Diesel engine YD25DDTi cars Nissan Serena 2 (C24)
On-car service
Air cleaner filter element Replacement frequency: every 60,000 km. Compression 1. Warm up the engine to operating temperature and turn it off. 2. Use CONSULT to check...
Air cleaner filter element Replacement frequency: every 60,000 km. Compression 1. Warm up the engine to operating temperature and turn it off. 2. Use CONSULT to check...
Drive belts — check
The check is performed on a cold engine or 30 minutes or more after the engine has been stopped. Visually inspect the outer and inner sides of the belts for damage along...
The check is performed on a cold engine or 30 minutes or more after the engine has been stopped. Visually inspect the outer and inner sides of the belts for damage along...
Drive belts — adjustment
Make the adjustment as follows. Attention: After replacing the belt with a new one, slightly increase the tension of the new belt compared to the old one to allow for...
Make the adjustment as follows. Attention: After replacing the belt with a new one, slightly increase the tension of the new belt compared to the old one to allow for...
Drive belts — removal and installation
Removal the belts 1. Remove the right engine guard from the bottom side. 2. Loosen all belts (see the "Adjustment" section above) and remove the air conditioning...
Removal the belts 1. Remove the right engine guard from the bottom side. 2. Loosen all belts (see the "Adjustment" section above) and remove the air conditioning...
Air Cleaner and Duct — Removal and Installation
Preparatory work Remove the air mass sensor wiring connector. Remove the left wing guard (if the resonator located under the wing is removed). Removal and installation...
Preparatory work Remove the air mass sensor wiring connector. Remove the left wing guard (if the resonator located under the wing is removed). Removal and installation...
Intercooler — Removal and Installation
Removal Disconnect from the bottom bracket. Caution: After removing the intercooler, cover the open holes on the turbocharger side and on the intake manifold side with a...
Removal Disconnect from the bottom bracket. Caution: After removing the intercooler, cover the open holes on the turbocharger side and on the intake manifold side with a...
Intake manifold — removal and installation
Preparatory work Drain the coolant. Remove the air cleaner housing and air duct. Remove the intercooler. Remove the engine cover (see point 1). Remove the intercooler...
Preparatory work Drain the coolant. Remove the air cleaner housing and air duct. Remove the intercooler. Remove the engine cover (see point 1). Remove the intercooler...
Intake manifold — check
Checking the intake manifold for warpage Connect the hand vacuum pump to the drive, close the air swirl control valve, pumping out the air. Using a ruler and feeler...
Checking the intake manifold for warpage Connect the hand vacuum pump to the drive, close the air swirl control valve, pumping out the air. Using a ruler and feeler...
Catalyst — removal and installation
Preparatory work Remove the engine protection from the bottom. Drain the coolant. Remove the radiator fans as an assembly. Remove the water inlet pipe. Removal and...
Preparatory work Remove the engine protection from the bottom. Drain the coolant. Remove the radiator fans as an assembly. Remove the water inlet pipe. Removal and...
Exhaust manifold and turbocharger — removal and installation
Preparatory work Removal and installation the exhaust manifold assembly Drain the coolant. Remove the air cleaner and air intake tube. Remove the intercooler. Remove the...
Preparatory work Removal and installation the exhaust manifold assembly Drain the coolant. Remove the air cleaner and air intake tube. Remove the intercooler. Remove the...
Exhaust manifold and turbocharger — check
Warping of the exhaust manifold Using a ruler and feeler gauge, check the mounting surface for warpage. Warpage Limit: 0.3mm
Warping of the exhaust manifold Using a ruler and feeler gauge, check the mounting surface for warpage. Warpage Limit: 0.3mm
Exhaust manifold and turbocharger — disassembly and assembly
Removal and installation a turbocharger Removal Lubricate the mounting bolts with a rust remover and after soaking, loosen and unscrew them. Warning: Do not disassemble...
Removal and installation a turbocharger Removal Lubricate the mounting bolts with a rust remover and after soaking, loosen and unscrew them. Warning: Do not disassemble...
Checking turbocharger parts
The test areas and names of the places are shown in the figure on the next page. Attention: In case of failure of the compressor wheel, turbine wheel, rotor shaft, to...
The test areas and names of the places are shown in the figure on the next page. Attention: In case of failure of the compressor wheel, turbine wheel, rotor shaft, to...
Valve cover — removal and installation
Preparatory work Remove the intercooler. Remove the engine cover. Removal and installation the valve cover Removal Loosen the mounting bolts in the reverse order shown...
