Rocker NISSAN TERRANO 2004 Service User Guide

q1Rocker cover
q
2Rocker cover gasket
q
3Valve cotter
q
4Spring retainer
q
5Valve oil seal
q
6Valve spring Valve spring ring q
7Injection nozzle holder
q
8Nozzle washer
q
9Nozzle gasket
q
10Cylinder head
q
11Valve seat
q
12Intake valve q
13Exhaust valve
q
14Valve lifter
q
15Cylinder head gasket
q
16Push rod
q
17Glow plug
q
18Rocker shaft
NEM239
CYLINDER HEADTD27Ti
EM-104
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Removal
1. Set No. 1 cylinder at TDC on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block andradiator.
3. Remove air cleaner and intercooler components.
4. Remove the following parts: Ð Water temperature connectors
Ð Throttle chamber vacuum hoses
Ð EGR valve vacuum hose
Ð Connectors located on the intake manifold
Ð Connector located on the thermostat housing
Ð Heater tubes
Ð Connectors of the injection pump
5. Remove alternator adjusting bolt.
6. Disconnect exhaust manifold from front exhaust tube.
7. Remove turbocharger oil and water tubes.
8. Remove turbocharger bracket bolts.
9. Disconnect radiator outlet hose and thermostat housing water inlet hose.
10. Remove fuel injection tube assembly and spill tube.
11. Remove injection nozzle holder from first cylinder with a spe- cial tool (KV119E0030). Remove injection nozzles from cylin-
ders 2, 3 and 4 using a deep socket wrench.
12. Remove thermostat housing bolts shown at left.
13. Remove rocker cover and ventilation hose.
14. Remove rocker shaft with rocker arms.
15. Remove push rods.
16. Remove cylinder head bolts in numerical order and remove cylinder head.
Head warpage or cracking could result from removing in incor-
rect order.
EEM092
SEM621B
EEM103
SEM623B
CYLINDER HEADTD27Ti
EM-105
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Disassembly
1. Remove following parts:
IEGR tube
I Intake manifold
I Heat shield plates
I Exhaust manifold
I Thermostat housing
I Alternator adjusting bar & engine slinger
I Glow plate and glow plugs
2. Remove valve component parts with Tool.
3. Remove valve oil seals with Tool.
4. Disassemble rocker shaft assembly.
a. Remove rocker shaft lock bolt.
b. Remove valve rocker and rocker shaft bracket.
If it is difficult to remove rocker shaft brackets, immerse rocker
shaft assembly in oil of 70ÉC (158ÉF) for a few minutes and
then remove brackets.
SEM624B
SEM625B
SEM626B
NEM160
CYLINDER HEADTD27Ti
EM-106
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Inspection
CYLINDER HEAD DISTORTION
Cylinder head distortion:StandardLess than 0.07 mm (0.0028 in)
Limit 0.2 mm (0.008 in)
If beyond the specified limit, correct with a surface grinder. Cylinder head minimum height:89.9 mm (3.539 in)
VALVE GUIDE CLEARANCE
IValve guide clearance should be measured parallel with
rocker arm. (Generally, a large amount of wear occurs in
this direction.)
Valve to guide clearance: LimitIntake 0.15 mm (0.0059 in)
Exhaust 0.15 mm (0.0059 in)
Maximum allowable deflection
(Dial indicator reading) Intake 0.35 mm (0.0138 in)
Exhaust 0.35 mm (0.0138 in)
I To determine the correct replacement part, measure valve
stem diameter and valve guide inner diameter.
Valve stem diameter: StandardIntake7.965 - 7.980 mm (0.3135 - 0.3142 in)
Exhaust 7.945 - 7.960 mm (0.3128 - 0.3134 in)
Valve guide inner diameter: 8.000 - 8.015 mm (0.3150 - 0.3156 in)
VALVE GUIDE REPLACEMENT
1. Heat cylinder head 150 to 160ÉC (302 to 320ÉF) in oil.
2. Drive out valve guide with a hammer and suitable tool.
SEM648B
SEM586A
EM030
SEM649B
SEM628B
CYLINDER HEADTD27Ti
EM-107
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VALVE LIFTER AND PUSH ROD
Valve lifter
1. Check valve lifters for excessive wear on the surfaces.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:Standard0.030 - 0.073 mm (0.0012 - 0.0029 in)
Limit Less than 0.20 mm (0.0079 in)
Valve lifter outer diameter ªAº: Standard25.960 - 25.970 mm (1.0220 - 1.0224 in)
Cylinder block valve lifter hole diameter ªBº: Standard26.000 - 26.033 mm (1.0236 - 1.0249 in)
