service NISSAN TERRANO 2004 Service Service Manual

Commercial Service Tools
Tool nameDescription
Piston ring expander
Removing and installing piston ring
PREPARATIONTD27Ti
EM-99
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3. Press service valve guide into cylinder head using suitable tooluntil the guide projects out 16 0.2 mm (0.63 0.008 in).
4. Ream valve guide. Finished size:8.000 - 8.015 mm (0.3150 - 0.3156 in)
VALVE SEATS
Check valve for any evidence of pitting at valve contact surface,
and reseat or replace if worn out excessively.
IWhen repairing valve seats, check valve and valve guide
for wear beforehand. If worn, replace them. Then correct
valve seat.
I The cutting should be done with both hands for uniform
cutting.
REPLACING VALVE SEAT FOR SERVICE PARTS
1. Before out old seat until it collapses or remove valve seats with
Tool.
Place a copper seat between contact surface of Tool and cyl-
inder head.
2. Place new valve seats on dry ice and allow them to cool for five minutes.
WARNING:
Do not touch cooled valve seats with bare hand.
3. Heat cylinder head to 80ÉC (176ÉF).
4. Install cooled valve seats on cylinder head with Tool.
NEM178
SEM630B
SEM024
SEM631B
SEM632B
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-108
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General Specifications
Engine modelTD27Ti
Cylinder arrangement 4, in-line
Displacement cm
3(cu in) 2,663 (162.5)
Bore x stroke mm (in) 96 x 92 (3.8 x 3.6)
Valve arrangement OHV
Firing order 1-3-4-2
Number of piston rings Compression 2
Oil 1
Number of main bearings 5
Compression ratio 21.9 0.2
Unit: kPa (bar, kg/cm
2, psi)/rpm
Compression pressureStandard 2,942 (29.4, 30, 427)/200
Minimum 2,452 (24.5, 25, 356)/200
Differential limit between
cylinders 294 (2.9, 3, 43)/200
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
EM-143
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Inspection and Adjustment
CYLINDER BLOCK AND CYLINDER LINER
Unit: mm (in)
NEM227
Nominal cylinder block height (H) (From
crankshaft center)252.95 - 253.05
(9.959 - 9.963)
Cylinder bore Inner diameterStandard
Grade No. 1 96.000 - 96.010
(3.7795 - 3.7799)
Grade No. 2 96.010 - 96.020
(3.7799 - 3.7803)
Grade No. 3 96.020 - 96.030
(3.7803 - 3.7807)
Wear limit 0.20 (0.0079)
Out-of-round (X þ Y) Less than 0.020 (0.0008)
Taper (A þ B) Less than 0.20 (0.0079)
Division of each cylinder Less than 0.05 (0.0020)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
EM-144
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VALVE GUIDE
Unit: mm (in)
StandardService
Valve guide outside
diameter 12.233 - 12.244
(0.4816 - 0.4820) Ð
Valve guide inner diam-
eter (Finished size) 8.000 - 8.015 (0.3150 - 0.3156)
Cylinder head valve
guide hole diameter 12.200 - 12.211
(0.4803 - 0.4807) Ð
Interference fit of valve
guide 0.022 - 0.044 (0.0009 - 0.0017)
Standard Limit
Valve to guide clearance
Intake 0.020 - 0.050
(0.0008 - 0.0020) 0.15 (0.0059)
Exhaust 0.040 - 0.070
(0.0016 - 0.0028) 0.15 (0.0059)
Valve deflection limit Intake 0.35 (0.0138)
Exhaust 0.35 (0.0138)
VA LV E S E AT
Unit: mm (in)
SEM953C
Intake
Outer diameter ªD
1º
Standard 44.535 - 44.545
(1.7533 - 1.7537)
0.5 (0.020) Oversize
(Service) 45.035 - 45.045
(1.7730 - 1.7734)
Inner diameter ªD
2º 38.0 0.1
(1.50 0.0039)
Diameter of seat ªD
3º 42.4 - 42.6
(1.669 - 1.677)
Cylinder head valve seat diam-
eter
Standard 44.515 - 45.035
(1.7526 - 1.7730)
0.5 (0.020) Oversize
(Service) 45.015 - 45.535
(1.7722 - 1.7927)
Valve seat face angle ªf º89 - 90É
Exhaust Outer diameter ªD
