NISSAN TERRANO 2002 Service Repair Manual

INSTALLATION
1. Install oil strainer.
2. Install oil pan.
a. Use a scraper to remove all traces of liquid gasket from mating
surfaces.
IAlso remove traces of liquid gasket from mating surface of cyl-
inder block, front cover.
IRemove old liquid gasket from the bolt hole and thread.
b. Apply a continuous bead of liquid gasket to mating surface of
oil pan.
IUse Genuine Liquid Gasket or equivalent.
IApply liquid gasket to the groove on the mating surface.
IAllow 8 mm (0.31 in) clearance around center of bolt holes.
c. Apply liquid gasket to inner sealing surface as shown in figure.
IBe sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.188 in).
IAttaching should be done within 5 minutes after coating.
2. Tighten the mounting bolts in the order shown in the figure.
Then tighten in the same order to the torque stated.
3. The torque of the installation bolts will differ depending on posi-
tion.
4. Install in the reverse order of removal.
SEM159F
JEM774G
JEM773G
OIL PAN & OIL STRAINERZD
Removal and Installation (Cont'd)
EM-23

Removal and Installation
REMOVAL
1. Remove the following parts.
IRadiator under side
IRadiator shroud
ICooling fan
IChain cover front side
IA/T cooler hose (Disconnect)
IVacuum hose
IIntercooler cover (When removing vacuum tank)
2. Remove the installation bolts and pull the vacuum pump from
the engine front directly.
3. If it is difficult to remove from the spline shaft connection, tap
lightly with a plastic hammer.
SEM320G
SEM321G
VACUUM PUMPZD
EM-24

INSPECTION
1. Remove the vacuum hose. Connect the vacuum gauge through
the 3-way connector. Otherwise, remove the welch valve of the
vacuum pipe and attach the vacuum gauge directly. (The illus-
tration shows the second method.)
IRemove an appropriate part to measure the vacuum pump load
pressure directly and install the vacuum gauge. Refer to the
figure.
2. Start the engine, and measure the load pressure with the
engine idling.
Vacuum pressure:
Standard
þ93.3 to þ101.3 kPa (þ933 to þ1,013 mbar, þ700
to þ760 mmHg, þ27.56 to þ29.92 inHg)
3. If outside the standard value, make sure that there is no intake
of air within the circuit and measure again.
4. Replace the vacuum pump if still outside the standard value.
INSTALLATION
IInstall in the reverse order of removal.
SEM322G
VACUUM PUMPZD
Removal and Installation (Cont'd)
EM-25

Removal and Installation
CAUTION:
As the internal mechanism of the idler gear must first of all,
and always, be set by a bolt when removing the timing chain
before removing the fuel injection pump and timing gear, fol-
low the procedures on EM-38, ªRemoval of timing chain after
setting idler gearº, ªElectronic controlled fuel injection pumpº.
IThis chapter will deal with the summary of removing the timing
chain before removing the camshaft and cylinder head.
Removal
1. Remove the following parts.
IEngine cover
IIntercooler
IAir inlet pipe
IThrottle body
IRocker cover
ISpill tube
ICoolant (Drain)
IRadiator upper hose
IWater outlet
IRadiator shroud
ICooling fan
IAuxiliary belt
IVacuum pipe
IVacuum pump
YEM028
TIMING CHAINZD
EM-26

2. Move the following parts.
ITDC sensor harness
IPower steering oil pump
3. Remove the chain cover.
IRemove the holding bolts A to C shown in the figure.
CAUTION:
While the chain cover is removed, be careful not to allow entry
of dust or foreign objects.
4. Set the No. 1 cylinder to the TDC.
1) Turn the crankshaft pulley clockwise, and match the timing
indicator of the gear case to the timing mark of the crankshaft
pulley.
2) Make sure that the cam sprocket match mark is in the position
shown in the figure.
IIf the match mark is not in position, turn the crankshaft pulley
once more and position it.
IWhen removing at No. 1 cylinder TDC, each sprocket and chain
is fitted using the match mark, therefore there is no need to
apply any match marks beforehand.
5. Remove the chain tensioner.
1) Loosen upper and lower holding bolts.
2) Holding the chain tensioner in your hand, remove the upper
holding bolt and release the spring tension.
3) Remove the lower holding bolt, then remove the chain ten-
sioner.
IThe chain tensioner does not have a mechanism which pre-
vents the ejection of the plunger. (It does have a mechanism
which prevents the plunger from returning.)
CAUTION:
Be careful not to drop the plunger and spring.
FEM004
SEM342G
FEM005
FEM006
TIMING CHAINZD
Removal (Cont'd)
EM-27

