Nissan YD22DDTi engine factory workshop and repair manual download
Nissan YD22DDTi diesel engine factory workshop and repair manual
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Covers the Nissan ZD30DD and KA24DE engine
Drive Belts
Air Cleaner
Throttle Body
Intake Manifold
Catalyst
Exhaust Manifold Turbocharger
Oil Pan and Strainer
Glow Plug
Vacuum Pump
Injection Tube and Fuel Injector
Fuel Pump
Rocker Cover
Camsahft
Timing Chains
Cylinder HEad
Engine Assembly
Cylinder Block
Specs
About the YD22DDTi Engine
The YD engine is a 2.2 L & 2.5 L Diesel I4 piston motor from Nissan. It has a cast iron block & aluminium head with chain driven DOHC. Winner of the FY 1998 Sho-Ene Taisho (The Energy Conservation Prize). The YD22DD is utilized in the Y11 Nissan AD van& W11 Expert. It is a non turbo engine utilising the VP44 electronic controlled rotary injection pump. The YD22DDT is utilized in the X-Trail, N16 Almera. It features the VP44 electronic rotary injection system and wastegated turbochargers. The VP44 pump models are easily spotted due to a flat acoustic cover over the motor.
The YD22DDTi was a commonrail diesel introduced in 2003, during the first little facelift of the P12 Primera, N16 Almera and V10 Almera Tino. It ian additionally fitted to the Nissan X-trail. The injection system is commonrail with a variable vane turbocharger is intercooled and produces the most torque and power of all the YD22 engines. Cars with this commonrail engine generally carry the DCi badge. The commonrail version is easily distinguished from the VP44 model by the 4 injector bumps on the top of the acoustic cover.Non intercooled versions of this motor were also available with a reduced power rating.
This motor features the VP44 rotary injection pump and is turbocharged and intercooled. In the Presage/Bassara it is fitted sideways with a variable vane turbocharger (garrett GT1749V) and torque is limited to approximately 280 NÃÃm (207 lbÃÃft) accommodate the 4 speed automatic gearbox attached. In the D22 Navara/Kingcab/Frontier the engine is essentially the same other than modifications to mounts, plumbing system and accessories to accommodate the longitudinal engine layout. The turbo is a wastegated IHI RHF4 which is also intercooled. The stronger gearbox allows it to produce more torque than the Presage/Bassara version.
1998–2001 Nissan Presage
1998–2001 Nissan Bassara
Nissan D22 pickup (Navara / Kingcab / Frontier)
Nissan D40 pickup (Navara)
–present Nissan Frontier
The model description YD25DDTi technically refers to the YD25 engines which use the VP44 rotary electric injection pump and run injection lines to each cylinder. This DDTi engine had been last utilized in the the D22 and Presage/Bassara navara.The common rail versions of this engine are referred to in Europe as DCi. The commonrail engines are used in the D40 navara, late model D22 navara and the R51 pathfinder. This is the engine referred to below.YD25DDTi High Power had been developed in 2005 for the Nissan Navara (D40an as well as the Nissan Pathfinder (R51). It at first produced 126 kW (171 PS; 169 hp) @ 4,000 rpm and 403 NÃÃm (297 lbÃÃft) of torque. In 2010, Nissan updated the engine for the Nissan Navara (D40) and Nissan Pathfinder (R51) facelift to create 140 kW (190 PS; 188 hp) and 450 NÃÃm (332 lbÃÃft) of torque. In 2011 the Nissan Murano was fitted with the updated engine creating 140 kW (190 PS; 188 hp) and 450 NÃÃm (332 lbÃÃft) of torque.
2006–present Nissan Navara (D40)
2005–2012 Nissan Pathfinder (R51)
2011-present Nissan Murano
2013-present Nissan NV350 Caravan E26
Nissan YD22DDTi Engine factory workshop and repair manual Download
1) Purpose and failure theory (short)
- The spring seat (perch) provides a concentric bearing surface and axial stop for the coil spring and usually locates a rubber insulator. It transfers spring load into the strut/axle and keeps the spring indexed so the coil ends sit in their seats.
