engine NISSAN TERRANO 2002 Service Repair Manual

3. Measure camshaft end play between locating plate and gear.
If beyond the specified limit, replace camshaft locating plate.
Camshaft end play:
Standard
0.08 - 0.28 mm (0.0031 - 0.0110 in)
Limit
Less than 0.5 mm (0.020 in)
4. Measure camshaft cam height. If beyond the specified limit,
replace camshaft.
Cam height:
Standard
Intake
41.570 mm (1.6366 in)
Exhaust
41.900 mm (1.6496 in)
Limit
Intake
Less than 41.20 mm (1.6220 in)
Exhaust
Less than 41.40 mm (1.6299 in)
SEM671B
SEM037
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-137

Assembly
PISTON
1. Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap cor-
responding to each cylinder. Care should be taken to avoid
a wrong combination including bearing.
b. When inserting piston pin in connecting rod, heat piston
with a heater or hot water [approximately 60 to 70ÉC (140
to 158ÉF)] and apply engine oil to pin and small end of
connecting rod.
c. After assembling, ascertain that piston swings smoothly.
2. Install piston assembly.
CAUTION:
a. Stretch the piston rings just enough to fit them in the pis-
ton grooves.
b. Be sure the manufacturer's mark faces upward.
c. Install No. 1 piston ring (oil ring) in such a way that its gap
faces the direction of engine front, as shown in illustration
at left; and then install 2nd and top rings so that their gap
is positioned at 120É one to another.
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing is
reused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however
lower bearings do not.
NEM174
NEM175
NEM182
NEM176
ENGINE OVERHAULTD27Ti
EM-138

(2) Apply engine oil to crankshaft journal and pin and install crank-
shaft.
(3) Install main bearings caps.
a) Install main bearing cap with the lowest number facing the front
of vehicle.
b) Apply engine oil to main bearing cap and cylinder block contact
surfaces.
c) Install rear oil seal assembly. Apply engine oil to contact surface
of rear end oil seal and crankshaft.
(4) Install crankshaft thrust washer at the 4th journal from front.
Install thrust washer so that oil groove can face crankshaft.
(5) Tighten bearing cap bolts gradually in stages, starting from two
to three separate stages, from center bearing and moving out-
ward in sequence.
(6) Measure crankshaft free end play at No. 4 bearing.
Crankshaft free end play:
Standard
0.060 - 0.25 mm (0.002 - 0.01 in)
Limit
0.4 mm (0.016 in)
If beyond the limit, replace No. 4 main bearing thrust washer.
Refer to SDS.
SEM674B
SEM057
SEM675B
SEM677B
SEM063
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-139

2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
IBe careful not to scratch cylinder wall with connecting rod.
IApply engine oil to cylinder wall, piston and bearing.
IThe leaf type combustion chamber on piston head must be
facing toward the fuel pump side.
(2) Install connecting rod bearing caps.
3. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.10 - 0.22 mm (0.0039 - 0.0087 in)
Limit
0.22 mm (0.0087 in)
If beyond the limit, replace connecting rod and/or crankshaft.
4. Install oil strainer and oil pan.
5. Install all removed parts.
GEAR TRAIN
1. Set No. 1 piston at its Top Dead Center.
2. Align each gear mark and install gears.
EEM108
SEM678B
SEM488
NEM177
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-140

TIMING GEAR CASE
Installation
1. Before installing timing gear case, remove all traces of liquid
gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of front
plate.
2. Apply a continuous bead of liquid gasket to mating surface of
timing gear case and install the two rubber seals as shown.
IBe sure liquid gasket is 2.5 to 3.5 mm (0.098 to 0.138 in)
wide.
IAttach timing gear case to front plate within 20 minutes
after coating.
IWait at least 30 minutes before refilling engine coolant or
starting engine.
Iuse Genuine Liquid Gasket or equivalent.
NEM183
NEM184
NEM185
SEM683B
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-141

