torque NISSAN TERRANO 2004 Service Owner's Manual

Connecting rod bearing undersize list
Unit: mm (in)
SizeThickness
US 0.25 (0.0098) 1.630 - 1.638 (0.0642 - 0.0645)
US 0.50 (0.0197) 1.755 - 1.763 (0.0691 - 0.0694)
US 0.75 (0.0295) 1.880 - 1.888 (0.0740 - 0.0743)
US 1.00 (0.0394) 2.005 - 2.013 (0.0789 - 0.0793)
CAUTION:
When grinding crank pins to use undersize bearings, avoid
damaging corners of fillet.
Corner dimension (Standard):Pin3.3 - 3.7 mm (0.130 - 0.146 in)
Journal 2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING OIL CLEARANCE
Method by measurement
I Install main bearings to cylinder block and bearing caps, and
tighten bearing cap bolts to the specified torque. Measure main
bearing inner diameter.
Bearing clearance = Bearing inner diameter þ Crankshaft jour-
nal outer diameter
Standard: 0.035 - 0.083 mm (0.0014 - 0.0033 in)
I If out of specification, check main bearing housing inner diam-
eter and crankshaft journal outer diameter, and select appropri-
ate main bearing to adjust clearance to specifications.
Refer to ªMain bearing undersize listº on the next page.
Method using plastigage
IRemove contamination such as oil, dust completely from crank-
shaft journals and each bearing surface.
I Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
I Install main bearings to caps, and tighten connecting rod nuts
to the specified torque.
CAUTION:
Never rotate crankshaft.
I Remove bearing caps and bearings, and measure plastigage
width using scale on plastigage bag.
FEM119
FEM120
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-78
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CAUTION:
If out of specification, take same action mentioned in ªMethod
by measurementº.
Undersize bearing usage
IIf bearing clearance is out of specifications for main bearings
in standard size, use undersize bearings.
I When using undersize bearings, measure bearing inner diam-
eter with bearing installed, and grind crank journals to adjust
clearance to specification.
Main bearing undersize list
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.130 - 2.138 (0.0839 - 0.0842)
US 0.50 (0.0197) 2.255 - 2.263 (0.0888 - 0.0891)
US 0.75 (0.0295) 2.380 - 2.388 (0.0937 - 0.0940)
US 1.00 (0.0394) 2.505 - 2.513 (0.0986 - 0.0989)
CAUTION:
When grinding crank journals to use undersize bearings,
avoid damaging corners of fillet.
Corner dimension (Standard):Pin3.3 - 3.7 mm (0.130 - 0.146 in)
Journal 2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING CRUSH HEIGHT
I Tighten bearing caps to the specified torque with main bearings
installed, and remove caps. The bearing end must then be
higher than the flat surface.
Standard: Crush height must exist.
I If out of specification, replace main bearings.
FEM119
FEM122
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-79
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Assembly
1. Blow air sufficiently to inside coolant passage, oil passage,crankcase, and cylinder bore to remove foreign matter.
2. Install main bearings and thrust bearings.
1) Remove contamination, dust and oil from bearing mounting positions on cylinder block and main bearing caps.
2) Install thrust bearings on both sides of No. 4 housing on cylin- der block.
I Install thrust bearings with oil groove facing to crankshaft arm
(outside).
3) Being careful with the direction, install main bearings.
I Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the lower cylinder block side.
I While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them com-
pletely.
I Align stopper notches on bearings to install them.
I Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
3. Install crankshaft to cylinder block.
I While rotating crankshaft by hand, check for smooth rotation.
4. Install lower cylinder block.
I Apply a continuous bead of liquid gasket to lower cylinder block
as shown in the figure.
I Using slots on engine sub-attachment, install the lower cylinder
block to the cylinder block, avoiding interference of dowel pins.
5. Tighten lower cylinder mounting bolts to the torque shown below in 3 consecutive steps in the order shown in the figure.
