unit NISSAN TERRANO 2002 Service Repair Manual

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

General Specifications
Cylinder arrangementIn-line 4
Displacementcm
3(cu in) 2,953 (180.19)
Bore and strokemm (in) 96 x 102 (3.78 x 4.02)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil1
Number of main bearings5
Compression ratio17.9
Compression Pressure
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Compression pressureStandard 2,942 (29.42, 30.0, 427)
Minimum 2,452 (24.52, 25.0, 356)
Differential limit between cylinders 294 (2.94, 3.0, 43)
Cylinder Head
Unit: mm (in)
Standard Limit
Head surface distortion Less than 0.05 (0.0020) 0.2 (0.008)
SEM368G
Valve
VA LV E
Unit: mm (in)
FEM067
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-84

Valve head diameter ªDºIntake 31.9 - 32.1 (1.256 - 1.264)
Exhaust 29.9 - 30.1 (1.177 - 1.185)
Valve length ªLºIntake 113.5 (4.4685)
Exhaust 113.5 (4.4685)
Valve stem diameter ªdºIntake 6.962 - 6.977 (0.2741 - 0.2747)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)
Valve seat angle ªaºIntake
45É00¢- 45É30¢
Exhaust
Valve margin ªTºIntake 1.5 (0.059)
Exhaust 1.5 (0.059)
Valve stem end surface grinding limitLess than 0.2 (0.008)
VALVE CLEARANCE
Unit: mm (in)
Cold
Intake0.30 - 0.40 (0.0118 - 0.0157)
Exhaust0.30 - 0.40 (0.0118 - 0.0157)
*: Approximately 80ÉC (176ÉF)
AVAILABLE SHIMS
Thickness mm (in) Identification mark
2.35 (0.0925) 2.35
2.40 (0.0945) 2.40
2.45 (0.0965) 2.45
2.50 (0.0984) 2.50
2.55 (0.1004) 2.55
2.60 (0.1024) 2.60
2.65 (0.1043) 2.65
2.70 (0.1063) 2.70
2.75 (0.1083) 2.75
2.80 (0.1102) 2.80
2.85 (0.1122) 2.85
2.90 (0.1142) 2.90
2.95 (0.1161) 2.95
3.00 (0.1181) 3.00
3.05 (0.1201) 3.05
SEM252G
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
Valve (Cont'd)
EM-85

VALVE SPRING
Free height mm (in) 55.43 (2.1823)
Pressure N (kg, lb) at height mm (in) 354 (36.1, 79.6) at 32.3 (1.2717)
Out-of-square mm (in) 2.4 (0.094)
VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter 34.450 - 34.465 (1.3563 - 1.3569)
Lifter guide inner diameter 34.495 - 34.515 (1.3581 - 1.3589)
Clearance between lifter and lifter guide 0.030 - 0.065 (0.0012 - 0.0026)
VALVE GUIDE
Unit: mm (in)
FEM071
Standard
Valve guideOuter diameter 11.023 - 11.034 (0.4340 - 0.4344)
Inner diameter (Finished size) 7.000 - 7.015 (0.2756 - 0.2762)
Cylinder head valve guide hole diameter 10.975 - 10.996 (0.4321 - 0.4329)
Interference fit of valve guide0.027 - 0.059 (0.0011 - 0.0023)
Standard
Stem to guide clearanceIntake 0.023 - 0.053 (0.0009 - 0.0021)
Exhaust 0.040 - 0.070 (0.0016 - 0.0028)
Valve deflection limit0.2 (0.0079)
Projection length12.8 - 13.2 (0.5309 - 0.5197)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
Valve (Cont'd)
EM-86

Valve Seat
Unit: mm (in)
SEM374G
SEM373G
SEM375G
Standard Service
Cylinder head seat recess diameter
(D)Intake 33.000 - 33.015 (1.2992 - 1.2998) 33.500 - 33.515 (1.3189 - 1.3195)
Exhaust 31.495 - 31.510 (1.2400 - 1.2405) 31.995 - 32.010 (1.2596 - 1.2602)
Valve seat interference fitIntake 0.050 - 0.078 (0.0020 - 0.0031)
Exhaust 0.040 - 0.066 (0.0016 - 0.0026)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-87

Camshaft and Camshaft Bearing
Unit: mm (in)
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.09 (0.0035)
Inner diameter of camshaft bearing 30.000 - 30.021 (1.1811 - 1.1819) Ð
Outer diameter of camshaft journal 29.931 - 29.955 (1.1784 - 1.1793) Ð
Camshaft runout [TIR*] Ð 0.02 (0.0008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) Ð
Camshaft end play 0.065 - 0.169 (0.0026 - 0.0067) 0.2 (0.008)
*: Total indicator reading
EM671
Cam height ªAºIntake 40.468 - 40.508 (1.5932 - 1.5948)
Exhaust 40.830 - 40.870 (1.6075 - 1.6091)
Wear limit of cam height0.15 (0.0059)
Valve timing
SEM372G
Unit: degree
abcde
234 220 10 34 50
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-89

Cylinder Block
Unit: mm (in)
SEM370G
Surface flatnessStandardLess than 0.03 (0.0012)
Limit0.10 (0.0039)
Cylinder bore Inner diameterStandardGrade 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 (AþBþC)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 cylindersLimitLess than 0.05 (0.0020)
Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
Unit: mm (in)
SEM369G
Piston skirt diameter ªAº StandardGrade 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 dimension10 (0.39)
Piston pin hole diameter32.997 - 33.005 (1.2991 - 1.2994)
Piston clearance to cylinder block0.040 - 0.060 (0.0016 - 0.0024)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-90

PISTON RING
Unit: mm (in)
Standard Limit
Side clearanceTop 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 gapTop 0.30 - 0.45 (0.0118 - 0.0177) 1.5 (0.059)
2nd 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil (rail ring) 0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
PISTON PIN
Unit: mm (in)
Piston pin outer diameter32.993 - 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 clearanceStandard 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 distance154.5 (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 35.087 - 36.000 (1.3814 - 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 clearanceStandard 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