Nissan D01 D02 Series Forklift Internal Combustion Workshop Service Repair Manual

ENGINE LUBRICATION & COOLING SYSTEMS SECTION LC CONTENTS SERVICE DATA AND SPECIFICATIONS (SDS) ............2 Engine Lubrication System..........................................2 Engine Cooling System ...............................................2 TROUBLE DIAGNOSES AND CORRECTIONS.............4 Engine Lubrication System..........................................4 Engine Cooling System ...............................................5 ENGINE LUBRICATION SYSTEM ..................................6 Lubrication Circuit ........................................................6 Oil Pressure Check (On-vehicle service) ....................8 Oil Pump (H series engine) .........................................9 Oil Pump (TD27 engine)............................................10 ENGINE COOLING SYSTEM........................................12 Cooling Circuit ...........................................................12 Cooling System Inspection ........................................13 Thermostat .................................................................14 SPECIAL SERVICE TOOLS..........................................15

Engine Lubrication System GENERAL SPECIFICATIONS Lubrication method Pressed feed flow Oil pump Spur gear type Oil filter Full flow and cartridge type INSPECTION AND ADJUSTMENT Oil pump H series engine Unit: mm (in) Pump gear to pump body clearance Less than 0.40 (0.0157) Pump gear backlash Less than 0.50 (0.0197) Pump gear vertical clearance Less than 0.30 (0.0118) TD27 engine Unit: mm (in) Gear side clearance 0.05 - 0.13 (0.0020 - 0.0051) Gear backlash 0.07 - 0.11 (0.0028 - 0.0043) Oil pump bushing clearance Less than 0.15 (0.0059) Oil pump bushing inside diameter 13.012 - 13.098 (0.5123 - 0.5157) Drive gear shaft outside diameter 12.974 - 12.992 (0.5108 - 0.5115) Oil pressure Unit: kPa (bar, kg/cm 2 , psi) Engine H20-II, H25 TD27 Approximate dis- charge pressure Idle speed 98 (0.98, 1.0, 14) 98 (0.98, 1.0, 14) 3,000 rpm 333 - 372 (3.33 - 3.73, 3.4 - 3.8, 48 - 54) 294 - 441 (2.94 - 4.41, 3.0 - 4.5, 43 - 64) TIGHTENING TORQUE H series engine N⋅m kg-m ft-lb in-lb Oil pump mount- ing bolt 16 - 18 1.6 - 1.9 12 - 13 — Oil pump cover bolt 6.9 - 8.8 0.7 - 0.9 — 61 - 78 Oil pan bolt 6.4 - 7.4 0.65 - 0.76 — 57 - 65 Oil pan drain plug 20 - 39 2.0 - 4.0 15 - 28 — TD27 engine N⋅m kg-m ft-lb Oil pump fixing bolt 13 - 18 1.3 - 1.9 10 - 13 Oil cooler securing bolt 16 - 20 1.6 - 2.1 12 - 15 Oil filter bracket fixing bolt 16 - 20 1.6 - 2.1 12 - 15 Oil jet bolt (for piston) 30 - 39 3.0 - 4.0 22 - 28 Oil pump relief valve 30 - 49 3.0 - 5.0 22 - 36 Oil cooler short valve 30 - 49 3.0 - 5.0 22 - 36 Regular valve 30 - 49 3.0 - 5.0 22 - 36 Engine Cooling System GENERAL SPECIFICATIONS Cooling method Water-cooled, forced circulation Water pump Centrifugal type Thermostat Wax-pellet type SERVICE DATA AND SPECIFICATIONS (SDS) LC-2

INSPECTION AND ADJUSTMENT Radiator Unit: kPa (bar, kg/cm 2 , psi) Cap relief pressure 88 (0.88, 0.9, 13) Leakage test pressure 88 (0.88, 0.9, 13) Limit 147 (1.47, 1.5, 21) Thermostat Frigid type Standard type Valve opening temperature °C (°F) 88 (190) 82 (180) Max. valve lift mm/°C (in/°F) 8/100 (0.31/212) 8/95 (0.31/203) Water pump Fan belt deflection [When pushing with a force of 98 N (10 kg, 22 lb)] mm (in) 11 - 13 (0.43 - 0.51) TIGHTENING TORQUE H series engine N⋅m kg-m ft-lb Water pump bolt 16 - 18 1.6 - 1.9 12 - 13 Water inlet bolt 16 - 18 1.6 - 1.9 12 - 13 TD27 engine N⋅m kg-m ft-lb in-lb Water pump M8 16 - 20 1.6 - 2.1 12 - 15 — M10 31 - 41 3.1 - 4.2 23 - 30 — Thermostat housing bolt 16 - 20 1.6 - 2.1 12 - 15 — Water outlet bolt 16 - 20 1.6 - 2.1 12 - 15 — Fan securing bolt 6.9 - 8.8 0.7 - 0.9 — 61 - 78 Cylinder block drain plug 20 - 29 2.0 - 3.0 15 - 21 — Water temperature sensor 20 - 29 2.0 - 3.0 15 - 21 — SERVICE DATA AND SPECIFICATIONS (SDS) Engine Cooling System (Cont’d) LC-3

Engine Lubrication System Condition Probable cause Corrective action Oil leakage Damaged or cracked pump body cover. Replace. Oil leakage from gasket and oil seal. Replace. Oil leakage from regulator valve. Tighten or replace. Oil leakage from blind plug. Replace. Decreased oil pressure Lack of oil in engine oil pan. Correct. Dirty oil strainer. Clean or replace. Damaged or worn pump rotors. Replace. Malfunctioning regulator. Replace. Use of poor quality engine oil. Replace. Warning light remains “on” - engine running Decreased oil pressure. Previously mentioned. Oil pressure switch unserviceable. Replace. Electrical fault. Check circuit. Noise Excessive backlash in pump rotors. Replace. TROUBLE DIAGNOSES AND CORRECTIONS LC-4

Engine Cooling System Condition Probable cause Corrective action Water leakage Damaged radiator seams. Repair. Water leakage from water pump shaft seal. Replace as pump assembly. Water leakage from water temperature gauge. Tighten. Loose joints. Tighten. Damaged cylinder head gasket. Replace. Check engine oil for contamination. Cracked cylinder block. Replace. Check engine oil in crankcase for mixing with water by pull- ing oil level gauge. Cracked cylinder head. Replace. Loose cylinder head bolts. Tighten. Poor circulation Restriction in system. Check hoses for crimps, and clear the system of rust and sludge by flushing radiator. Insufficient coolant. Replenish. Inoperative water pump. Replace. Loose fan belt. Adjust. Inoperative thermostat. Replace. Corrosion Excessive impurity in water. Use soft, clean water (rain water is satisfactory). Infrequent flushing and draining of system. Cooling system should be drained and flushed thoroughly. Overheating Faulty thermostat. Replace. Radiator fin choked with mud, chaff, etc. Clean out air passage thoroughly by using air compressed air. Incorrect ignition and valve timing. Adjust. Dirty oil and sludge in engine. Flush engine and refill oil. Inoperative water pump. Replace. Loose fan belt. Adjust. Restricted radiator. Flush radiator. Inaccurate temperature gauge. Replace. Impurity in water. Use soft, clean water. Overcooling Faulty thermostat. Replace. Inaccurate temperature gauge. Replace. Noise Squeak at water pump mechanical seal. Use suitable water pump seal lubricant. Damaged or worn water pump bearing. Replace as pump assembly. TROUBLE DIAGNOSES AND CORRECTIONS LC-5

Nissan D01 D02 Series Forklift Internal Combustion Workshop Service Repair Manual

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