine rear PTO
Allowable maximum torque
N·m {kgf·m, ft·lbf} 343 {35, 253}
Direction of rotation Clockwise (as viewed from the rear)
Gear ratio (PTO gear : crankshaft gear) 1.264 (67 : 53)
Vacuum pump Type Vane —
Model VD-30 —
FE6-XXXXXXC*
Engine serial number Engine model
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
NOTE
z
It is recommended that API CD class multi-grade oil be used as engine oil for turbocharged
engines.
RECOMMENDED SAE VISCOSITY NUMBER
Use oil having the proper viscosity beforehand which meets tem-peratures forecast for areas where you are planning to drive.
CAPACITIES (APPROXIMATELY)
NOTE
z
Capacities shown are for reference only. When filling, observe the specified level.
z
* Vehicle model PKC210 (for TAIWAN only) and PKC212 (for HONG KONG only).
Lubricant Specifications Remarks
Engine oil API CC or CD For further details, refer to the recom-mended SAE viscosity chart.
Power steering fluid DEXRON® or DEXRON® II GM ATF type
Bearing grease NLGI No. 2 Lithium soap base
Antifreeze — Ethylene glycol base
Fuel Above –7ºC (20ºF) 2-D Diesel fuel or equivalent blended diesel fuel Check with the service establishment to
be sure you get the properly blended fuel. Below –7ºC (20ºF) 1-D Diesel fuel or equivalent blended diesel fuel
Item Liter (Imp measure)
Engine oil
Engine oil pan (H-level) FE6A, FE6B, FE6T, FE6TA 12 (2-5/8 gal)
FE6TA* 14 (3-1/8 gal)
Total FE6A, FE6B, FE6T, FE6TA 15 (3-1/4 gal)
FE6TA* 17 (3-3/4 gal)
Power steering system MK and LK series 3 (2-5/8 qt)
PK series 5.5 (4-7/8 qt)
Cooling system 22 (4-7/8 gal)
Fuel tank Square type 100 (22 gal) 130 (28-5/8 gal) 200 (44 gal) 100 + 100 (22 gal + 22 gal) Round type 109 (24 gal) 150 (33 gal) 227 (50 gal)
PRECAUTIONS
PREPARATION
Observe the following when servicing the vehicle.
z
Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle
may move abruptly.
z
Engage the parking brake and chock the wheels securely.
zIf the engine is hot, wait until it cools off.
z
Set the transmission gear shift lever to “NEUTRAL”.
z
Turn the key switch to “OFF”. Disconnect the ground cable when servicing the electrical system.
zDo not touch rotating parts of the engine if servicing requires engine operation. Always operate the
engine in a well-ventilated area.
z
When tilting the cab indoors, make sure that there is a
clearance of at least 4 m (13.1 ft) in H and a clearance of 1
m (3.3 ft) in F.
GENERAL REMARKS REGARDING IN
DISAS-SEMBLY OPERATIONS
Checks before disassembly
Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For instance, if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil leakage. Recognizing the problem in advance will be extremely helpful in locating which part of the engine needs to be disassembled and which part does not. It will also save time and labor.
Work required during disassembly
Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original posi-tions. When repairs involve the electrical system, disconnect the ground cable from the battery.
Checks during disassembly
Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work effi-ciency will be degraded after all parts have been disassembled.
Keeping disassembled parts in order
Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc. Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contami-nated with water or oil. Keep them in one place and away from those having engine oil on them.
Cleaning disassembled parts
Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned, scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems after reassembly.
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.). Apply a coat of grease, liquid packing or sealer to designated parts.
CLEANING AND INSPECTION
CLEANING
The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include steam cleaning, light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely while the cleaning is in process.
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel and cast iron parts quite well.
NOTE
z
If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent
(such as boric acid solution), since the alkaline solution must be immediately washed from the
skin or eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages to make sure that they are free. Clean the oil passages with solvent that is injected under pressure from a nozzle.
PROTECTION AGAINST CORROSION
After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them to prevent corrosion.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limit from preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the “red” (penetration) method, whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities, the affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed. Abnormalities z
Uneven wear
zGraded wear
zScratches
zCracks
zDeformity
z
Fatigue or weakness (for springs and rubbers, etc.)
zBends
z
Loose fit
z
Unusual noise (for bearings)
zDiscoloration or jamming
zRust formation
STANDARD TIGHTENING TORQUE
The tightening torque of the bolts and other fasteners that secure the major components parts is specified in the text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened accord-ing to the followaccord-ing table of bolt standard tightenaccord-ing torque.
NOTE
z
All bolts and nuts are sized using the metric system. Do not use parts other than those
desig-nated.
NOTE
z
Special parts are excluded.
z
This standard is applicable to bolts having the following marks embossed on the bolt head.