- Failures: corrosion, lip wear, crushed or pitted bore, broken/missing insulator or fractured perch. Result: spring moves off-seat (noise, clunks), reduced/uneven ride height, poor spring preload and alignment, excessive localized stress on strut or body, accelerated wear of other suspension parts.
- Repair goal: restore the correct seat geometry, height and seating surface (and insulator) so the spring bears over its full circumference and is retained axially. That restores load paths, ride height and eliminates lateral movement and noise.
2) Preparatory diagnosis and safety
- Symptoms that point to a bad seat: clunking over bumps, spring visibly shifted, low corner/uneven ride height, metal-on-metal contact or missing rubber pad, visible rust-through at perch.
- Safety: Always work on a flat surface. Use a hoist or properly rated jack and stands. Coil springs are high-energy parts — use a suitable spring compressor for struts or securely support the axle so the spring is unloaded before removing retaining hardware.
3) Tools & consumables (minimum)
- Jack and stands or hoist, wheel chocks
- Spring compressor (strut-type) or floor jack to support axle
- Sockets, ratchet, torque wrench
- Penetrating oil, wire brush, grinder
- Replacement spring seat/perch or new strut assembly OR welding equipment and filler rod if rebuilding
- New rubber insulator/pad, anti-seize, rustproof paint
4) Ordered repair procedure (MacPherson front strut — adjust for rear/axle coil per notes)
A. Lift & initial inspection
- Lift vehicle, chock, remove wheel.
- Visually inspect spring seat, spring ends, insulator and strut tube for corrosion/pitting or lip breakage. Confirm fault.
B. Unload spring and remove strut
- Support lower control arm or hub with a jack so the spring is not carrying weight (unloaded).
- Remove any stabilizer links / brake line brackets restricting strut removal.
- If removing strut as an assembly: loosen top strut nut (do not remove fully), unbolt lower strut bolts, remove strut from vehicle.
- Use a proper spring compressor on the coil (compress coils evenly to release spring preload) and then remove top nut and mount to free the spring and seat.
Theory: you must remove preload safely because the spring stores substantial energy; compressing removes load so you can separate parts without the spring forcing components apart.
C. Remove and inspect seat and insulator
- Take the spring and insulator off and clean the perch area.
- Measure/inspect dimension and profile of the seat lip and the bore where the spring seats. Note corrosion depth, lip thickness and concentricity.
D. Decide repair method (replace vs rebuild)
- Replace whole strut or replacement OEM perch: best reliability and alignment — restores original dimensions and material.
- Replace only perch insert (if available): good if part is serviceable.
- Rebuild by welding/build-up: acceptable if no parts available and done correctly — requires skilled welding, machining/grinding to original profile and to the correct diameter/height. Poor welding will change seat geometry, create stress risers, or burn the strut tube.
- Why replacement preferred: guarantees correct geometry, heat treatment, and surface finish. Rebuilding must restore concentricity and radial lip to retain spring forces.
E. Rebuild or install new seat
- Replacement: install new perch/seat and rubber insulator. Clean contact surfaces, apply anti-seize where required, ensure correct orientation.
- Welding rebuild (theory & key controls): strip paint and rust, weld incremental small passes to build the lip or fill pitted zones, allow cooling between passes to avoid warping, grind and machine to the original radius and height so the spring seating step is continuous and concentric. Finish with rustproof coating and fit a new rubber pad.
- Important: final seat height and circumferential surface must match the spring coil end geometry so coil end bears fully. Any gap or sharp discontinuity lets the coil tip dig in or move sideways.
F. Reassemble
- Refit spring with new insulator into the rebuilt/replaced seat, compress spring evenly, fit the strut mount and torque top nut to specification while the spring is compressed.
- Reinstall strut into vehicle, torque lower and top fasteners to factory spec, reconnect links/brackets.
- For axle/perch types: lower axle slowly so spring bears full load in the new seat; check that spring is centered and sits in the seat groove.
G. Final checks
- Verify ride height and compare to spec. Check spring indexing: coil end in correct groove and insulator seated.
- Road test for noise, clunks, and handling. Re-torque fasteners after a short test drive.
- If ride height or alignment changed, perform wheel alignment.
5) How each repair step fixes the fault (concise)
- Removing preload and inspecting isolates the failed component so you can confirm the cause (seat geometry vs spring vs insulator).
