lock NISSAN TERRANO 2004 Service User Guide

Checking Idle Speed
Preparation
1. Make sure that injection timing is correct.
2. Make sure that injection nozzle are in good condition.
3. Make sure that the following parts are in good condition.
IAir cleaner clogging
I Glow system
I Engine oil and coolant levels
I Valve clearance
I Air intake system (Oil filler cap, oil level gauge, etc.)
4. Set shift lever in ªNeutralº position. Engage parking brake and lock both front and rear wheels with wheel chocks.
5. Turn off air conditioner, lights and accessories.
I Warm up engine until water temperature indicator points to middle of gauge.
I Lights, heater fan and all accessories are off.
I Attach tachometer's pick-up to No. 1 fuel injection tube.
In order to take accurate reading of engine rpm, remove clamps that secure No. 1 fuel injection tube.
Start engine.
SMA406B
SMA021A
Run engine at about 2,000 rpm for
about 2 minutes under no-load.
Run engine for one minute at idle
speed.F
Check idle speed.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- IDLE SPEED: 700+ 50 rpm
OK
ENG Adjust idle speed by turning idle speed adjust-
ing screw.
EMA049
END
I
Race engine two or three times and allow engine to return to idle speed. If idle speed is not within
the specified range, check acceleration linkage for binding and correct it if necessary.
H
H
H
H
H
ENGINE MAINTENANCETD
MA-26
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4. Remove cylinder block drain plug located at left center of cyl-inder block.
5. Remove reservoir tank and drain coolant.
ÐREFILLING ENGINE COOLANTÐ
6. Install reservoir tank, radiator drain plug, and cylinder block drain plugs.
I Apply sealant to the thread of cylinder block drain plug.
Cylinder block drain plug:
:24-26N ×m (2.4 - 2.7 kg-m, 18 - 19 ft-lb)
7. Move heater TEMP control knob all the way to HOT.
8. Fill radiator with coolant up to the filler neck.
For coolant mixture ratio, refer to MA-19.
9. Fill reservoir tank with coolant up to the MAX level.
Coolant capacity (With reservoir tank):10.6 (9-3/8 Imp qt)
Reservoir tank capacity (for MAX level): 0.75 (5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.
10. Install radiator cap.
11. Warm up engine to normal operating temperature.
12. Run engine at 2,000 rpm for 10 seconds and return to idle speed.
I Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
13. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
14. Remove the radiator cap and check coolant level.
I If necessary, refill radiator up to filler neck with coolant.
15. Refill reservoir tank to Max line with coolant.
16. Repeat step 9 through step 15 two or more times.
17. Warm up engine, and check for sound of coolant flow while running engine from idle up to 2,000 rpm with heater tempera-
ture control set at several positions between COOL and HOT.
I Sound may be noticeable at heater water core.
18. If sound is heard, bleed air from cooling system by repeating steps 11 through 17 until coolant level no longer drops.
I Clean excess coolant from engine.
Checking Cooling System
CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
SMA108D
SMA182B
SMA412B
YMA014
ENGINE MAINTENANCEZD
Changing Engine Coolant (Cont'd)
MA-32
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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 - 147.7 mm (5.42 - 5.81 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 nut q
A, rotate adjusterqB.
(2) Tighten lock nut q
A.
