NISSAN TERRANO 2002 Service Repair Manual

Measurement of Compression Pressure
1. Warm up engine and switch off the ignition switch.
2. Remove glow plate and glow plugs.
3. Fit compression gauge adapter to cylinder head.
Compression gauge adapter:
:15-20N×m
(1.5 - 2.0 kg-m, 11 - 14 ft-lb)
4. Ensure the ignition switch is in the ªLOCKº position and discon-
nect harness connector (gray colored) from injection pump.
5. Crank engine, then read gauge indication.
IAlways use a fully-charged battery to obtain specified
engine revolution.
IEngine compression measurement should be made as
quickly as possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)
Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3, 43)
6. If cylinder compression in one or more cylinders is low, pour a
small amount of engine oil into cylinders through the glow holes
and retest compression.
IIf adding oil helps the compression pressure, piston rings
may be worn or damaged.
IIf pressure stays low, valve may be sticking or seating
incorrectly.
IIf cylinder compression in any two adjacent cylinders is
low, and if adding oil does not help the compression, there
is leakage past the gasket surface.
Leakage past the cylinder gasket can result in oil and water
becoming mixed in the engine block cooling and lubrica-
tion chambers.
SEM618B
NEM005
SEM355F
COMPRESSION PRESSURETD27Ti
EM-103

q1Rocker cover
q
2Rocker cover gasket
q
3Valve cotter
q
4Spring retainer
q
5Valve oil seal
q
6Valve spring
Valve spring ringq
7Injection nozzle holder
q
8Nozzle washer
q
9Nozzle gasket
q
10Cylinder head
q
11Valve seat
q
12Intake valveq
13Exhaust valve
q
14Valve lifter
q
15Cylinder head gasket
q
16Push rod
q
17Glow plug
q
18Rocker shaft
NEM239
CYLINDER HEADTD27Ti
EM-104

Removal
1. Set No. 1 cylinder at TDC on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block and
radiator.
3. Remove air cleaner and intercooler components.
4. Remove the following parts:
Ð Water temperature connectors
Ð Throttle chamber vacuum hoses
Ð EGR valve vacuum hose
Ð Connectors located on the intake manifold
Ð Connector located on the thermostat housing
Ð Heater tubes
Ð Connectors of the injection pump
5. Remove alternator adjusting bolt.
6. Disconnect exhaust manifold from front exhaust tube.
7. Remove turbocharger oil and water tubes.
8. Remove turbocharger bracket bolts.
9. Disconnect radiator outlet hose and thermostat housing water
inlet hose.
10. Remove fuel injection tube assembly and spill tube.
11. Remove injection nozzle holder from first cylinder with a spe-
cial tool (KV119E0030). Remove injection nozzles from cylin-
ders 2, 3 and 4 using a deep socket wrench.
12. Remove thermostat housing bolts shown at left.
13. Remove rocker cover and ventilation hose.
14. Remove rocker shaft with rocker arms.
15. Remove push rods.
16. Remove cylinder head bolts in numerical order and remove
cylinder head.
Head warpage or cracking could result from removing in incor-
rect order.
EEM092
SEM621B
EEM103
SEM623B
CYLINDER HEADTD27Ti
EM-105

Disassembly
1. Remove following parts:
IEGR tube
IIntake manifold
IHeat shield plates
IExhaust manifold
IThermostat housing
IAlternator adjusting bar & engine slinger
IGlow plate and glow plugs
2. Remove valve component parts with Tool.
3. Remove valve oil seals with Tool.
4. Disassemble rocker shaft assembly.
a. Remove rocker shaft lock bolt.
b. Remove valve rocker and rocker shaft bracket.
If it is difficult to remove rocker shaft brackets, immerse rocker
shaft assembly in oil of 70ÉC (158ÉF) for a few minutes and
then remove brackets.
SEM624B
SEM625B
SEM626B
NEM160
CYLINDER HEADTD27Ti
EM-106

Inspection
CYLINDER HEAD DISTORTION
Cylinder head distortion:
Standard
Less than 0.07 mm (0.0028 in)
Limit
0.2 mm (0.008 in)
If beyond the specified limit, correct with a surface grinder.
Cylinder head minimum height:
89.7 mm (3.531 in)
VALVE GUIDE CLEARANCE
IValve guide clearance should be measured parallel with
rocker arm. (Generally, a large amount of wear occurs in
this direction.)
Valve to guide clearance:
Limit
Intake 0.15 mm (0.0059 in)
Exhaust 0.20 mm (0.0079 in)
Maximum allowable deflection
(Dial indicator reading)
Intake 0.30 mm (0.0118 in)
Exhaust 0.40 mm (0.0157 in)
ITo determine the correct replacement part, measure valve
stem diameter and valve guide inner diameter.
Valve stem diameter:
Standard
Intake
7.965 - 7.980 mm (0.3135 - 0.3142 in)
Exhaust
7.945 - 7.960 mm (0.3128 - 0.3134 in)
Valve guide inner diameter:
8.000 - 8.015 mm (0.3150 - 0.3156 in)
VALVE GUIDE REPLACEMENT
1. Heat cylinder head 150 to 160ÉC (302 to 320ÉF) in oil.
2. Drive out valve guide with a hammer and suitable tool.
SEM648B
SEM586A
EM030
SEM649B
SEM628B
CYLINDER HEADTD27Ti
EM-107

