NISSAN TERRANO 2002 Service Repair Manual

CONNECTING ROD BEND AND TORSION
Use connecting rod aligner to check bend and torsion.
Bend limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Connecting rod big end inner diameter
Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter.
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in) dia.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL
END)
Connecting rod small end inner diameter
Use inside micrometer to measure small end inner diameter.
Standard:
33.025 - 33.038 mm (1.3002 - 1.3007 in) dia.
Piston pin outer diameter
Use micrometer to measure piston pin outer diameter.
Standard:
32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
Calculation of connecting rod bushing clearance
Connecting rod small end bushing clearance = Connecting rod
small end inner diameter þ Piston pin outer diameter
Standard:
0.025 - 0.045 mm (0.0010 - 0.0018 in)
IIf out of specifications, replace connecting rod and/or piston
and piston pin assembly.
FEM102
FEM103
FEM104
FEM098
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-73

INew connecting rods are classified into 8 weight classes at
factory. The same class connecting rods are used on a engine.
Weight grade symbol Weight class g (oz)
H 1,261 - 1,264 (44.5 - 44.6)
I 1,264 - 1,267 (44.6 - 44.7)
K 1,267 - 1,270 (44.7 - 44.8)
L 1,270 - 1,273 (44.8 - 44.9)
M 1,273 - 1,276 (44.9 - 45.0)
O 1,276 - 1,279 (45.0 - 45.1)
P 1,279 - 1,282 (45.1 - 45.2)
S 1,282 - 1,285 (45.2 - 45.3)
CYLINDER BLOCK TOP SURFACE DISTORTION
IUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of oil and coolant pas-
sages.
IUse straightedge and feeler gauge to check block upper sur-
face for distortion.
Limit: 0.1 mm (0.004 in)
MAIN BEARING HOUSING INNER DIAMETER
IInstall main bearing caps without main bearings. Tighten
mounting bolts to the specified torque.
IUse bore gauge to measure main bearing housing inner diam-
eter.
Standard:
74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
IIf out of specification, replace cylinder block and lower cylinder
block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder bore inner diameter
IUsing bore gauge, measure cylinder inner diameters at 6 posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
Cylinder inner diameter (Standard):
96.000 - 96.030 mm (3.7795 - 3.7807 in) dia.
Wear limit: 0.2 mm (0.008 in)
Out-of-round limit (X - Y): 0.02 mm (0.0008 in)
Taper limit (A - C): 0.02 mm (0.0008 in)
FEM106
FEM107
FEM108
FEM109
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-74

IIf clearance exceeds the limit, or any flaws or seizures are
found on inner surface of cylinder, horn or bore the applicable
cylinder.
Piston outer diameter
Use micrometer to measure piston skirt outer diameter.
Measurement position:
10 mm (0.39 in) upper from the lower end of pis-
ton
Standard:
95.950 - 95.980 mm (3.7776 - 3.7787 in) dia.
Calculation of piston to piston bore clearance
ICalculate using piston skirt outer diameter and cylinder inner
diameter (direction X, position B).
Clearance = Cylinder inner diameter þ Piston skirt outer diam-
eter
Specifications at room temperature [20ÉC (68ÉF)]:
0.040 - 0.060 mm (0.0016 - 0.0024 in)
IIf out of specification, replace piston and piston pin assembly.
SELECTIVE PISTON COMBINATION
When using new cylinder block
IConfirm cylinder bore grade (1, 2, 3) on left upper surface of
cylinder block, and refer to ªSelective combination chartº below
to select appropriate piston.
IPart No. is given to a piston and piston pin as a set.
When re-using an old cylinder block
1. Measure cylinder block bore inner diameter.
2. Referring to ªCylinder block bore inner diameterº in ªSelective
combination chartº, select appropriate piston according to cyl-
inder bore grade.
FEM110
FEM111
FEM112
FEM113
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-75