Preparatory work Remove the intercooler. Remove the engine cover. Removal and installation the valve cover Removal Loosen the mounting bolts in the reverse order shown...
Vacuum Pump — Removal
1. Remove the following parts. Air cleaner housing and duct, intercooler, engine cover, valve cover, move the boat ventilation hose to the side, remove the exhaust...
1. Remove the following parts. Air cleaner housing and duct, intercooler, engine cover, valve cover, move the boat ventilation hose to the side, remove the exhaust...
Vacuum pump — installation
1. Assemble the vacuum pump with the rear cylinder head cover (see section below " Assembly "). 2. Install the vacuum pump with the rear cylinder head cover assembly....
1. Assemble the vacuum pump with the rear cylinder head cover (see section below " Assembly "). 2. Install the vacuum pump with the rear cylinder head cover assembly....
Vacuum pump — check
Remove the vacuum hose, install the tee and connect the vacuum gauge (special tool). Install the tee in a location where you can read the readings directly (the figure...
Remove the vacuum hose, install the tee and connect the vacuum gauge (special tool). Install the tee in a location where you can read the readings directly (the figure...
Vacuum pump — disassembly and assembly
Disassembly Assembly Install all parts on the rear cylinder head cover in the following order. 1. Install the vacuum pump. 2. Install the chain tensioner. Tension...
Disassembly Assembly Install all parts on the rear cylinder head cover in the following order. 1. Install the vacuum pump. 2. Install the chain tensioner. Tension...
Oil pan, coarse oil filter — removal and installation
Preparatory work (*: removing components from above) Drain the engine oil. Remove the engine protection from the bottom. Remove the right mudguard. Remove the front...
Preparatory work (*: removing components from above) Drain the engine oil. Remove the engine protection from the bottom. Remove the right mudguard. Remove the front...
Starter — removal and installation
Removal 1. Remove the air cleaner and air duct. 2. Disconnect the automatic transmission control cable from the top of the starter, move the active engine mount system...
Removal 1. Remove the air cleaner and air duct. 2. Disconnect the automatic transmission control cable from the top of the starter, move the active engine mount system...
High pressure fuel pipes and injectors assemblies — removal and installation
Preparatory work Remove the intercooler, engine cover, engine underbody protection, front exhaust pipe. Disconnect all electrical wiring, tubes and hoses and set aside....
Preparatory work Remove the intercooler, engine cover, engine underbody protection, front exhaust pipe. Disconnect all electrical wiring, tubes and hoses and set aside....
High Pressure Fuel Lines and Injectors Assemblies — Checking
Checking the drain tube for leaks Check before installing the valve cover. Connect the vacuum pump to the drain pipe. Create a vacuum and make sure it is maintained at a...
Checking the drain tube for leaks Check before installing the valve cover. Connect the vacuum pump to the drain pipe. Create a vacuum and make sure it is maintained at a...
Electronically controlled high pressure fuel pump (HPFP) — device
Attention: The electronically controlled fuel injection pump cannot be disassembled. Note: From now on, the electronically controlled high-pressure fuel pump will be...
Attention: The electronically controlled fuel injection pump cannot be disassembled. Note: From now on, the electronically controlled high-pressure fuel pump will be...
Fuel injection pump — removal
1. Remove the following parts: Engine underbody protection and left mudguard Front exhaust pipe Disconnect the right drive shaft from the transfer case side and move it...
1. Remove the following parts: Engine underbody protection and left mudguard Front exhaust pipe Disconnect the right drive shaft from the transfer case side and move it...
Fuel injection pump — installation
There is no need to adjust the injection timing by changing the installation angle, as in old injection pumps, so it is enough to install the injection pump on the pins...
There is no need to adjust the injection timing by changing the installation angle, as in old injection pumps, so it is enough to install the injection pump on the pins...
Secondary Timing Chain — Removal
If the secondary timing chain is removed to remove the injection pump, see the preparatory work in the section above " Electronically controlled injection pump ". If the...
If the secondary timing chain is removed to remove the injection pump, see the preparatory work in the section above " Electronically controlled injection pump ". If the...
Secondary Timing Chain — Installation
The figure shows the secondary timing chain, its associated parts and their names. 1. Install the secondary timing chain tensioner. Install by aligning the sprocket...
The figure shows the secondary timing chain, its associated parts and their names. 1. Install the secondary timing chain tensioner. Install by aligning the sprocket...
Primary Timing Chain — Removal
1. Remove the engine with the gearbox assembly (see section " Removal the engine "). 2. Separate the engine from the gearbox and install the engine on the stand (special...
