1995 truck/pathfinder engine knock after cold start
Contents
1. Remove the original gasket sealer from the bolt threads Oil Water TC960676 Install new oil filter mounting stud Carefully remove the dipstick guide tube Apply Loctite 540 or equivalent to the dipstick tube and press it into the new block Install in the same position on the new block Check the new block for alternate dipstick tube installation points which may not be plugged Install brass plugs if necessary P N 11022 U6700 Install connector to knock sensor on top of block before thermostat housing and intake manifold There is limited access to the knock sensor after these parts are installed Install intake manifold Install all parts removed in step 1 page 5 Tighten all bolts in numerical order A B C Tightening procedure Tighten all bolts and nuts to 2 2 3 6 ft lb 3 5 Nem 0 3 0 5 kg m Tighten all bolts to 12 14 ft lb 16 20 Nem 1 6 2 0 kg m Tighten all nuts to 17 20 ft lb 24 27 Nem 2 4 2 8 kg m Tighten all bolts to 12 14 ft lb 16 20 Nem 1 6 2 0 kg m Tighten all nuts to 17 20 ft lb 24 27 Nem 2 4 2 8 kg m Tighten bolts in numerical order TC960486 9 13 9 Install the fuel tube assembly e Tape the fuel tube spacers to the fuel tube before installation e Install new fuel injector insulators Ensure the insulators are properly seated in the intake manifold e Torque the 4 fuel tube securing bolts to 12 15 ft lb 16 21 Nem 1 6 2 1 kg m 12. battery Drain engine coolant and engine oil Remove heater hoses at engine and reposition for clearance Disconnect engine harness electrical connectors and ground strap at the right front of the cylinder head Remove plastic clips securing harness to the bracket at the rear of the cylinder head TC960521 3 13 Plastic clip TC960514 TC960474 11 Remove throttle cable bracket leaving cables attached Remove throttle and ASCD cables from accelerator drum 12 Remove P S pump and A C compressor Re position for clearance 13 Remove A T lines from radiator 4 13 14 Remove top and bottom radiator hoses 15 Remove radiator fan and shroud 16 Remove drive belts cm De SP cable VS a ros GESE SON FOLK EE Accelerator SBN s TC960472 Ai 17 Remove two fuel hoses at engine Use special tool to remove the fuel hoses MAC HFL 4790 NOTE Replace the fuel tube if it becomes damaged 18 Remove front exhaust tube TC960476 5 13 Steps 19 21 apply to 4WD models only 19 Remove the front differential support three nuts on top two bolts at the side two bolts at the front 20 Remove drive shaft to differential and half shafts to each wheel 21 While supporting the differential on a suitable stand lower the rear part of the differential first then remove the assembly 22 Remove the starter TC960515 23 Remove wires from alternator and oil pressure sending unit 24 Attach
3. pilot A T only Kit crankshaft pulley Nut exhaust manifold NOTES 1 Replace only if damaged PART QUANTITY 1010B 0S210RE 14033 75P00 1 iaossveeoa O 2 ta0o37 V500 2 2069t30P0 2 i10s 0mMos 1 16635 88600 6 s213 W0400 n istaegipoo T 32202 89500 1 128800 NIN N h h mk 2 Required for vehicles originally equipped with 25 mm crankshaft 12 13 CLAIMS INFORMATION Submit a Primary Failed Part PP line claim using the following claims coding DESCRIPTION PFP OP CODE SYM DIA FRT RPL Long Engine Assy AA20AA NOTES 1 Please reference the Parts Information tables on page 12 and use the indicated remanufactured engine P N as the PFP 2 Please reference the current Nissan Warranty Flat Rate Manual and select the applicable AA20AA Flat Rate Time including any add ons for A C and P S 13 13
4. 0 On M T vehicles install a new pilot bushing P N 32202 B9500 On A T vehicles install converter pilot P N 12330 14L00 Bolt al Washer Lock l8 Ti nm 0 8 1 1 kg m 69 95 in EE Spacer Tube assy Injector insulator EM96005A Install Engine Assembly Installation is reverse of removal 1 Pay special attention to the following points during installation e Harness routing and attachment points e Electrical connectors are securely fastened e A C fittings are secure e Connect the battery cable positive and negative terminals with the ignition switch OFF after all the repairs are completed 2 Adjust the throttle cable A Loosen the lock nut and tighten the adjusting nut until the throttle drum starts to move B Turn back the adjusting nut 1 5 to 2 turns and torque the lock nut CAUTION Check that the throttle valve opens fully when the accelerator pedal is fully depressed and that the throttle valve returns to the idle position when released 3 Adjust the ASCD cable A Loosen the lock nut and tighten the adjusting nut until the throttle drum starts to move B Turn back the adjusting nut 0 5 to 1 turn and secure the lock nut 10 13 4 When installing the fuel inlet and return hoses tighten the hose clamps by hand The clamp is properly tightened when a dime will just fit into the gap An overtightened clamp may damage the hose and cause a fuel leak Setting clamp wi
5. AR NISSAN NORTH AMERICA INC NISSAN Copyright SERVICE BULLETIN Classification EM96 005A NTB96 065A November 13 2000 1995 TRUCK PATHFINDER ENGINE KNOCK AFTER COLD START ATTENTION This bulletin replaces NTB96 059 and NTB96 030 and amends NTB96 065 The information in the Parts and Claims Information sections of NTB96 065 was updated Please discard all paper copies of NTB96 059 NTB96 030 and NTB96 065 APPLIED VEHICLES 1995 Truck D21 1995 Pathfinder WD21 APPLIED DATES Truck April 21 1995 to December 31 1995 Pathfinder April 20 1995 to September 28 1995 APPLIED ENGINE S Truck VG30 816606C through VG30 912495C Pathfinder VG30 090208Y through VG30 164493Y SERVICE INFORMATION An engine knocking noise may be noted in some vehicles when the engine is started after an overnight cold soak especially in cold weather If there is noise it may be most noticeable during the first several minutes after starting the engine then gradually diminishes as the engine nears operating temperature The knock is loudest under light load 1 8 throttle at 1200 1800 RPM It is audible in the passenger cabin and outside the vehicle SERVICE PROCEDURE The procedures in this bulletin cover key points of the repair for this incident Review the procedures in the service manual for additional information about removal and installation of accessories manifolds oil pan cylinder heads torque specifications amp s