Mark 4T ... 4 7T ... 7 9T ... 9
Standard tightening torque of tubing connector
Nominal size Bolt dia. mm Pitch mm
Standard tightening torque (Without lubricant)
4T 7T 9T N·m kgf·m ft·lbf N·m kgf·m ft·lbf N·m kgf·m ft·lbf M6 6.0 1.0 5.1 0.52 3.8 8.4 0.86 6.2 12 1.2 9 M8 8.0 1.25 13 1.3 9 21 2.1 15 29 3.0 22 1.0 13 1.3 9 22 2.2 16 31 3.2 23 M10 10.0 1.5 25 2.5 18 41 4.2 30 59 6.0 43 1.25 25 2.6 19 43 4.4 32 62 6.3 46 M12 12.0 1.75 42 4.3 31 71 7.2 52 98 10.0 72 1.25 46 4.7 34 77 7.9 57 108 11.0 80 M14 14.0 1.5 74 7.5 54 127 13.0 94 177 18.0 130 M16 16.0 1.5 108 11.0 80 186 19.0 137 275 28.0 203 M18 18.0 1.5 167 17.0 123 275 28.0 203 392 40.0 289 M20 20.0 1.5 226 23.0 166 382 39.0 282 549 56.0 405 M22 22.0 1.5 304 31.0 224 510 52.0 376 736 75.0 542
Item Standard tightening torque
N·m kgf·m ft·lbf
Flared nut Tube O.D. mm (in)
4.76 (0.1874) 13 - 18 1.3 - 1.8 9 - 13 6.35 (0.2500) 16 - 24 1.6 - 2.4 12 - 17 8.0 (0.315) 29 - 39 3.0 - 4.0 22 - 29 10.0 (0.394) 39 - 49 4.0 - 5.0 29 - 36 12.0 (0.472) 59 - 78 6.0 - 8.0 43 - 58 15.0 (0.591) 69 - 93 7.0 - 9.5 51 - 69
Nipple nut [Tube O.D. 6.35 mm (0.2500 in)] 21 - 28 2.1 - 2.9 15 - 21
MAINTENANCE
CONTENTS
SERVICE DATA...
MA-1-1SERVICE DATA ... MA-1-1 TIGHTENING TORQUE ... MA-1-2
TOOLS ...
MA-2-1PERIODIC MAINTENANCE
SCHEDULES ...
MA-3-1MAINTENANCE INTERVALS... MA-3-2 PERIODIC PARTS REPLACEMENT ... MA-3-4
MAINTENANCE PROCEDURE...
MA-4-1BASIC MECHANICAL SYSTEM... MA-4-1 LUBRICATION SYSTEM ... MA-4-4 COOLING SYSTEM... MA-4-9 FUEL SYSTEM ... MA-4-17 INTAKE AND EXHAUST SYSTEM... MA-4-27 OTHERS ... MA-4-32
SERVICE DATA
SERVICE DATA
Item Maintenancestandard Service limit Remarks
Basic mechanical system
Valve clearance mm (in)
Intake (0.012 - 0.016)0.3 - 0.4 —
When engine is cold Exhaust (0.012 - 0.016)0.3 - 0.4 —
Cylinder compression pressure
kPa {kgf/cm2, psi} 2,942 {30, 427} 1,961 {20, 284}
At 200 rpm with engine warm Difference between cylinders kPa {kgf/cm2, psi} Less than
392 {4, 57} — Valve timing FE6A FE6B FE6TA 173 kW {235 PS} Intake Open 15° B.T.D.C. — Closed 40° A.B.D.C. — Exhaust Open 53° B.B.D.C — Closed 9° A.T.D.C. — FE6T FE6TA 157 kW {213 PS} Intake Open 15° B.T.D.C. — Closed 30° A.B.D.C. — Exhaust Open 53° B.B.D.C — Closed 9° A.T.D.C. — Cooling syste m V-belt deflection mm (in) Fan pulley
-alternator pulley 10 - 15 (0.39 - 0.59) — With a force of about 98 N {10 kgf, 22 lbf} applied to the mid part
Fan pulley
-cooler compressor pulley 7 - 12 (0.28 - 0.47) — Radiator cap operating pressure
kPa {kgf/cm2, psi} 39 - 59 {0.4 - 0.6, 6 - 9} — Pressure side Thermostat Valve opening temperature °C (°F) 76.5 (170) (166 - 173)74.5 - 78.5 (161 - 179)71.5 - 81.5 82 (180) 80 - 84 (176 - 183) 77 - 87 (171 - 189) 88 (190) 86 - 90 (187 - 194) 85 - 93 (185 - 199) Valve lift/
tem-perature mm/°C (in/°F)
76.5 (170) More than 10/90(0.39/194) Less than 9/90(0.35/194) 82 (180) More than 10/95(0.39/203) Less than 9/95(0.35/203) 88 (190) More than 10/100(0.39/212) Less than 9/100(0.35/212)
TIGHTENING TORQUE
Unit: N·m {kgf·m, ft·lbf}
F
uel sy
stem
Fuel injection timing (B.T.D.C.) FE6A 14° — FE6B 119 kW {162 PS} 15° — 132 kW {180 PS} 12° — FE6T 135 kW {183 PS} 12° — 151 kW {205 PS} 10° — 162 kW {220 PS} 9° —
FE6TA 157 kW {213 PS} 3° — “MD-TICS” system 173 kW {235 PS} 12° —
Idle speed rpm
FE6A, FE6B, FE6T 600 — FE6TA 157 kW {213 PS} 650 — 173 kW {235 PS} 550 — Maximum speed rpm 3,200 — No-load maximum engine speed rpm 3,600 —
Item Maintenance
standard Service limit Remarks
Item Tightening torque
Basic mechanical system
Valve clearance adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
Cylinder head mounting bolt 177 - 196 {18.0 - 20.0, 130 - 145}
Air intake manifold mounting bolt and nut 16 - 20 {1.6 - 2.0, 12 - 14}
Exhaust manifold mounting nut 34 - 44 {3.5 - 4.5, 25 - 33}
Compression gauge mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Crank damper mounting bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Lubrication