1º
Standard 39.535 - 39.545
(1.5565 - 1.5569)
0.5 (0.020) Oversize
(Service) 40.035 - 40.045
(1.5762 - 1.5766)
Inner diameter ªD
2º 32.9 - 33.1
(1.295 - 1.303)
Diameter of seat ªD
3º 36.9 - 37.1
(1.453 - 1.461)
Cylinder head valve seat diam-
eter
Standard 39.495 - 39.510
(1.5549 - 1.555)
0.5 (0.020) Oversize 39.995 - 40.010
(1.5746 - 1.5758)
Valve seat face angle ªf º89 - 90É
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-145
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VA LV E
Unit: mm (in)
SEM188
Valve head diameter ªDºIntake 42.5 (1.67)
Exhaust 37 (1.5)
Valve length ªLº Intake 117 (4.61)
Exhaust
Valve stem diameter ªdº
Intake 7.965 - 7.980
(0.3136 - 0.3142)
Exhaust 7.945 - 7.960
(0.3128 - 0.3134)
Valve seat angle ªa º
Intake 45É - 45É30¢
Exhaust
Valve margin ªTº limit 1.5 (0.059)
Valve stem end surface grinding
limit 0.2 (0.008)
Valve clearance (Hot) Intake 0.25 (0.01)
Exhaust
VALVE SPRING
Free length mm (in)
Painted red 53.9 (2.12)
Pressure height mm/N (mm/kg, in/lb) 31.8/713.5 - 788.5
(31.8/72.7 - 80.4,
1.252/160.0 - 177.3)
Assembled height mm/N (mm/kg, in/lb)
Standard 42.3/314.5 - 361.5
(42.3/32.1 - 36.9,
1.665/70.5 - 81.1)
Limit 42.3/296.2
(42.3/30.2,
1.665/66.6)
Out of square mm (in)2.0 (0.079)
CYLINDER HEAD TO VALVE DISTANCE
Unit: mm (in)
SEM724C
Standard Limit
Intake 0.8 - 1.2
(0.031 - 0.047) Less than 1.75
(0.0689)
Exhaust 0.8 - 1.2
(0.031 - 0.047) Less than 1.75
(0.0689)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-146
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CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
StandardLimit
Camshaft journal to
bushing clearance 0.020 - 0.109
(0.0008 - 0.0043) Less than 0.15
(0.0059)
Camshaft journal
diameter
Front 50.721 - 50.740
(1.9969 - 1.9976) Ð
2nd 50.521 - 50.540
(1.9890 - 1.9898) Ð
3rd 50.321 - 50.340
(1.9811 - 1.9819) Ð
4th 50.121 - 50.140
(1.9733 - 1.9740) Ð
Rear 49.921 - 49.940
(1.9654 - 1.9661) Ð
Camshaft bend (Total
indicator reading) Less than 0.02
(0.0008) Less than 0.06
(0.0024)
Camshaft end play 0.08 - 0.28
(0.0031 - 0.0110) Less than 0.50
(0.0197)
EM671
Standard Limit
Cam height ªAº 41.570 (1.6366)Less than
41.20 (1.6220)
Intake
Exhaust 41.900 (1.6496) Less than
41.40 (1.6299)
VALVE LIFTER AND PUSH ROD
Unit: mm (in)
Standard Limit
Valve lifter outer
diameter 24.960 - 24.970
(0.9827 - 0.9831) Ð
Cylinder block valve
lifter hole diameter 25.000 - 25.033
(0.9843 - 0.9855) Ð
Valve lifter to lifter
hole clearance 0.030 - 0.073
(0.0012 - 0.0029) Less than 0.20
(0.0079)
Push rod bend (TIR) Less than 0.3
(0.012É) Less than 0.5
(0.020)
*: Total indicator reading
ROCKER SHAFT AND ROCKER ARM
Standard Limit
Rocker shaft
Outer diameter 19.979 - 20.00
(0.7866 - 0.7874) Ð
Rocker shaft bend
(TIR)* 0 - 0.10
(0 - 0.0039) less than 0.30
(0.0188)
Rocker arm
Inner diameter 20.014 - 20.035
(0.7880 - 0.7888) Ð
Clearance between
rocker arm and
rocker shaft 0.014 - 0.056
(0.0006 - 0.0022) less than 0.15
(0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-147
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PISTON, PISTON RING AND PISTON PIN
Available piston
Unit: mm (in)
SEM778A
Piston skirt diameter ªAº
StandardGrade No. 1 95.905 - 95.915
(3.7758 - 3.7762)
Grade No. 2 95.915 - 95.925
(3.7762 - 3.7766)
Grade No. 3* 95.925 - 95.935
(3.7766 - 3.7770)
ªaº dimension 42.0 (1.654)
Piston pin hole diameter 30.002 - 30.007
(1.1812 - 1.1814)
Piston to cylinder liner clearance 0.043 - 0.077
(0.0017 - 0.0030)
ªAº dimension 69.2 (2.724)
Grade No. 3 piston is not provided as a service part.
