NISSAN TERRANO 2004 Service Repair Manual

Cylinder Block
Unit: mm (in)
SEM370G
Surface flatnessStandard
Less than 0.03 (0.0012)
Limit 0.10 (0.0039)
Cylinder bore Inner diameter StandardGrade No. 1 96.000 - 96.010 (3.7795 - 3.7799)
Grade No. 2 96.010 - 96.020 (3.7799 - 3.7803)
Grade No. 3 96.020 - 96.030 (3.7803 - 3.7807)
Wear limit 0.20 (0.0079)
Out-of-round (X þ Y) Less than 0.02 (0.0008)
Taper (A þBþC) Less than 0.02 (0.0008)
Main journal inner diameter (Without bearing) 74.981 - 75.000 (2.9520 - 2.9528)
Difference in inner diam-
eter between cylinders Limit
Less than 0.05 (0.0020)
Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
Unit: mm (in)
SEM369G
Piston skirt diameter ªAºStandardGrade No. 1 95.950 - 95.960 (3.7776 - 3.7779)
Grade No. 2 95.960 - 95.970 (3.7779 - 3.7783)
Grade No. 3 95.970 - 95.980 (3.7783 - 3.7787)
ªaº dimension 10 (0.39)
Piston pin hole diameter 32.997 - 33.005 (1.2991 - 1.2994)
Piston clearance to cylinder block 0.040 - 0.060 (0.0016 - 0.0024)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-90
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PISTON RING
Unit: mm (in)
StandardLimit
Side clearance Top
0.05 - 0.07 (0.0020 - 0.0028) 0.5 (0.020)
2nd 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)
End gap Top
0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
2nd 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil (rail ring) 0.25 - 0.50 (0.0098 - 0.0197) 1.5 (0.059)
PISTON PIN
Unit: mm (in)
Piston pin outer diameter 32.993 - 33.000 (1.2989 - 1.2992)
Interference fit of piston pin to piston þ0.003 to 0.012 (þ0.0001 to 0.0005)
Piston pin to connecting rod bushing clearance Standard 0.025 - 0.045 (0.0010 - 0.0018)
Limit 0.045 (0.0018)
*: Values measured at ambient temperature of 20ÉC (68ÉF)
Connecting Rod
Unit: mm (in)
Center distance 154.5 (6.083)
Bend [per 100 (3.94)] Limit 0.05 (0.0020)
Torsion [per 100 (3.94)] Limit 0.05 (0.0020)
Connecting rod small end inner diameter 35.987 - 36.000 (1.4168 - 1.4173)
Piston pin bushing inner diameter* 33.025 - 33.038 (1.3002 - 1.3007)
Connecting rod big end inner diameter 59.987 - 60.000 (2.3617 - 2.3622)
Crankshaft journal bearing inner diameter* 70.955 - 70.990 (2.7935 - 2.7949)
Side clearance Standard 0.10 - 0.22 (0.0039 - 0.0087)
Limit 0.22 (0.0087)
*: After installing in connecting rod
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
Piston, Piston Ring and Piston Pin (Cont'd)
EM-91
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Crankshaft
Unit: mm (in)
Main journal dia. ªDmº70.907 - 70.920 (2.7916 - 2.7921)
Pin journal dia. ªDpº Grade No. 0 56.913 - 56.926 (2.2407 - 2.2412)
Center distance ªrº 50.95 - 51.05 (2.0059 - 2.0098)
Out-of-round (X þ Y) Standard Less than 0.01 (0.0004)
Taper (A þ B) Standard Less than 0.01 (0.0004)
Runout [TIR*] Standard Less than 0.01 (0.0004)
Limit Less than 0.03 (0.0012)
Free end play Standard 0.055 - 0.140 (0.0022 - 0.0055)
Limit 0.25 (0.0098)
SEM645EM715
*: Total indicator reading
Available Main Bearing
UNDERSIZE
FEM127
Size
Thickness ªTº mm (in) Width ªWº mm (in)Main journal diameter ªDmº
Standard 2.005 - 2.013 (0.0789 - 0.0793)
25.74 - 26.00 (1.0134 - 1.0236)Grind so that bearing clearance is
the specified value.