1. Remove the engine with the gearbox assembly (see section " Removal the engine "). 2. Separate the engine from the gearbox and install the engine on the stand (special...
Primary Timing Chain — Installation
1. Install the rear chain cover. Install as follows. (1) Apply a continuous bead of Three Bond 1207C sealant (KR510 00150) to the areas shown in the figure. In areas...
1. Install the rear chain cover. Install as follows. (1) Apply a continuous bead of Three Bond 1207C sealant (KR510 00150) to the areas shown in the figure. In areas...
Camshafts — device
Note: The camshafts on this engine are different from conventional DOHC. The following abbreviations are used in this section. Right camshaft: The camshaft located on...
Note: The camshafts on this engine are different from conventional DOHC. The following abbreviations are used in this section. Right camshaft: The camshaft located on...
Camshafts — Removal
1. Remove the following parts and assemblies. Engine protection from the bottom Front exhaust pipe Air duct and air cleaner housing Intercooler Engine cover Valve cover...
1. Remove the following parts and assemblies. Engine protection from the bottom Front exhaust pipe Air duct and air cleaner housing Intercooler Engine cover Valve cover...
Camshafts — Checking
Visual inspection of the camshaft Check for burrs and wear. If any defects are found, replace the camshaft. Camshaft runout Place the camshaft on the prisms under main...
Visual inspection of the camshaft Check for burrs and wear. If any defects are found, replace the camshaft. Camshaft runout Place the camshaft on the prisms under main...
Camshafts — installation
1. Install the valve lifters and adjusting washers. Install each part in its original place. 2. Install the camshafts. The difference between camshafts is determined by...
1. Install the valve lifters and adjusting washers. Install each part in its original place. 2. Install the camshafts. The difference between camshafts is determined by...
Checking valve clearances
The check is performed in case of replacement of parts related to camshafts or valves, as well as in case of abnormal engine operation caused by changes in valve...
The check is performed in case of replacement of parts related to camshafts or valves, as well as in case of abnormal engine operation caused by changes in valve...
Adjusting valve clearances
Remove the adjusting washer from the valve whose clearance is not within the norm. 1. Remove the drain pipe. 2. Carefully wipe off the oil from the top of the cylinder...
Remove the adjusting washer from the valve whose clearance is not within the norm. 1. Remove the drain pipe. 2. Carefully wipe off the oil from the top of the cylinder...
Cylinder head — removal and installation
Preparatory work (for details, see the section "Preparatory work" in the relevant sections) Drain the coolant, remove the intercooler, valve cover, vacuum pump, cylinder...
Preparatory work (for details, see the section "Preparatory work" in the relevant sections) Drain the coolant, remove the intercooler, valve cover, vacuum pump, cylinder...
Cylinder head — disassembly
1. Remove the adjusting washers and valve lifters. Mark the installation location and store the parts so that they do not get mixed up during subsequent installation. 2....
1. Remove the adjusting washers and valve lifters. Mark the installation location and store the parts so that they do not get mixed up during subsequent installation. 2....
Cylinder head — check
Cylinder head warping Check the cylinder head underside for warpage at several points in six directions. Warpage Limit: 0.04 mm Valve sizes Use a micrometer to check the...
Cylinder head warping Check the cylinder head underside for warpage at several points in six directions. Warpage Limit: 0.04 mm Valve sizes Use a micrometer to check the...
Cylinder head — assembly
1. If the valve guides were removed, install them (see section " Valve guide clearance "), 2. If the valve seats were removed, install them. 3. Install the valve seals....
1. If the valve guides were removed, install them (see section " Valve guide clearance "), 2. If the valve seats were removed, install them. 3. Install the valve seals....
Removal the engine
Attention: Follow safety rules and do not do unnecessary things. Do not start work until the exhaust system and cooling system have completely cooled down. When...
Attention: Follow safety rules and do not do unnecessary things. Do not start work until the exhaust system and cooling system have completely cooled down. When...
Engine installation
Installation is carried out in the reverse order of removal, taking into account the following. Be careful not to get oil on the insulators or damage the insulators...
Installation is carried out in the reverse order of removal, taking into account the following. Be careful not to get oil on the insulators or damage the insulators...
Checking the engine
Before starting the engine, check the level of coolant, lubricating oils, power steering oil and top up if necessary. Start the engine and check for any extraneous...
Before starting the engine, check the level of coolant, lubricating oils, power steering oil and top up if necessary. Start the engine and check for any extraneous...
Cylinder Block — Component Selection Order
Since the markings on the part reflect its original dimensions, do not rely on them if the part is reused. On recycled and processed parts, it is necessary to measure...