SBR461A
SMA441B
EMA050
SBR032A
CHASSIS AND BODY MAINTENANCE
Checking Drum Brake (Cont'd)
MA-42
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Body
LUBRICATING HOOD LATCHES, LOCKS AND HINGES
EMA040
EMA041
EMA042
CHASSIS AND BODY MAINTENANCE
MA-45
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TIGHTENING TORQUE
UnitN×m kg-m ft-lb
Clutch Pedal stopper lock nut 12 - 15 1.2 - 1.5 8.7 - 10.8
Master cylinder push rod
lock nut 8 - 11 0.8 - 1.1 5.8 - 8.0
Manual transmission Drain and filler plugsFS5R30A 25 - 34 2.5 - 3.5 18 - 25
Differential carrier Drain and filler plugsR180A 39 - 59 4 - 6 28.8 - 43.5
H233B 59 - 98 6 - 10 43.5 - 72.3
Front axle and front suspen-
sion Tie-rod lock nut 60 - 70 6.1 - 7.1 44.3 - 51.6
Brake system Air bleeder valve 7 - 9 0.7 - 0.9 5.1 - 6.5
Wheel and tire
Wheel nut 118 - 147 12.0 - 15.0 87.0 -
108.4
SERVICE AND SPECIFICATIONS (SDS)
Chassis and Body Maintenance (Cont'd)
MA-50
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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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NVH Troubleshooting Chart Ð Engine Noise
Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location ofnoise Type of
noise Operating condition of engine
Source of
noise Check item Reference
page
Before
warm-up After
warm-up When
starting When
idling When
racing While
driving
To p o f
engine
Rocker
cover
Cylinder
head Ticking or
clicking
C AÐA BÐ Tappet
noiseValve clearance MA section
(ªAdjusting
Intake &
Exhaust
Valve
Clearanceº,
ªENGINE
MAINTE-
NANCEº)
Rattle C A Ð A B C Camshaft
bearing
noiseCamshaft bushing clearance
Camshaft runout
EM-31, 31
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan Slap or
knock
ÐAÐB BÐ Piston pin
noisePiston and piston pin clear-
ance
Connecting rod bushing
clearance
EM-71, 73
Slap or rap A Ð Ð B B A Piston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion EM-75, 72,
72, 73
Knock A B C B B B Connecting
rod bearing
noiseConnecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)
EM-73, 77
Knock A B Ð A B C Main bear-
ing noiseMain bearing oil clearance
Crankshaft runout
EM-78, 76
Front of
engine
Timing gear
cover Tapping or
ticking
AAÐBBB Timing gear
noiseTiming gear backlash EM-41
Front of
engine Squeaking
or fizzing
A BÐBÐC Other drive
belts (Stick-
ing or slip-
ping)Drive belts deflection
MA section
(ªChecking
Drive Beltsº,
ªENGINE
MAINTE-
NANCEº)
Creaking
ABABAB Other drive
belts (Slip-
ping)Idler pulley bearing operation
Squall
Creak ABÐBAB Water pump
bearing
noiseWater pump bearing opera-
tion LC section
(ªWater
Pump
Inspectionº,
ªENGINE
COOLING
SYSTEMº)
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGZD
EM-9
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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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INSTALLATION
1. Install oil strainer.
2. Install oil pan.
a. Use a scraper to remove all traces of liquid gasket from matingsurfaces.
I Also remove traces of liquid gasket from mating surface of cyl-
inder block, front cover.
I Remove old liquid gasket from the bolt hole and thread.
b. Apply a continuous bead of liquid gasket to mating surface of oil pan.
I Use Genuine Liquid Gasket or equivalent.
I Apply liquid gasket to the groove on the mating surface.
I Allow 8 mm (0.31 in) clearance around center of bolt holes.
c. Apply liquid gasket to inner sealing surface as shown in figure.
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in).
I Attaching should be done within 5 minutes after coating.
2. Tighten the mounting bolts in the order shown in the figure. Then tighten in the same order to the torque stated.
3. The torque of the installation bolts will differ depending on posi- tion.
4. Install in the reverse order of removal.
SEM159F
JEM774G
JEM773G
OIL PAN & OIL STRAINERZD
Removal and Installation (Cont'd)
EM-23
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2. Move the following parts.
ITDC sensor harness
I Power steering oil pump
3. Remove the chain cover.
I Remove the holding bolts A to C shown in the figure.
CAUTION:
While the chain cover is removed, be careful not to allow entry
of dust or foreign objects.
4. Set the No. 1 cylinder to the TDC.
1) Turn the crankshaft pulley clockwise, and match the timing indicator of the gear case to the timing mark of the crankshaft
pulley.
2) Make sure that the cam sprocket match mark is in the position shown in the figure.
I If the match mark is not in position, turn the crankshaft pulley
once more and position it.
I When removing at No. 1 cylinder TDC, each sprocket and chain
is fitted using the match mark, therefore there is no need to
apply any match marks beforehand.
5. Remove the chain tensioner.
1) Loosen upper and lower holding bolts.
2) Holding the chain tensioner in your hand, remove the upper holding bolt and release the spring tension.
3) Remove the lower holding bolt, then remove the chain ten- sioner.
I The chain tensioner does not have a mechanism which pre-
vents the ejection of the plunger. (It does have a mechanism
which prevents the plunger from returning.)
CAUTION:
Be careful not to drop the plunger and spring.
FEM004
SEM342G
FEM005
FEM006
TIMING CHAINZD
Removal (Cont'd)
EM-27
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