Piston pin
Unit: mm (in)
Piston pin outer diameter 29.995 - 30.000
(1.1809 - 1.1811)
Piston pin to piston clearance 0.002 to 0.012
(0.0001 to 0.0005)
Piston pin to connecting rod
clearance
Standard 0.025 - 0.043
(0.0010 - 0.0017)
Limit 0.15 (0.0059)
Piston ring
Unit: mm (in)
Standard Limit
Side clearance
To p 0.00 - 0.05
(0.0 - 0.0020) 0.50 (0.0197)
2nd 0.04 - 0.072
(0.0016 - 0.0028) 0.30 (0.0118)
Oil 0.02 - 0.055
(0.0008 - 0.0022) 0.15 (0.0059)
Ring gap To p 0.25 - 0.40
(0.0098 - 0.0157)
1.5 (0.059)
2nd 0.40 - 0.55
(0.0157 - 0.0217)
Oil (rail ring) 0.25 - 0.55
(0.0098 - 0.0217)
CONNECTING ROD
Unit: mm (in)
Center distance 156.975 - 157.025
(6.1801 - 6.1821)
Bend, torsion [per 200 (7.87)] Limit 0.15 (0.0059)
Piston pin bore dia. 30.025 - 30.038
(1.1821 - 1.1826)
Side clearance
Standard 0.10 - 0.32
(0.0039 - 0.0126)
Limit 0.32 (0.0126)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-148
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CRANKSHAFT
Unit: mm (in)
SEM100A
Journal diameter ªAº70.907 - 70.920
(2.7916 - 2.7921)
Pin diameter ªBº 56.913 - 56.926
(2.2407 - 2.2412)
Center distance ªSº 46.0 (1.811)
EM715
Taper of journal and pin ªA-Bº Standard Less than 0.01 (0.0004)
Limit 0.02 (0.0008)
Out-of-round of journal and pin
ªX-Yº Standard Less than 0.01 (0.0004)
Limit 0.02 (0.0008)
Crankshaft bend Standard 0 - 0.03 (0 - 0.0012)
Limit 0.10 (0.0039)
Crankshaft end play
Standard 0.060 - 0.25
(0.0024 - 0.0098)
Limit 0.40 (0.0157)
AVAILABLE MAIN BEARING
Bearing clearance
Unit: mm (in)
Main bearing clearance
Standard 0.035 - 0.083
(0.0014 - 0.0033)
Limit Less than 0.15 (0.0059)
Connecting rod bearing clearance
Standard 0.035 - 0.077
(0.0014 - 0.0030)
Limit Lees than 0.15 (0.0059)
Mean bearing undersize
Unit: mm (in)
Crank journal diameter
Standard 70.907 - 70.920
(2.7916 - 2.7921)
Undersize
0.25 (0.0098) 70.657 - 70.670
(2.7818 - 2.7823)
0.50 (0.0197) 70.407 - 70.420
(2.7719 - 2.7724)
0.75 (0.0295) 70.157 - 70.170
(2.7621 - 2.7626)
1.00 (0.0394) 69.907 - 69.920
(2.7522 - 2.7528)
AVAILABLE CONNECTING ROD BEARING
Connecting rod bearing undersize
Unit: mm (in)
Crank pin journal diameter
Standard 56.913 - 56.926
(2.2407 - 2.2412)
Undersize
0.25 (0.0098) 56.663 - 56.676
(2.2308 - 2.2313)
0.50 (0.0197) 56.413 - 56.426
(2.2210 - 2.2215)
0.75 (0.0295) 56.163 - 56.176
(2.2111 - 2.2116)
1.00 (0.0394) 55.913 - 55.926
(2.2013 - 2.2018)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-149
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AVAILABLE THRUST WASHER
Unit: mm (in)
Thrust washer thickness
Standard 2.275 - 2.325 (0.0896 - 0.0915)
Oversize 0.20 (0.0079) 2.475 - 2.525 (0.0974 - 0.0994)
0.40 (0.0157) 2.675 - 2.725 (0.1053 - 0.1073)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
Gear trainBacklash of each gear
Standard 0.07 - 0.11 (0.0028 - 0.0043)
Limit 0.20 (0.0079)
Flywheel Runout (Total indicator
reading) Less than 0.15 (0.0059)
Front plate Warpage limit 0.2 (0.008)
Cylinder head Head surface distorsion
Standard Less than 0.07 (0.0028)
Limit 0.2 (0.008)
Minimum height 89.7 (3.532)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
Inspection and Adjustment (Cont'd)
EM-150
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