NISSAN TERRANO 2002 Service Repair Manual

5. Remove cylinder head assembly.
ILoosen and remove mounting bolts in the reverse order shown
in the figure.
ILift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
IDo not drop the O-ring located between the front of cylin-
der head and the rear of gear case into the engine.
IRemove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head, or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.
IFor glow plug removal, the following shall be noted.
CAUTION:
ITo avoid breakage, do not remove glow plug unless nec-
essary.
IPerform continuity test with glow plug installed.
IKeep glow plug from any impact. (Replace if dropped from
a height 10 cm (3.94 in) or higher.)
IDo not use air impact wrench.
6. Remove idler gear.
CAUTION:
While removing idler gear, keep the rear of idler gear facing up
to prevent idler shaft from falling.
Inspection
CYLINDER HEAD BOLT DEFORMATION (ELONGATION)
IUsing micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.
IIf the necking point can be identified, set it as measuring point
d2.
ICalculate the difference between d1 and d2.
Limit: 0.15 mm (0.0059 in)
IDLER GEAR END PLAY
ITighten mounting bolts to the specified torque.
IUsing feeler gauge, measure the clearance between gear plate
and idler gear.
Standard: 0.07 - 0.14 mm (0.0028 - 0.0055 in)
Limit: 0.2 mm (0.0079 in)
IIf the measured value exceeds the limit value, replace idler
gear, shaft, and gear plate.
FEM055
SEM379G
FEM056
CYLINDER HEADZD
Removal (Cont'd)
EM-53

IDLER GEAR OIL CLEARANCE
IMeasure the inner diameter (d1) of idler gear shaft hole.
Standard: 26.000 - 26.020 mm (1.0236 - 1.0244 in)
IMeasure the outer diameter (d
2) of idler shaft.
Standard: 25.967 - 25.980 mm (1.0223 - 1.0228 in)
ICalculate gear clearance.
Clearance = d
1þd2Standard: 0.023 - 0.053 mm (0.0009 - 0.0021 in)
Installation
1. Install cylinder head gasket.
ICylinder head gasket to be installed is selected by its thickness
through the following procedure.
When replacing gasket only
IInstall gasket with same thickness as the one removed.
IGasket thickness is identified by the number of notches located
on rear-left side.
GradeGasket thickness*
mm (in)No. of notches
1 0.65 (0.0256) 1
2 0.70 (0.0276) 2
*: Thickness of gasket tightened with head bolts
IThe number of notches can be checked at the position shown
in the figure before cylinder head is removed. (It is necessary
to remove exhaust manifold.)
When repairing/replacing the following
IWhen the top of cylinder block or crankshaft pin/journal is
ground, or
IWhen cylinder block, piston, connecting rod, or crankshaft is
replaced
1) Move piston toward TDC.
2) Position dial indicator on cylinder block as shown in the figure,
and adjust the needle to ª0º.
3) Move dial indicator stand aside, and position the dial indicator
to the measuring point as shown in the figure.
4) Rotate crankshaft slowly, and read the value on dial indicator
at piston's maximum height.
5) Repeat above procedure at 2 positions of each cylinder (8
positions in total for 4 cylinders), and select the appropriate
gasket by comparing the maximum crown depression with the
table.
FEM057
YEM031
FEM059
FEM060
CYLINDER HEADZD
Inspection (Cont'd)
EM-54

Unit: mm (in)
GradePiston crown
depressionGasket thick-
ness*1No. of notches
1Less than þ0.078
(þ0.0031)*20.65 (0.0256) 1
2More than þ0.078
(þ0.0031)*30.70 (0.0276) 2
*1: Thickness of gasket tightened with head bolts
*2: Indicates values such as þ0.080 mm (þ0.0031 in).
*3: Indicates values such as þ0.075 mm (þ0.0030 in).
2. Install idler gear and idler shaft.
ICheck that the counter marks with cam gear, ªAAº and ªBBº, are
located on the front side of the engine.
Refer to EM-52.
CAUTION:
Since idler gear cannot be installed or removed with cylinder
head assembly mounted on the engine because of interfer-
ence with gear case, make sure that there are no reverse
installations or uninstalled parts.
3. Install cylinder head assembly.
1) Attach gasket onto the rear of gear case.
2) Install O-ring to the rear of gear case.
3) Align cylinder head assembly with dowel pin of cylinder block
and install.
CAUTION:
IMake sure the O-ring does not fall off. Be careful not to
drop the O-ring.
IDo not damage gasket located at the front.
4. Position cylinder head assembly close to the rear of the gear
case.
1) Install cylinder head bolts to the front and rear of cylinder head
respectively, and tighten to the specified torque.
:40-49N×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
2) Loosen cylinder head bolts completely.
3) Install gear case mounting bolts to 2 positions shown by arrows
in the figure, and tighten to the specified torque.
: Less than 9.8 N×m (1.0 kg-m, 87 in-lb)
5. Tighten cylinder head bolts in the order indicated in the figure.
1) Apply engine oil to installation bolt threads and washers.
2) Tighten bolts to 98 to 102 N×m (10.0 to 10.5 kg-m, 73 to 75 ft-
lb).
3) Loosen bolts completely until the torque becomes 0 N×m(0
kg-m, 0 in-lb).
CAUTION:
For procedure 3), loosen bolts in the reverse order as indi-
cated in the figure.
4) Tighten bolts to 40 to 44 N×m (4.0 to 4.5 kg-m, 29 to 32 ft-lb).
5) Tighten bolts at the angle of 90 to 95É (target is 95É). (Angle
tightening)
FEM061
FEM062
FEM055
CYLINDER HEADZD
Installation (Cont'd)
EM-55