6. anifold e All fuel injector harnesses e Fuel tube assembly secured by four bolts e Engine coolant temperature sensor harness connector e Thermal transmitter harness connector e Water hose from thermostat housing B Remove intake manifold collector loosen intake manifold bolts in numerical order and remove the intake manifold NOTE The thermostat housing does not have to be removed from the suction pipe Loosen bolts in numerical order TC960480 2 Remove exhaust manifold nuts in numerical order then remove exhaust manifolds LH side Loosen nuts in exhaust manifold numerical order TC960668 7 13 RH side Loosen nuts in exhaust manifold numerical order TC960667 3 Remove one water jacket plug located near cylinder 1 and one oil gallery plug located near cylinder 5 Apply sealant to the water and oil plug threads and install on the new block Be careful not to allow any foreign material into the oil passage NOTE Remove the original gasket sealer from the bolt threads Water TC960677 4 Remove the water jacket plug located near cylinder 2 on the outside of the block Apply sealant to water plug threads and install the plug on the new block Remove the oil plug to the left of cylinder 2 Replace the washer P N 11026 01MO02 on the oil gallery plug and install the plug on the new block Be careful not to allow any foreign material into the oil passage 8 13 NOTE
7. engine sling One lifting hook is installed at the rear of the left cylinder head Install the other lifting hook at the front of the right cylinder head at the point where the battery ground strap was removed 25 Remove bolts attaching engine to transmission 26 Remove engine mount bolts on both sides 27 Remove transmission lower support brackets on both sides 28 The engine may be removed without removing the transmission if the following cautions are observed e Support the front of the transmission so it does not drop e On M T vehicles make sure the clutch plate is clear of the input shaft before lifting engine e When removing engine be sure that other components in engine compartment such as the A C compressor throttle cables and connectors are not damaged by the engine assembly 29 When lifting the engine with the hoist make sure the lifting chain does not apply pressure on any fragile components such as electrical connectors or the air regulator Re position for clearance if necessary Use rags to protect the valve covers from contact with the chain 30 Lift engine with hoist and secure it to an engine stand 31 Before disassembling the engine make notes of engine harness routing vacuum hose routing and attachment points to ensure correct re assembly of these components 6 13 Transfer Parts to New Long Engine Assembly 1 Remove the intake manifold A The following parts should be disconnected to remove the intake m
8. equence sealant application etc Take a few minutes before starting the repair to note engine harness routing position of hoses and clamps and general layout of components in the engine compartment CONFIRM THE INCIDENT Confirm the incident matches the description above before beginning this repair procedure The evaluation requires the vehicle to experience an overnight cold soak Perform a cylinder power balance test to isolate the knock to a particular cylinder The knock should be reduced or eliminated when cylinders 3 and or 4 are disabled The repair for this incident consists of replacing the long engine assembly 1 13 Table of Contents Engine Removal GE MS AE AA AE ee uefa ene ee ESE DR nenna 3 Transfer Parts to New Long Engine Assembly iese ees ee RA ee ee ee ee ee Re ee ee ee ee ee 7 Install Eridine Assembly se Ee Ra EG DE Ge RE Oe EE Ee GE Ee 10 Ttuek Parts Informatio EE EE EG EE EE at ale EE ale alta De 12 Pathfinder Paris lformaliofi ss ieke se ee nee sen ei ene ee ee ER se oe oe bee Ee HEER Eg 12 DER el de AE EE EE OE EE EE ER 13 2 13 Engine Removal 1 2 3 9 DOT Note AM and FM radio presets before beginning this repair Remove the engine undercovers and hood Use compressed air to blow the engine free of dust while wearing proper eye protection and a respirator Release fuel pressure see MA section of 94 Truck Pathfinder Service Manual page MA 12 Disconnect negative cable from the
9. th a dime TC960519 Start and run the engine at 2000 rpm for five minutes Enter the radio pre sets noted at the beginning of this procedure Shut the engine off Replace the engine oil and filter Allow the engine to cool down Then re start and allow the engine to idle e Check for fuel coolant power steering or other oil leaks e Check coolant power steering and other fluid levels OOND Overtightened Properly Tightened TC960520 11 13 PARTS INFORMATION D21 TRUCK DESCRIPTION Engine ass y long 2WD Engine ass y long 4WD Gasket intake manifold plenum Gasket manifold to head Gasket exh manifold Gasket exh man to tube Washer oil gallery Insulators injector Stud oil filter Guide oil level gauge Pilot bushing M T only Converter pilot A T only Kit crankshaft pulley Nut exhaust manifold NOTES 1 Replace only if damaged PART QUANTITY 1010B 0S910RE 1010B 0S210RE 14033 75P00 1 16635 88G00 6 15213 W0400 1 15146 01P00 1 32202 B9500 1 12330 14L00 1 l l dk l 2 Required for vehicles originally equipped with 25 mm crankshaft PARTS INFORMATION WD21 PATHFINDER DESCRIPTION Engine ass y long Gasket intake manifold plenum Gasket manifold to head Gasket exh manifold Gasket exh man to tube Washer oil gallery Insulators injector Stud oil filter Guide oil level gauge Pilot bushing M T only Converter
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