system Oil pan drain plug 59 - 69 {6.0 - 7.0, 43 - 51}
Cooling system
Alternator adjusting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
Alternator anchor bolt and nut 59 - 74 {6.0 - 7.5, 43 - 54}
Fuel system
Injection pump drive coupling bolt and nut
FE6A, FE6B, FE6T, FE6TA
173 kW {235 PS}
29 - 34 {3.0 - 3.5, 22 - 25} FE6TA
157 kW {213 PS} 59 - 64 {6.0 - 6.5, 43 - 47}
Injection pump drive coupling cot-ter bolt
FE6A, FE6B, FE6T, FE6TA
173 kW {235 PS}
59 - 64 {6.0 - 6.5, 43 - 47} FE6TA
157 kW {213 PS} 83 - 93 {8.5 - 9.5, 61 - 69}
Delivery valve holder
FE6A, FE6B, FE6T, FE6TA
173 kW {235 PS}
49 - 54 {5.0 - 5.5, 36 - 40} FE6TA
157 kW {213 PS} 103 - 113 {10.5 - 11.5, 76 - 83}
Injection nozzle retaining nut 59 - 78 {6.0 - 8.0, 43 - 58}
Nozzle holder mounting bolt 25 - 29 {2.5 - 3.0, 18 - 22}
Injection pump bleeder screw 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Fuel filter (center bolt type) center bolt 20 - 29 {2.0 - 3.0, 14 - 22}
Primary fuel filter center bolt Type I 20 - 29 {2.0 - 3.0, 14 - 22}
Type II 59 - 69 {6.0 - 7.0, 43 - 51}
Primary fuel filter drain plug (Type II only) 16 - 22 {1.6 - 2.2, 12 - 16}
Fuel strainer center bolt 15 - 20 {1.5 - 2.0, 11 - 14}
Fuel filter eye bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Air intake and exhaust system
Compressor housing and back plate mounting bolt
N·m {kgf·cm, in·lbf} T04B
T04E 11.3 - 14.7 {115 - 150, 100 - 130}
RHC62E
RHC62V 7.4 - 8.3 {75 - 85, 65 - 74}
Turbine housing and center hous-ing mounthous-ing bolt
N·m {kgf·cm, in·lbf} T04B
T04E 18.0 - 21.5 {184 - 219, 160 - 190}
RHC62E
RHC62V 27.0 - 28.9 {275 - 295, 239 - 256}
TOOLS
* Tool number designated by Zexel Co.
Tool name and number Description Shape
Feeler gauge 99541 Z5000
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)
Timing plate 99646 Z5001
For measuring valve timing
Compression gauge 99640 Z5500
For measuring compression pressure
Compression gauge hose 99644 97000
Used with the compression gauge (99640 Z5500) when the gauge cannot be installed directly due to interference with the air duct, etc.
*Plate 157944-9520
Tool name and number Description Shape Pin vice
99727 Z5005
For cleaning nozzle injection hole.
Nozzle cleaner 99726 Z5000
PERIODIC MAINTENANCE SCHEDULES
Abbreviations: A = Adjust, R = Replace, I = Inspect. Correct, adjust or replace if necessary. C = Cleaning, RB = Rebuilding, T = Tighten to specified torque,
= Initial maintenance NOTE
z
The maintenance or lubrication service shown below are to be performed at the indicated
inter-vals (km, miles or months, whichever occurs first).
z
Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be
con-tinued at the same intervals as before except the initial maintenance.
z
Under the following severe operating conditions, more frequent servicing will be required.
– Operation in heavy dust conditions
– Operation at extremely low or high ambient temperature
– Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight)
– Extended low-speed operation
– Frequent stop-and-go operation
z
Any replacement parts used for required maintenance service or repairs should be genuine
Nissan Diesel parts.
EMISSIONS CONTROL SYSTEMS MAINTENANCE
(FOR TAIWAN ONLY)
To maintain efficient emissions control systems operation, have the maintenance services shown in this section performed at the inter-vals indicated.
CAUTION
z
Do not modify, alter, disconnect or remove any part of the vehicle which could affect, directly or
MAINTENANCE INTERVALS
Remarks:
(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the sched-uled replacement.
(2) If the warning light comes on even before the scheduled replacement, clean or replace element. (3) Service every 6 months.
(4) Service every 12 months.
(5) With turbocharger engine equipped vehicles only.
