maintenance nissan cwb

8/18/2019 maintenance nissan cwb

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MAINTENANCE

CONTENTSSERVICE DATA .......................................... MA-1- 1

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

TIGHTENING TORQUE ............................. MA-1- 2

TOOLS ........................................................... MA-2- 1

MAINTENANCE PROCEDURE ............ MA-3- 1BASIC MECHANICAL SYSTEM ................. MA-3- 1

FUEL SYSTEM ........................................... MA-3- 5

INTAKE AND EXHAUST SYSTEM ............. MA-3- 8

SUPPLEMENTAL OUTLINE

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


2/13

SERVICE DATA

Unit: mm (in)

Item Maintenance standard Service limit Remarks

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

Valve clearance

Intake 0.30 - 0.40

(0.012 - 0.016) —

When engine is cold

Exhaust 0.30 - 0.40

(0.012 - 0.016) —

Valve timing

IntakeOpen 20° B.T.D.C. —

Closed 42° A.B.D.C. —

ExhaustOpen 60° B.B.D.C. —

Closed 10° A.T.D.C. —

Cylinder compression pressure

kPa {kgf/cm2, psi} 3,040 {31, 441} 1,961 {20, 284}

At 180 - 220 rpm

(With engine warm)

Compression pressure difference

kPa {kgf/cm2, psi} Less than 392 {4, 57} —

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

Water tank cap operating pressure

kPa {kgf/cm2

, psi}

49 - 69

{0.5 - 0.7, 7 - 10}

— Pressure side

Deflection of V-belt

Fan pulley

- Tension pulley 8 - 12 (0.31 - 0.47) —

With a force of about

98 N {10 kgf, 22 lbf}

applied to the mid partIdler (cooler compres-

sor) pulley

- Alternator pulley

15 - 18 (0.59 - 0.71) —

Thermostat

Valve opening tem-

perature °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)

F u e l s y

s t e m

Fuel injection timing B.T.D.C. 5° —

Idle speed rpm 445 - 500 —

SERVI CE DATA

MA-1-1

SERVICE DATA


3/13


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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)

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 includ-

ing 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

TOOLS

MA-2-1

TOOLS


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Tool name and number Description Shape

Plate

157944-9520

For fixing nozzle holder

NOTE

+ Tool number designated by ZEXEL CORPO-

RATION

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

TOOLS

MA-2-2


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WMA003A

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 theflywheel.

NOTE+ When turning the flywheel to align the stamp, turn it

counterclockwise when viewed from behind the engine.

EP4-23

2. When the stamps on the injection pump housing and timer areclose to each other, it indicates T.D.C. on the compressionstroke. When they are located opposite to each other, itindicates T.D.C. on the exhaust stroke.

WMA166A

3. Turn the flywheel an additional 20°counterclockwise from theT.D.C. stamp mark ‘‘1|6’’ so that the stamp mark ‘‘A’’ on theflywheel 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.

Valve clearance adjusting sequence

Stamp mark on flywheel

Cylinder No. 1 2 3 4 5 6

Valve arrangement IN E X IN EX IN EX IN E X I N EX IN EX

Valve No. 1 2 3 4 5 6 7 8 9 10 11 12

A No. 1 piston at T.D.C. on compression

stroke (stamp mark ‘‘1|6’’) +20° — + + + +

C No. 2 piston at T.D.C. on compression

stroke (stamp mark ‘‘2|5’’) +20°Flywheel turned 240°counter-clockwise from stamp mark ‘‘A’’

. . . .

B No. 3 piston at T.D.C. on compression

stroke (stamp mark ‘‘4|3’’) +20°

Flywheel turned 240°counter-

clockwise from stamp mark ‘‘C’’ m m m m

Stamp mark on flywheel

Cylinder No. 1 2 3 4 5 6

Valve arrangement IN E X IN EX IN EX IN E X I N EX IN EX

Valve No. 1 2 3 4 5 6 7 8 9 10 11 12

A No. 6 piston at T.D.C. on compression

stroke (stamp mark ‘‘1|6’’) +20° — j j j j

C No. 5 piston at T.D.C. on compression

stroke (stamp mark ‘‘2|5’’) +20°Flywheel turned 240°counter-clockwise from stamp mark ‘‘A’’

> > > >

B No. 4 piston at T.D.C. on compression

stroke (stamp mark ‘‘4|3’’) +20°Flywheel turned 240°counter-clockwise from stamp mark ‘‘C’’

n n n n

MAINTENANCE PROCEDURE

MA-3-1



7/13

WMA167A

4. Refer to the ‘‘Valve clearance adjusting sequence’’ table for thestamp mark ‘‘A’’. The adjustable valve clearance locations areindicated by + or j. Push the actuator plunger in until itreaches B.D.C.

