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Nissan D22 Navara Brochure
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D-22 ENGINE MECHANICAL
132047661 Emnissan Navara
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The Infamous D22 Engine Problem
Its been all over the news and the internet as well as gossip o n the streets, the problems with the Nissan Navara D22 engine destroying itself. So, once and for all a true summary of the problem and the solution to make sure you dont fall victim to this.
This includes Chris Vinces info on what the problem is, why it happ ens and what can be done to sort it. Also included are sources for parts needed and associated part numbers. Finally a brief decription of work invloved in vloved to replace bolts, bearings and oil seal More detailed information can be found by rea ding the full thread:viewtopic.php?f=3&t=611
Also the sticky big end bearing change:viewtopic.php?f=3&t=1983
Assuming you are in the EU and your y our engine number is before YD25DDT1219661 in your log book or with yd25 yd25 2.5 tdi engine engine (2002 (2002found above the alternator on the block, then it is at risk d22 s with 2005), especially around the 60,000mile mark. However it can happen at any mileage and regardless of full service history, so if you have a D22 of this age it is HIGHLY RECOMMENDED that this work i undertaken. If you look at the engine number on a machined m achined part of the block approx 50mm 5 0mm x 30mm immediately behind the alternator it will be b e stamped YD25 plus your engine number.
The fundamental fault lies with con rod bolts that are NOT up to the job. I think that the bolts are perm anently damaged during the angle torquing phase of their installation, also the lack of quality of these bolts bolt s means that they pass through their elastic limi ts (meaning that when undone they should return to their exact original size, specification a nd condition) into their plastic limits (meaning that permanent changes change s to their dimensions has occurred (due to being overstretched), and to their molecular makeup (causing graining to take place, a form of workhardening, leading to a critical catastrophic failure or snapping after further use). More worrying, all of the shells fitted to the rods have Äòpicked upÄô on the beari ng surfaces whilst those in the end caps look OK apart from the f act that there is a distinct lack of a wear surface across the entire shell, the only visible indicators being in the middle of the shells other unfortunate owners suffering the same catastrophic failures they do d o not mention a long term knocking that was getting worse with age (indicating a slow wear rate taking place), many just state that the car was driving perfectly normally, when a loud knocking was heard (I believe this to be the first bolt snapping Read Free Foron Days Sign toterminal vote this title allowing the endcap to open up) this thi s was then closely followed by up the termin al30failure of a rodcoming through the block (second bolt snapping)! Useful anytime. Not useful My only explanation for this is the failure f ailure of the securing method i.e.Cancel t he end cap bolts, even if there the Special offer for students: Only in $4.99/month. was wear the big ends pa st the accepted limits causing the characteristic b ig end knocking to be heard, the end cap bolts should have e asily coped with this and held the parts together!