Selective combination chart
Unit: mm (in)
q: Preferable combination
g: Allowable combination
X: NG combinationPiston grade
12
95.950 - 95.960
(3.7776 - 3.7779)95.960 - 95.970
(3.7779 - 3.7783)
Cylinder
bore grade
(Cylinder
block bore
inner
diameter)196.000 - 96.010
(3.7795 - 3.7799)qX
296.010 - 96.020
(3.7799 - 3.7803)gq
396.020 - 96.030
(3.7803 - 3.7807)gq
IPiston grade 3 (95.980/95.970) is applicable at factory only.
INew pistons are classified into 4 weight classes at factory. The
same class pistons are used on a engine.
Weight grade symbol Weight class g (oz)
E 600 - 605 (21.2 - 21.3)
F 605 - 610 (21.3 - 21.5)
G 610 - 615 (21.5 - 21.7)
H 615 - 620 (21.7 - 21.9)
CRANKSHAFT JOURNAL OUTER DIAMETER
Use micrometer to measure journal outer diameter.
Standard: 70.907 - 70.920 mm (2.7916 - 2.7921 in) dia.
CRANKSHAFT PIN OUTER DIAMETER
Use micrometer to measure pin outer diameter.
Standard: 56.913 - 56.926 mm (2.2407 - 2.2412 in) dia.
CRANKSHAFT OUT-OF-ROUND AND TAPER
IUsing micrometer, measure each journal and pin at 4 points
shown in the figure.
IOut-of-round value is indicated by difference in dimensions
between directions A and B at points 1 and 2.
ITaper value is indicated by difference in dimensions between
points 1 and 2 in directions A and B.
Out-of-round limit: 0.01 mm (0.0004 in)
Taper limit: 0.01 mm (0.0004 in)
CRANKSHAFT RUNOUT
IPlace V-block onto surface plate to support journals at both
ends of crankshaft.
IPosition dial indicator vertically onto No. 3 journal.
IRotate crankshaft to read needle movement on dial indicator.
ICrankshaft bend value is 1/2 of needle movement.
Limit: 0.03 mm (0.0012 in)
FEM114
FEM115
FEM116
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-76

CONNECTING ROD BEARING OIL CLEARANCE
Method by measurement
IInstall connecting rod bearings to connecting rods and caps,
and tighten connecting nuts to the specified torque. Use inside
micrometer to measure connecting rod bearing inner diameter.
Bearing clearance = Connecting rod bearing inner diameter þ
Crankshaft pin outer diameter
Standard: 0.035 - 0.077 mm (0.0014 - 0.0030 in)
IIf out of specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select appro-
priate connecting rod bearing to adjust clearance to specifica-
tions.
Refer to ªConnecting rod bearing undersize listº on the next
page.
Method using plastigage
IRemove contamination such as oil, dust completely from crank-
shaft pins and each bearing surface.
ICut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
IInstall connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
IRemove connecting rod caps and bearings, and measure plas-
tigage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in ªMethod
by measurementº.
Undersize bearing usage
IIf bearing clearance is out of specifications for connecting rod
bearings in standard size, use undersize bearings.
IWhen using undersize bearings, measure bearing inner diam-
eter with bearing installed, and grind pins to adjust clearance
to specification.
FEM103
FEM118
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-77

Connecting rod bearing undersize list
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.630 - 1.638 (0.0642 - 0.0645)
US 0.50 (0.0197) 1.755 - 1.763 (0.0691 - 0.0694)
US 0.75 (0.0295) 1.880 - 1.888 (0.0740 - 0.0743)
US 1.00 (0.0394) 2.005 - 2.013 (0.0789 - 0.0793)
CAUTION:
When grinding crank pins to use undersize bearings, avoid
damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING OIL CLEARANCE
Method by measurement
IInstall main bearings to cylinder block and bearing caps, and
tighten bearing cap bolts to the specified torque. Measure main
bearing inner diameter.
Bearing clearance = Bearing inner diameter þ Crankshaft jour-
nal outer diameter
Standard: 0.035 - 0.083 mm (0.0014 - 0.0033 in)
IIf out of specification, check main bearing housing inner diam-
eter and crankshaft journal outer diameter, and select appropri-
ate main bearing to adjust clearance to specifications.
Refer to ªMain bearing undersize listº on the next page.
Method using plastigage
IRemove contamination such as oil, dust completely from crank-
shaft journals and each bearing surface.
ICut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
IInstall main bearings to caps, and tighten connecting rod nuts
to the specified torque.
CAUTION:
Never rotate crankshaft.
IRemove bearing caps and bearings, and measure plastigage
width using scale on plastigage bag.
FEM119
FEM120
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-78

