lock NISSAN TERRANO 2004 Service Owner's Guide

IDLER GEAR OIL CLEARANCE
IMeasure the inner diameter (d1) of idler gear shaft hole.
Standard: 26.000 - 26.020 mm (1.0236 - 1.0244 in)
I Measure the outer diameter (d
2) of idler shaft.
Standard: 25.967 - 25.980 mm (1.0223 - 1.0228 in)
I Calculate gear clearance.
Clearance = d
1þd2Standard: 0.023 - 0.053 mm (0.0009 - 0.0021 in)
Installation
1. Install cylinder head gasket.
ICylinder head gasket to be installed is selected by its thickness
through the following procedure.
When replacing gasket only
IInstall gasket with same thickness as the one removed.
I Gasket thickness is identified by the number of notches located
on rear-left side.
Grade Gasket thickness*
mm (in) No. of notches
1 0.65 (0.0256) 1
2 0.70 (0.0276) 2
*: Thickness of gasket tightened with head bolts
I The number of notches can be checked at the position shown
in the figure before cylinder head is removed. (It is necessary
to remove exhaust manifold.)
When repairing/replacing the following
IWhen the top of cylinder block or crankshaft pin/journal is
ground, or
I When cylinder block, piston, connecting rod, or crankshaft is
replaced
1) Move piston toward TDC.
2) Position dial indicator on cylinder block as shown in the figure, and adjust the needle to ª0º.
3) Move dial indicator stand aside, and position the dial indicator to the measuring point as shown in the figure.
4) Rotate crankshaft slowly, and read the value on dial indicator at piston's maximum height.
5) Repeat above procedure at 2 positions of each cylinder (8 positions in total for 4 cylinders), and select the appropriate
gasket by comparing the maximum crown depression with the
table.
FEM057
YEM031
FEM059
FEM060
CYLINDER HEADZD
Inspection (Cont'd)
EM-54
http://vnx.su/

Unit: mm (in)
GradePiston crown
depression Gasket thick-
ness*1 No. of notches
1 Less than þ0.078
(þ0.0031)*2 0.65 (0.0256) 1
2 More than þ0.078
(þ0.0031)*3 0.70 (0.0276) 2
*1: Thickness of gasket tightened with head bolts
*2: Indicates values such as þ0.080 mm (þ0.0031 in).
*3: Indicates values such as þ0.075 mm (þ0.0030 in).
2. Install idler gear and idler shaft.
I
Check that the counter marks with cam gear, ªAAº and ªBBº, are
located on the front side of the engine.
Refer to EM-52.
CAUTION:
Since idler gear cannot be installed or removed with cylinder
head assembly mounted on the engine because of interfer-
ence with gear case, make sure that there are no reverse
installations or uninstalled parts.
3. Install cylinder head assembly.
1) Attach gasket onto the rear of gear case.
2) Install O-ring to the rear of gear case.
3) Align cylinder head assembly with dowel pin of cylinder block and install.
CAUTION:
I Make sure the O-ring does not fall off. Be careful not to
drop the O-ring.
I Do not damage gasket located at the front.
4. Position cylinder head assembly close to the rear of the gear case.
1) Install cylinder head bolts to the front and rear of cylinder head respectively, and tighten to the specified torque.
:40-49N ×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
2) Loosen cylinder head bolts completely.
3) Install gear case mounting bolts to 2 positions shown by arrows in the figure, and tighten to the specified torque.
: Less than 9.8 N ×m (1.0 kg-m, 87 in-lb)
5. Tighten cylinder head bolts in the order indicated in the figure.
1) Apply engine oil to installation bolt threads and washers.
2) Tighten bolts to 98 to 102 N×m (10.0 to 10.5 kg-m, 73 to 75 ft- lb).
3) Loosen bolts completely until the torque becomes 0 N ×m(0
kg-m, 0 in-lb).
CAUTION:
For procedure 3), loosen bolts in the reverse order as indi-
cated in the figure.
4) Tighten bolts to 40 to 44 N ×m (4.0 to 4.5 kg-m, 29 to 32 ft-lb).
5) Tighten bolts at the angle of 90 to 95É (target is 95É). (Angle tightening)
FEM061
FEM062
FEM055
CYLINDER HEADZD
Installation (Cont'd)
EM-55
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YEM059
CYLINDER BLOCKZD
EM-66
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Selection Procedure for Selective Part
Combination
LocationSelective part combination ItemMethod
Cylinder block - piston Piston and piston assembly
(Part No. is given to a piston and piston pin as a set.) Piston grade (Piston outer
diameter) Refer to ªSelective combination
chartº.
IIdentification grade stamped on each part represents initial
dimension of new part. This grade will not be applied to a
reused part.
I Measure correct dimensions of a reused or modified part, then
refer to ªSelective combination chartº in this manual to identify
the grade.
I Refer to the applicable pages for measurement method for
each part, standards for reuse, and selecting method for selec-
tive part combination.
Disassembly
1. Remove engine assembly from vehicle.
Refer to EM-63, ªENGINE REMOVALº.
2. Remove pilot bushing from flywheel using pilot bearing puller (SST), if necessary (M/T model).
3. Install engine to engine stand (SST).
1) Remove flywheel (M/T model) or drive plate (A/T model).
I Using ring gear stopper (SST), secure ring gear, and remove
mounting bolts.
CAUTION:
Do not disassemble flywheel.
I Flywheel has a two-piece structure. When being pressed
forward/backward, or twisted in rotating direction, transmission-
side mass will be moved with audible sound. This is not a
problem.
2) Remove pilot converter (A/T model) and rear plate.
SEM364G
YEM043
CYLINDER BLOCKZD
EM-67
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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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7. Remove piston and connecting rod assembly.
