lock NISSAN TERRANO 2004 Service Owner's Manual

3. Remove injection tube and injection nozzle assembly. Refer toEC section, ªInjection Tube and Injection Nozzleº in ªBASIC
SERVICE PROCEDUREº.
4. Remove the camshaft.
I Place distinguishing marks on the right and left sides with paint.
I Loosen and remove the installation bolt in reverse order shown
in the figure.
5. Remove the adjusting shim and valve lifter.
I Remove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
Inspection
VISUAL CHECK OF CAMSHAFT
ICheck the camshaft for one sided wear or scratches.
I Replace the camshaft if there are abnormalities.
CAMSHAFT RUNOUT
IPrepare V-block on a flat surface and secure camshaft journals
No. 1 and No. 5.
I Set the dial gauge vertically on journal No. 3.
I Rotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)
HEIGHT OF CAM NOSE
Measure by using a micrometer. Standard:Intake40.468 - 40.508 mm (1.5932 - 1.5948 in)
Exhaust 40.830 - 40.870 mm (1.6075 - 1.6091 in)
CAMSHAFT OIL CLEARANCE
Measure by using a micrometer. Cam journal outer diameter:Standard29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
FEM012
FEM013
FEM014
FEM015
CAMSHAFTZD
Removal (Cont'd)
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Inspection
IWhen the camshaft or parts in connection with valves are
removed or replaced, and a fault has occurred (poor starting,
idling, or other faults) due to the misadjustment of the valve
clearance, inspect as follows.
I Inspect and adjust when the engine is cool (at normal tempera-
ture).
I Be careful of the intake and exhaust valve arrangement. (The
valve arrangement is different from that in a normal engine.)
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
1. Remove the following parts.
I Intercooler cover
I Intercooler
I Rocker cover
2. Set the No. 1 cylinder at TDC.
1) Rotate the crankshaft pulley clockwise, and align the TDC mark of the crankshaft pulley with the timing indicator of the TDC
sensor bracket.
2) Confirm that the cam nose of the No. 1 cylinder and the knock pin of the cam sprocket is in the position shown in the figure.
I Rotate the crankshaft pulley again if not in the position shown
in the figure.
3. While referring to the figure, measure the valve clearance in the circled area of the table below.
Measuring point No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDC qqq q
I
The injection order is 1-3-4-2.
I Measure the valve clearance using a JIS high grade feeler
gauge when the engine is cool (at normal temperature).
Standard: Intake and exhaust0.35 0.05 mm (0.0138 0.0020 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft clock- wise once.
FEM010
SEM342G
FEM024
FEM025
FEM026
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
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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
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12. Remove the idler gears (A) and (B).
ICheck the backlash of each gear before removing. Refer to
ªBACKLASH OF EACH GEARº, ªInspectionº.
CAUTION:
I Do not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
I During removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
13. Set the fuel injection timing gear with the pulley holder (SST).
14. Remove injection pump timing gear.
15. Extract the balancer shaft taking care not to damage the inner bushes of the cylinder block.
16. Remove the fuel injection pump.
17. Remove the front plate.
Inspection
BACKLASH OF EACH GEAR
Method using a fuse wire
I Tighten the holding bolts of each gear to specification.
I Place a wire in the biting area of the teeth between the gears
to be checked, rotate the crankshaft in the operating direction
so that the wire is taken inwards.
I Measure the crushed area of the wire with a micrometer.
Method using dial gauge
ITighten the holding bolts of each gear to specification.
I Place the dial gauge on the tooth surface area of the gear to
be checked.
I With the other gear in a set position, measure the dial gauge
value while moving the gear left and right.
Standard: 0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit: 0.20 mm (0.0079 in)
I If it exceeds the limit, replace the gear and measure again.
I If it exceeds the limit again, check for the installation condition
of the gear driving parts, wear of shaft and gear, and oil clear-
ance.
SEM348G
SEM378G
SEM352G
FEM035
FEM036
TIMING GEARZD
Removal (Cont'd)
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2. Using Tool, remove balancer shaft rear bearing from engine.
3. Install the rear and front balancer shaft bearings.
IInstall from the cylinder block hole to the rear journal and then
the front journal.
I Install the groove of the balancer shaft bearing facing the front
and the under right direction.
(Align the guide plate and bar knock pin and then force in the
balancer shaft bearing.)
I Align the balancer shaft bearing groove with the knock pin of
the bar (SST) and install the balancer shaft bearing.)
I On rear journals, so the bearing does not get out of position,
wrap tape around the bar.
SEM381G
SEM382G
SEM383G
EMV0514D
TIMING GEARZD
Inspection (Cont'd)
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IMake an alignment mark 11.0 0.8 mm (0.433 0.031 in) from
the bar No. 2 engraved line with a marker pen. This alignment
mark q
Bwill be the point to where the rear bearing is pushed.
