NISSAN TERRANO 2002 Service Repair Manual

Precautions
IDo not perform operation unless it is perfectly safe.
IDo not start operation unless the exhaust system and coolant
are cooled down.
ILift the engine at the designated support points only.
IPerform operations for the items other than the engine body,
referring to the applicable sections.
IRefer to MT section and AT section for rear mount.
Removal
IAfter removing transmission, hoist the engine and remove it.
Preparation
1. Drain coolant from radiator drain plugs.
2. Remove the following parts.
IEngine hood
IUndercover
IUnder protector
IBattery
IIntercooler
IRadiator shroud
IRadiator
IAccessory belt
ICooling fan
IExhaust front tube
YEM032
ENGINE REMOVALZD
EM-63

Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.
5. Disconnect harness connectors from alternator and air com-
pressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor and
inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent
coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.
Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix it
to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move har-
nesses to the side of the vehicle.
Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and remove
rear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting
bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount mem-
bers to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to trans-
mission.
Removal operation
19. Remove air conditioner high pressure pipes at the rear of the
engine room.
IThis is due to some inconvenience in the rear slinger installa-
tion.
20. Install the engine slingers (standard service part) to front-left
and rear-right.
:25-28N×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
FEM082
ENGINE REMOVALZD
Removal (Cont'd)
EM-64

21. Hook hoists to slingers to secure the position.
22. Remove installation nuts for left and right engine mount insula-
tors.
23. While adjusting position frequently, hoist and remove the
engine.
CAUTION:
IWhile performing operation, check that all necessary wires
and pipes are disconnected.
IAvoid interference with parts on the vehicle.
Installation
Install the engine in the reverse order of the removal procedure.
IKeep each mount insulator from oil adherence and damage.
IWhile keeping each mount insulator free from twisting, tighten
mounting bolts and nuts for the engine mount.
Inspection
IBefore starting the engine, check coolant level and grease
amount, and if necessary, refill them to the specified level.
IStart the engine, and check that there is no abnormal noise or
vibration.
IWarm up the engine to the sufficient temperature, and check
that there is no leakage of coolant, greases, fuel, or exhaust
gas.
YEM042
ENGINE REMOVALZD
Removal (Cont'd)
EM-65

YEM033
CYLINDER BLOCKZD
EM-66

Selection Procedure for Selective Part
Combination
Location Selective part combination Item Method
Cylinder block - pistonPiston and piston assembly
(Part No. is given to a piston
and piston pin as a set.)Piston grade (Piston outer
diameter)Refer to ªSelective combination
chartº.
IIdentification grade stamped on each part represents initial
dimension of new part. This grade will not be applied to a
reused part.
IMeasure correct dimensions of a reused or modified part, then
refer to ªSelective combination chartº in this manual to identify
the grade.
IRefer to the applicable pages for measurement method for
each part, standards for reuse, and selecting method for selec-
tive part combination.
Disassembly
1. Remove engine assembly from vehicle.
Refer to EM-63, ªENGINE REMOVALº.
2. Remove pilot bushing from flywheel using pilot bearing puller
(SST), if necessary (M/T model).
3. Install engine to engine stand (SST).
1) Remove flywheel (M/T model) or drive plate (A/T model).
IUsing ring gear stopper (SST), secure ring gear, and remove
mounting bolts.
CAUTION:
Do not disassemble flywheel.
IFlywheel has a two-piece structure. When being pressed
forward/backward, or twisted in rotating direction, transmission-
side mass will be moved with audible sound. This is not a
problem.
2) Remove pilot converter (A/T model) and rear plate.
SEM364G
YEM043
CYLINDER BLOCKZD
EM-67

3) Install engine sub-attachment (SST) to the rear side of cylinder
block.
IAlign knock pin on cylinder block with pin hole on attachment
to install engine sub-attachment.
IMounting bolts are provided with engine sub-attachment.
4) Install engine attachment (SST).
IUse commercially available M12 mounting bolts and nuts (4
sets) with strength grade of 9T (minimum).
5) Hoist engine and install it to the engine stand (SST).
IEngine attachment and engine sub-attachment can be installed
to engine stand before engine installation.
4. Drain engine oil and coolant from engine.
5. Remove the following parts and related parts. (Only major parts
are listed.)
IAccessory belt
ICatalytic converter
ITurbocharger
IExhaust manifold
IInjection tube
IIntake manifold
IRocker cover
IOil pan (upper/lower)
IWater pump
IThermostat and water pipes
IVacuum pump
IInjection tube
ITiming chain
IElectronic high pressure fuel injection pump
ITiming gear
IHigh pressure injection nozzle assembly
ICamshaft
ICylinder head
IOil cooler
IAccessory and accessory brackets
6. Remove rear oil seal and retainer assembly.
IInsert flat-bladed screwdriver between lower cylinder block and
rear oil seal retainer to remove the assembly.
INo part No. is given to oil seal.
FEM083
FEM084
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-68