REAR PLATE
Installation
1. Before installing rear plate, remove all traces of liquid gasket
from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of cyl-
inder block.
2. Apply a continuous bead of liquid gasket to mating surface of
cylinder block.
3. Fit the rear plate into the cylinder block and apply liquid gasket
in the area indicated by discontinuous line.
4. After the transmission is installed, apply liquid gasket in the
area indicated by arrows.
5. Install all removed parts.
EEM109
EEM110
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-142

General Specifications
Engine model TD27Ti
Cylinder arrangement 4, in-line
Displacement cm
3(cu in) 2,663 (162.5)
Bore x stroke mm (in) 96 x 92 (3.8 x 3.6)
Valve arrangement OHV
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Number of main bearings 5
Compression ratio 21.9 0.2
Unit: kPa (bar, kg/cm
2, psi)/rpm
Compression pressure
Standard 2,942 (29.4, 30, 427)/200
Minimum 2,452 (24.5, 25, 356)/200
Differential limit between
cylinders294 (2.9, 3, 43)/200
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
EM-143

(1) When installing each rubber part, final tightening must be car-
ried out under unladen condition * with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
(2) When removing each suspension part, check wheel alignment
and adjust if necessary.
(3) Use Tool when removing or installing brake tubes.
SBR820B
PRECAUTIONS
FA-2

qA
Was the vehicle started after the
transfer lever was shifted from the
ª2Hº to the ª4Hº or ª4Lº position?
No
EYe s
A clicking noise can sometimes
occur in the auto hub when the
gears are engaged. This is not a
problem.
Noise can be encountered during
rapid acceleration while rear
wheels are slipping on snowy
roads, muddy roads, slopes, etc.
(Fig.
,Fig.).
In such a case, release the accel-
erator pedal to reduce engine
speed. Gears will then be
engaged and the noise will cease
(Fig.
).
Was the vehicle backed up when
the transfer lever was in the ª4Hº
or the ª4Lº position, or was the
vehicle backed up while on a
downgrade when the transfer
lever was in the ª4Hº or the ª4Lº
position?
No
EYe s
When backing up the vehicle with
the transfer in the ª4Hº or the ª4Lº
position, auto-hub gears some-
times disengage but soon reen-
gage (Fig.
,Fig.,Fig.
) with a clicking noise. This is
not a problem. Noise will also
occur if the vehicle is accelerated
rapidly while the gears are disen-
gaged. In such a case, release the
accelerator pedal once to
decrease engine speed. Gears will
then be engaged and the noise
will cease (Fig.
).
Was the vehicle turned on a dry
pavement, when the transfer lever
was in the ª4Hº or the ª4Lº posi-
tion?
No
EYe s
Under these conditions, noise
occurs in tires (creaking) or in the
power train (rattling) Ð not in the
auto hub.
Avoid driving in the conditions
described above as it may lead to
tire wear.
qB
SFA519A
SFA520A
SFA521A
SFA522A
SFA523A
H
H
H
H
FRONT AXLE Ð Auto-lock Free-running Hub
Trouble-shooting (Cont'd)
FA-16

INSTALLATION AND ADJUSTMENT
Adjustment of anchor arm adjusting nut is in tightening direc-
tion only.
Do not adjust by loosening anchor arm adjusting nut.
1. Coat multi-purpose grease on the serration of torsion bar
spring.
2. Place lower link in the position where bound buffer clearance
ªCº is 0.
Clearance ªCº: 0 mm (0 in)
3. Install torsion bar spring with torque arm.
Be sure to install right and left torsion bar springs correctly.
4. Set anchor arm.
Standard length ªGº
TD27Ti engine:
38 - 49 mm (1.50 - 1.93 in)
ZD30DDTi engine:
40 - 51 mm (1.57 - 2.01 in)
5. Install snap ring to anchor arm and dust cover.
SFA549
SFA854
EFA009
FRONT SUSPENSION
Torsion Bar (Cont'd)
FA-31