unit NISSAN TERRANO 2002 Service Repair Manual

CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
Standard Limit
Camshaft journal to
bushing clearance0.020 - 0.109
(0.0008 - 0.0043)Less than 0.15
(0.0059)
Camshaft journal
diameter
Front50.721 - 50.740
(1.9969 - 1.9976)Ð
2nd50.521 - 50.540
(1.9890 - 1.9898)Ð
3rd50.321 - 50.340
(1.9811 - 1.9819)Ð
4th50.121 - 50.140
(1.9733 - 1.9740)Ð
Rear49.921 - 49.940
(1.9654 - 1.9661)Ð
Camshaft bend (Total
indicator reading)Less than 0.02
(0.0008)Less than 0.06
(0.0024)
Camshaft end play0.08 - 0.28
(0.0031 - 0.0110)Less than 0.50
(0.0197)
EM671
Standard Limit
Cam height ªAº
41.570 (1.6366) Less than
Intake
Exhaust 41.900 (1.6496) Less than
VALVE LIFTER AND PUSH ROD
Unit: mm (in)
Standard Limit
Valve lifter outer
diameter24.960 - 24.970
(0.9827 - 0.9831)Ð
Cylinder block valve
lifter hole diameter25.000 - 25.033
(0.9843 - 0.9855)Ð
Valve lifter to lifter
hole clearance0.030 - 0.073
(0.0012 - 0.0029)Less than 0.20
(0.0079)
Push rod bend (TIR)Less than 0.3
(0.012É)Less than 0.5
(0.020)
*: Total indicator reading
ROCKER SHAFT AND ROCKER ARM
Standard Limit
Rocker shaft
Outer diameter19.979 - 20.00
(0.7866 - 0.7874)Ð
Rocker shaft bend
(TIR)*0 - 0.10
(0 - 0.0039)less than 0.30
(0.0188)
Rocker arm
Inner diameter20.014 - 20.035
(0.7880 - 0.7888)Ð
Clearance between
rocker arm and
rocker shaft0.014 - 0.056
(0.0006 - 0.0022)less than 0.15
(0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-147

PISTON, PISTON RING AND PISTON PIN
Available piston
Unit: mm (in)
SEM778A
Piston skirt diameter ªAº
Standard
Grade No. 195.890 - 95.900
(3.7752 - 3.7756)
Grade No. 295.900 - 95.910
(3.7756 - 3.7760)
Grade No. 3*95.910 - 95.920
(3.7760 - 3.7764)
ªaº dimension 45.2 (1.780)
Piston pin hole diameter29.992 - 30.000
(1.1808 - 1.1811)
Piston to cylinder liner clearance0.043 - 0.077
(0.0017 - 0.0030)
ªAº dimension 69.2 (2.724)
Grade No. 3 piston is not provided as a service part.
Piston pin
Unit: mm (in)
Piston pin outer diameter29.993 - 30.000
(1.1808 - 1.1811)
Piston pin to piston clearanceþ0.008 to 0.007
(þ0.0003 to 0.0003)
Piston pin to connecting rod
clearance
Standard0.025 - 0.045
(0.0010 - 0.0018)
Limit 0.15 (0.0059P)
Piston ring
Unit: mm (in)
Standard Limit
Side clearance
To p0.00 - 0.05
(0.0 - 0.0020)0.50 (0.0197)
2nd0.04 - 0.072
(0.0016 - 0.0028)0.30 (0.0118)
Oil0.035 - 0.040
(0.0014 - 0.0016)0.15 (0.0059)
Ring gap
To p0.25 - 0.35
(0.0098 - 0.0014)
1.5 (0.059) 2nd0.50 - 0.75
(0.0197 - 0.0295)
Oil (rail ring)0.25 - 0.55
(0.0098 - 0.0217)
CONNECTING ROD
Unit: mm (in)
Center distance156.975 - 157.025
(6.1801 - 6.1821)
Bend, torsion [per 200 (3.94)]
Limit 0.15 (0.0059)
Piston pin bore dia.30.025 - 30.038
(1.1821 - 1.1826)
Side clearance
Standard0.10 - 0.22
(0.0039 - 0.0087)
Limit 0.22 (0.0087)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-148