Unit: N ×m (kg-m, ft-lb)
Main bolt (Nos. 1 - 10) Sub-bolt (Nos. 11 - 20)
1st 20 (2.0, 14) 98 (10, 72)
2nd 98 (10, 72) 20 (2.0, 14)
3rd 167 - 176 (17 - 18, 123 - 130) 40 - 46 (4.0 - 4.7, 29 - 33)
I Sub-bolt No. 17 has shorter length than that of other sub-bolts.
FEM126
FEM127
FEM128
FEM092
CYLINDER BLOCKZD
EM-80
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6. Install mounting bolts for engine sub-attachment shown byarrows in the figure.
I After tightening bolts to the specified torque, check crankshaft
for smooth rotation.
I Check crankshaft end play.
Refer to EM-71, ªCRANKSHAFT END PLAYº.
7. Install pistons to connecting rod.
1) Using long nose pliers, install snap rings to grooves on piston rear side.
I Fit snap rings correctly into grooves.
2) Install pistons to connecting rods.
I Using industrial dryer, heat pistons up to approx. 60 to 70ÉC
(140 to 158ÉF) until piston pin can be pressed down by finger
touch. Then insert piston pins into piston and connecting rod
from front side of piston toward rear.
I Assemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
3) Install snap rings to front side of pistons.
I Refer to above 1) for precaution on snap ring installation.
I After installation, check connecting rods for smooth movement.
8. Use piston ring expander (multi-purpose tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
I Install top ring and second ring with stamped surfaces facing
upward.
Identification stamp: Top ring: R
Second ring: RN
9. Install connecting rod bearings to connecting rods and caps.
I While installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces, but
clean them completely.
I Align stoppers on connecting rod bearings with connecting rod
stopper notches to install connecting rod bearings.
FEM091
FEM131
FEM132
FEM133
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-81
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Parts Requiring Angular Tightening
ISome important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
I If these parts are tightened using a torque setting method, dis-
persal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
I Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
I To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
I Before tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
I The bolts and nuts which require the angular-tightening method
are as follows:
(1) Cylinder head bolts
(2) Connecting rod cap nuts
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface and
grooves, and then completely clean any oil stains from
these portions.
b. Apply a continuous bead of liquid gasket to mating sur- faces. (Use Genuine Liquid Gasket or equivalent.)
IBe sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (oil pan).
I Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perimeter. (Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and engine coolant.
SEM371C
PRECAUTIONSTD27Ti
EM-95
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c. Install the tightening bolt [Part No.: 81-20620-28, thread diam-eter: M6, under head: 20 mm (0.79 in), pitch: 1.0 mm (0.039 in)]
to the idler gear tightening bolt hole, and tighten to the speci-
fied torque:
: 2.5 - 3.4 N ×m (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
I To protect the idler gear from damage, do not use the sub-
stitute part for the tightening bolt.
I Hereafter, do not turn the crankshaft to avoid hitting tight-
ening bolt head against the gear case.
I Do not remove the idler gear tightening bolt before instal-
lations of the timing chain and related parts are completed.
7. Make mating marks on the cam sprocket, fuel injection pump sprocket, and timing chain with paint.
8. Make mating marks on the fuel injection pump gear and idler gear with paint.
9. Remove the chain tensioner.
(1) Loosen the upper and lower installation bolts.
(2) While holding the chain tensioner by hand, remove the upper installation bolt to release the spring tension.
(3) Remove the lower installation bolt first, and then the chain ten- sioner.
I Since the chain tensioner does not have a mechanism to pre-
vent the plunger pop-out, watch out for the fall of the plunger
and spring. (Return prevention mechanism is available.)
10. Remove the timing chain slack guide.
11. Remove the cam sprocket and timing chain at the same time.
I Make mating marks on each sprocket and timing chain.
I Hold the hexagon head of the camshaft on the exhaust mani-
fold side, and loosen the cam sprocket installation bolt.
