ESP NISSAN TERRANO 2002 Service Service Manual

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

WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely
cooled off.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Be sure to hoist engine in a safe manner.
f. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
IWhen lifting engine, be careful not to strike adjacent parts,
especially, brake lines and brake master cylinder.
IIn hoisting the engine, always use engine slingers in a safe
manner.
ENGINE REMOVALTD27Ti
EM-124

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. 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

Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
1. Do not operate the engine for an extended period of time with-
out proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
2. Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting and towing
before working on the vehicle.
These operations should be done on a level surface.
3. When removing a heavy component such as the engine or
transaxle/transmission, take care not to lose your balance and
drop it. Also, do not allow it to strike adjacent parts, especially
the brake tubes and master cylinder.
4. Before starting repairs which do not require battery power,
always turn off the ignition switch, then disconnect the ground
cable from the battery to prevent accidental short circuit.
5. To prevent serious burns, avoid contact with hot metal parts
such as the radiator, exhaust manifold, tail pipe and muffler. Do
not remove the radiator cap when the engine is hot.
SGI285
SGI231
SGI232
SGI233
PRECAUTIONS
GI-2

Number Item Description
q19Current flow arrowIArrow indicates electric current flow, especially where the direction of standard
flow (vertically downward or horizontally from left to right) is difficult to follow.
IA double arrow ªFÐ
Eº shows that current can flow in either direction depending on
circuit operation.
q20System branchIThis shows that the system branches to another system identified by cell code
(section and system).
q21Page crossingIThis arrow shows that the circuit continues to another page identified by cell code.
IThe C will match with the C on another page within the system other than the next
or preceding pages.
q22Shielded lineIThe line enclosed by broken line circle shows shield wire.
q23Component box in wave
lineIThis shows that another part of the component is also shown on another page
(indicated by wave line) within the system.
q24Component nameIThis shows the name of a component.
q25Connector numberIThis shows the connector number.
IThe letter shows which harness the connector is located in.
Example:M: main harness. For detail and to locate the connector, refer to EL sec-
tion (ªMain Harnessº, ªHARNESS LAYOUTº). A coordinate grid is included for com-
plex harnesses to aid in locating connectors.
q26Ground (GND)IThe line spliced and grounded under wire color shows that ground line is spliced
at the grounded connector.
q27Ground (GND)IThis shows the ground connection.
q28Connector viewsIThis area shows the connector faces of the components in the wiring diagram on
the page.
q29Common componentIConnectors enclosed in broken line show that these connectors belong to the
same component.
q30Connector colorIThis shows a code for the color of the connector. For code meaning, refer to wire
color codes, Numberq14of this chart.
q31Fusible link and fuse boxIThis shows the arrangement of fusible link(s) and fuse(s), used for connector
views of ªPOWER SUPPLY ROUTINGº in EL section.
The open square shows current flow in, and the shaded square shows current
flow out.
q32Reference areaIThis shows that more information on the Super Multiple Junction (SMJ) and Joint
Connectors (J/C) exists on the foldout page. Refer to GI-18 for details.
HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
GI-13

TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE
Whenever abnormal pressure of high and/or low sides of the system is noted, diagnosis must be conducted
by using a manifold gauge. The large-line zone on the gauge scale (see illustrations.) shown in the following
table refers to the standard (normal) pressure range for the corresponding pressure side (high or low). Since
the standard (normal) pressure, however, differs from vehicle to vehicle, refer to the ªAmbient air temperature-
to-compressor pressure tableº.
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure
sides are too high.
AC359A
IPressure is reduced soon
after water is splashed on
condenser.Excessive refrigerant charge in
refrigeration cycleReduce refrigerant until speci-
fied pressure is obtained.
Air suction by radiator or con-
denser fan is insufficient.Insufficient condenser cooling
performance
"
q
1Condenser fins are clogged.
q
2Improper rotation of radiator
fan or condenser fanIClean condenser.
ICheck and repair radiator or
condenser fan as necessary.
ILow-pressure pipe is not
cold.
IWhen compressor is stopped
high-pressure value quickly
drops by approximately 196
kPa (2 kg/cm
2, 28 psi). It
then decreases gradually
thereafter.Poor heat exchange in con-
denser
(After compressor operation
stops, high pressure
decreases too slowly.)
"
Air in refrigeration cycleEvacuate repeatedly and
recharge system.
Engine tends to overheat. Engine cooling systems mal-
function.Check and repair each engine
cooling system.
IAreas near low-pressure
pipe connection and service
valves are considerably cold
compared with areas near
expansion valve outlet or
evaporator.
IPlates are sometimes cov-
ered with frost.IExcessive liquid refrigerant
on low-pressure side
IExcessive refrigerant dis-
charge flow
IExpansion valve is open a
little compared with the
specification.
"
q
1Improper thermal valve
installation
q
2Improper expansion valve
adjustmentReplace expansion valve.
DIAGNOSES Ð Overall System
Performance Test Diagnoses (Cont'd)
HA-32

