compression ratio NISSAN TERRANO 2002 Service Repair Manual

Symptom Matrix Chart
SYSTEM Ð Basic engine control sys-
temSYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART
(EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE NO START (with first firing)
NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGWarranty symptom code AA AB AC AD AE AF
Electronic control fuel injection pump
mainframe4444444445534 Ð *1
Injection nozzle33333333344 3EC-24 *2
Glow system1111EC-239
Engine body3333333 344 3 EMsection *3
EGR system3 3 EC-222
Air cleaner and ducts 3 3 MA section *4
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*1: Fuel injection system malfunction or fuel injection timing control system malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
EC-56

SYSTEM Ð Basic engine control sys-
temSYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutBLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
Electronic control fuel injection pump
mainframe443 4 54 333 Ð *1
Injection nozzle 3 3 4 EC-24 *2
Glow system 1 EC-239
Engine body 3 3 3 3 3 3 EM section *3
EGR system 3 EC-222
Air cleaner and ducts 3 3 MA section *4
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*1: Fuel injection system malfunction or fuel injection timing control system malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-57

Symptom Matrix Chart
SYSTEM
Ð Basic engine
control systemSYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutNO START (with first firing)
NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATING
BLACK SMOKE
WHITE SMOKENew CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec-
tion
timingAdvancedqq
IIqIqqIqEC-338
Retardedqq
IIqIqqIqEC-338
Electric injection
pump mainframe
IIIIqqqqqIqqqIIqqIq qqqÐ*1
Injection nozzleqqqqqqq
Iqq qII IEC-313 *2
Glow systemqq
II I IEC-389
Engine body
qq
IIqqqIqq qIIqqqIEM-
section*3
EGR system
II IEC-431
Air cleaner and
ducts
II IqMA-
section*4
I; High Possibility Item
q; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSESTD27Ti
EC-340

ENGINE MECHANICAL
SECTION
EM
CONTENTS
ZD
PRECAUTIONS...............................................................3
Parts Requiring Angular Tightening .............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION................................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................8
NVH Troubleshooting Chart - Engine Noise ...............9
MEASUREMENT OF COMPRESSION PRESSURE....10
INTERCOOLER............................................................. 11
Removal and Installation ........................................... 11
INTAKE MANIFOLD......................................................12
Removal and Installation ...........................................12
Inspection...................................................................13
CATALYST AND TURBOCHARGER............................14
Removal and Installation ...........................................14
Inspection...................................................................15
EXHAUST MANIFOLD..................................................18
Removal and Installation ...........................................18
Inspection...................................................................19
ROCKER COVER..........................................................20
Removal and Installation ...........................................20
OIL PAN & OIL STRAINER...........................................22
Removal and Installation ...........................................22
VACUUM PUMP............................................................24
Removal and Installation ...........................................24
TIMING CHAIN..............................................................26
Removal and Installation ...........................................26
Removal .....................................................................26
Installation ..................................................................28
CAMSHAFT...................................................................30
Removal and Installation ...........................................30
Removal .....................................................................30
Inspection...................................................................31
Installation ..................................................................33VALVE CLEARANCE INSPECTIONS AND
ADJUSTMENTS.............................................................35
Inspection...................................................................35
Adjustments ...............................................................36
TIMING GEAR...............................................................38
Removal and Installation ...........................................38
Removal .....................................................................39
Inspection...................................................................41
Installation ..................................................................46
OIL SEAL REPLACEMENT..........................................50
CYLINDER HEAD..........................................................52
Removal and Installation ...........................................52
Removal .....................................................................52
Inspection...................................................................53
Installation ..................................................................54
Disassembly...............................................................57
Inspection...................................................................58
Assembly ...................................................................61
ENGINE REMOVAL.......................................................63
Precautions ................................................................63
Removal .....................................................................63
Installation ..................................................................65
Inspection...................................................................65
CYLINDER BLOCK.......................................................66
Selection Procedure for Selective Part
Combination ...............................................................67
Disassembly...............................................................67
Inspection...................................................................71
Assembly ...................................................................80
SERVICE DATA AND SPECIFICATIONS (SDS)..........84
General Specifications ...............................................84
Compression Pressure ..............................................84
Cylinder Head ............................................................84
Valve ..........................................................................84
Valve Seat..................................................................87
Camshaft and Camshaft Bearing ..............................89
Cylinder Block ............................................................90
Piston, Piston Ring and Piston Pin ...........................90

