engine NISSAN TERRANO 2002 Service Repair Manual

4. Wipe clean fuel filter mounting surface on fuel filter bracket and
smear a little fuel on rubber seal of fuel filter.
5. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 or a turn.
6. Install fuel filter sensor to new fuel filter. (Type A)
7. Bleed air from fuel filter.
Refer to ªAir Bleedingº in EC section.
8. Start engine and check for leaks.
DRAINING WATER
1. Drain water as follows.
Type A
Loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
If water does not drain properly, move the priming pump up and
down.
Type B
Loosen air bleeder screw from the sedimentor cover and then
loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
2. Bleed air.
Refer to ªAir Bleedingº in EC section.
Checking Fuel Lines
Check fuel lines and tank for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
CAUTION:
Keep clean parts with compressed air when assembling.
SMA010
SMA825B
SMA281C
SMA803A
ENGINE MAINTENANCEZD
Checking and Replacing Fuel Filter and
Draining Water (Cont'd)
MA-34

Cleaning and Replacing Air Cleaner Filter
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any clean-
ing operation between renewal.
SMA151D
ENGINE MAINTENANCEZD
MA-35

2. Check oil level.
Never start engine while checking oil level.
Filler plug:
:25-34N×m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
Changing M/T Oil
Oil capacity:
3.5 liters (6-1/8 Imp pt)
Checking Water Entry
Check water entry in the clutch housing by removing the seal-
ing grommet, whenever driving in deep water or mud.
Checking Transfer Oil
1. Check transfer for leakage.
2. Check oil level.
Never start engine while checking oil level.
ªDEXRON
TMº type Automatic Transmission Fluid is used for
the transfer in the factory. Never add gear oil (API GL-4) to
Automatic Transmission Fluid.
SMA103
SMA255A
SMA369B
SMT483A
YMA009
CHASSIS AND BODY MAINTENANCE
Checking M/T Oil (Cont'd)
MA-37

TEMPORARY METHOD FOR CHECKING LINING WEAR
Remove inspection hole plug and check for lining wear.
Checking Foot Brake Pedal Operation
Check brake pedal free height, depressed height and for smooth
operation.
H: Free height:
RHD: 196 - 206 mm (7.72 - 8.11 in)
LHD: 210 - 220 mm (8.27 - 8.66 in)
D: Depressed height:
Under force of 490 N (50 kg, 110 lb)
with engine running
RHD: 137.7 - 148.7 mm (5.42 - 5.85 in)
LHD: 142.5 - 152.5 mm (5.61 - 6.00 in)
A: Pedal free play
1.0 - 3.0 mm (0.039 - 0.118 in)
Checking Parking Brake
1. Pull lever with specified amount of force.
Check lever stroke and for smooth operation.
Number of notches
[At pulling force of 196 N (20 kg, 44 lb)]:
9-10
2. Use adjuster to adjust lever stroke.
(1) Loosen lock nutq
A, rotate adjusterqB.
(2) Tighten lock nutq
A.
SBR461A
SMA441B
EMA050
SBR032A
CHASSIS AND BODY MAINTENANCE
Checking Drum Brake (Cont'd)
MA-42

Checking Body Corrosion
Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing, etc.) or
damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut lower in engine
compartment, etc.
Panel edge
Trunk lid opening, sun roof opening, fender wheel-arch flange, fuel filler lid flange, around holes in panel, etc.
Parts contact
Waist moulding, windshield moulding, bumper, etc.
Protectors
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage or separation of anti-corrosion materials under the body.
Drain holes
Condition of drain holes at door and side sill.
When repairing corroded areas, refer to the Corrosion Repair Manual.
CHASSIS AND BODY MAINTENANCE
MA-47