7. Remove piston and connecting rod assembly.
IBefore removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer to EM-71, ªCONNECTING ROD SIDE CLEARANCEº.
1) Move crankshaft pin to be removed to approximately BDC.
2) Remove connecting rod caps.
3) Using the grip of a hammer, press the piston and connecting
rod assembly out to cylinder head side.
CAUTION:
When removing the piston and connecting rod assembly, pre-
vent the big end of the connecting rod from interfering with the
oil jet.
8. Remove connecting rod bearings from connecting rods and
caps.
IKeep them by cylinder to avoid confusion.
9. Remove piston rings from pistons using piston ring expander
(multi-purpose tool).
CAUTION:
IWhen removing, prevent pistons from being damaged.
IDo not expand piston rings excessively. This may damage
the piston rings.
10. Remove pistons from connecting rods.
1) Using long nose pliers, remove snap rings.
2) Using industrial dryer, heat pistons up to 60 to 70ÉC (140 to
158ÉF).
FEM085
FEM086
FEM087
FEM088
FEM089
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-69

3) Using rod with outer diameter of 30 mm (1.18 in), press piston
pins out.
11. Remove lower cylinder block.
IThe lower cylinder block is the lower part of the cylinder block,
which works as the main bearing cap (beam) and oil pan
mounting face.
1) Remove mounting bolts for engine sub-attachment shown by
arrows in the figure.
2) Loosen and remove mounting bolts in the reverse order shown
in the figure.
3) Insert flat-bladed screwdriver into 5 locations shown by arrows
in the figure. Lift lower cylinder block evenly, and remove liquid
gasket.
CAUTION:
Prevent mating faces from being damaged.
4) When removing lower cylinder block, use slot to prevent dowel
pin from interfering with engine sub-attachment.
INo part No. is given to lower cylinder block, because it is
machined with the cylinder block.
12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder block
and lower cylinder block.
CAUTION:
Check mounting positions. Keep them to avoid confusion.
FEM090
FEM091
FEM092
FEM093
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-70

Inspection
CRANKSHAFT END PLAY
IUsing dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward, or
IUsing feeler gauge, measure crankshaft travel amount with the
lower cylinder block removed.
Standard: 0.055 - 0.140 mm (0.0022 - 0.0055 in)
Limit: 0.250 mm (0.0098 in)
IIf measured value exceeds the limit, select appropriate thrust
bearings.
Unit: mm (in)
Grade symbol Thickness of thrust bearing
A 2.275 - 2.325 (0.0896 - 0.0915)
B 2.300 - 2.350 (0.0906 - 0.0925)
C 2.325 - 2.375 (0.0915 - 0.0935)
OS 020 2.475 - 2.525 (0.0974 - 0.0994)
IOS 020 has part No. of 12280 2W215 and OS 0.20 marked on
bearing surface.
CONNECTING ROD SIDE CLEARANCE
IUsing feeler gauge, measure side clearance between connect-
ing rod and crank arm.
Standard: 0.10 - 0.22 (0.0039 - 0.0087 in)
Limit: 0.22 mm (0.0087 in)
IIf measured value exceeds the limit, replace connecting rod
and repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston pin hole inner diameter
Using inside micrometer, measure piston pin hole inner diameter.
Standard: 32.997 - 33.005 mm (1.2991 - 1.2994 in) dia.
Piston pin outer diameter
Using micrometer, measure piston pin outer diameter.
Standard: 32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
FEM094
FEM095
FEM096
FEM097
FEM098
CYLINDER BLOCKZD
EM-71

Calculation of piston to piston pin clearance
Piston pin clearance = Piston pin hole inner diameter þ Piston pin
outer diameter
Standard: þ0.003 (Tightening clearance) to 0.012 mm
(þ0.0001 to 0.0005 in)
If out of specifications, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE
IUsing feeler gauge, measure clearance between piston ring
and piston ring groove.
Unit: mm (in)
Standard Limit
Top ring 0.05 - 0.07 (0.0020 - 0.0028) 0.5 (0.020)
Second ring 0.04 - 0.08 (0.0016 - 0.0031) 0.3 (0.012)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
IAlign top ring and external surface of piston. Measure lower
side clearance of top ring with top ring pressed onto upper side
of ring groove.
IIf side clearance exceeds the limit, replace piston ring.
ICheck clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP
ICheck that cylinder bore diameter is within specifications.
Refer to EM-74, ªPISTON TO CYLINDER BORE CLEAR-
ANCEº.
IUsing piston, press piston ring to cylinder mid point, and mea-
sure end gap.
Unit: mm (in)
Standard Limit
Top ring 0.3 - 0.45 (0.0118 - 0.0177)
1.5 (0.059) Second ring 0.5 - 0.65 (0.0197 - 0.0256)
Oil ring 0.25 - 0.45 (0.0098 - 0.0177)
FEM099
FEM100
FEM101
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-72