Push rod
1. Inspect push rod for excessive wear on the surfaces.
2. Replace if worn or damaged beyond repair.
3. Check push rod for bend using a dial gauge. Maximum allowable bend
(Total indicator reading):Less than 0.5 mm (0.020 in)
ROCKER SHAFT AND ROCKER ARM
1. Check valve rockers, brackets and rocker shafts for scoring,wear or distortion. Replace if necessary.
SEM636B
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-111
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2. Check clearance between valve rockers and rocker shaft. Ifspecified clearance is exceeded, replace affected valve rockers
or shaft.Specified clearance: LimitLess than 0.15 mm (0.0059 in)
Rocker shaft outer diameter ªAº: Standard19.979 - 20.000 mm (0.7866 - 0.7874 in)
Rocker arm inner diameter ªBº: Standard20.014 - 20.035 mm (0.7880 - 0.7888 in)
3. Check rocker shaft bend at its center. If bend is greater than specified limit, replace rocker shaft.Rocker shaft bend
(Total indicator reading): LimitLess than 0.3 mm (0.012 in)
MEASURING CYLINDER HEAD TO VALVE DISTANCE
Measure distance from cylinder head surface to intake and exhaust
valves. If specified distance is exceeded, replace valve(s) or valve
seat(s). Specified distance:StandardIntake0.8 - 1.2 mm
(0.031 - 0.047 in)
Exhaust 0.8 - 1.2 mm
(0.031 - 0.047 in)
Limit Less than 1.75 mm (0.0689 in)
for intake and exhaust valves
SEM027
SEM028
SEM026
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-112
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Assembly
1. Assemble rocker shaft component parts.
IIdentification of rocker arms
Identification mark
(on rocker arm) For use with
B Intake valve
C Exhaust valve
2. Install valve component parts.
I Always use new valve oil seal. Refer to ªVALVE STEM OIL
SEALº.
I Intake and exhaust valve springs are interchangeable.
3. Assemble all removed parts in reverse order of disassembly.
SEM637B
EEM093
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EM-113
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2. Install cylinder head.
ICylinder head identification mark
3. Apply oil to threaded portion and seat surface of bolts and tighten cylinder head bolts using Tool.
CAUTION:
I Tightening procedure
1st: Tighten bolts to 39 - 44 N×m (4.0 - 4.5 kg-m, 29 - 33 ft-lb)
2nd: Tighten bolts to 54 - 59 N ×m
(5.5 - 6.0 kg-m, 40 - 43 ft-lb)
3rd: (1) Mark exhaust side of cylinder head and cylin-der head bolts with paint as shown.
(2) Turn all bolts 90   10 degrees clockwise.
(3) Check that paint mark of each bolt is facing the front of the vehicle.
4. Apply engine oil and install push rods.
5. Install rocker shaft assembly. Adjust intake and exhaust valve clearance carefully.
Refer to MA section in order to accomplish valve adjustment.
NEM179
SEM641B
SEM580C
SEM642B
CYLINDER HEADTD27Ti
Installation (Cont'd)
EM-115
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6. Install rocker cover.
IBe sure to tighten bolts in the order shown in the illustration.
I When replacing rocker cover gasket, bend slit of rocker cover
baffle plate a little to hold the gasket. Do not twist gasket.
7. Install glow plugs and glow plate.
8. Install new top nozzle gasket and injection nozzle.
9. Install thermostat housing bolts shown at left.
10. Install spill tube and injection tube. Spill tube nut:
:39-49N ×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Injection tubes:
:20-25N ×m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
11. Connect thermostat housing water inlet hose and radiator hose.
12. Install all removed parts in reverse order of removal.
13. After assembling all disassembled parts, fill radiator and engine with new coolant up to filler opening.
Refer to MA section.
NEM163
SEM618B
EEM103
SEM621B
CYLINDER HEADTD27Ti
Installation (Cont'd)
EM-116
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VALVE STEM OIL SEAL
1. Remove rocker cover.
2. Remove rocker shaft assembly.
3. Remove valve spring.
Piston concerned should be set at TDC to prevent valve from
falling.
4. Remove valve oil seals.
5. Apply engine oil to valve oil seal and install it in place.
SEM645B
SEM626B
SEM646B
SEM223B
OIL SEAL REPLACEMENTTD27Ti
EM-117
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