Items Maintenance intervals Remarks Kilometers x 1,000 Daily 1 5 10 15 20 25 30 35 40 45 50 55 60 Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36 Months — 1 2 3 4 5 6 7 8 9 10 11 12 Valve clearance I
Cylinder head and manifold bolts T Crank damper : After 200,000 km (125,000 miles)
I: Every 100,000 km (62,500 miles)
Cylinder compression pressure I Oil leakage I I I I I I I I I I I I I Oil level and contamination I I I I I I I I I I I I I Engine oil and
filter
Full-flow type R: Every 10,000 km (6,000 miles) or 6 months (1) Full-flow and bypass
type R: Every 15,000 km (9,000 miles) or 6 months (1) Coolant leakage I I I I I Coolant level I I I I I I I I I I I I I Coolant (incl. anticorrosive) R R (3) Coolant (incl. antifreeze) R (4)
Radiator cap I
Fan clutch I
V-belt I I I I I I I I I I I I I
Thermostat I
Injection timing I
Nozzle (injection pressure and pattern) I Fuel leakage I I I I I I I I I I I I I Fuel filter element R Primary fuel filter DrainI DrainI DrainI DrainI DrainI DrainI DrainI DrainI DrainI DrainI DrainI DrainI Primary fuel filter element R R Fuel strainer DrainI DrainI DrainI DrainI DrainI DrainI/C Fuel level I
Air cleaner element I/C I/C I/C I/C I/C I/C (2) Air cleaner element (Dry type) R (2) Condition of exhaust I I I I I I I I I I I I I Turbocharger I (5) I T I I I R R I I
For Taiwan only
“*” refers to items related to the Emission Control System Maintenance.
Maintenance Item Maintenance intervals Remarks Kilometers x 1,000 Daily 1 5 10 15 20 25 30 35 40 45 50 55 60 Miles x 1,000 0.6 3 6 9 12 15 18 21 24 27 30 33 36 Months — 1 2 3 4 5 6 7 8 9 10 11 12 *Idle speed I
Acceleration and deceleration I *Air intake system (duct, hose and
clamp) I I I I I I
Intake* and exhaust manifold I *Air cleaner element I/C I/C I/C I/C I/C R Cylinder compression pressure I
*Valve clearance A
*Engine oil and oil filters
Oil CC or CD class Every 10,000 km (6,000 miles) or 6 months : R FE6 engine Oil CD class Every 10,000 km (6,000 miles) or 6 months : R
FE6T, FE6T-Z and FE6TA engines *Engine oil and
bypass oil filter (if equipped)
Oil CD class Every 15,000 km (9,000 miles) or 6 months : R Oil level and contamination I
Oil pressure I Coolant and fuel level I Coolant, oil and fuel leakage I Strainer (if equipped) I
*Fuel filter element R *Primary fuel filter element
(if equipped) I Drain I Drain I Drain I Drain I Drain R I Drain I Drain I Drain I Drain I Drain R *Governor setting (checking seals) Every 30,000 km (18,000 miles) or 6 months : I
*Nozzle (injector tip) Every 80,000 km (50,000 miles) : C *Nozzle holder (injector) Every 240,000 km (145,000 miles) : RB *Injection timing Every 60,000 km (36,000 miles) or 12 months : I
Fuel tubing I
Accelerator linkage I Drive belt (V-belt) I
Crank damper Every 24 months : I Cooling system (hose and clamp) I
Engine coolant R
Water filter (if equipped) R
Thermostat I
Fan clutch I
Fan and fan shroud I
Exhaust tubing and muffler I
Alternator I
Starter I
*PCV valve Every 80,000 km (50,000 miles) : R I FE6 engine *PCV system (hose and clamp) I I I I I I FE6 engine (piping) I FE6 engine *Turbocharger Every 240,000 km (145,000 miles) : C
FE6T, FE6T-Z and FE6TA engines I I R R R I
PERIODIC PARTS REPLACEMENT
Periodic replacement parts are rubber parts such as the fuel hose, etc. which deteriorate with the lapse of time and require maintenance. It is absolutely necessary to replace those parts periodically to maintain driving safety.
Remarks: (1) AOH brake vehicles.
Items PERIODIC PARTS REPLACEMENT INTERVAL Remarks
Number of years 1 2 3 4 5 6 7 8 9 10
ENGINE
Fuel hose (engine side) R R R R R
Fuel hose (fuel tank side) R R
MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
z
Ensure the engine is cool when checking and adjusting
the valve clearance.
1.
Remove the rocker cover.
2.
Remove the pointer cover from the upper section of the
fly-wheel housing. Secure the pointer to the flyfly-wheel housing
using bolts.
3.
Using a lever, rotate the ring gear on the outer edge of the
flywheel in the standard direction (or counterclockwise as
viewed from the flywheel side) until the mark “1·6” stamped
on the outer edge of the flywheel is aligned with the pointer.
If the mark goes past the pointer, back it off past the pointer
and then rotate in the standard direction until the mark is
aligned with the pointer. At this point, if the mark stamped
on the fuel injection pump timer is nearly aligned with the
mark on the pump housing, the No. 1 cylinder is at TDC
(Top Dead Center) on the compression stroke. If the mark
on the timer is not visible, the No. 6 cylinder is at TDC on
the compression stroke.
4.
