NISSAN TERRANO 2002 Service Repair Manual

VALVE LIFTER BORE DIAMETER
Measure the bore diameter of the cylinder head valve lifter with an
inside micrometer.
Standard: 34.495 - 34.515 mm (1.3581 - 1.3589 in) dia.
VALVE LIFTER CLEARANCE CALCULATIONS
Clearance = Valve lifter bore diameter þ Valve lifter outer diameter
Standard: 0.030 - 0.065 mm (0.0012 - 0.0026 in)
If it exceeds the standard value, refer to the outer diameter and
bore diameter standard values and replace valve lifter and/or cyl-
inder head.
Installation
1. Install the valve lifter and adjusting shim.
IMake sure that these are installed in the same position as
before the removal process.
2. Install the camshaft.
IFollow the distinguishing marks that were placed on in the
removal process.
IFace the key in the direction shown in the figure.
3. Install the camshaft bracket.
IRefer to the camshaft bracket upper side journal No. and install.
ILooking from the exhaust manifold side (left side of engine),
install in the direction that the journal number can be read cor-
rectly.
IPlace baffle plate onto upper face of No. 1 camshaft bracket,
and tighten together.
4. Tighten the installation bolts in numerical order in the figure.
1) Tighten to 10 to 14 N×m (1.0 to 1.5 kg-m, 8 to 10 ft-lb).
IMake sure that the thrust portion of the camshaft is fitted prop-
erly in the head installation side.
2) Tighten to 20 to 23 N×m (2.0 to 2.4 kg-m, 15 to 17 ft-lb).
FEM019
FEM020
FEM021
FEM012
CAMSHAFTZD
Inspection (Cont'd)
EM-33

5. Install the cam gear.
IAlign the match marks, and install the idler gear and each cam
gear to the position shown in the figure.
ITighten the cam gear installation bolt by fixing the hexagonal
portion of the camshaft.
6. Install the timing chain, all other related parts and chain cover.
Refer to ªTIMING CHAINº, EM-26.
7. After installing the timing chain, check and adjust the valve
clearance before installing the spill tube.
Refer to ªVALVE CLEARANCEº, EM-35.
8. Install in the reverse order of removal.
FEM023
CAMSHAFTZD
Installation (Cont'd)
EM-34

Inspection
IWhen the camshaft or parts in connection with valves are
removed or replaced, and a fault has occurred (poor starting,
idling, or other faults) due to the misadjustment of the valve
clearance, inspect as follows.
IInspect and adjust when the engine is cool (at normal tempera-
ture).
IBe careful of the intake and exhaust valve arrangement. (The
valve arrangement is different from that in a normal engine.)
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
1. Remove the following parts.
IIntercooler cover
IIntercooler
IRocker cover
2. Set the No. 1 cylinder at TDC.
1) Rotate the crankshaft pulley clockwise, and align the TDC mark
of the crankshaft pulley with the timing indicator of the TDC
sensor bracket.
2) Confirm that the cam nose of the No. 1 cylinder and the knock
pin of the cam sprocket is in the position shown in the figure.
IRotate the crankshaft pulley again if not in the position shown
in the figure.
3. While referring to the figure, measure the valve clearance in the
circled area of the table below.
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCqqq q
IThe injection order is 1-3-4-2.
IMeasure the valve clearance using a JIS high grade feeler
gauge when the engine is cool (at normal temperature).
Standard:
Intake and exhaust
0.35 0.05 mm (0.0138 0.0020 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft clock-
wise once.
FEM010
SEM342G
FEM024
FEM025
FEM026
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
EM-35