Since the markings on the part reflect its original dimensions, do not rely on them if the part is reused. On recycled and processed parts, it is necessary to measure...
Cylinder Block — Disassembly
1. Remove the engine with the gearbox and suspension beam assembly and separate the engine from the gearbox and suspension beam (see section " Removal and installation...
1. Remove the engine with the gearbox and suspension beam assembly and separate the engine from the gearbox and suspension beam (see section " Removal and installation...
Crankshaft axial play — check
Using a dial indicator, measure the clearance between the thrust bearing and the crank arm by moving the crankshaft back and forth. Standard clearance: 0.10-0.25 mm...
Using a dial indicator, measure the clearance between the thrust bearing and the crank arm by moving the crankshaft back and forth. Standard clearance: 0.10-0.25 mm...
Connecting rod side clearance — check
Using a feeler gauge, measure the clearance between the connecting rod and the crank arm. Standard: 0.200-0.350 mm Limit: 0.4 mm If the measured clearance is greater...
Using a feeler gauge, measure the clearance between the connecting rod and the crank arm. Standard: 0.200-0.350 mm Limit: 0.4 mm If the measured clearance is greater...
Piston to Piston Pin Clearance — Check
Inner diameter of the piston hole Using a bore gauge, measure the inside diameter of the piston pin hole. Standard diameter: 27.997-28.005 mm Piston pin outer diameter...
Inner diameter of the piston hole Using a bore gauge, measure the inside diameter of the piston pin hole. Standard diameter: 27.997-28.005 mm Piston pin outer diameter...
Lateral clearance in piston rings
Using a feeler gauge, measure the side clearance between the piston ring and the ring groove. Standard clearance: Upper compression ring: 0.05-0.09 mm Second compression...
Using a feeler gauge, measure the side clearance between the piston ring and the ring groove. Standard clearance: Upper compression ring: 0.05-0.09 mm Second compression...
Clearance in the piston ring lock
Make sure the cylinder is of standard dimensions (see section " Clearance between piston and cylinder "). Install the piston ring into the cylinder, use the piston to...
Make sure the cylinder is of standard dimensions (see section " Clearance between piston and cylinder "). Install the piston ring into the cylinder, use the piston to...
Bending and twisting of the connecting rod
Perform a check using a connecting rod end alignment tester. Limit bending: 0.12 mm (per 100 mm length) Torsion Limit: 0.12mm (per 100 mm length)
Perform a check using a connecting rod end alignment tester. Limit bending: 0.12 mm (per 100 mm length) Torsion Limit: 0.12mm (per 100 mm length)
Big End Bore Diameter
Install the connecting rod cap without the bearing, tighten it to the standard torque and measure the inside diameter of the hole in the big end of the connecting rod....
Install the connecting rod cap without the bearing, tighten it to the standard torque and measure the inside diameter of the hole in the big end of the connecting rod....
Oil clearance in the connecting rod small end bushing
Inner diameter of small connecting rod head Using a bore gauge, measure the inside diameter of the small end of the connecting rod. Standard diameter: 28.026-28.038 mm...
Inner diameter of small connecting rod head Using a bore gauge, measure the inside diameter of the small end of the connecting rod. Standard diameter: 28.026-28.038 mm...
Warping of the upper surface of the cylinder block
Using a scraper, remove any remaining old gasket, oil, carbon deposits, etc. from the contact surface of the cylinder block. Caution: Do not allow sealant residue to...
Using a scraper, remove any remaining old gasket, oil, carbon deposits, etc. from the contact surface of the cylinder block. Caution: Do not allow sealant residue to...
Inner diameter of main bearing housing
Install the main bearing caps without bearings and tighten the mounting bolts to the specified torque. Using a bore gauge, measure the inside diameter of the main...
Install the main bearing caps without bearings and tighten the mounting bolts to the specified torque. Using a bore gauge, measure the inside diameter of the main...
Clearance between piston and cylinder
Inner diameter of the cylinder Using a bore gauge, check each cylinder for wear, out-of-roundness and taper at 6 different positions along the X and Y axes at locations...
Inner diameter of the cylinder Using a bore gauge, check each cylinder for wear, out-of-roundness and taper at 6 different positions along the X and Y axes at locations...
The order of selection of pistons
When a new cylinder block is used Check the cylinder class on the rear left side of the cylinder block (1, 2 or 3) and select pistons of the same class. Note: Pistons...
When a new cylinder block is used Check the cylinder class on the rear left side of the cylinder block (1, 2 or 3) and select pistons of the same class. Note: Pistons...
