Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Remove the cooling fan and the cooling fan shroud. For additional information, refer to Section 303-03. 3. Remove the accessory drive belt. For additional information, refer to Section 303-01A. 4. Remove the parts in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. 6. To install, reverse the removal procedure. Item 1: Crankshaft Pulley Bolt Removal Note 1. Remove the bolts and position the power steering cooler aside. 2. CAUTION: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley, remove and discard the damper bolt. Item 2: Crankshaft Pulley Removal Note 1. Using the special tools and two 8 mm (0.31 in) x 1.25 x 100 mm bolts, remove the crankshaft pulley. Item 3: Front Crankshaft Seal Removal Note 1. Using the special tool, remove the crankshaft front seal. Item 3: Front Crankshaft Seal Installation Note 1. Using the special tool, install the crankshaft front seal. Item 2: Crankshaft Pulley Installation Note

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Some 1998-2003 E-Series, 1999-2003 Super Duty, 2000-2003 Excursion, and 2000-2003 F650/750 vehicles equipped with a 7.3L Diesel engine may exhibit an oil leak at the high pressure oil pump outlet fittings and/or end plug (see Figure 1). The leak may appear to be a rear main crankshaft seal, oil pan gasket, or other engine oil leak due to the drain hole machined in the crankcase valley which allows any oil in the valley to run down the back of the engine. ACTION High pressure oil pump leaks at the outlet fittings and/or end plug can be serviced without removing the pump assembly. Replace the O-rings on the fittings and the end plug using Kit 2C3Z-9G804-AA. All three (3) O-rings should be replaced. Apply liquid thread sealer (included in the kit) prior to reinstallation. Refer to the following Service Procedure for details.

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1. 2. 3. 4. Disconnect negative cable from battery. Remove timing belt. Remove timing belt rear cover. Remove oil pan. 5. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 104). 6. Remove crankshaft key (Fig. 105). 7. Remove oil pick-up tube. 8. Remove oil pump (Fig. 106) and front crankshaft seal. DISASSEMBLY 1. To remove the relief valve, proceed as follows: a. Remove the threaded plug and gasket from the oil pump (Fig. 107). b. Remove spring and relief valve (Fig. 107). 2. Remove oil pump cover fasteners, and lift off cover (Fig. 108). 3. Remove pump rotors (Fig. 108). 4. Wash all parts in a suitable solvent and inspect carefully for damage or wear. CLEANING Clean all parts thoroughly. INSPECTION 1. Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 109). Replace pump cover if scratched or grooved. 2. Lay a straightedge across the pump cover surface (Fig. 110). If a 0.025 mm (0.001 inch) feeler gauge can be inserted between cover and straight edge, cover should be replaced. 3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.40 mm (0.370 inch) or less (Fig. 111), or if the diameter is 79.95 mm (3.148 inch) or less, replace outer rotor. 4. If inner rotor measures 9.40 mm (0.370 inch) or less replace inner rotor (Fig. 112) . ASSEMBLY 1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. 2. Prime oil pump before installation by filling rotor cavity with engine oil. 3. Install cover and tighten fasteners to 12 Nm (105 inch lbs.) (Fig. 108). CAUTION: Oil pump pressure relief valve must be installed as shown in

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Install the crankshaft sprocket, making sure the mating marks face the front of the engine. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. Install the lower chain guides. Front cover installation: a. Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. b. Install new crankshaft seal in front cover. c. Install new oil passage O-rings and apply a continuous bead of RTV sealant to the front cover (see Figure 1). NOTE: Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent. d. Install the front cover to the engine. CAUTION: Be careful not to tear or damage the cylinder head gasket or oil seal. Align oil pump drive spacer with the oil pump, and install. Install the oil strainer. Install oil pan, referring to “Installation” in the “OIL PAN” section of the Service Manual. Install upper timing chain and sprockets, using the painted reference marks made during removal. Install upper chain tensioner. 1996 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) a. b. Before installing the chain tensioner, insert a suitable pin into the pin hole of the chain tensioner (see Figure 2) to hold the tensioner in. Once the tensioner is installed, remove the pin. 10. Install the lower chain tensioner (See Figure 3). NOTE: Make sure the gasket is facing the proper direction before installing the tensioner. CAUTION: Now rotate the crankshaft by hand. Check that no binding or interference problems occur when the engine is rotated. 11. Install the thermostat housing. a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the engine front cover and the thermostat housing.

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Material 1. 2. 3. 4. With the vehicle in NEUTRAL, position it on a hoist. Remove the fan shroud. Remove the accessory drive belt. Remove the parts in the order indicated in the illustration and table.5. To install. reverse the removal procedure. 6. To install, reverse the removal procedure. Item 1: Crankshaft Pulley Bolt Removal Note 1. Remove the bolts and position the power steering cooler aside. 2. CAUTION: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley. remove and discard the damper bolt. Item 2: Crankshaft Pulley Removal Note 1. Using the special tool and two 8 mm (0.31 inch) x 1.25 x 100 mm bolts, remove the crankshaft pulley. Item 3: Front Crankshaft Seal Removal Note 1. Using the special tool, remove the crankshaft front seal. Item 3: Front Crankshaft Seal Installation Note 1. Using the special tool, install the crankshaft front seal.