CRANKSHAFT
Unit: mm (in)
SEM100A
Journal diameter ªAº70.907 - 70.920
(2.7916 - 2.7921)
Pin diameter ªBº56.913 - 56.926
(2.2407 - 2.2412)
Center distance ªSº 46.00 (1.8110)
EM715
Taper of journal and pin ªA-Bº
Standard Less than 0.01 (0.0004)
Limit 0.02 (0.0008)
Out-of-round of journal and pin
ªX-Yº
Standard Less than 0.01 (0.0004)
Limit 0.02 (0.0008)
Crankshaft bend
Standard 0 - 0.03 (0 - 0.0012)
Limit 0.10 (0.0039)
Crankshaft end play
Standard0.060 - 0.25
(0.0024 - 0.0098)
Limit 0.40 (0.0157)
AVAILABLE MAIN BEARING
Bearing clearance
Unit: mm (in)
Main bearing clearance
Standard0.035 - 0.087
(0.0014 - 0.0034)
Limit Less than 0.15 (0.0059)
Connecting rod bearing clearance
Standard0.035 - 0.081
(0.0014 - 0.0032)
Limit Lees than 0.15 (0.0059)
Mean bearing undersize
Unit: mm (in)
Crank journal diameter
Standard70.907 - 70.920
(2.7916 - 2.7921)
Undersize
0.25 (0.0098)70.657 - 70.670
(2.7818 - 2.7823)
0.50 (0.0197)70.407 - 70.420
(2.7719 - 2.7724)
0.75 (0.0295)70.157 - 70.170
(2.7621 - 2.7626)
1.00 (0.0394)69.907 - 69.920
(2.7522 - 2.7528)
AVAILABLE CONNECTING ROD BEARING
Connecting rod bearing undersize
Unit: mm (in)
Crank pin journal diameter
Standard56.913 - 56.926
(2.2407 - 2.2412)
Undersize
0.25 (0.0098)56.663 - 56.676
(2.2308 - 2.2313)
0.50 (0.0197)56.413 - 56.676
(2.2210 - 2.2313)
0.75 (0.0295)56.163 - 56.176
(2.2111 - 2.2116)
1.00 (0.0394)55.913 - 55.926
(2.2013 - 2.2018)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-149

AVAILABLE THRUST WASHER
Unit: mm (in)
Thrust washer thickness
Standard 2.275 - 2.325 (0.0896 - 0.0915)
Oversize
0.20 (0.0079) 2.475 - 2.525 (0.0974 - 0.0994)
0.40 (0.0157) 2.675 - 2.725 (0.1053 - 0.1073)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Gear train
Backlash of each gear
Standard 0.07 - 0.11 (0.0028 - 0.0043)
Limit 0.20 (0.0079)
Flywheel
Runout (Total indicator
reading)Less than 0.15 (0.0059)
Front plate
Warpage limit 0.2 (0.008)
Cylinder head
Head surface distorsion
Standard Less than 0.07 (0.0028)
Limit 0.2 (0.008)
Minimum height 89.7 (3.532)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-150

Terminal Arrangement
YEL277D
ELECTRICAL UNITS

6. Before servicing the vehicle, protect fenders, upholstery and
carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person do
not scratch the paint.
7. Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
assembled locations and sequence.
11. Do not touch the terminals of electrical components which use
microcomputers (such as electronic control units).
Static electricity may damage internal electronic components.
12. After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
13. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents
when required.
15. Use tools and recommended special tools where specified for
safe and efficient service repairs.
16. When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System)
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-
tensionerº, used along with a seat belt, help to reduce the risk or
severity of injury to the driver and front passenger in a frontal col-
lision. The Supplemental Restraint System consists of air bag mod-
ules (located in the center of the steering wheel and on the instru-
ment panel on the passenger side), seat belt pre-tensioners, a
diagnosis sensor unit, warning lamp, wiring harness and spiral
cable.
WARNING:
ITo avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death (in the event
of a collision which would result in air bag inflation), all
maintenance must be performed by an authorized NISSAN
dealer.
IImproper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related
to the SRS unless instructed to do so in this Service
Manual. SRS wiring harnesses are covered with yellow
SGI234
SGI646
PRECAUTIONS
GI-3

Precautions for Multiport Fuel Injection System
or Engine Control System
1. Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM (Engine Control
Module):
Turn ignition switch to ªOFFº position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
2. Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure to eliminate danger.
3. Be careful not to jar components such as control unit and air
flow meter.
Precautions for Catalyst
If a large amount of unburned fuel enters the converter, the con-
verter temperature will rise to excessively high values. To prevent
this, follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriously
damage the catalytic converter.
2. When checking for ignition spark or measuring engine
compression, perform tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, as a result
the engine may misfire causing damage to the converter.
4. Do not place the vehicle on inflammable material. Keep inflam-
mable material off the exhaust pipe.
Precautions for Turbocharger
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean
supply of oil flowing through the turbocharger and to follow all
required maintenance instructions and operating procedures.
For proper operation of the system, follow the procedure below:
1. Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
2. Avoid accelerating engine to a high rpm immediately after start-
ing.
3. If engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting it off.
SGI787
SGI290
SGI292
PRECAUTIONS
GI-5