CAUTION:
If out of specification, take same action mentioned in ªMethod
by measurementº.
Undersize bearing usage
IIf bearing clearance is out of specifications for main bearings
in standard size, use undersize bearings.
IWhen using undersize bearings, measure bearing inner diam-
eter with bearing installed, and grind crank journals to adjust
clearance to specification.
Main bearing undersize list
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.130 - 2.138 (0.0839 - 0.0842)
US 0.50 (0.0197) 2.255 - 2.263 (0.0888 - 0.0891)
US 0.75 (0.0295) 2.380 - 2.388 (0.0937 - 0.0940)
US 1.00 (0.0394) 2.505 - 2.513 (0.0986 - 0.0989)
CAUTION:
When grinding crank journals to use undersize bearings,
avoid damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING CRUSH HEIGHT
ITighten bearing caps to the specified torque with main bearings
installed, and remove caps. The bearing end must then be
higher than the flat surface.
Standard: Crush height must exist.
IIf out of specification, replace main bearings.
FEM119
FEM122
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-79

Assembly
1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase, and cylinder bore to remove foreign matter.
2. Install main bearings and thrust bearings.
1) Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
2) Install thrust bearings on both sides of No. 4 housing on cylin-
der block.
IInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
3) Being careful with the direction, install main bearings.
IInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the lower cylinder block side.
IWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them com-
pletely.
IAlign stopper notches on bearings to install them.
ICheck that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
3. Install crankshaft to cylinder block.
IWhile rotating crankshaft by hand, check for smooth rotation.
4. Install lower cylinder block.
IApply a continuous bead of liquid gasket to lower cylinder block
as shown in the figure.
IUsing slots on engine sub-attachment, install the lower cylinder
block to the cylinder block, avoiding interference of dowel pins.
5. Tighten lower cylinder mounting bolts to the torque shown
below in 3 consecutive steps in the order shown in the figure.
Unit: N×m (kg-m, ft-lb)
Main bolt (Nos. 1 - 10) Sub-bolt (Nos. 11 - 20)
1st 20 (2.0, 14) 98 (10, 72)
2nd 98 (10, 72) 20 (2.0, 14)
3rd 167 - 176 (17 - 18, 123 - 130) 40 - 46 (4.0 - 4.7, 29 - 33)
ISub-bolt No. 17 has shorter length than that of other sub-bolts.
FEM126
FEM127
FEM128
FEM092
CYLINDER BLOCKZD
EM-80

6. Install mounting bolts for engine sub-attachment shown by
arrows in the figure.
IAfter tightening bolts to the specified torque, check crankshaft
for smooth rotation.
ICheck crankshaft end play.
Refer to EM-71, ªCRANKSHAFT END PLAYº.
7. Install pistons to connecting rod.
1) Using long nose pliers, install snap rings to grooves on piston
rear side.
IFit snap rings correctly into grooves.
2) Install pistons to connecting rods.
IUsing industrial dryer, heat pistons up to approx. 60 to 70ÉC
(140 to 158ÉF) until piston pin can be pressed down by finger
touch. Then insert piston pins into piston and connecting rod
from front side of piston toward rear.
IAssemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
3) Install snap rings to front side of pistons.
IRefer to above 1) for precaution on snap ring installation.
IAfter installation, check connecting rods for smooth movement.
8. Use piston ring expander (multi-purpose tool) to install piston
rings.
CAUTION:
When installing, prevent piston from being damaged.
IInstall top ring and second ring with stamped surfaces facing
upward.
Identification stamp:
Top ring: R
Second ring: RN
9. Install connecting rod bearings to connecting rods and caps.
IWhile installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces, but
clean them completely.
IAlign stoppers on connecting rod bearings with connecting rod
stopper notches to install connecting rod bearings.
FEM091
FEM131
FEM132
FEM133
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-81

10. Install piston and connecting rod assembly to crankshaft.
IMove crankshaft pin to be removed to BDC.
IAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
IUsing piston ring compressor (multi-purpose tool), install piston
and connecting rod assembly with front mark on piston crown
facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, prevent
the big end of connecting rod from interfering with oil jet.
11. Install connecting rod caps and mounting nuts.
IAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
IAfter tightening nuts, check crankshaft for smooth rotation.
ICheck connecting rod side clearance.
Refer to EM-71, ªCONNECTING ROD SIDE CLEARANCEº.
12. Install rear oil seal and retainer assembly.
IApply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
13. Press fit pilot bushing into flywheel (M/T model).
1) Using drift with outer diameter of 35 mm, press fit spacer until
it is in contact with the flywheel to prevent displacement at
removal.
2) Using drift with outer diameter of 20 mm, press fit pilot bushing
by the length shown in the figure.
14. Install rear plate.
15. Install removed parts to engine in the reverse order of disas-
sembly.
16. Remove engine from engine stand.
FEM134
FEM131
FEM053
SEM366G
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-82