IBefore removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer to EM-71, ªCONNECTING ROD SIDE CLEARANCEº.
1) Move crankshaft pin to be removed to approximately BDC.
2) Remove connecting rod caps.
3) Using the grip of a hammer, press the piston and connecting rod assembly out to cylinder head side.
CAUTION:
When removing the piston and connecting rod assembly, pre-
vent the big end of the connecting rod from interfering with the
oil jet.
8. Remove connecting rod bearings from connecting rods and caps.
I Keep them by cylinder to avoid confusion.
9. Remove piston rings from pistons using piston ring expander (multi-purpose tool).
CAUTION:
I When removing, prevent pistons from being damaged.
I Do not expand piston rings excessively. This may damage
the piston rings.
10. Remove pistons from connecting rods.
1) Using long nose pliers, remove snap rings.
2) Using industrial dryer, heat pistons up to 60 to 70ÉC (140 to 158ÉF).
FEM085
FEM086
FEM087
FEM088
FEM089
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-69
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3) Using rod with outer diameter of 30 mm (1.18 in), press pistonpins out.
11. Remove lower cylinder block.
I The lower cylinder block is the lower part of the cylinder block,
which works as the main bearing cap (beam) and oil pan
mounting face.
1) Remove mounting bolts for engine sub-attachment shown by arrows in the figure.
2) Loosen and remove mounting bolts in the reverse order shown in the figure.
3) Insert flat-bladed screwdriver into 5 locations shown by arrows in the figure. Lift lower cylinder block evenly, and remove liquid
gasket.
CAUTION:
Prevent mating faces from being damaged.
4) When removing lower cylinder block, use slot to prevent dowel pin from interfering with engine sub-attachment.
I No part No. is given to lower cylinder block, because it is
machined with the cylinder block.
12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Check mounting positions. Keep them to avoid confusion.
FEM090
FEM091
FEM092
FEM093
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-70
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Inspection
CRANKSHAFT END PLAY
IUsing dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward, or
I Using feeler gauge, measure crankshaft travel amount with the
lower cylinder block removed.
Standard: 0.055 - 0.140 mm (0.0022 - 0.0055 in)
Limit: 0.250 mm (0.0098 in)
I If measured value exceeds the limit, select appropriate thrust
bearings.
Unit: mm (in)
Grade symbol Thickness of thrust bearing
A 2.275 - 2.325 (0.0896 - 0.0915)
B 2.300 - 2.350 (0.0906 - 0.0925)
C 2.325 - 2.375 (0.0915 - 0.0935)
OS 020 2.475 - 2.525 (0.0974 - 0.0994)
IOS 020 has part No. of 12280 2W215 and OS 0.20 marked on
bearing surface.
CONNECTING ROD SIDE CLEARANCE
IUsing feeler gauge, measure side clearance between connect-
ing rod and crank arm.
Standard: 0.10 - 0.22 (0.0039 - 0.0087 in)
Limit: 0.22 mm (0.0087 in)
I If measured value exceeds the limit, replace connecting rod
and repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston pin hole inner diameter
Using inside micrometer, measure piston pin hole inner diameter.
Standard: 32.997 - 33.005 mm (1.2991 - 1.2994 in) dia.
Piston pin outer diameter
Using micrometer, measure piston pin outer diameter.Standard: 32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
FEM094
FEM095
FEM096
FEM097
FEM098
CYLINDER BLOCKZD
EM-71
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Calculation of piston to piston pin clearance
Piston pin clearance = Piston pin hole inner diameter þ Piston pin
outer diameterStandard: þ0.003 (Tightening clearance) to 0.012 mm (þ0.0001 to 0.0005 in)
If out of specifications, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE
I Using feeler gauge, measure clearance between piston ring
and piston ring groove.
Unit: mm (in)
Standard Limit
Top ring 0.05 - 0.07 (0.0020 - 0.0028) 0.5 (0.020)
Second ring 0.04 - 0.08 (0.0016 - 0.0031) 0.3 (0.012)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
I Align top ring and external surface of piston. Measure lower
side clearance of top ring with top ring pressed onto upper side
of ring groove.
I If side clearance exceeds the limit, replace piston ring.
I Check clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP
ICheck that cylinder bore diameter is within specifications.
Refer to EM-74, ªPISTON TO CYLINDER BORE CLEAR-
ANCEº.
I Using piston, press piston ring to cylinder mid point, and mea-
sure end gap.
Unit: mm (in)
Standard Limit
Top ring 0.25 - 0.45 (0.0098 - 0.0177)
1.5 (0.059)
Second ring 0.50 - 0.65 (0.0197 - 0.0256)
Oil ring 0.25 - 0.50 (0.0098 - 0.0197)
FEM099
FEM100
FEM101
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-72
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CONNECTING ROD BEND AND TORSION
Use connecting rod aligner to check bend and torsion.Bend limit:0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit: 0.05 mm (0.0020 in)/100 mm (3.94 in)
Connecting rod big end inner diameter
Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter. Standard:59.987 - 60.000 mm (2.3617 - 2.3622 in) dia.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL
END)
Connecting rod small end inner diameter
Use inside micrometer to measure small end inner diameter. Standard:33.025 - 33.038 mm (1.3002 - 1.3007 in) dia.
Piston pin outer diameter
Use micrometer to measure piston pin outer diameter. Standard:32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
Calculation of connecting rod bushing clearance
Connecting rod small end bushing clearance = Connecting rod
small end inner diameter þ Piston pin outer diameter Standard:0.025 - 0.045 mm (0.0010 - 0.0018 in)
I If out of specifications, replace connecting rod and/or piston
and piston pin assembly.
FEM102
FEM103
FEM104
FEM098
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-73
http://vnx.su/