6) Once again, tighten bolts at the angle of 90 to 95É (target is
95É). (Angle tightening)
CAUTION:
Perform the following procedure to check turning angle of
angle tightening, and do not judge by visual check.
ANGLE TIGHTENING PROCEDURE
With protractor
IMake counter marks on the bolt head of cylinder head and cyl-
inder head surface with paint, and check the turning angle.
With angle wrench (SST)
ICheck the turning angle using angle indicator of angle wrench.
6. Loosen gear case mounting bolts which were tightened in 3) of
procedure 4, retighten them to the specified torque.
7. Install glow plug.
I2 different types (manufacturers) of glow plugs are provided in
parallel. (Refer to the figure for identification.)
IDo not install 2 different types of glow plugs in the engine. Make
sure that the same glow plugs are installed.
IUsing reamer, remove the carbon adhering to the installation
hole of glow plug, and install glow plug.
FEM063
FEM064
CYLINDER HEADZD
Installation (Cont'd)
EM-56

8. Install oil return pipe to the rear side of the cylinder head.
IWhen reinstalling a stud bolt, apply Three Bond 1207C (KP510
00150) to the thread of the bolt.
Disassembly
1. Remove adjusting shims and valve lifters.
Check the installation positions, and keep them to avoid being
confused.
2. Using valve spring compressor (SST), compress valve spring.
Using magnetic hand, remove valve collets.
3. Remove valve spring retainers and valve springs.
4. Remove valves as pressing valve stems toward combustion
chamber.
IBefore removing the valve, check the valve guide clearance.
(Refer to EM-58.)
ICheck installation positions, and keep them to avoid being con-
fused.
IRefer to the figure for intake/exhaust valve positions. (Intake
and exhaust valve driving cams are provided alternately for
each camshaft.)
FEM081
SEM361G
FEM010
CYLINDER HEADZD
Installation (Cont'd)
EM-57

5. Remove valve oil seals using valve oil seal puller (SST).
6. Remove valve spring seats.
7. Before removing valve spring seats, perform valve seat contact
check. (Refer to EM-60.)
8. Before removing valve guides, perform valve guide clearance
check. (Refer to below.)
Inspection
CYLINDER HEAD DISTORTION
Using straightedge and feeler gauge, check the bottom of the cyl-
inder head for distortion.
Limit: 0.2 mm (0.008 in)
VALVE DIMENSION
Using micrometer, measure the dimensions of each part.
Standard
Unit: mm (in)
Intake valve Exhaust valve
L 113.5 (4.4685) 113.5 (4.4685)
T 1.5 (0.0591) 1.5 (0.0591)
fd6.962 - 6.977
(0.2741 - 0.2747)6.945 - 6.960
(0.2734 - 0.2740)
fD31.9 - 32.1
(1.2559 - 1.2638)29.9 - 30.1
(1.1772 - 1.1850)
a(degree) 45É00¢- 45É30¢45É00¢- 45É30¢
VALVE GUIDE CLEARANCE
IPerform the inspection before removing valve guides.
ICheck that the valve stem diameter is within specifications.
IPush valve approximately 25 mm (0.98 in) toward combustion
chamber, move valve toward dial indicator to measure valve
movement.
IValve guide clearance is 1/2 of movement on dial indicator.
FEM065
FEM066
FEM067
FEM068
CYLINDER HEADZD
Disassembly (Cont'd)
EM-58