I Insert the bar with the bearing installed into the cylinder block
and install the guide plate (SST).
I Align the guide plate with the ZD engraving and install the bolts.
CAUTION:
Use a washer of the same thickness used on the front plate to
prevent the guide plate from bending.
I Push the engraved bar alignment mark q
Bto the same position
of the guide plate tip q
A.
I After all the journals have been installed, make sure that all the
journal and cylinder block oil holes are aligned.
4. Install the front balancer shaft bearing.
I Align the journal and cylinder block oil holes.
I Use a drift (SST) to force in the tip of the journal to 8.0 0.3 mm
(0.315 0.012 in) inside the cylinder block.
I After installing the journal, make sure that the journal and cyl-
inder block oil holes are aligned.
SEM385G
SEM384G
SEM386G
SEM380G
TIMING GEARZD
Inspection (Cont'd)
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Installation
1. Install the front plate.
1) Install the O-ring and gasket to the cylinder block.
2) Install the front plate.
ILightly tap with a hammer if the dowel pin cannot be inserted
easily.
CAUTION:
Make sure that the O-ring does not pop out.
3) Apply Three Bond 1207C (KP510 00150) with a spreader between the cylinder block plate under the cylinder block (oil
pan side) and the front plate (shown by the arrows in the fig-
ure).
2. Install the fuel injection pump.
I After installing the front plate, align the 6 mm (0.24 in) dia. hole
of the pump flange and the 6 mm (0.24 in) dia. hole position of
the pump body.
3. Install each timing gear.
I Align the match marks of the timing gears by referring to the
figure below.
I When installing timing gear, follow the order ( q
1,q2) shown in
the dotted box in the figure below to facilitate installation.
SEM387G
FEM041
FEM042
TIMING GEARZD
Inspection (Cont'd)
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4. Install the front oil seal to the gear case.
IApply engine oil to the fitting side.
I Evenly insert the front oil seal using a drift [outer dia.: approx.
64 mm (2.52 in)] completely.
CAUTION:
Make sure the oil seal does not spill off the end side of the gear
case.
5. Install the gear case.
1) Before installing gear case, remove all traces of liquid gasket from mating surface using a scraper.
2) Align gasket with dowel and install.
3) Install the O-rings to the gear case.
I The O-ring at the top position shown in the figure can be
installed in during cylinder head installation.
4) Apply a continuous bead of liquid gasket to gear case.
I Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach gear case to cylinder block within 5 minutes after coating.
c. Wait at least 30 minutes before refilling engine oil or start- ing engine.
FEM043
FEM044
SEM353G
FEM045
TIMING GEARZD
Installation (Cont'd)
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CRANKSHAFT FRONT OIL SEAL
1. Remove the front cover. Refer to ªTIMING GEARº.
2. Remove front oil seal with a suitable tool.
3. Apply engine oil to new oil seal and install oil seal using a suit-able tool.
CRANKSHAFT REAR OIL SEAL
1. Remove oil pan assembly. Refer to EM-22, ªOIL PANº.
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove oil seal retainer assembly.
5. Apply a continuous bead of liquid gasket to rear oil sealretainer.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach oil seal retainer to cylinder block within five min- utes after coating.
c. Wait at least 30 minutes before refilling engine oil or start- ing engine.
d. Use Genuine Liquid Gasket or equivalent.
SEM358G
FEM044
SLC822
FEM053
OIL SEAL REPLACEMENTZD
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5. Remove cylinder head assembly.
ILoosen and remove mounting bolts in the reverse order shown
in the figure.
I Lift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
I Do not drop the O-ring located between the front of cylin-
der head and the rear of gear case into the engine.
I Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head, or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.
I For glow plug removal, the following shall be noted.
CAUTION:
I To avoid breakage, do not remove glow plug unless nec-
essary.
I Perform continuity test with glow plug installed.
I Keep glow plug from any impact. (Replace if dropped from
a height 10 cm (3.94 in) or higher.)
I Do not use air impact wrench.
6. Remove idler gear.
CAUTION:
While removing idler gear, keep the rear of idler gear facing up
to prevent idler shaft from falling.
Inspection
CYLINDER HEAD BOLT DEFORMATION (ELONGATION)
I Using micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.
I If the necking point can be identified, set it as measuring point
d2.
I Calculate the difference between d1 and d2.
Limit: 0.15 mm (0.0059 in)
IDLER GEAR END PLAY
I Tighten mounting bolts to the specified torque.
I Using feeler gauge, measure the clearance between gear plate
and idler gear.
Standard: 0.07 - 0.14 mm (0.0028 - 0.0055 in)
Limit: 0.2 mm (0.0079 in)
I If the measured value exceeds the limit value, replace idler
gear, shaft, and gear plate.
FEM055
SEM379G
FEM056
CYLINDER HEADZD
Removal (Cont'd)
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