5. While referring to the figure, measure the valve clearance in the
circled area of the table below.
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDCqq qq
6. If the valve clearance is outside the specification, adjust as fol-
lows.
Adjustments
IRemove the adjusting shim for parts which are outside the
specified valve clearance.
1. Remove the spill tube.
2. Extract the engine oil on the upper side of the cylinder head (for
the air gun used in step 7).
3. Rotate the crankshaft to face the cam for adjusting shims that
are to be removed upward.
4. Grip the camshaft with camshaft pliers (SST), the using the
camshaft as a support point, push the adjusting shim downward
to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, or the outer cir-
cumference of the valve lifter.
5. With the valve spring in a compressed state, remove the cam-
shaft pliers (SST) by securely setting the outer circumference
of the valve lifter with the end of the lifter stopper (SST).
IHold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the camshaft
will be damaged.
6. Move the rounded hole of the adjusting shim to the front with a
very thin screwdriver.
IWhen the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 with the end of the lifter stopper
(SST) touching the adjusting shim.
7. Remove the adjusting shim from the valve lifter by blowing air
through the rounded hole of the shim with an air gun.
CAUTION:
To prevent any remaining oil from being blown around, thor-
oughly wipe the area clean and wear protective goggles.
FEM027
FEM028
FEM029
FEM030
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Inspection (Cont'd)
EM-36

8. Remove the adjusting shim by using a magnetic hand.
9. Measure the thickness of the adjusting shim using a microme-
ter.
IMeasure near the center of the shim (the part that touches the
cam).
10. Select the new adjusting shim from the following methods.
Calculation method of the adjusting shim thickness:
t=t
1+(C1þC2)
t = Adjusting shim thickness
t
1= Thickness of the removed shim
C
1= Measured valve clearance
C
2= Specified valve clearance
[when the engine is cool (at normal temperature)]
0.35 mm (0.0138 in)
INew adjusting shims have the thickness stamped on the rear
side.
Stamped Shim thickness mm (in)
2.35
2.40
.
.
.
3.052.35 (0.0925)
2.40 (0.0945)
.
.
.
3.05 (0.1201)
IThe thickness of the adjusting shim ranges from 2.35 to 3.05
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm
(0.0020 in). There are 15 types of shims available.
11. Fix the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve lifter.
12. Compress the valve spring using the camshaft pliers and
remove the lifter stopper (SST).
13. Rotate the crankshaft 2 to 3 times by hand.
14. Confirm that the valve clearance is within the specification.
FEM031
FEM032
FEM033
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Adjustments (Cont'd)
EM-37

Removal and Installation
2 idler gears are shown in this chapter. Idler gear (A) has scissors gear, and idler gear (B) does not.
YEM029
TIMING GEARZD
EM-38

Removal
1. Remove the engine assembly.
Refer to ªENGINE REMOVALº, EM-63.
2. Place the engine on an engine stand (SST).
Refer to ªCYLINDER BLOCKº, EM-67.
3. Remove the following.
IAuto tensioner bracket
IAir conditioner bracket
IAlternator bracket
IOil tube
IVacuum pump
IRocker cover
IOil pan (upper, lower)
IInjection tube
ISpill tube
IHigh pressure nozzle assembly
4. Remove the chain cover, timing chain and other parts in con-
nection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the fig-
ure. Refer to ªTIMING CHAINº, EM-26.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
IDo not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
IDo not drop or hit the sensor.
IStore in a clean place free of iron filings, etc.
IDo not place near any magnetic equipment.
6. Remove the water pump.
Refer to ªWATER PUMPº in LC section.
7. Remove the water inlet.
SEM376G
TIMING GEARZD
EM-39