Precautions for Fuel
DIESEL ENGINE*:
Diesel fuel of at least 50 cetane for ZD30DDTi engine.
* If two types of diesel fuel are available, use summer or winter
fuel properly according to the following temperature conditions.
IAbove þ7ÉC (20ÉF) ... Summer type diesel fuel.
IBelow þ7ÉC (20ÉF) ... Winter type diesel fuel.
CAUTION:
IDo not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
IDo not use summer fuel at temperature below þ7ÉC (20ÉF).
The cold temperature will cause wax to form in the fuel. As
a result, it may prevent the engine from running smoothly.
IDo not add gasoline or other alternate fuels to diesel fuel.
Precautions for Engine Oils
Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer. Adequate
means of skin protection and washing facilities must be provided.
HEALTH PROTECTION PRECAUTIONS
1. Avoid prolonged and repeated contact with oils, particularly
used engine oils.
2. Wear protective clothing, including impervious gloves where
practicable.
3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly underwear, with oil.
5. Heavily soiled clothing and oil-impregnated footwear should not
be worn. Overalls must be cleaned regularly.
6. First Aid treatment should be obtained immediately for open
cuts and wounds.
7. Use barrier creams, applying them before each work period, to
help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is removed (skin
cleansers and nail brushes will help). Preparations containing
lanolin replace the natural skin oils which have been removed.
9. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or sol-
vents for cleaning skin.
10. If skin disorders develop, obtain medical advice without delay.
11. Where practicable, degrease components prior to handling.
12. Where there is a risk of eye contact, eye protection should be
worn, for example, chemical goggles or face shields; in addition
an eye wash facility should be provided.
(For the United Kingdom, see also HSE Cautionary Notice SHW
397 ªEffects of Mineral Oil on the Skinº.)
ENVIRONMENTAL PROTECTION PRECAUTIONS
Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating sys-
tem must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt check with the
appropriate local authority and/or manufacturer of the approved
appliance.
PRECAUTIONS
GI-6

1.A QUICK REFERENCE INDEX, a black tab (e.g.) is provided on the first page. You can quickly find
the first page of each section by mating it to the section's black tab.
2.THE CONTENTSare listed on the first page of each section.
3.THE TITLEis indicated on the upper portion of each page and shows the part or system.
4.THE PAGE NUMBERof each section consists of two letters which designate the particular section and a
number (e.g. ªBR-5º).
5.THE LARGE ILLUSTRATIONSare exploded views (See below) and contain tightening torques, lubrica-
tion points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriatePARTS CATALOG.
6.THE SMALL ILLUSTRATIONSshow the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary.
SBR364A
HOW TO USE THIS MANUAL
GI-8

7. The followingSYMBOLS AND ABBREVIATIONSare used:
,: Tightening torque
: Should be lubricated with grease.
Unless otherwise indicated, use rec-
ommended multi-purpose grease.
: Should be lubricated with oil.
: Sealing point
: Checking point
: Always replace after every disassem-
bly.
L.H., R.H.: Left-Hand, Right-Hand
FR, RR : Front, Rear
2WD : 2-Wheel Drive
4WD : 4-Wheel Drive
qP: Apply petroleum jelly.
: Apply A.T.F.
A.T.F. : Automatic Transmission Fluid
H: Select with proper thickness.
I: Adjustment is required.
M/T : Manual Transaxle/Transmission
A/C : Air Conditioner
P/S : Power Steering
S.S.T. : Special Service Tools
S.D.S. : Service Data and Specifications
SAE : Society of Automotive Engineers, Inc.
L.H.D. : Left-Hand Drive
R.H.D. : Right-Hand Drive
8. TheUNITSgiven in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
ªExampleº
Tightening torque:
59-78N×m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
9.TROUBLE DIAGNOSESare included in sections dealing with complicated components.
10.SERVICE DATA AND SPECIFICATIONSare contained at the end of each section for quick reference of
data.
11. The captionsWARNINGandCAUTIONwarn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle.
IWARNINGindicates the possibility of personal injury if instructions are not followed.
ICAUTIONindicates the possibility of component damage if instructions are not followed.
IBOLD TYPED STATEMENTSexceptWARNINGandCAUTIONgive you helpful information.
HOW TO USE THIS MANUAL
GI-9