EKO-003

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

EKO-004

6. If the valve clearance is not within maintenance standards,loosen the adjusting screw lock nut and turn the adjustingscrew in or out until the valve clearance is correct.

Unit: mm (in)

Item Maintenance standard Service limit

Valve clearance

(While cold)

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 screwand tighten the lock nut.

: 69 - 78 N·m {7.0 - 8.0 kgfzm, 51 - 58 ftzlbf}

WMA168A

8. Turn the flywheel 240° in the direction of standard enginerotation until the T.D.C. stamp mark ‘‘2|5’’ position is reached.From that position, turn the flywheel an additional 20°until thestamp 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 thestamp mark ‘‘C’’. The adjustable valve clearance locations areindicated by . or >. Push the actuator plunger in until itreaches B.D.C. If the valve clearance is not within maintenancestandards, adjust it in a manner similar to steps 5 through 7above.


MA-3-2


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WMA169A

10. Turn the flywheel 240° in the direction of standard enginerotation so that the T.D.C. stamp mark ‘‘4|3’’ is aligned with thepointer. 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 thestamp mark ‘‘B’’. The adjustable valve clearance locations areindicated by m or n. Push the actuator plunger in until itreaches B.D.C. If the valve clearance is not within maintenancestandards, adjust it in a manner similar to steps 5 through 7above.

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

Procedure for checking valve timing1. 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 graduallyrotate it back in the normal direction until it is set in theproper position.

JMA578A

3. Attach the timing plate (99646 Z5001) and adapter (9980896500) to the end of the crankshaft. Also attach a needlepointer utilizing the front cover mounting bolt, and align theneedle to ‘‘0’’.

4. Set a dial gauge so that the contact arm is in contact with theupper valve spring seats of the intake valve and exhaust valve.


MA-3-3


9/13

WMA149A

WMA004A

5. If the needle of the dial gauge begins to move, it means that thevalve is beginning to open; the movement of the needle willstop as the valve closes. Read the needle position on the timingplate on each occasion.

Item Valve timing Remarks

Intake valveOpen 20° B.T.D.C. j1

Closed 42° A.B.D.C. j2

Exhaust valve Open 60° B.B.D.C. j3

Closed 10° A.T.D.C. j4

WMA170A

CRANK DAMPERCheck the crank damper for cracks or flaking, and the mountingbolts 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.


MA-3-4


10/13

WMA165A

FUEL SYSTEM

INJECTION TIMING1. 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 untilalignment is made.


Fuel injection timing

(B.T.D.C.) 5° —

EP4-23

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

EMA1002E

Adjustment of fuel injection timing1. Make sure the pointer points to the specified injection timing

graduation on the outer periphery of the flywheel and loosenthe coupling bolts (2 places).

2. Back the timer off a little in the reverse direction of the normaltimer direction. Turn the timer in the normal direction to adjustthe 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


11/13

IDLE SPEED

NOTE+ When checking engine idle speed ensure that the engine

idle control knob inside the cab is set to the low-speedposition.

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


Idle speed 445 - 500 —

Idle speed adjustment1. 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 read-ing. 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 nozzle1. Remove the nozzle holder assembly from the engine. Refer to

the ‘‘ENGINE DISASSEMBLY AND REASSEMBLY’’ sectionfor details.

2. Clamp the nozzle holder in a vise with a holder plate (157944-9520).

WEF292A

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


MA-3-6


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WMA017A

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 cornerof a hard piece of wood. Do not use waste or any other materialto push carbon into the openings.

WMA018A

6. Removing carbon in openingsUse the pin vice (99727 Z5005) and wire to clean the openings.

Unit: mm (in)

Nozzle identifica-

tion mark

Number of injec-

tion 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 casewithdrawal proves difficult. The wire should protrude no morethan 2.0 to 2.5 mm (0.079 to 0.098 in).

+ Carefully push the carbon into the nozzle. Too much force willbend the wire. Proceed slowly.

WMA019A

+ Remove carbon at the inside end of the openings with thenozzle cleaner (99726 Z5000).Exercise care to avoid damaging the surface which the nozzleneedle contacts. The use of compressed air may clog theopenings with foreign particles.

7. Tighten the retaining nut.

: 59 - 78 N·m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}


MA-3-7


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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 side1. 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 abrush 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 tothe ENGINE ‘‘IE’’ section for cleaning instructions.

4. When the impeller is wet with cleaning solvent, dry withcompressed air.

CAUTION+ Hold the impeller by hand to prevent it from turning while

drying.

5. Install the compressor housing in its original position.

: Model TE459.0 - 11.3 N·m {0.92 - 1.15 kgfzm, 6.7 - 8.3 ftzlbf}

To clean the turbine side1. Remove the turbine housing and check the condition of the

turbine. If the turbine is not excessively dirty, clean the turbineand 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 TE4517.0 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 airleakage.


maintenance nissan cwb

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