8. Remove the crankshaft pulley.
ITo fix the crankshaft, clamp the bar between the drive plate
holding bolts, and set by touching the engine sub-attachment
(SST).
IAs another method, set by clamping a hammer handle, etc. in
the counterweight portion of the crankshaft.
CAUTION:
IDo not damage the crankshaft.
IMake sure that no foreign objects get inside the engine.
IDo not damage or magnetize the signal detection protru-
sions of the crankshaft pulley.
IAfter removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.
9. Remove the gear case.
IUsing the grooved places shown in the figure, remove the gear
case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a screw-
driver.
CAUTION:
Do not damage the gear case.
11. Fix the internal mechanism setting bolt [part No.: 81-20620-28,
screw dia.: M6, dimension below neck: 20 mm (0.79 in)] to the
bolt hole of the idler gear (A) and tighten to the specification.
: 2.5 - 3.4 N×m (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
IOnly use the genuine setting bolt, or the idler gear (A) will
be damaged.
IDo not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
IDo not remove the setting bolt from the idler gear (A) until
the timing chain and all of the parts in connection have
been installed.
IIf these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit
the idler gear from being reusable.
FEM050
YEM030
FEM052
SEM377G
TIMING GEARZD
Removal (Cont'd)
EM-40

12. Remove the idler gears (A) and (B).
ICheck the backlash of each gear before removing. Refer to
ªBACKLASH OF EACH GEARº, ªInspectionº.
CAUTION:
IDo not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
IDuring removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
13. Set the fuel injection timing gear with the pulley holder (SST).
14. Remove injection pump timing gear.
15. Extract the balancer shaft taking care not to damage the inner
bushes of the cylinder block.
16. Remove the fuel injection pump.
17. Remove the front plate.
Inspection
BACKLASH OF EACH GEAR
Method using a fuse wire
ITighten the holding bolts of each gear to specification.
IPlace a wire in the biting area of the teeth between the gears
to be checked, rotate the crankshaft in the operating direction
so that the wire is taken inwards.
IMeasure the crushed area of the wire with a micrometer.
Method using dial gauge
ITighten the holding bolts of each gear to specification.
IPlace the dial gauge on the tooth surface area of the gear to
be checked.
IWith the other gear in a set position, measure the dial gauge
value while moving the gear left and right.
Standard: 0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit: 0.20 mm (0.0079 in)
IIf it exceeds the limit, replace the gear and measure again.
IIf it exceeds the limit again, check for the installation condition
of the gear driving parts, wear of shaft and gear, and oil clear-
ance.
SEM348G
SEM378G
SEM352G
FEM035
FEM036
TIMING GEARZD
Removal (Cont'd)
EM-41

IDLER GEAR END PLAY
ITighten the holding bolts to the specification.
IMeasure the clearance between the gear plate and idler gear
using a feeler gauge.
Unit: mm (in)
Standard Limit
Idler gear (A)
0.06 - 0.12
(0.0024 - 0.0047)0.15 (0.0059)
Idler gear (B)
IIf it exceeds the limit, replace the idler gear, shaft, and gear
plate.
IDLER GEAR OIL CLEARANCE
IMeasure the inner diameter (d1) of the idler gear shaft.
Standard:
Idler gear (A)
43.000 - 43.020 mm (1.6929 - 1.6937 in) dia.
Idler gear (B)
28.600 - 28.620 mm (1.1260 - 1.1268 in) dia.
IMeasure the outer diameter (d2) of the idler shaft.
Standard:
Idler gear (A)
42.959 - 42.975 mm (1.6913 - 1.6919 in) dia.
Idler gear (B)
28.567 - 28.580 mm (1.1247 - 1.1252 in) dia.
ICalculate the oil clearance.
Clearance = d1 þ d2
Unit: mm (in)
Standard Limit
Idler gear (A)0.025 - 0.061
(0.0010 - 0.0024)
0.2 (0.0079)
Idler gear (B)0.020 - 0.053
(0.0008 - 0.0021)
IIf it exceeds the limit, refer to each standard specification and
replace the idler gear and/or shaft.
BALANCER SHAFT END PLAY
IMeasure the clearance between the plate and gear using a
feeler gauge.
Standard: 0.07 - 0.22 mm (0.0028 - 0.0087 in)
IIf it exceeds the specification, replace the balancer shaft
assembly.
IAs the gears are press-fitted, there are no setting for individual
parts.
FEM037
FEM038
TIMING GEARZD
Inspection (Cont'd)
EM-42