Engine Maintenance
INSPECTION AND ADJUSTMENT
Drive belt deflection
Unit: mm (in)
Used belt deflection
Deflection of
new belt
LimitDeflection after
adjustment
Engine TD27Ti TD27Ti TD27Ti
Alternator20
(0.79)11-13
(0.43 - 0.51)9-11
(0.35 - 0.43)
Air conditioner12
(0.47)6 - 7.5
(0.236 - 0.295)5 - 6.5
(0.197 - 0.256)
Power steering
oil pump15
(0.59)8 - 9.5
(0.315 - 0.374)7 - 8.5
(0.276 - 0.335)
Applied pushing
force98 N (10 kg, 22 lb)
Oil capacity (Refill capacity)
TD27Ti engine
Unit:(Imp qt)
With oil filter change 6.2 (5-1/2)
Without oil filter change 5.5 (4-7/8)
ZD30DDTi engine
Unit:(Imp qt)
With oil filter change 6.7 (5-7/8)
Without oil filter change 6.2 (5-1/2)
Cooling system check
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 98 (0.98, 1.0, 14)
Radiator cap relief pressure78-98
(0.78 - 1.0, 0.8 - 1.0, 11 - 14)
Coolant capacity (Refill capacity)
Unit:(Imp qt)
Engine TD27Ti ZD30DDTi
Without reservoir tank 10 (8-3/4) 10.6 (9-3/8)
Reservoir tank 0.8 (3/4) 0.75 (5/8)
Valve clearance (Hot)
Unit: mm (in)
Engine TD27Ti
Intake
0.25 (0.0098)
Exhaust
Injection nozzle
Unit: kPa (bar, kg/cm2, psi)
Engine TD27Ti
Initial injection pressure
New12,259 - 12,749 (122.6 - 127.5, 125 -
130, 1,778 - 1,849)
Used12,749 - 13,730 (127.5 - 137.3, 130 -
140, 1,849 - 1,991)
Idle speed
Unit: rpm
Engine TD27Ti
With A/C 850 50
Without A/C 700 50
SERVICE AND SPECIFICATIONS (SDS)
MA-48

Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT
Clutch
Unit: mm (in)
Vehicle model All
Pedal free heightRHD
210 - 220
(8.27 - 8.66)LHD
227 - 237
(8.94 - 9.33)
Pedal free play 1.0 - 3.0 (0.039 - 0.118)
Pedal free travel 155 - 160 (6.10 - 6.30)
Front axle and front suspension
(Unladen)*1
Unit: degree
Model H/T VAN H/T WAGON
Camber 0É30¢ 30¢
Caster 0É29¢ 30¢0É30¢ 30¢0É30¢ 30¢
Kingpin inclination 12É37¢
Toe-in
A-B mm (in)3.5 - 5.5
(0.14 - 0.22)3-5
(0.12 - 0.20)3-5
(0.12 - 0.20)
Front wheel turning
angle (degrees)
(Full turn)*2
Inside 34É27¢
Outside 33É38¢
*1: Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positions.
*2: Wheel turning force (at circumference of steering wheel) of 98 to
147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
Brake
Disc brake mm (in)
LD28VA
Pad
Standard thickness 15.5 (0.61)
Minimum thickness 2.0 (0.079)
Rotor
Standard thickness 2.60 (1.02)
Minimum thickness 24.0 (0.94)
Drum brake mm (in)
LT28
Lining
Standard thickness
Leading 8.95 (0.352)
Trailing 3.95 (0.156)
Minimum thickness 1.52 (0.06)
Drum
Standard diameter 280 (11.02)
Maximum diameter 282 (11.10)
Pedal mm (in) RHD LHD
Free height196 - 206
(7.7 - 8.1)210 - 220
(8.3 - 8.7)
Free play 1.0 - 3.0 (0.039 - 0.118)
Full stroke137.7 - 148.7
(5.42 - 5.85)142.5 - 152.5
(5.61 - 6.00)
Parking brake
Number of notches [at pulling
force 196 N (20 kg, 44 lb)]9-10
SERVICE AND SPECIFICATIONS (SDS)
MA-49

Removal
Transmission has to be removed as a unit together with transfer
box.
Remove transmission assembly as follows:
IDisconnect negative battery terminal.
IRemove shift levers of transmission and transfer.
IRemove front and rear propeller shafts. Ð Refer to PD section.
IInsert plug into rear oil seal after removing propeller shaft.
IRemove RPM-sensor from transmission upper side.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
IRemove torsion bar spring. Ð Refer to FA Section.
IRemove third crossmember (the one supporting front differen-
tial).
IRemove fifth crossmember (the one situated at the rear of
transfer).
ISupport transmission and transfer with a suitable transmission
jack.
WARNING:
Support transmission and transfer with suitable jacks, while
removing them.
IRemove fourth crossmember (the one supporting transmis-
sion).
IRemove clutch operating cylinder.
IRemove starter motor.
IRemove exhaust tube bracket from transmission.
IDisconnect electrical connectors.
IRemove transmission from engine.
REMOVAL AND INSTALLATIONFS5R30A
MT-7

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

General Specifications
Engine TD27Ti and ZD30DDTi
Transmission model FS5R30A
No. of speeds 5
Shift pattern
Synchromesh type Warner
Gear ratio
1st 3.580
2nd 2.077
3rd 1.360
4th 1.000
OD 0.811
Reverse 3.631
No. of teeth
Mainshaft
drive
1st 32
2nd 30
3rd 29
4th 22
OD 24
Reverse 30
Countershaft
Drive
1st 13
2nd 21
3rd 31
4th 32
OD 43
Reverse 12
Reverse idler gear 22
Oil capacity(lmp pt) 3.6 (6-3/8)
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-34