- Replacing or rebuilding the seat restores the axial stop and radial support so the spring no longer shifts off-seat; that removes metal-to-metal clunks and prevents the spring from unloading locally (fixes noise and restores consistent spring rate and ride height).
- A proper rubber insulator isolates high-frequency vibration and prevents squeak; replacing it removes noise and wear between coil and seat.
- Restoring concentric bearing surface corrects load distribution so the strut and hub do not receive eccentric loads; that stops accelerated wear and poor handling.
- Correct reassembly and torqueing restores the original suspension geometry and preload, ensuring predictable handling and eliminating secondary faults (alignment, uneven tyre wear).
6) Common pitfalls and warnings (short)
- Never release a compressed spring outside a proper compressor. Spring energy can cause severe injury.
- Welding the strut body without controlling heat can destroy material properties; if unsure, replace the strut or the seat component.
- Restoring only one corner and not checking ride height/alignment can mask problems — always check all corners and perform alignment as needed.
Done. rteeqp73
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Brief safety first (read this): work on the transmission on jack stands or a lift, engine is hot — wear gloves/eye protection, block wheels, chock and set parking brake, never work under a vehicle supported only by a jack, and have a fire extinguisher nearby. Transmission fluid is hot — be careful.
What this job is and why it’s needed (plain language)
- “Band adjustment” means setting the clearance/tension on the transmission’s band(s). In many automatic gearboxes those bands wrap around a drum to hold part of the gearset still when a gear is engaged.
- If bands are too loose you get slipping, delayed or harsh engagements, burning smell, loss of drive. If too tight you get continuous drag, overheating, accelerated wear, and poor fuel economy.
- Analogy: the band is like a seatbelt strap that has to clamp the drum just enough to hold it when needed. Too loose and the person slips through; too tight and the belt chafes constantly.
Basic theory — how the system works
- Automatic transmissions use hydraulic pressure to select gears. Friction elements (clutches and bands) hold parts of planetary gearsets to create different gear ratios.
- A band sits around a drum connected to part of the geartrain. When the valve body directs pressurized fluid to the servo piston, the servo pulls the band tight around the drum to lock that part of the train.
- The band itself is a steel strap lined with friction material. One end is anchored to the case; the other end is hooked to an adjuster or linkage and pulled by the servo.
- Over time the friction lining wears, so the band sits looser and needs tightening to maintain correct clearance with the drum.
Main components (what each part is and what it does)
- Band (strap with friction lining): wraps around a drum to hold it when engaged. Wear surface = friction lining.
- Drum (or “band drum”): the round component the band clamps to; connected to clutch packs/planetary gears.
- Anchor/anchor pin: fixed point where one end of the band is attached to the transmission case.
- Adjuster screw/bolt + locknut (or cam adjuster): the mechanism used to change band tension/clearance. Some are simple threaded screws with locknuts; some use cams or eccentric bolts.
- Servo and servo piston: hydraulically actuated device that pulls the band via a mechanical linkage when fluid pressure is applied.
- Return spring: releases the band when hydraulic pressure is removed.
- Transmission case access (inspection cover / adjuster access): the cover or hole through which you reach the adjuster or see the drum.
- Valve body & hydraulic passages: route fluid to servos and clutches; problems here can mimic band problems.
- Oil pump/clutch pack: separate components that interact with the bands to change gear ratios.
- Fill/level plug and dipstick: used to check and refill fluid during/after service.
Tools and materials you’ll need
- Factory service manual or correct Nissan transmission specs (you must have these).
- Metric sockets, wrenches, torque wrench.
- Feeler gauge set and/or a small dial indicator (depending on method).
- Screwdriver, pick, or pliers for springs/links.
- Clean transmission oil and a drain pan; replacement transmission fluid per Nissan spec.
- Clean rags, brake cleaner, parts tray.
- Jack stands or lift, wheel chocks.
- Optional: band adjustment special tool (if the manual calls for one).
- Replacement band(s) and gaskets if linings are worn or leaking.