Valve clearances (1), (2), (4), (5), (8) and (9) can be
checked and adjusted when No. 1 cylinder is at TDC on the
compression stroke; valve clearances (3), (6), (7), (10), (11)
and (12) can be checked and adjusted when the No. 6
cyl-inder is at TDC on the compression stroke.
5.
Place a feeler gauge between the valve stem and rocker
arm to ensure that the gauge fits snugly.
Unit: mm (in)
Item Maintenance standard Service
limit Remarks Valve clearance Intake 0.3 - 0.4 (0.012 - 0.016) — When engine is cold Exhaust 0.3 - 0.4 (0.012 - 0.016) —
Valve clearance adjustment
1.
If the valve clearance is not correct, loosen the lock nut for
the adjusting screw and adjust the screw until the specified
clearance is obtained.
2.
After adjusting the valve clearance, hold the adjusting
screw and tighten the lock nut.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
3.
Recheck the valve clearance.
4.
Rotate the flywheel one complete turn until the mark “1·6” is
aligned with the pointer. Next, check and adjust the
remain-ing valve clearances.
If the engine operates erratically or vibrates even though
the valve clearances are properly adjusted, problems may
be due to improperly adjusted valve timing which results
from incorrect assembling of the timing gear train, etc. If
erratic operation is noticed, check the valve timing as
described below.
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
pis-ton is at the TDC on the compression stroke.
NOTE
z
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) 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.
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.
CYLINDER HEAD AND MANIFOLD BOLTS
Check the cylinder head, air intake and exhaust manifold mounting bolts and nuts for proper torque. Also check the manifolds for dam-age or traces of leakdam-age at the cylinder head connections.
Cylinder head mounting bolt
: 177 - 196 N·m {18.0 - 20.0 kgf·m, 130 - 145 ft·lbf}
Air intake manifold bolt
: 16 - 20 N·m {1.6 - 2.0 kgf·m, 12 - 14 ft·lbf}
Exhaust manifold bolt
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting bolts for looseness. Replace faulty parts if necessary.
Crank damper mounting bolt
: 59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf}
CYLINDER COMPRESSION PRESSURE
1.
Warm up the engine.
2.
Disconnect all nozzle tubes and remove all nozzle holders.
Refer to the “DR” section for details.
Item Maintenance standard Service limit Remarks Valve timing FE6A FE6B FE6TA 173 kW {235 PS} Intake Open 15° B.T.D.C. — (1) Closed 40° A.B.D.C. — (2) Exhaust Open 53° B.B.D.C. — (3) Closed 9° A.T.D.C. — (4) FE6T FE6TA 157 kW {213 PS} Intake Open 15° B.T.D.C. — (1) Closed 30° A.B.D.C. — (2) Exhaust Open 53° B.B.D.C. — (3) Closed 9° A.T.D.C. — (4)
3.
Install a compression gauge (99640 Z5500) on the nozzle
hole using a nozzle holder gasket. Press the gauge bleeder
to set the pointer to “zero”.
Compression gauge mounting bolt
: 25 - 29 N·m {2.5 - 3.0 kgf·m, 18 - 22 ft·lbf}
NOTEz
Be careful to prevent foreign matter from getting into the
other nozzle holder holes.
z
Be sure to remove the old nozzle holder gasket.
4.
Move the engine stop lever completely in the “FUEL CUT”
direction and hold it at that position.
5.
Crank the engine until the gauge pointer stabilizes. Read
the cylinder compression pressure. Measure compression
pressure for the remaining cylinders as described above. If
the measured values or the differences in compression
pressure between cylinders are not within specifications,
pistons and/or piston rings may be worn or the valve
mech-anism may be faulty. Overhaul the engine and repair as
necessary.
Unit: kPa {kgf/cm2, psi}
NOTE
z
The above engine rpm range refers to that when the
bat-tery is fully charged and the starting motor is in good
condition.
LUBRICATION SYSTEM
OIL LEAKAGE
Check the cylinder head, timing gear case cover, oil pan, oil filters and other related parts for sign of leakage. If necessary, replace gaskets. After replacing the gasket, check that point to ensure there is no leakage.
OIL LEVEL AND CONTAMINATION
WARNING
WARNING
z
To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
Item Maintenance stan-dard Service limit Remarks
Compression pressure 2,942 {30, 427} 1,961 {20, 284} At 200 rpm with engine warm Difference
Check the engine oil level and for contamination of engine oil before driving the vehicle each day and when you stop for fuel. Check the oil level with the engine off. When checking the oil level after stopping the engine, wait at least 15 minutes to allow the oil to return to the oil pan.
To check the engine oil level
1.
Park the vehicle on a flat surface.
2.
Remove the oil dipstick located on the left hand side of the
engine. Wipe the dipstick clean with a rag and reinsert it.
Remove the dipstick and check the oil level. Maintain the oil
level between the H and L marks on the dipstick.
3.
If oil level is low, add engine oil of the proper viscosity for
the anticipated temperature range during the service
inter-val through the oil filler port located on the inter-valve cover on
top of the engine. Do not add oil above the H mark on the
dipstick.
CAUTION
z
Use care to keep dirt and debris from entering the
crank-case through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills
acci-dentally.