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D-22 ENGINE MECHANICAL
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say 60-90,000 miles, and having endured numerous temperature cycles in a very hostile environment it can be reasonably expected for the O ring to change in shape, size and or malleability, thereby compromising the sealing effect. If/when this occurs it could be reasonably assumed that air will be drawn into the oil pump causing cavitations thereby starving the engine of oi l, instigating hammering on the bearings during the power stroke until an increasingly common catastrophic event occurs. This ring is ALL that stops the engine oil pump from sucking air, then running the big ends dry, hammering and stripping the bearing linings eventually (in a very short time) p utting a rod through the block! if a big end bearing is so badly worn that it can no longer be ignored due to itÄôs knocking, the bolts should hold the rod together, and not snap, as is the c ase with the OE bolts:-
1. Replacing the big end bolts with items made by ARP. Bolts cost ¬£63 Nissan ones approx ¬£46 2. Replace the ÄòOÄô ring, using a standard one but modify the way it is installed by: Cost ¬£1-43 a. Placing a 23mm x 1.5mm ÄòOÄô ring inside the top recess, to increase the surface area of seal. Pence b. Using liquid gasket on both sides of the ÄòOÄô ring flange during installation 3. As the sump is already off, fitting a new set of upgraded bearing shells from another manufacturer
Nissan have postioned 2 x 6mm bolts directly behind the flywheel, so the engine/g earbox DO need to be seperated to remove the sump. both units can remain in the vehicle, you only nee d enough room for a 1/4 drive socket exte nsion ARP bolts from co ordsport.part no 202-6005 ¬£43.97.tel 01384216102. The parts to modify the troubled engines cost around ¬£150 and the engine stays in place. The job takes around 20 hours by the DIY mechanic working of axel stands but if they had a g arage vehicle ramp/lift could be done in 10 hours. You're Reading a Preview Bolts: Nissan SR20 Rod Bolt Set Part no ARP 202-6005 = ¬£6 4.02 + carriage Unlock full access with a free trial. Arrow Precision 12 Barleyfield Hinckley Fields Industrial Estate Download With Free Trial Hinckley Leicestershire LE10 1YE Tel: 01455 234200 Big end bearings: ACL 4B2626 (no filing reqÄôd) or 4B2751 (filing reqÄôd). Size of bearing Standard Master your semester with Scribd if crankshaft not damaged = ¬£26.06 + carriage, in their Duraglide material (this istitle lead/copper). Read Free Foron 30this Days Sign up to vote also do an Aluglide range which is aluminium/tin overlay, i s to be avoided in a D22. & The New ACLYork Times Useful Not useful Engine Parts (UK) LTD Special offer for students: Only $4.99/month.
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bolts arp 202-6005 from pri racing (0161 718 6721) £43+vat bolts from JDM Performance ARP202-6005 £43inc delivery. oil seal 15066-vk500 nissan main dealer. £2-3 filter kit 002042k milner off road (01629 734411) £10+vat.
You can do this job with the engine in the car. If you intend to replace the pathetic bolts it would be stupidity in the extreme not to change the big end shells, it will take approx another 1.5 hours but you would have already done the hard work getting to the crankshaft, and will rejuvinate your engine by removing the already present wear!! I was amazed to find that the end shells on my replacement engine with just 24K miles were almost at the upper wear limit. Drain oil Remove: Engine undertray Front diff by removing its crossmember support (leave propshaft connected to transfer b ox) Air con compressor (but just enough to tie it up do NOT touch the pipes!!) Undo the nearside steering idler from the chassis (no need to disconnect and swivel joints, le t it hang down out of the way) Disconnect rear prop shaft joint Undo rear gearbox mounting bolts 2off (no need the remove gear levers etc) Undo bell housing and withdraw approx 20mm from en gine (just enough to get a 1/4 drive 10mm socket to the 2 bolts) Remove lower sump Remove upper sump You're Reading The crankshaft and big ends will then be right in front a ofPreview you, the O ring is captive i n the upper sump. Unlock fullfiaccess trial. The Nissan con rod bolts are an interference t, andwith needa free to be carefully tapped out, on each rod, after removing one replace it with a slightly loose fitting tightened nut and bolt before tapping out the other, to avoid distorting the end cap. Download With Free Trial If you use ACL 4B2751 end shells as I did, the only mod needed is to reduce the width of the tang by approx 1.2 mm with a few stokes of an engineers file. Basically the original slot for the tang (this stops the shell spinning in the housing) is ever so slightly too narrow for the ACL bearings. All that is involved is, you hav to narrow the ACL tang to allow it to fit the slots inthe bearing housings this is very easily done by filing it with a small file,about half a dozen passes equ ally on each side. Read Free Foron 30this Days Sign up to vote title You must remove material from both sides to ke ep the shells central in the housings.
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The ARP are just about the best available, they are truly elastic and meant to be used and Special offer for students: Onlybolts $4.99/month.
removed over and over again, make sure you coat the threads with the special ARP grease (supplied
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