General step-by-step method (generic, beginner-friendly)
Note: Nissan transmissions and models vary; ALWAYS confirm the exact procedure, clearances, and torque specs from the factory service manual for the specific gearbox paired to a YD22DDTi. The steps below describe the common, safe approach used on many automatics.
1) Preparation
- Warm the transmission to normal operating temperature (drive until normal temp). Warm fluid gives the correct clearances.
- Park on level ground, engine idling in Park, parking brake on, wheels chocked. Then for safety switch engine off when working under vehicle except where the manual requires engine running.
- Raise and support vehicle securely.
2) Locate adjuster(s)
- Find the band adjuster access on the transmission case (on the side). Remove any covers or splash shields. You might need to remove an inspection plate to reach the adjuster.
3) Check fluid level and condition
- Before adjusting, ensure fluid is at correct level and condition. Old burnt fluid or metal contamination means internal wear — adjusting won’t fix worn bands.
4) Identify which band to adjust and the required specification
- Many transmissions have two bands (1st/3rd, low/reverse, etc.). The manual tells which gear position to select, and whether to adjust with engine running or with the output shaft rotated.
- Example generic rule used on many units: tighten adjuster until band just drags on the drum, then back off a specified number of turns or to a specified clearance. DO NOT guess the number — refer to manual.
5) Typical adjustment technique (generic)
- With the drum accessible, either rotate the drum/output slowly by hand (if manual rotation is possible) or follow the manual’s method (some require engine running and selector in a specific gear).
- Loosen the locknut on the adjuster. Turn the adjuster screw clockwise to take up slack until you feel slight drag on the drum. That “slight drag” is the band touching the drum — analogous to tightening a bicycle brake until the wheel just stops turning freely.
- Back off the adjuster the precise amount specified by the manual (for many designs that back-off is a fraction of a turn). The back-off creates the required clearance so the band won’t drag when released but will apply correctly when actuated.
- Hold the adjuster and torque the locknut to spec while ensuring the adjuster didn’t move. Re-check clearance/drag after locking the nut.
6) Final checks
- Operate the gearbox (either run through gears with engine running as the manual requires) and re-check for leaks, correct fluid level, and correct operation.
- Road-test carefully. Watch for slipping, harsh engagement, or unusual noises. Recheck level after test drive.
Signs you need more than an adjustment (when to rebuild)
- Continuous slipping after correct adjustment, burnt-smelling fluid, heavy black debris in fluid, or band linings are worn down to metal — these indicate internal wear or a burnt band that must be replaced/rebuilt.
- Broken servo, leaking seals, stretched bands, or scored drums require partial or full transmission teardown.
- If the drum surface is glazed/scored, new bands will not hold — drum machining or replacement needed.
What can go wrong during adjustment (and how to avoid it)
- Over-tightening: causes continuous drag, overheating, rapid wear. Avoid by following manual back-off spec; don’t guess.
- Under-tightening: persistent slipping and clutch damage. If adjustment doesn’t stop slipping, inspect bands and drums for wear.
- Stripped adjuster threads or broken locknut: use correct tools and hold adjuster steady while tightening; don’t cross-thread.
- Damaging seals/gaskets when removing covers: replace gaskets and use correct torque.
- Contaminating fluid: keep everything clean; don’t let dirt enter the pan or fill hole.
- Incorrect procedure for that transmission: every design differs. If manual calls for special tools or a specific gear/engine state, follow it exactly.
Quick troubleshooting checklist after adjustment
- Fluid level correct and clean
- No drag while in neutral/park (unless specified otherwise)
- No slipping in gears; shifts are smooth
- No overheating or burning smell
- No leaks at adjuster or case
Summary (practical rules)
- Get the correct factory manual for the exact transmission model used with your YD22DDTi — that manual gives the exact adjuster locations, number of turns/back-off or clearance, torque specs, and special tools.
- The correct technique is: warm the trans, access the adjuster, take up slack until contact, then back-off to the exact clearance or turns specified, secure the locknut, and verify operation.
- If bands or drums are visibly worn, burned, or contaminated, adjust won’t fix it — rebuild or replace is required.
Final note: I intentionally gave a safe, generalized procedure and emphasized that you must use the Nissan factory service data for the exact gearbox. Follow the manual exactly; the wrong clearance or method will damage the transmission. rteeqp73