4.
Change the oil if it shows signs of contamination such as
discoloration and changes in oil texture. See the
instruc-tions in this manual under the caption CHANGING ENGINE
OIL.
5.
After adding oil, wait at least 6 minutes, then recheck the oil
level.
6.
After checking, securely insert the oil dipstick.
CAUTION
z
Do not drive the vehicle with the oil level below the L
mark on the oil dipstick. An insufficient quantity of
engine oil can cause engine seizure.
To check for engine oil contamination
Remove the oil dipstick and check the oil on it for signs of contami-nation such as discoloration and changes in texture. See the instructions in this manual under the caption ENGINE OIL AND OIL FILTER.
CHANGING ENGINE OIL AND OIL FILTER
Engine oil
WARNING
WARNING
z
To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
NOTE
z
Try to avoid direct skin contact with used oil. If skin
con-tact is made, wash thoroughly with soap or hand cleaner
as soon as possible.
The engine oil and oil filter change interval varies with the type of engine oil used and vehicle driving conditions. If the vehicle is driven for extended periods of time at high or low speeds, in dusty areas, with frequent idling or carrying heavy loads, engine oil will deteriorate faster and require more frequent changing.
As the temperature rises, the engine oil’s viscosity decreases, reducing its lubricating effect. To choose an oil with the proper vis-cosity for the anticipated ambient temperature range, refer to the viscosity chart in the “GE” section of this manual.
To change the engine oil
1.
Loosen the oil filler cap.
2.
Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
3.
Place a container under the drain plugs in the bottom of the
oil pan and oil filter. Remove the plugs and drain the oil into
the container.
4.
When all the oil has been drained from the oil pan and oil
fil-ter, replace the drain plugs in the drain hole and tighten the
drain plug.
Oil pan drain plug
:
59 - 69 N·m {6.0 - 7.0 kgf·m, 43 - 51 ft·lbf}
5.
Replace the oil filter. See the instructions under the caption
OIL FILTER.
6.
Add engine oil through the oil filler port to the specified
level.
7.
After refilling the engine oil, wait for at least 6 minutes, then
using the dipstick check the oil level. If the oil level is low,
add additional oil. Wait 6 minutes, then recheck the oil level.
Repeat this procedure until the engine oil reading on the
dipstick is between H and L.
8.
Install the engine undercover (if equipped).
Oil filter
WARNING
WARNING
z
Do not handle hot oil filter without hand protection.
Fail-ure to do so may result in burn injury.
NOTE
z
Use genuine filter or equivalent in quality and design.
z
Use of an inferior filter could hinder engine operation and
emission controls.
z
Always replace the oil filter at the same time engine oil is
To replace the oil filter
1.
Undo the four engine undercover catchers (on the left and
right sides of the engine), and remove the undercover
assembly (if equipped).
2.
Place a container under the oil filter and remove the drain
plug in the bottom of the oil filter. Drain oil from the filter.
3.
Remove the filter with a filter wrench and drain all oil into
the container.
4.
Apply a thin coat of clean engine oil to the packing of a new
oil filter.
CAUTION
z
Installation of the oil filter without coating the packing
with oil may damage the packing, resulting in loss of
engine oil and damage to the engine and/or lubrication
system.
5.
Install the new filter by hand. After the packing comes in
contact with the bracket sealing surface, tighten an
addi-tional 3/4 turn (Full flow only type) or 1-1/8 to 1-1/8 turn (Full
flow & bypass combination type).
CAUTION
z
When installing an oil filter, tighten it by hand. Do not use
a wrench or other tools which could result in
overtighten-ing and damage to the filter.
6.
Run the engine. Check the filter and seal for leaks.
7.
After checking, install the under cover.
COOLING SYSTEM
The engine cooling system was filled at the factory with a high-qual-ity, year-round, coolant solution with a 50/50 antifreeze/water mix-ture. The antifreeze solution contains rust and corrosion inhibitors. The solution provides protection against freezing to approximately -30°C (-22°F). The solution must remain in the system year round to provide protection against freezing, boiling, rust and corrosion. Do not use additional cooling system additives or inhibitors. They may interfere with the proper operation of the cooling system.
Check the engine, radiator, hoses and pipes daily. Repair any leaks. Replace swollen and worn hoses and tighten loosen clamps. Check the OVERHEATING AND COOLANT LEVEL warning light daily to be sure that it does not operate.
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z
Do not open the radiator filler cap while the engine
cool-ing system is hot. Wait until it cools down.
z
Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
COOLANT LEAKAGE
Check the cooling system for leakage, especially at tube and hose connections. Also check piping for fractures, cracks or damage. Replace parts if faulty.
If water leaks through the small hole in the water pump body, the water seal may be faulty.
WATER HOSE AND CLAMP
Check the water rubber hose and clamp of the cooling system for installation, cracks or damage. Replace faulty parts if necessary.
COOLANT LEVEL
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z
Do not open the radiator filler cap while the engine
cool-ing system is hot; wait until it cools.
z
Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
z
If the coolant is accidentally ingested, force the person to
vomit and secure medical help immediately. If the
cool-ant gets in the eye, flood the eye with lots of water and
get medical attention immediately.