US 025 2.130 - 2.138 (0.0839 - 0.0842)
US 050 2.255 - 2.263 (0.0888 - 0.0891)
US 075 2.380 - 2.388 (0.0937 - 0.0940)
US 100 2.505 - 2.513 (0.0986 - 0.0989)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-92
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Available Connecting Rod Bearing
CONNECTING ROD BEARING
Grade numberThickness ªTº mm (in) Width ªWº mm (in)
Standard 1.505 - 1.513 (0.0593 - 0.0596)
25.9 - 26.1 (1.020 - 1.028)
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
BALANCER SHAFT BUSH
Unit: mm (in)
SEM371G
Balancer shaft journal outer diameter
Front 50.875 - 50.895 (2.0029 - 2.0037)
Rear 50.675 - 50.695 (1.9951 - 1.9959)
Balancer shaft bearing inner diameter Front 53.980 - 54.010 (2.1252 - 2.1264)
Rear 53.780 - 53.810 (2.1173 - 2.1185)
Balancer shaft journal oil clearance Standard 0.045 - 0.135 (0.0018 - 0.0053)
Limit 0.180 (0.0071)
Balancer shaft bush outer diameter (d) Front 54.090 - 54.130 (2.1295 - 2.1311)
Rear 53.890 - 53.930 (2.1216 - 2.1232)
Thickness (t) Front 0.2 - 0.4 (0.008 - 0.016)
Rear 0.2 - 0.4 (0.008 - 0.016)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-93
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Miscellaneous Components
Unit: mm (in)
Flywheel runout [TIR]*Less than 0.15 (0.0059)
Drive plate runout [TIR]* Less than 0.1 (0.0039)
*: Total indicator reading
BEARING CLEARANCE
Unit: mm (in)
Main bearing clearance Standard 0.035 - 0.083 (0.0014 - 0.0033)
Connecting rod bearing clearance Standard 0.035 - 0.077 (0.0014 - 0.0030)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-94
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Parts Requiring Angular Tightening
ISome important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
I If these parts are tightened using a torque setting method, dis-
persal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
I Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
I To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
I Before tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
I The bolts and nuts which require the angular-tightening method
are as follows:
(1) Cylinder head bolts
(2) Connecting rod cap nuts
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface and
grooves, and then completely clean any oil stains from
these portions.
b. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.)
IBe sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (oil pan).
I Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perimeter. (Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and engine coolant.
SEM371C
PRECAUTIONSTD27Ti
EM-95
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Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST0501S000*
Engine stand assembly
q
1ST05011000
Engine stand
q
2ST05012000
Base
Disassembling and assembling
KV10106500*
Engine attachment
KV11103200*
Engine sub-attachment
q1KV10109210*
Valve spring
compressor
q
2KV10111200*
Adapter
Disassembling and assembling valve
components
KV10107900*
Valve oil seal puller
Disassembling valve oil seal
KV11103400
Valve oil seal drift
Installing valve oil seal
ST11033000*
Valve guide drift
Removing valve guide
PREPARATIONTD27Ti
EM-96
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV11103900*
Valve guide drift
Installing valve guide
q
1K V 111 0 111 0
Valve seat remover
q
2KV11103610
Adapter (Intake)
q
3KV11103620
Adapter (Exhaust)
Removing valve seat
q
1ST15243000
Valve seat drift
q
2KV11103810
Adapter (Intake)
q
3KV11103820
Adapter (Exhaust)
Installing valve seat
EM03470000*
Piston ring compressor
Installing piston into cylinder
KV111033S0
Engine stopper
q
1KV11103310
Stopper plate
q
2KV10105630
Stopper gear
Preventing crankshaft from rotating
ST16610001*
Pilot bushing puller
Removing pilot bushing
PREPARATIONTD27Ti
Special Service Tools (Cont'd)
EM-97
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV111045SO
Cam bushing replacer
set
q
1KV11104510
Replacer bar
q
2KV1104520
Guide plate
q
3KV11104530
Adapter
(1st bushing)
q
4ST15243000
Drift
Removing cam bushing or installing cam
bushing
KV10109300*
Injection pump drive
gear holder
Preventing drive gear from rotating
KV11103000*
Injection pump drive
gear puller
Removing drive gear
q
1ED19601000
Compression gauge
q
2ED19600600
Compression gauge
adapter (for glow plug
hole)
q
3ED19600700
Compression gauge
adapter (for injector
hole)
Checking compression pressure
WS39930000*
Tube presser
Pressing the tube of liquid gasket
KV119E0030
Nozzle holder socket
Removing and installation injection
nozzle assembly
ST11032000*
Valve guide reamer
8.0 mm (0.315 in) dia.
Reaming valve guide
PREPARATIONTD27Ti
Special Service Tools (Cont'd)
EM-98
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Commercial Service Tools
Tool nameDescription
Piston ring expander
Removing and installing piston ring
PREPARATIONTD27Ti
EM-99
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