Nissan TD23 TD25 TD27 TD27T Diesel Engine Factory Service Manual (P/N 16700-44G04)

• 277 PDF pages across seven files cover Nissan TD23, TD25, TD27, and turbocharged TD27T engines. Factory application tables cross-reference Y31, D21, E24, and F22 installations as well as regional, cold-area, high-altitude, manual-transmission, and automatic-transmission pump configurations.
• Factory fuel-pump coverage identifies the TD25 VE pump P/N 16700-44G04 as the cold-area version for Europe and general markets, paired with pump assembly 104740-9632. The same table separates 16700-44G03 standard, 16700-44G05 high-altitude-compensator, and 16700-44G06 load-timer versions.
• Covers in-line and VE injection-pump removal, installation, disassembly, inspection, reassembly, timing, governor and timer adjustment, pump-tester setup, and injection-volume calibration.
• Steps through compression testing, cylinder-head repair, on-engine oil-seal replacement, complete engine overhaul, and TD27T turbocharger removal, installation, and fault diagnosis.
• Includes oil-pressure testing, oil-pump inspection, lubrication and cooling circuits, water-pump and thermostat service, sub-radiator checks, injection-nozzle testing, fuel-system bleeding, and idle-speed adjustment.
• Electrical and control coverage includes the fuel heater, fuel-return control system, solenoid timer, potentiometer, EGR system, sub-radiator fan circuit, special service tools, and system-specific Service Data and Specifications tables.

Published by Nissan Motor Co. in 1989, this factory engine manual set is a focused repair reference rather than a vehicle-wide chassis manual. It is best suited to experienced diesel technicians and equipped fuel-injection shops: Nissan states that injection-pump disassembly and assembly belong in an authorized shop and require a pump tester. Coverage is organized by engine and pump application, not by one blanket vehicle VIN or serial-number range.

Fuel Injection Pump Coverage and Bench Calibration

The fuel section traces the circuit from the tank and sedimentor through the filter, in-line or VE pump, injection tubes, nozzles, and return path. Five VE-system layouts are shown. The application matrix distinguishes standard, cold-area, high-altitude-compensator, load-timer, manual-transmission, and automatic-transmission builds so the correct calibration page can be matched before repair work begins. Separate in-line TD27 data identifies 16700-11T61 without an altitude compensator and 16700-11T62 with one.

Workshop procedures cover in-line pump governor, feed-pump, timer, control-rack, injection-timing, and delivery adjustments. VE coverage goes through the distributor head, drive shaft, cam disc, roller holder, flyweight and governor assemblies, feed pump, timing device, high-altitude compensator, and load timer. Bench-test sections define the required test-oil, nozzle, line, temperature, feed-pressure, rotation, and injection-sequence conditions, followed by pump-specific setting and injection-volume tables. Shim-selection charts are included for distributor-head geometry, plunger dimension, flyweight-holder end play, and nozzle opening-pressure adjustment.

Representative Nissan tools include the KV11216432 timer wrench and KV11231612 tappet clamp for the in-line pump, plus the KV11215842 governor-shaft adjusting device, KV11229542 feed-pump holder, KV11229752/KV11229762 high-altitude block gauges, and KV11222090 drive-shaft oil-seal guide for VE work.

The manual specifically warns that the VE drive-shaft keyway can damage the oil seal and that tilting the roller holder can drop its rollers. It also cautions against mixing matched in-line pump parts between cylinders.

Engine Repair, Diagnostics, and System Diagrams

The mechanical chapters cover cylinder-head removal, disassembly, inspection, assembly, and installation; valve guides and seats; rocker gear; combustion chambers; liners; pistons; connecting rods; crankshaft and bearings; gear train; camshaft bushings; and final assembly checks. The TD27T turbocharger section provides removal, installation, inspection, and symptom-based diagnosis, but expressly says not to disassemble the turbocharger.

Maintenance and on-engine procedures address manifold fasteners, valve clearance, drive belts, oil and filter service, coolant replacement, fuel and air filters, nozzle checks, base idle, and air-conditioner fast-idle control. Lubrication and cooling coverage adds oil-pressure diagnosis, oil-pump clearances, oil cooler and oil jets, cooling-system leak checks, water-pump inspection, thermostat testing, and the sub-radiator. Vehicle-specific oil and coolant capacities are not supplied here; Nissan directs the reader to the applicable vehicle service manual because capacities vary by installation.

Representative graphics include in-line and VE fuel-routing diagrams, injection-pump component and assembly views, the engine lubrication circuit, cooling circuit, EGR control schematic and wiring diagram, fuel-heater control circuit, and sub-radiator fan-motor wiring. Service Data and Specifications sections consolidate torque tables, compression data, wear limits, clearances, pump and nozzle test specifications, calibration settings, and electrical checks.

Page breakdown: Quick Reference Index, 1 page; General Information, 8 pages; Maintenance, 14 pages; Engine Mechanical, 58 pages; Engine Lubrication & Cooling Systems, 18 pages; Engine Fuel, 170 pages; Emission Control System, 8 pages.

Fuel-injection and nozzle testing involve combustible fuel and high-pressure spray. Follow the manual’s ventilation, fire-safety, eye-protection, and body-clearance precautions before performing diagnosis or repair.