Open the front lid.
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located behind the front lid.
The coolant level should be between the HIGH and LOW lines. If the coolant level is below the LOW line, add the proper coolant solution to the HIGH line.
Be sure to use an ethylene glycol antifreeze with water at the proper mixture ratio. To ensure the proper mixture ratio, carefully read the instructions on the container or obtain the instructions from the antifreeze manufacturer. Examples are shown below.
Antifreeze concentration greater than 60 to 70% will adversely affect freezing protection, corrosion inhibitor additives and heat transfer rates. Follow the instructions on the container or obtain the instructions from the antifreeze manufacturer for proper concentra-tion.
A complete drain, flush and refill with proper antifreeze and coolant is recommended once a year. This recommendation applies to all vehicles including those with low total annual mileage.
Outside temperature
down to Antifreeze Soft water
°C (°F)
-10 (14) 30% 70%
-20 (-4) 40% 60%
CAUTION
z
Antifreeze made with methoxy propanol or propylene
glycol is not recommended for use with Nissan Diesel
engines. These types of antifreeze can damage engine
internal seals and coolant hoses and create a potential
fire hazard due to lower flash points than ethylene glycol
type antifreeze.
z
Use only municipally supplied water (tap water) in the
cooling system. River, well or other water produces scale
in the cooling system, which may cause damage to the
engine or cooling system.
z
Do not add water without adding ethylene glycol
anti-freeze to the engine cooling system, except in an
emer-gency. If plain water is added in an emergency, restore
the proper mixture of antifreeze and water as soon as
possible.
z
If the coolant should get extremely low and the engine
very hot, let the engine cool before adding coolant; then,
with the engine running, add coolant slowly. Adding cold
coolant to a hot engine may crack the cylinder head or
crankcase. Never use water alone.
CHECKING AND CLEANING RADIATOR
To maintain cooling system efficiency and keep the engine from overheating, always keep the front surface of the radiator core clean. Remove insects, dirt and other debris by directing pressur-ized air at the rear surface of the radiator core.
CAUTION
z
Do not direct pressurized air to the front surface of the
radiator (that is, with the air hose pointed toward the
engine). Doing so will force insects, dirt and other debris
into the radiator core and possibly cause engine
over-heating.
CHANGING COOLANT
WARNING
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
z
Do not open the radiator filler cap while the engine
cool-ing system is hot. Wait until it cools down.
z
Be extremely careful when opening the radiator filler cap.
Place a thick cloth on the cap and slowly loosen to allow
a reduction in pressure in the cooling system.
Once a year the cooling system should be drained and thoroughly flushed.
Unless the cooling system is treated with a corrosion preventive, rust and scale will eventually clog up passages in the radiator and water jackets. This condition is aggravated in some localities by for-mation of insoluble salts from the water used.
CAUTION
z
Do not use chemical mixtures to stop radiator leaks
except in an emergency. Never use such solutions in
place of needed radiator repair.
To clean the cooling system
1.
Move the heater control temperature lever to the HOT
posi-tion.
2.
Open the radiator filler cap.
3.
Place containers under the radiator drain cock and the
cyl-inder block drain cock.
4.
Connect a drain hose to the radiator drain cock.
5.
Open the radiator drain cock and the cylinder block drain
cock.
6.
Drain all coolant solution from the system into the
contain-ers.
7.
Shut the drain cocks. Fill the cooling system with a proper
mixture of water and a good quality cooling system
deter-gent. (Refer to the additional instructions on the detergent
container.)
8.
Start the engine and run it at a high idling speed until the
indicator points to the middle region of the coolant
tempera-ture gauge. Maintaining the above coolant temperatempera-ture with
the thermostat open, run the engine and allow the detergent
to circulate throughout the cooling system for at least 15
minutes.
9.
Stop the engine. Open the drain cocks and completely drain
the detergent from the system.
10. Shut the drain cocks and fill the cooling system with plain
water. Start the engine and run it at a moderate speed in
the same manner as described in step 8.
11. Stop the engine. Open the drain cocks and drain the rinsing
water.
12. Repeat rinsing procedure 2 or 3 times until the discharged
rinsing water appears clean.
13. Drain the coolant from the coolant reservoir tank as
neces-sary.
14. Close the drain cocks and remove the drain hose from the
radiator drain cock.
To fill up the cooling system (with coolant)
Use the following refill procedure to remove air from the system and provide proper coolant level.
1.
Fill the radiator slowly with the proper coolant solution up to
the filler opening.
Add coolant solution up to the HIGH level of the coolant
res-ervoir tank.
The cooling system holds approximately 22 liters (4-7/8 Imp
gal) of coolant solution.
Then properly close the radiator filler cap and the reservoir
tank cap.
2.
Operate the engine at a slightly higher than normal idling
speed with the engine idling control button until the coolant
temperature indicator points the middle region of the gauge.
Run the engine an additional 10 minutes to allow the air to
escape from the engine cooling system.
3.
Stop the engine. After the engine has completely cooled
down, remove the radiator filler cap and check the coolant
level in the radiator. If low, add coolant to the radiator filler
opening.
Reinstall the radiator filler cap.