DUAL-PRESSURE SWITCH
High-pressure side line pressure
kPa (kg/cm2, psi)Operation Continuity
Decreasing to 157 - 216 (1.6 - 2.2, 23 - 31)
Increasing to 2,452 - 2,844 (25 - 29, 356 - 412)Turn OFFDoes not
exist
Increasing to 157 - 235 (1.6 - 2.4, 23 - 34)
Decreasing to 1,863 - 2,256 (19 - 23, 270 - 327)Turn ON Exists
THERMO CONTROL AMP.
Evaporator outlet air temperature
ÉC (ÉF)Thermo amp.
operationTester
Decreasing to 0.1 - 0.9 (32 - 34) Turn OFF Approx. 12V
Increasing to 2.5 - 3.5 (37 - 38) Turn ON Approx. 0V
A/C RELAY, COOLING FAN RELAY
Check circuit continuity between terminals by supplying 12 volts to
coil side terminals of relay.
Apply 12V to terminalsq
1andq2and check continuity between
terminalsq
3andq5.
Conditions Continuity
12V direct current supply between terminalsq
1
andq2YES
No current supply NO
If NG, replace relay.
Refer to EL section for Description.
Control Linkage Adjustment
VENTILATOR DOOR CONTROL ROD
1. Move side link in direction of arrow.
2. With upper and lower ventilator door levers held in the direction
of the arrow, connect rodsq
1andq2to their corresponding ven-
tilator door levers in that order.
RHA023E
YHA435
YHA436
RHA024E
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
HA-61

IRaise the unit with a hoist.
IPosition the transmission assembly on a portable jack and
secure it with a suitable tool.
Lift the assembly until the gearbox input shaft faces its hous-
ing.
Move the assembly towards the engine. The assembly must be
rotated slightly so that the starter motor housing clears the
projection on the companion floor. Insert input shaft into its
housing (slightly raising the rear of the transfer box may facili-
tate the introduction of the shaft into its housing).
ITighten the screws securing the gearbox to the engine.
:39-49N×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
IConnect the electrical wiring. Secure with the respective clips.
IFit the RPM-sensor to the transmission upper side.
IFit the exhaust pipe support bracket to the transfer box.
:13-16N×m (1.3 - 1.6 kg-m,9-12ft-lb)
IFit the starter motor. Secure the earth wire to the starter motor
lower screw.
:31-41N×m (3.2 - 4.2 kg-m, 23 - 30 ft-lb)
IFit the clutch slave cylinder.
:30-40N×m (3.1 - 4.1 kg-m, 22 - 30 ft-lb)
IInstall fourth crossmember (Note the ªfrontº mark).
Crossmember fixing bolts to chassis:
:41-52N×m (4.2 - 5.3 kg-m, 30 - 38 ft-lb)
Crossmember fixing bolts to transmission:
:68-87N×m (6.9 - 8.9 kg-m, 50 - 64 ft-lb)
ITake away the portable jack holding boxes assembly.
IInstall fifth crossmember.
:59-78N×m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
IInstall third crossmember.
: Screws: 41 - 52 N×m (4.2 - 5.3 kg-m,
30 - 38 ft-lb)
Nuts: 68 - 87 N×m (6.9 - 8.9 kg-m,
50 - 64 ft-lb)
IInstall torsion bar springs. Ð Refer to FA section.
IInstall front and rear propeller shafts. Ð Refer to PD section.
IInstall shift levers of transmission and transfer.
:14-18N×m (1.4 - 1.8 kg-m, 10 - 13 ft-lb)
Bolt head dimensions:
Bolt A: 12 mm (0.472 in)
Bolt B: 13 mm (0.512 in)
IConnect negative battery cable.
SMT446B
REMOVAL AND INSTALLATIONFS5R30A
Installation (Cont'd)
MT-9

2. Remove extension tube and differential side shaft assembly.
3. Remove differential side flange.
4. Mark side retainers for identification. Remove side retainers.
Be careful not to confuse right and left side retainers and
shims.
5. Extract differential case from final drive housing.
6. Remove side outer races.
Tool number:
ST33290001
Be careful to keep the side bearing outer races together with
their respective inner cones Ð do not mix them up.
7. Remove side oil seal.
NPD005
SPD713
SPD639
SPD309
PD243
DISASSEMBLY (R180A)
Final Drive Housing (Cont'd)
PD-16