6. Remove the timing chain slack guide.
7. Remove the timing chain with cam sprocket.
ILoosen the cam sprocket holding bolt by fixing the hexagonal
portion of the intake manifold side camshaft with a spanner, etc.
IIf the spill tube is not removed, fix the hexagonal portion of the
exhaust manifold side camshaft.
CAUTION:
Do not loosen the holding bolt by using the tension of the
chain.
8. Remove the timing chain tension guide.
Installation
1. Install the timing chain tension guide.
2. Install the cam sprocket and the timing chain together.
IInstall by aligning the sprocket and timing chain match marks.
ITighten the cam sprocket holding bolt by fixing the hexagonal
portion of the camshaft.
CAUTION:
Do not tighten in the holding bolt using the tension of the
chain.
3. Install the timing chain slack guide.
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Do not over-tighten.
4. Install the chain tensioner.
1) With the chain tensioner in the position shown in the figure (with
the plunger on the outer side), temporarily tighten the holding
bolt.
2) Press the plunger into the tensioner body while pressing on the
clips which prevent the plunger from returning.
3) Install the upper side holding bolt while holding the plunger
down with your finger and rotating it 180 degrees.
4) Tighten the holding bolt to the specified torque.
5. Install the chain cover.
1) Before installing chain cover, remove all traces of liquid gasket
from mating surface using a scraper.
2) Apply a continuous bead of liquid gasket to chain cover.
IUse Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0
mm (0.079 to 0.118 in) dia. range.
b. Attach chain cover to gear case within 5 minutes after
coating.
c. Wait at least 30 minutes before refilling engine oil or start-
ing engine.
SEM335G
FEM007
FEM008
FEM009
TIMING CHAINZD
Removal (Cont'd)
EM-28

3) Install the chain cover.
IThe dimension below the neck of the holding bolt will vary
depending on the part.
Dimension below the neck:
A: 20 mm (0.79 in)
B: 50 mm (1.97 in)
C: 60 mm (2.36 in)
6. Install by following all removal procedures in reverse.
CAUTION:
IArrange the TDC sensor harness in the position shown in
the figure.
IMake sure that the harness has no deflection around the
vicinity of the crankshaft pulley when installing the clamp.
FEM004
SEM349G
TIMING CHAINZD
Installation (Cont'd)
EM-29

Removal and Installation
IThis engine will have a different valve arrangement from nor-
mal DOHC 4-valve type engines. As both camshafts on this
engine have intake and exhaust cams, in this chapter they are
named as follows:
Camshaft (Right side): Intake manifold side camshaft
Camshaft (Left side): Exhaust manifold side camshaft
IThe same parts are used for the right and left sides.
IRefer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
Removal
1. Set the No. 1 cylinder at TDC, then remove the chain case,
timing chain and other parts in connection. Refer to ªTIMING
CHAINº, EM-26.
2. Remove the cam gear.
ILoosen the cam gear installation bolt by fixing the hexagonal
portion of the camshaft.
IThe idler gear cannot be removed at this point as the gear case
is in the way. (The cylinder head can be removed as a single
unit.)
SEM350G
FEM010
FEM011
CAMSHAFTZD
EM-30

3. Remove injection tube and injection nozzle assembly. Refer to
EC section, ªInjection Tube and Injection Nozzleº in ªBASIC
SERVICE PROCEDUREº.
4. Remove the camshaft.
IPlace distinguishing marks on the right and left sides with paint.
ILoosen and remove the installation bolt in reverse order shown
in the figure.
5. Remove the adjusting shim and valve lifter.
IRemove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
Inspection
VISUAL CHECK OF CAMSHAFT
ICheck the camshaft for one sided wear or scratches.
IReplace the camshaft if there are abnormalities.
CAMSHAFT RUNOUT
IPrepare V-block on a flat surface and secure camshaft journals
No. 1 and No. 5.
ISet the dial gauge vertically on journal No. 3.
IRotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)
HEIGHT OF CAM NOSE
Measure by using a micrometer.
Standard:
Intake
40.488 0.02 mm (1.5940 0.0008 in)
Exhaust
40.850 0.02 mm (1.6083 0.0008 in)
CAMSHAFT OIL CLEARANCE
Measure by using a micrometer.
Cam journal outer diameter:
Standard
29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
FEM012
FEM013
FEM014
FEM015
CAMSHAFTZD
Removal (Cont'd)
EM-31

CAMSHAFT BRACKET INNER DIAMETER
IInstall camshaft bracket and tighten bolts to the specified
torque.
IMeasure inner diameter of camshaft bracket using an inside
micrometer.
Standard: 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
CAMSHAFT OIL CLEARANCE CALCULATIONS
Oil clearance = Cam bracket inner diameter þ Cam journal outer
diameter
Standard: 0.045 - 0.090 mm (0.0018 - 0.0035 in) dia.
IIf it exceeds the standard value, refer to the standard value of
each unit, then replace the camshaft and/or cylinder head.
IAs the camshaft bracket is manufactured with the cylinder
head, it is impossible to replace only the camshaft bracket.
CAMSHAFT END PLAY
ISet the dial gauge to the front end of the camshaft. Measure
the end play by moving the camshaft in the direction of the axle.
Standard: 0.065 - 0.169 mm (0.0026 - 0.0067 in)
Limit: 0.2 mm (0.0079 in)
IIf end play exceeds the limit, replace camshaft and measure
camshaft end play again.
IIf end play still exceeds the limit after replacing camshaft,
replace cylinder head.
VISUAL INSPECTION OF VALVE LIFTER
Check lifter side for any signs of wear or damage. Replace if there
are any abnormalities.
VISUAL INSPECTION OF ADJUSTING SHIM
Check cam nose contact and sliding surfaces for wear and
scratches. Replace if there are any abnormalities.
VALVE LIFTER CLEARANCE
Measure the outer diameter of the valve lifter with a micrometer.
Standard: 34.450 - 34.465 mm (1.3563 - 1.3569 in) dia.
FEM016
FEM017
FEM018
CAMSHAFTZD
Inspection (Cont'd)
EM-32