4.
Check the coolant level in the coolant reservoir tank. If the
level is between the LOW and HIGH lines, it is normal. If it is
below the LOW level, add coolant solution up to the HIGH
level.
5.
If the added coolant solution is more than 500 milliliter (17.6
Imp fl oz), check and correct for any sign of leakage, then
repeat steps 1 to 4.
6.
Check the drain cock for leaks.
COOLIG FAN AND FAN SHROUD
Check the cooling fan and fan shroud for proper installation, cracks or damage. Replace faulty parts.
WARNING
WARNING
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Never get your hand near the fan, when the engine is
operated.
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If fan clutch is equipped, the fan rotating speed may
seem to slow when the coolant is cool, but never try to
touch the fan and other rotating parts while the engine is
running.
RADIATOR CAP
Attach the radiator cap to a cap tester, and measure the operating pressure of the radiator cap valve. If the measured value exceeds the maintenance standard, replace.
Unit: kPa {kgf/cm2, psi}
FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1.
Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2.
Check the fan clutch for proper operation:
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Rotate the cooling fan by hand (adjacent parts should be
cool) to ensure it moves smoothly without binding.
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Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the “H” range. Stop
the engine to ensure that the cooling fan no longer rotates
by hand.
NOTE
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The fan clutch operates in a manner similar to a “direct
drive” when the temperature of parts near the bimetal
located at the front center of the clutch reaches
approxi-mately TºC (TºF). For this reason, it is best to measure
the temperature of those parts to assure proper
mainte-nance during inspection.
Unit: ºC (ºF)
Maintenance standard Service limit
39 - 59 {0.4 - 0.6, 6 - 9} — Item Run the engine continu-ously Operating tempera-ture (T) FE6A FE6B 119 kW {162 PS} FE6B 132 kW {180 PS} FD1300L ON - OFF type 3,000 rpm 75±5 (167±9) FE6B 132 kW {180 PS} FE6T 135 kW {183 PS} FE6T 151 kW {205 PS} FE6TA 157 kW {213 PS} FDL1700 Linear type 3,400 rpm 65±10 - 80±5 (149±18 - 176±9) FE6T 151 kW {205 PS} FE6T 162 kW {220 PS} FE6TA 157 kW {213 PS} FE6TA 173 kW {235 PS} FDL2000 50±10 - 80±5 (122±18 - 176±9)
V-BELT
Be sure the engine is off and the transmission is in “Neutral”. Engage the parking brake securely.
1.
Visually check the V-belt daily for cracks and damage. If the
belt is cracked or damaged excessively, replace it. Also
check that the belt does not come in contact with the bottom
of the pulley groove. Replace the belt if necessary.
2.
Check the drive belt for proper deflection by depressing the
midpoint with a force of 98 N {10 kgf, 22 lbf}.
Unit: mm (in)
<To adjust V-belt deflection>
Fan belt
1.
Loosen the alternator anchor bolt and the adjusting bolt.
2.
Adjust the alternator position so that the belt deflects as
specified and tighten the adjusting bolt.
: 34 - 44 N·m {3.5 - 4.5 kgf·m, 25 - 33 ft·lbf}
3.
Tighten the alternator anchor bolt.
: 59 - 74 N·m {6.0 - 7.5 kgf·m, 43 - 54 ft·lbf}
Cooler belt
1.
Loosen the lock nut.
2.
Adjust the belt tension to the specified value by the
adjust-ing bolt.
3.
Tighten the lock nut.
: 35 - 47 N·m {3.6 - 4.8 kgf·m, 26 - 35 ft·lbf}
Item Maintenance standard Service limit
Fan pulley - alternator pulley 10 - 15 (0.39 - 0.59) —
THERMOSTAT
1.
Drain coolant completely. Refer to the “CHANGING
COOL-ANT” for procedures.
2.
Remove the upper radiator hose, water outlet and
thermo-stat.
3.
Check the thermostat as described below, and replace if
faulty.
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Ensure that the valve contacts the seat at room
tempera-ture.
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Check the valve opening temperature and the “lift” of the
valve.
NOTE
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The valve opening temperature (82, 88, etc.) is marked on
the thermostat.
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Ensure that the difference between the valve opening and
closing temperatures is less than 5ºC (9ºF).
4.
Install the thermostat, the outlet and the gasket. Connect
the upper radiator hose. Three types of thermostats, which
open at different temperatures, are used.
5.
Add coolant to the radiator. Refer to “CHANGING
COOL-ANT” for procedures.
Item Maintenancestandard Service limit
Ther-mostat Valve opening temperature ºC (ºF) 76.5 (170) (166 - 173)74.5 - 78.5 (161 - 179)71.5 - 81.5 82 (180) (176 - 183)80 - 84 (171 - 189)77 - 87 88 (190) (187 - 194)86 - 90 (185 - 199)85 - 93
Valve lift/ tem-perature
mm/ºC (in/ºF)
76.5 (170) More than 10/90(0.39/194) Less than 9/90(0.35/194) 82 (180) More than 10/95(0.39/203) Less than 9/95(0.35/203) 88 (190) More than 10/100(0.39/212) Less than 9/100(0.35/212)
