Pressure NISSAN TERRANO 2004 Service User Guide

CHECKING RADIATOR CAP
Apply pressure to radiator cap (side with pressure valve) with cap
tester to see if it is satisfactory.Radiator cap relief pressure:108 - 128 kPa
(1.08 - 1.28 bar, 1.1 - 1.3 kg/cm
2, 16 - 18 psi)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage. Testing pressure:157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
CAUTION:
Use of higher pressure than the specified value may cause
damage to radiator.
Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs.
REPLACING FUEL FILTER
1. Disconnect harness connector and drain fuel.
2. Remove fuel filter using band-type filter wrench.
3. Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator.
SLC613
SMA871B
JMA110D
DMA011
SMA111D
ENGINE MAINTENANCEZD
Checking Cooling System (Cont'd)
MA-33
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Engine Maintenance
INSPECTION AND ADJUSTMENT
Drive belt deflection
Unit: mm (in)
Used belt deflectionDeflection of
new belt
Limit Deflection after
adjustment
Engine TD27Ti TD27Ti TD27Ti
Alternator 20
(0.79) 11-13
(0.43 - 0.51) 9-11
(0.35 - 0.43)
Air conditioner 12
(0.47) 6 - 7.5
(0.236 - 0.295) 5 - 6.5
(0.197 - 0.256)
Power steering
oil pump 15
(0.59) 8 - 9.5
(0.315 - 0.374) 7 - 8.5
(0.276 - 0.335)
Applied pushing
force 98 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
TD27Ti engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
ZD30DDTi engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 108 - 128
(1.08 - 1.28, 1.1 - 1.3, 16 - 18)
Coolant capacity (Refill capacity)
Unit: (Imp qt)
Engine TD27TiZD30DDTi
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
New 12,259 - 12,749 (122.6 - 127.5, 125 -
130, 1,778 - 1,849)
Used 12,749 - 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
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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 ..................................................................33 VALVE 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
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Connecting Rod .........................................................91
Crankshaft..................................................................92
Available Main Bearing ..............................................92
Available Connecting Rod Bearing............................93
Miscellaneous Components.......................................94TD27Ti
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 ........................................................104 Removal ...................................................................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
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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
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1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated forself-diagnosis items. Refer to EC section, ªFuel Pressure
Releaseº.
I Do 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.
I Intercooler
I Throttle body
I Rocker 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.
I Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
I Carefully remove glow plugs to prevent any damage or
breakage.
I Handle 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.
I Always 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)/ 200 2,452 (24.52, 25.0, 356)/
200 294 (2.94, 3.0, 43)/200
I
When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
I If 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
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Removal and Installation
CAUTION:
To avoid damaging intercooler core when flushing intercooler
with high pressure water, apply water straight to the core face.
YEM037
INTERCOOLERZD
EM-11
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Rotor shaft end play
Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.Standard: 0.044 - 0.083 mm (0.0017 - 0.0033 in)
Turbine wheel
ICheck that there is no oil adhesion.
I Check that there is no carbon accumulation.
I Check that blades of the turbine wheel are not bent or broken.
I Check that the turbine wheel does not interfere with the turbine
housing.
Compressor wheel
ICheck that there is no oil adhesion inside the air inlet.
I Check that the compressor wheel does not interfere with the
compressor housing.
I Check that the wheel is not bent or broken.
VNT control actuator
IConnect the handy pump to the actuator, and check that the rod
strokes smoothly in compliance with the following pressure.
I First, apply the inspection negative pressure of about þ66.7
kPa (þ667 mbar, þ500 mmHg, 19.69 inHg), and then measure
the values while reducing the negative pressure to 0.
Standard (Vacuum pressure/rod stroke amount): þ46.9 1.3 kPa (þ469 13 mbar, þ352 10 mmHg,
þ13.86 0.39 inHg)/0.2 mm (0.008 in)
þ30.8 0.7 kPa (þ308 7 mbar, þ231 5 mmHg,
þ9.09 0.20 inHg)/5.0 mm (0.197 in)
Approximately þ22.7 kPa (þ227 mbar, þ170 mmHg,
þ6.69 inHg)/Rod stroke end
SEM299G
SEM300G
SEM310G
SEM311G
CATALYST AND TURBOCHARGERZD
Inspection (Cont'd)
EM-16
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Trouble diagnosis of turbocharger
Preliminary check:
Check that the VNT control valve system has no malfunction. Refer
to EC section, ªECM Terminals and Reference Valueº in ªTROUBLE
DIAGNOSIS Ð GENERAL DESCRIPTIONº.
ICheck that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
I Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
I Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
I If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item
meets each inspection result)
Oil leak- age Smoke Noise Insuffi-
cient
power/ accel-
eration failure
Turbine wheel Oil leaks.
g
gg
Carbon is accumulated. g
qq
Friction with housing. gq
q
Blades are bent or broken.
Compressor wheel Inside the air inlet is seriously contami-
nated by oil.
qq
Friction with housing. gqq
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play. There is resistance when the rotor shaft
is rotated by your fingertips.
ggq
The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing. g gqg
Oil return port Carbon or sludge is accumulated in the
waste oil hole.g
gg
Operation of VNT control actuator I
The actuator does not operate
smoothly when vacuum pressure is
gradually applied.
I Stroke amount is not in compliance
with the vacuum pressure. q
: Large possibility
q: Medium possibility
g: Small possibility
INSTALLATION
1. Install catalyst.
:29-39N ×m (2.9 - 3.3 kg-m, 21 - 23 ft-lb)
Place the protruding area of the gasket between the turbocharger
and the exhaust outlet upwards, and install the lipped side to the
turbocharger side. Refer to the figure, EM-14.
2. Install in the reverse order of removal.
CATALYST AND TURBOCHARGERZD
Inspection (Cont'd)
EM-17
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INSPECTION
1. Remove the vacuum hose. Connect the vacuum gauge throughthe 3-way connector. Otherwise, remove the welch valve of the
vacuum pipe and attach the vacuum gauge directly. (The illus-
tration shows the second method.)
I Remove an appropriate part to measure the vacuum pump load
pressure directly and install the vacuum gauge. Refer to the
figure.
2. Start the engine, and measure the load pressure with the engine idling.Vacuum pressure: Standardþ93.3 to þ101.3 kPa (þ933 to þ1,013 mbar, þ700
to þ760 mmHg, þ27.56 to þ29.92 inHg)
3. If outside the standard value, make sure that there is no intake of air within the circuit and measure again.
4. Replace the vacuum pump if still outside the standard value.
INSTALLATION
I Install in the reverse order of removal.
SEM322G
VACUUM PUMPZD
Removal and Installation (Cont'd)
EM-25
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