Nissan TD23, TD25, TD27 & TD27T Diesel Engine Service Manual — 1989 (P/N SM7E00TDG1)

Nissan’s 1989 TD Series diesel engine service manual (P/N SM7E00TDG1) covers TD23, TD25, TD27, and turbocharged TD27T engines. This is an engine repair reference rather than a vehicle-wide chassis manual.

PDF Navigation and File Contents

Text search and diagram viewing: PDF text search and embedded bookmarks are not available in any of the seven files. Use the Quick Reference Index and section contents pages to locate topics. Small labels in the EGR wiring diagram require zooming; the checked fuel-heater and sub-radiator circuits remain readable at suitable magnification.

The ZIP contains seven printable English PDFs totaling 277 pages: Quick Reference Index, 1; General Information, 8; Maintenance, 14; Engine Mechanical, 58; Engine Lubrication & Cooling Systems, 18; Engine Fuel, 170; and Emission Control System, 8. This total includes the index, section title/contents pages, seven blank pages, and an additional scan of printed page EF-120.

Injection-Pump Calibration and Diesel Engine Repair

The following selected topics show the main repair and diagnostic coverage rather than reproduce the complete contents. Further subjects include recommended fuels and lubricants and standard-bolt torque references.

• Injection pumps: Step-by-step removal, disassembly, inspection, reassembly, timing, governor and timer adjustment, pump-tester setup, and injection-volume calibration for in-line and VE pumps.
• Engine overhaul: Cylinder-head and valve-train repair, cylinder-liner replacement, piston and connecting-rod inspection, crankshaft bearings, gear-train assembly, and camshaft-bushing replacement.
• On-engine service: Compression testing, oil-seal replacement, valve-clearance adjustment, drive belts, filters, fuel-system bleeding, base idle, and air-conditioner fast-idle control.
• Lubrication and cooling: Oil-pressure testing, oil-pump and relief-valve inspection, oil-cooler and oil-jet checks, cooling-system leak testing, thermostat service, and sub-radiator checks.
• TD27T turbocharger: Removal, installation, wheel and shaft inspection, bypass-controller checks, and symptom-based diagnosis for power loss, excessive power, oil consumption, and blue smoke.
• Controls and emissions: Fuel-heater and fuel-return systems, solenoid timer, potentiometer, EGR controls, and crankcase ventilation, with circuit diagrams and component tests.

The engine procedures suit experienced diesel technicians; injection-pump disassembly and assembly are specifically assigned to Nissan- or pump-manufacturer-authorized service shops and require a pump tester.

Pump Applications and Bench Calibration

The application tables distinguish regional, cold-area, high-altitude-compensator, load-timer, manual-transmission, and automatic-transmission pump configurations. Matching the engine, vehicle application, and pump number helps identify the appropriate calibration sheet before repair work begins.

For the TD25 D21 application, the table identifies 16700-44G04 as the cold-area pump for Europe and general markets, paired with assembly 104740-9632. It separately lists 16700-44G03 standard, 16700-44G05 high-altitude-compensator, and 16700-44G06 load-timer versions.

The TD27 F22 in-line application distinguishes 16700-11T61 without an altitude compensator from 16700-11T62 with one. In-line and VE fuel-routing diagrams show the filter, sedimentor, injection tubes, nozzles, and return paths; five VE-system layouts are illustrated.

Internal pump work: In-line procedures address the control rack, pneumatic and mechanical governor sections, feed pump, and timer. VE instructions cover the distributor head, drive shaft, cam disc, roller holder, flyweights, governor assemblies, timing device, high-altitude compensator, and load timer.

Bench-test sections define test oil, nozzle and line requirements, temperature, feed pressure, rotation, and injection sequence. Pump-specific setting tables follow, with shim-selection information for distributor-head geometry, plunger dimensions, flyweight-holder end play, and nozzle opening pressure.

Special tools: In-line references include the KV11216432 timer wrench and KV11231612 tappet clamp. VE references include the KV11215842 governor-shaft adjusting device, KV11229542 feed-pump holder, KV11229752/KV11229762 high-altitude block gauges, and KV11222090 drive-shaft oil-seal guide.

The VE drive-shaft keyway can damage its oil seal, and the roller-holder instructions warn against dropping rollers. In-line pump instructions also caution against mixing matched parts between cylinders.

Cylinder-Head Repair and Internal Engine Inspection

Head-repair instructions cover valve guides and seats, rocker gear, combustion chambers, and component identification marks. Head-gasket selection accounts for piston projection after relevant engine components have been repaired or replaced.

The overhaul section provides inspection methods, standard dimensions, wear limits, bearing-clearance checks, crankshaft measurement, gear backlash, and final assembly checks. Incorrect cylinder-head bolt removal can warp or crack the head.

Turbocharger scope: The TD27T section includes fault tables and bypass-controller testing, but expressly prohibits turbocharger disassembly; specified internal faults call for assembly replacement.

Maintenance, Lubrication, and Cooling

Maintenance procedures include manifold-fastener checks, oil and filter changes, coolant replacement, fuel-filter water draining, air-cleaner service, nozzle checks, and idle adjustment.

Lubrication and cooling circuit drawings support the inspection procedures. The water pump and fan coupling are inspected and replaced as units rather than internally rebuilt.

Sub-radiator coverage applies to E24/TD27 installations for Australia and E24/TD23 installations for tropical areas with air conditioning. Vehicle-specific oil and coolant capacities require the applicable vehicle service manual because capacities vary by installation.

Fuel Controls, EGR, and Electrical Checks

Fuel-heater coverage includes its control circuit and checks of the heater, oil-pressure switch, relay, harness, and fuse. Fuel-return control diagrams explain cold-fuel recirculation, while solenoid-timer sections relate cold-start timing advance to coolant temperature.

Potentiometer coverage includes removal, installation, inspection, and bench adjustment. EGR documentation provides a control schematic, wiring diagram, operating table, vacuum checks, control-unit output checks, and tests for the solenoid valves, potentiometer, engine-speed sensor, and water-temperature sensor. Sub-radiator fan-motor wiring and crankcase-ventilation valve checks are also included.

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.

A Preview of Compression and Valve-Adjustment Data

For compression testing on a warmed engine, the mechanical section lists 2,942 kPa as standard and 2,452 kPa as minimum at 200 rpm. Its diagnostic notes distinguish possible piston-ring, valve-sealing, and head-gasket causes of low readings.

The maintenance section specifies 0.35 mm intake and exhaust valve clearance with the engine warm and stopped, illustrating the operating conditions supplied alongside adjustment data.