Connecting Rod .........................................................91
Crankshaft..................................................................92
Available Main Bearing ..............................................92
Available Connecting Rod Bearing............................93
Miscellaneous Components.......................................94
TD27Ti
PRECAUTIONS.............................................................95
Parts Requiring Angular Tightening ...........................95
Liquid Gasket Application Procedure ........................95
PREPARATION..............................................................96
Special Service Tools ................................................96
Commercial Service Tools .........................................99
ENGINE COMPONENTS - Outer Parts.....................100
ENGINE COMPONENTS - Internal Parts..................102
COMPRESSION PRESSURE......................................103
Measurement of Compression Pressure .................103
CYLINDER HEAD........................................................104Removal ...................................................................105
Disassembly.............................................................106
Inspection.................................................................107
Assembly ................................................................. 113
Installation ................................................................ 114
OIL SEAL REPLACEMENT........................................ 117
TURBOCHARGER....................................................... 119
Removal and Installation ......................................... 119
Inspection................................................................. 119
ENGINE REMOVAL.....................................................123
ENGINE OVERHAUL..................................................125
Disassembly.............................................................125
Inspection.................................................................127
Assembly .................................................................138
SERVICE DATA AND SPECIFICATIONS (SDS)........143
General Specifications .............................................143
Inspection and Adjustment ......................................144
CONTENTS(Cont'd)
EM-2

Tool number
Tool nameDescription
KV101151S0
Lifter stopper set
q
1KV10115110
Camshaft pliers
q
2KV10115120
Lifter stopper
NT041
Changing shims
KV101092S0
Valve spring compressor
q
1KV10109210
Compressor
q
2KV10109220
Adapter
NT718
Disassembling and assembling valve compo-
nents
ED19600620
Compression gauge adapter
NT820
Checking compression pressure
ST16610000
Pilot bushing puller
NT045
Removing crankshaft pilot bushing
KV101111 0 0
Seal cutter
NT046
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder head,
etc.
PREPARATIONZD
Special Service Tools (Cont'd)
EM-5

1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC section, ªFuel Pressure
Releaseº.
IDo not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. Remove the following parts.
IIntercooler
IThrottle body
IRocker cover
6. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT A/T (15A)] from fuse box
on the right side of engine compartment.
7. Remove glow plugs from all the cylinders.
IBefore removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
ICarefully remove glow plugs to prevent any damage or
breakage.
IHandle with care to avoid applying any shock to glow
plugs.
8. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
:15-19N×m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
9. Connect battery negative terminal.
10. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
IAlways use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
2,942 (29.42, 30.0, 427)/
2002,452 (24.52, 25.0, 356)/
200294 (2.94, 3.0, 43)/200
IWhen engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
IIf engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylinder
head gaskets, piston rings, pistons, cylinder bores, cylinder
block upper and lower surfaces) and measure again.
11. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Replace glow plug oil seals and install glow plugs.
d. Install fuel injection pump fuse [ENG CONT A/T (15A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self-diagnosis. Refer to EC section, ªTrouble Diagno-
sis Ð Indexº.
YEM039
SEM334G
MEASUREMENT OF COMPRESSION PRESSUREZD
EM-10

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

*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV111045SO
Cam bushing replacer
set
q
1KV11104510
Replacer bar
q
2KV1104520
Guide plate
q
3KV11104530
Adapter
(1st bushing)
q
4ST15243000
Drift
Removing cam bushing or installing cam
bushing
KV10109300*
Injection pump drive
gear holder
Preventing drive gear from rotating
KV11103000*
Injection pump drive
gear puller
Removing drive gear
q
1ED19601000
Compression gauge
q
2ED19600600
Compression gauge
adapter (for glow plug
hole)
q
3ED19600700
Compression gauge
adapter (for injector
hole)
Checking compression pressure
WS39930000*
Tube presser
Pressing the tube of liquid gasket
KV119E0030
Nozzle holder socket
Removing and installation injection
nozzle assembly
ST11032000*
Valve guide reamer
8.0 mm (0.315 in) dia.
Reaming valve guide
PREPARATIONTD27Ti
Special Service Tools (Cont'd)
EM-98

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