Crankshaft journal diameters
Crankshaft journal diameter Using a micrometer, measure the diameter of the crankshaft main journal. Standard diameter: 62.951-62.975 mm Crankshaft journal diameter...
Crankshaft journal diameter Using a micrometer, measure the diameter of the crankshaft main journal. Standard diameter: 62.951-62.975 mm Crankshaft journal diameter...
Ovality and taper of crankshaft journals
Using a micrometer, measure the diameters of all main and rod journals at 4 different points shown in the illustration. Ovality is determined by the difference in size...
Using a micrometer, measure the diameters of all main and rod journals at 4 different points shown in the illustration. Ovality is determined by the difference in size...
Crankshaft runout
Place the prisms on a flat surface and install the crankshaft on them with the outer journals. Place the indicator vertically on main journal No.3. While turning the...
Place the prisms on a flat surface and install the crankshaft on them with the outer journals. Place the indicator vertically on main journal No.3. While turning the...
Connecting rod bearing oil clearance
Method of measurement Install the bearing into the connecting rod and cap and tighten the connecting rod bolts to the specified torque. Use a bore gauge to measure the...
Method of measurement Install the bearing into the connecting rod and cap and tighten the connecting rod bolts to the specified torque. Use a bore gauge to measure the...
The procedure for selecting connecting rod bearings
When a new crankshaft and connecting rod are used (1) Find the crankpin diameter class on the front side of the crankshaft (0, 1 or 2) and select connecting rod bearings...
When a new crankshaft and connecting rod are used (1) Find the crankpin diameter class on the front side of the crankshaft (0, 1 or 2) and select connecting rod bearings...
Main bearing oil clearance
Method of measurement Install the main bearings into the cylinder block and caps. Measure the inside diameters of the main bearings by tightening the bearing cap bolts...
Method of measurement Install the main bearings into the cylinder block and caps. Measure the inside diameters of the main bearings by tightening the bearing cap bolts...
The procedure for selecting main bearings
When a new cylinder block and crankshaft are used (1) The values in the top row of the main bearing selection table correspond to the bearing housing class (0, 1 or 2),...
When a new cylinder block and crankshaft are used (1) The values in the top row of the main bearing selection table correspond to the bearing housing class (0, 1 or 2),...
The protrusion of the main bearing above the plane of the bed joint
Install the main bearings and tighten the cap bolts to the required torque. Remove the caps. The edge of the bearing should protrude above the parting plane. Standard:...
Install the main bearings and tighten the cap bolts to the required torque. Remove the caps. The edge of the bearing should protrude above the parting plane. Standard:...
Main bearing cap bolt diameter difference
(1) Measure the diameters (d ₁) and (d ₂) at the locations shown in the figure. If a more worn area is found, measure the diameter d ₂ in this area. (2) Calculate the...
(1) Measure the diameters (d ₁) and (d ₂) at the locations shown in the figure. If a more worn area is found, measure the diameter d ₂ in this area. (2) Calculate the...
Connecting rod bolt outer diameter
Tighten the nut by hand and make sure that the nut freely reaches the end of the connecting rod bolt threads. If the nut does not tighten, measure the diameter of the...
Tighten the nut by hand and make sure that the nut freely reaches the end of the connecting rod bolt threads. If the nut does not tighten, measure the diameter of the...
Lubricating jet
Make sure there are no deformations or defects on the sprayer. Blow air from the sprayer side and make sure the sprayer is not clogged. If any defects are found, clean...
Make sure there are no deformations or defects on the sprayer. Blow air from the sprayer side and make sure the sprayer is not clogged. If any defects are found, clean...
Cylinder Block — Assembly
1. Blow out the coolant passages, oil passages, crankcase and cylinders with compressed air and remove foreign particles from them. 2. Install the safety valve of the...
1. Blow out the coolant passages, oil passages, crankcase and cylinders with compressed air and remove foreign particles from them. 2. Install the safety valve of the...
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- General information
- Control devices
- User manual
- Power unit
- Petrol engine SR20DE
- Diesel engine YD25DDTi
- Cooling and lubrication system
- Engine management SR20DE
- Engine management YD25DDTi
- Power and exhaust system
- Transmission
- Automatic gearbox
- Drive and cardan shafts
- Transfer case
- Chassis
- Front suspension
- Rear suspension
- Brake system
- Steering
- Body
- Safety system
- Interior (internal elements)
- Exterior (external elements)
- Doors, locks and windows
- Heating and air conditioning
- Electrical equipment
- Equipment and devices
- Lighting system
- Windshield wipers and washers
- Electrical circuits
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