Pressure NISSAN TERRANO 2004 Service Owner's Manual

Removal
1. Remove the engine assembly.Refer to ªENGINE REMOVALº, EM-63.
2. Place the engine on an engine stand (SST). Refer to ªCYLINDER BLOCKº, EM-67.
3. Remove the following.
I Auto tensioner bracket
I Air conditioner bracket
I Alternator bracket
I Oil tube
I Vacuum pump
I Rocker cover
I Oil pan (upper, lower)
I Injection tube
I Spill tube
I High pressure nozzle assembly
4. Remove the chain cover, timing chain and other parts in con- nection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the fig-
ure. Refer to ªTIMING CHAINº, EM-26.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
I Do not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
I Do not drop or hit the sensor.
I Store in a clean place free of iron filings, etc.
I Do not place near any magnetic equipment.
6. Remove the water pump. Refer to ªWATER PUMPº in LC section.
7. Remove the water inlet.
SEM376G
TIMING GEARZD
EM-39
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Removal and Installation
Removal
1. Remove the following. (Refer to corresponding chapter fordetailed auxiliary work.)
I Drain coolant
I Rocker cover
I Injection tube
I Spill tube
I High pressure injection nozzle assembly
I Timing chain
I Camshaft
I Catalytic converter
I Turbocharger assembly
I Exhaust manifold
2. Remove mounting bolts of the gear case and water pump as shown by arrows in the figure.
3. Remove oil return pipe from the rear side of cylinder head.
4. Remove intake manifold.
SEM359G
FEM054
CYLINDER HEADZD
EM-52
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Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.
5. Disconnect harness connectors from alternator and air com-pressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor and inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.
Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix it to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move har- nesses to the side of the vehicle.
Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and removerear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount mem- bers to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to trans- mission.
Removal operation
19. Remove air conditioner high pressure pipes at the rear of theengine room.
I This is due to some inconvenience in the rear slinger installa-
tion.
20. Install the engine slingers (standard service part) to front-left and rear-right.
:25-28N ×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
FEM082
ENGINE REMOVALZD
Removal (Cont'd)
EM-64
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3) Install engine sub-attachment (SST) to the rear side of cylinderblock.
I Align knock pin on cylinder block with pin hole on attachment
to install engine sub-attachment.
I Mounting bolts are provided with engine sub-attachment.
4) Install engine attachment (SST).
I Use commercially available M12 mounting bolts and nuts (4
sets) with strength grade of 9T (minimum).
5) Hoist engine and install it to the engine stand (SST).
I Engine attachment and engine sub-attachment can be installed
to engine stand before engine installation.
4. Drain engine oil and coolant from engine.
5. Remove the following parts and related parts. (Only major parts are listed.)
I Accessory belt
I Catalytic converter
I Turbocharger
I Exhaust manifold
I Injection tube
I Intake manifold
I Rocker cover
I Oil pan (upper/lower)
I Water pump
I Thermostat and water pipes
I Vacuum pump
I Injection tube
I Timing chain
I Electronic high pressure fuel injection pump
I Timing gear
I High pressure injection nozzle assembly
I Camshaft
I Cylinder head
I Oil cooler
I Accessory and accessory brackets
6. Remove rear oil seal and retainer assembly.
I Insert flat-bladed screwdriver between lower cylinder block and
rear oil seal retainer to remove the assembly.
I No part No. is given to oil seal.
FEM083
FEM084
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-68
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General Specifications
Cylinder arrangementIn-line 4
Displacement cm
3(cu in)2,953 (180.19)
Bore and stroke mm (in) 96 x 102 (3.78 x 4.02)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings Compression 2
Oil
1
Number of main bearings 5
Compression ratio 17.9
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
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VALVE SPRING
Free heightmm (in)55.43 (2.1823)
Pressure N (kg, lb) at height mm (in) 354 (36.1, 79.6) at 32.3 (1.2717)
Out-of-square mm (in) 2.4 (0.094)
VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter 34.455 - 34.465 (1.3565 - 1.3569)
Lifter guide inner diameter 34.495 - 34.515 (1.3581 - 1.3589)
Clearance between lifter and lifter guide 0.030 - 0.060 (0.0012 - 0.0024)
VALVE GUIDE
Unit: mm (in)
FEM071
Standard
Valve guide Outer diameter 11.023 - 11.034 (0.4340 - 0.4344)
Inner diameter (Finished size) 7.000 - 7.018 (0.2756 - 0.2763)
Cylinder head valve guide hole diameter 10.975 - 10.996 (0.4321 - 0.4329)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Standard
Stem to guide clearance Intake 0.023 - 0.056 (0.0009 - 0.0022)
Exhaust 0.040 - 0.073 (0.0016 - 0.0029)
Valve deflection limit 0.2 (0.0079)
Projection length 12.8 - 13.2 (0.5309 - 0.5197)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
Valve (Cont'd)
EM-86
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*: 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
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Measurement of Compression Pressure
1. Warm up engine and switch off the ignition switch.
2. Remove glow plate and glow plugs.
3. Fit compression gauge adapter to cylinder head.Compression gauge adapter:
:15-20N ×m
(1.5 - 2.0 kg-m, 11 - 14 ft-lb)
4. Ensure the ignition switch is in the ªLOCKº position and discon- nect harness connector (gray colored) from injection pump.
5. Crank engine, then read gauge indication.
I Always use a fully-charged battery to obtain specified
engine revolution.
I Engine compression measurement should be made as
quickly as possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)
Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3, 43)
6. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through the glow holes
and retest compression.
I If adding oil helps the compression pressure, piston rings
may be worn or damaged.
I If pressure stays low, valve may be sticking or seating
incorrectly.
I If cylinder compression in any two adjacent cylinders is
low, and if adding oil does not help the compression, there
is leakage past the gasket surface.
Leakage past the cylinder gasket can result in oil and water
becoming mixed in the engine block cooling and lubrica-
tion chambers.
SEM618B
NEM005
SEM355F
COMPRESSION PRESSURETD27Ti
EM-103
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(2) Align combustion chamber knock pin with cylinder head notch,and drive in combustion chamber with a soft hammer.
3. Check amount of protrusion of combustion chamber. Protrusion:StandardLess than 0.10 mm (0.0039 in)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to SDS.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
VALVE SPRING SQUARENESS
Out-of-square ªSº: Less than 2.0 mm (0.079 in)
VALVE SPRING PRESSURE
Refer to SDS.
SEM634B
SEM188A
SEM635B
EM113
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-110
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TURBINE WHEEL
Check turbine wheel for the following.
IOil
I Carbon deposits
I Deformed fins
I Contact with turbine housing
COMPRESSOR WHEEL
Check compressor wheel for the following.
IOil
I Deformed fins
I Contact with compressor housing
WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deformation
and smooth movement. Check valve seat surface for smoothness.
Check operation of by-pass valve controller.
IMove by-pass valve to make sure that it is not sticking or
scratched.
I Measure rod end play of the by-pass valve controller.
Do not apply more than 102.6 kPa (1,026 mbar, 770 mmHg,
30.31 inHg) pressure to controller diaphragm. By-pass valve controller stroke/pressure:0.38 mm (0.015 in)/92 kPa (920 mbar, 690 mmHg,
27.17 inHg)
SEM828D
SEM829D
SEM830D
SEC727B
TURBOCHARGERTD27Ti
Inspection (Cont'd)
EM-122
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