Unit: mm (in)
Standard Limit
Intake0.023 - 0.053
(0.0009 - 0.0021)0.18 (0.0071)
Exhaust0.040 - 0.070
(0.0016 - 0.0028)0.10 (0.0039)
IIf the measured value exceeds the limit, replace valve guide.
VALVE GUIDE REPLACEMENT
IThere is no setup for oversized valve guide.
1. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) in oil bath.
2. Using valve guide drift (multi-purpose tool: for 7.0 mm dia.), tap
valve guides out from the combustion chamber side.
3. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) in oil bath.
4. Using valve guide drift (multi-purpose tool: for 7.0 mm dia.),
press fit valve guides from camshaft side, referring to the
dimension shown in the figure.
5. Using valve guide reamer (multi-purpose tool), perform ream-
ing to the press-fitted valve guides.
Reaming specifications:
Intake/Exhaust
7.000 - 7.015 mm (0.2756 - 0.2762 in)
FEM069
FEM070
FEM071
FEM072
CYLINDER HEADZD
Inspection (Cont'd)
EM-59

VALVE SEAT CONTACT
Check valve for any evidence of pitting at valve contact surface,
and reseat or replace if worn out excessively.
IWhen repairing valve seats, check valve and valve guide
for wear beforehand. If worn, replace them. Then correct
valve seat.
IThe cutting should be done with both hands for uniform
cutting.
VALVE SEAT REPLACEMENT
IWhen removing valve seat, replace it with oversized [0.5 mm
(0.0020 in)] valve seat.
1. Cut valve seat to make it thin, and pull it out.
2. Machine cylinder head inner diameter at valve seat installation
position.
Machining dimension:
Intake
33.500 - 33.515 mm (1.3189 - 1.3195 in) dia.
Exhaust
31.995 - 32.010 mm (1.2596 - 1.2602 in) dia.
3. Heat cylinder head to approximately 110 to 130ÉC (230 to
266ÉF) in oil bath.
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
CAUTION:
Do not touch the cooled valve seats directly by hand.
5. Using valve seat cutter (multi-purpose tool), finish processing
referring to the dimensions shown in the figure.
CAUTION:
When using valve seat cutter, grasp cutter handle with both
hands, press cutter onto contacting face all around, and cut
thoroughly. If cutter is pressed unevenly or repeatedly, the
valve seat surface may be damaged.
6. Using compound, perform valve fitting.
7. Check again to make sure that contacting status is satisfactory.
FEM073
FEM074
FEM075
CYLINDER HEADZD
Inspection (Cont'd)
EM-60

For details of values (q1toq10), refer to EM-87, ªValve Seatº in
ªSERVICE DATA AND SPECIFICATIONS (SDS)º.
VALVE SPRING RIGHT ANGLE
Position a straightedge to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring
and the straightedge
Limit: 2.4 mm (0.0945 in)
VALVE SPRING FREE LENGTH AND COMPRESSIVE
LOAD
Using valve spring tester, check the following.
Free length: 55.43 mm (2.1823 in)
Installation height: 40.8 mm (1.6063 in)
Installation load: 180 - 206 N (18.4 - 21.0 kg, 40.6 -
46.3 lb)
Height at valve open: 32.3 mm (1.2717 in)
Load at valve open: 336 - 372 N (34.3 - 37.9 kg, 75.6 -
83.6 lb)
Assembly
1. Install valve guides, referring to EM-60, ªVALVE SEAT
REPLACEMENTº.
2. Install valve seats, referring to EM-60, ªVALVE SEAT CON-
TACTº.
3. Using valve oil seal drift (SST), install valve oil seals referring
to the dimension shown in the figure.
IThe figure shows the dimension before valve spring seats are
installed.
4. Install valve spring seats.
5. Install valves.
IInstall the valves with bigger openings to intake valve side.
INote that valve layout here is different from that of conventional
the engine.
YEM035
FEM077
FEM078
FEM079
CYLINDER HEADZD
Inspection (Cont'd)
EM-61

6. Install valve spring.
IWhen installing valve spring, make sure that a smaller pitch
side (identification paint-applied side) faces the cylinder head.
Identification color: pink
7. Install valve spring retainers.
8. Using valve spring compressor (SST), compress valve springs.
Using magnetic hand, install valve collets.
IAfter installing valve collets, tap the stem end using a plastic
hammer, and check the installation status.
9. Install valve lifters and adjusting shims to the same positions as
before.
FEM080
CYLINDER HEADZD
Assembly (Cont'd)
EM-62