CAUTION:
Do not loosen the installation bolt using a chain tension.
12. Remove the fuel injection pump sprocket and gear as an assembly.
I Fix the fuel injection pump gear with the pulley holder (SST),
and loosen the installation bolt for removal.
I Try not to move the pump shaft when removing.
I Connect the sprocket and gear with a dowel pin, and tighten
them together with the installation bolt.
JEF263Z
JEF264Z
JEF265Z
JEF266Z
JEF267Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-29
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17 CHECK GLOW PLUG
1. Remove glow plug connecting plate.
2. Check glow plug resistance.
MEC005EResistance: Approx. 0.5W[at 20ÉC (68ÉF)]
NOTE:
I Do not bump glow plug heating element. If it is bumped, replace glow plug with a new one.
I If glow plug is dropped from a height of 10 cm (3.94 in) or higher, replace with a new one.
I If glow plug installation hole is contaminated with carbon, remove it with a reamer or suitable tool.
I Hand-tighten glow plug by turning it two or three times, then tighten using a tool to specified torque.
:15-20N ×m (1.5 - 2.1 kg-m, 11 - 15 ft-lb)
OK or NG
OK EGO TO 18.
NG EReplace glow plug.
18 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
GLOW CONTROL SYSTEMZD30DDTi
Diagnostic Procedure (Cont'd)
EC-252
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Component Inspection
GLOW RELAY
1. Check relay terminalsq1andq2for coil continuity.
Continuity should exist.
2. Check relay operation by applying battery voltage across relay coil terminals.
Coil voltage at relay terminals
q
1andq2
Continuity at relay terminals
q
5andq3
0V
No
12V Yes
GLOW PLUG
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:Approximately 0.5W [at 25ÉC (77ÉF)]
I If NG, replace glow plug.
3. Install glow plug connecting plate securely.
I Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. [If glow plug is dropped
from a height above 10 cm (3.94 in), replace with new one.]
I If glow plug installation hole is contaminated with carbon,
remove using a reamer or suitable tool.
I Hand-tighten glow plug by turning it 2 to 3 times, then
tighten using a tool to specified torque.
:15-20N ×m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
GLOW INDICATOR
1. Turn ignition switch ªOFFº.
2. Disconnect combination meter harness connector.
3. Check continuity between terminals below.
Combination meter
(Glow indicator) CONDITION 1
+28
Continuity should not
exist.
þ47
CONDITION 2 þ28
Continuity should
exist.
+47
IF NG, repair or replace combination meter (Glow indicator). Refer
to EL section.
SEC564B
NEF507
SEC565B
YEC258A
DTC P0380 GLOW RELAY, DTC P0381 GLOW LAMPTD27Ti
EC-419
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6. Remove fuel pump with fuel tank chamber assy as follows:
a. Push the locking clip upwards and slide the pump chamberassy towards the rear of the vehicle.
b. Lift the pump chamber assy from the bracket.
c. Carefully remove the pump chamber assy and top plate from the tank.
7. Take off the fuel pump chamber lid by opening out the 4 clips. Remove the fuel pump from the fuel pump chamber.
INSTALLATION
Installation is reverse procedure of removal.
CAUTION:
IAlways use a new top plate seal.
I Tighten to specified torque.
Diesel engine
1. Remove inspection hole cover located under the luggage com-
partment carpet.
2. Disconnect fuel feed and return tubes and connector.
3. Remove the screws by which the fuel gauge is mounted to the fuel tank.
NFE015
NFE016
EFE016
NFE031
FUEL SYSTEMTD27Ti
Fuel Pump and Gauge (Cont'd)
FE-8
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4. Remove fuel gauge assembly.
INSTALLATION
Installation procedure is the reverse order of removal.
CAUTION:
ITighten to specified torque.
I Always use a new top plate seal.
EFE018
FUEL SYSTEMTD27Ti
Fuel Pump and Gauge (Cont'd)
FE-9
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