3. Press service valve guide into cylinder head using suitable tool
until the guide projects out 16 0.2 mm (0.63 0.08 in).
4. Ream valve guide.
Finished size:
8.000 - 8.015 mm (0.3150 - 0.3156 in)
VALVE SEATS
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.
REPLACING VALVE SEAT FOR SERVICE PARTS
1. Before out old seat until it collapses or remove valve seats with
Tool.
Place a copper seat between contact surface of Tool and cyl-
inder head.
2. Place new valve seats on dry ice and allow them to cool for five
minutes.
WARNING:
Do not touch cooled valve seats with bare hand.
3. Heat cylinder head to 80ÉC (176ÉF).
4. Install cooled valve seats on cylinder head with Tool.
NEM178
SEM630B
SEM024
SEM631B
SEM632B
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-108

5. Stake exhaust valve seat at five places with punch.
When staking valve seat, select different places than those
staked before.
6. Cut or grind valve seat using suitable tool at the specified
dimensions. Refer to SDS.
7. After cutting, lap valve seat with a lapping compound.
8. Check contact condition of valve seat.
COMBUSTION CHAMBER
Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER
Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot be
damaged.
2. Install combustion chamber.
IIdentification of combustion chambers
Identification mark
(on combustion chamber)Outer diameter ªDº
mm (in)
2 37 (1.46)
(1) Cool combustion chamber with dry ice for approximately 5 to 10
minutes.
WARNING:
Do not touch cooled combustion chamber with bare hands.
SEM087
NEM161
EEM116
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-109

(2) Align combustion chamber knock pin with cylinder head notch,
and drive in combustion chamber with a soft hammer.
3. Check amount of protrusion of combustion chamber.
Protrusion:
Standard
Less than 0.10 mm (0.0039 in)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to SDS.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
VALVE SPRING SQUARENESS
Out-of-square ªSº:
Less than 2.0 mm (0.079 in)
VALVE SPRING PRESSURE
Refer to SDS.
SEM634B
SEM188A
SEM635B
EM113
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-110

VALVE LIFTER AND PUSH ROD
Valve lifter
1. Check valve lifters for excessive wear on the surfaces.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:
Standard
0.030 - 0.073 mm (0.0012 - 0.0029 in)
Limit
Less than 0.20 mm (0.0079 in)
Valve lifter outer diameter ªAº:
Standard
25.960 - 25.970 mm (1.0220 - 1.0224 in)
Cylinder block valve lifter hole diameter ªBº:
Standard
26.000 - 26.033 mm (1.0236 - 1.0249 in)
Push rod
1. Inspect push rod for excessive wear on the surfaces.
2. Replace if worn or damaged beyond repair.
3. Check push rod for bend using a dial gauge.
Maximum allowable bend
(Total indicator reading):
Less than 0.5 mm (0.020 in)
ROCKER SHAFT AND ROCKER ARM
1. Check valve rockers, brackets and rocker shafts for scoring,
wear or distortion. Replace if necessary.
SEM636B
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-111

2. Check clearance between valve rockers and rocker shaft. If
specified clearance is exceeded, replace affected valve rockers
or shaft.
Specified clearance:
Limit
Less than 0.15 mm (0.0059 in)
Rocker shaft outer diameter ªAº:
Standard
19.979 - 20.000 mm (0.7866 - 0.7874 in)
Rocker arm inner diameter ªBº:
Standard
20.014 - 20.035 mm (0.7880 - 0.7888 in)
3. Check rocker shaft bend at its center. If bend is greater than
specified limit, replace rocker shaft.
Rocker shaft bend
(Total indicator reading):
Limit
Less than 0.3 mm (0.012 in)
MEASURING CYLINDER HEAD TO VALVE DISTANCE
Measure distance from cylinder head surface to intake and exhaust
valves. If specified distance is exceeded, replace valve(s) or valve
seat(s).
Specified distance:
Standard
Intake
0.79 - 1.19 mm
(0.0311 - 0.0469 in)
Exhaust
0.80 - 1.20 mm
(0.0315 - 0.0472 in)
Limit
Less than 1.75 mm (0.0689 in)
for intake and exhaust valves
SEM027
SEM028
SEM026
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-112