engine NISSAN TERRANO 2004 Service Workshop Manual

CHECKING RADIATOR CAP
Apply pressure to radiator cap (side with pressure valve) with cap
tester to see if it is satisfactory.Radiator cap relief pressure:108 - 128 kPa
(1.08 - 1.28 bar, 1.1 - 1.3 kg/cm
2, 16 - 18 psi)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage. Testing pressure:157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
CAUTION:
Use of higher pressure than the specified value may cause
damage to radiator.
Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs.
REPLACING FUEL FILTER
1. Disconnect harness connector and drain fuel.
2. Remove fuel filter using band-type filter wrench.
3. Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator.
SLC613
SMA871B
JMA110D
DMA011
SMA111D
ENGINE MAINTENANCEZD
Checking Cooling System (Cont'd)
MA-33
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4. Wipe clean fuel filter mounting surface on fuel filter bracket andsmear a little fuel on rubber seal of fuel filter.
5. Screw fuel filter on until a slight resistance is felt, then tighten an additional more than 2/3 or a turn.
6. Install fuel filter sensor to new fuel filter. (Type A)
7. Bleed air from fuel filter.
Refer to ªAir Bleedingº in EC section.
8. Start engine and check for leaks.
DRAINING WATER
1. Drain water as follows.
Type A
Loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
If water does not drain properly, move the priming pump up and
down.
Type B
Loosen air bleeder screw from the sedimentor cover and then
loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
2. Bleed air.
Refer to ªAir Bleedingº in EC section.
Checking Fuel Lines
Check fuel lines and tank for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
CAUTION:
Keep clean parts with compressed air when assembling.
SMA010
SMA825B
SMA281C
SMA803A
ENGINE MAINTENANCEZD
Checking and Replacing Fuel Filter and
Draining Water (Cont'd)
MA-34
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Cleaning and Replacing Air Cleaner Filter
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any clean-
ing operation between renewal.
SMA151D
ENGINE MAINTENANCEZD
MA-35
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2. Check oil level.
Never start engine while checking oil level.Filler plug:
:25-34N ×m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
Changing M/T Oil
Oil capacity:
3.5 liters (6-1/8 Imp pt)
Checking Water Entry
Check water entry in the clutch housing by removing the seal-
ing grommet, whenever driving in deep water or mud.
Checking Transfer Oil
1. Check transfer for leakage.
2. Check oil level.
Never start engine while checking oil level.
ªDEXRON
TMº type Automatic Transmission Fluid is used for
the transfer in the factory. Never add gear oil (API GL-4) to
Automatic Transmission Fluid.
SMA103
SMA255A
SMA369B
SMT483A
YMA018
CHASSIS AND BODY MAINTENANCE
Checking M/T Oil (Cont'd)
MA-37
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TEMPORARY METHOD FOR CHECKING LINING WEAR
Remove inspection hole plug and check for lining wear.
Checking Foot Brake Pedal Operation
Check brake pedal free height, depressed height and for smooth
operation.H: Free height:RHD: 196 - 206 mm (7.72 - 8.11 in)
LHD: 210 - 220 mm (8.27 - 8.66 in)
D: Depressed height: Under force of 490 N (50 kg, 110 lb)
with engine running
RHD: 137.7 - 147.7 mm (5.42 - 5.81 in)
LHD: 142.5 - 152.5 mm (5.61 - 6.00 in)
A: Pedal free play 1.0 - 3.0 mm (0.039 - 0.118 in)
Checking Parking Brake
1. Pull lever with specified amount of force.Check lever stroke and for smooth operation.Number of notches
[At pulling force of 196 N (20 kg, 44 lb)]: 9-10
2. Use adjuster to adjust lever stroke.
(1) Loosen lock nut q
A, rotate adjusterqB.
(2) Tighten lock nut q
A.
SBR461A
SMA441B
EMA050
SBR032A
CHASSIS AND BODY MAINTENANCE
Checking Drum Brake (Cont'd)
MA-42
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Checking Body Corrosion
Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing, etc.) or
damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut lower in engine
compartment, etc.
Panel edge
Back door lid opening, sun roof opening, fender wheel-arch flange, fuel filler lid flange, around holes in panel,
etc.
Parts contact
Waist moulding, windshield moulding, bumper, etc.
Protectors
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage or separation of anti-corrosion materials under the body.
Drain holes
Condition of drain holes at door and side sill.
When repairing corroded areas, refer to the Corrosion Repair Manual.
CHASSIS AND BODY MAINTENANCE
MA-47
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Engine Maintenance
INSPECTION AND ADJUSTMENT
Drive belt deflection
Unit: mm (in)
Used belt deflectionDeflection of
new belt
Limit Deflection after
adjustment
Engine TD27Ti TD27Ti TD27Ti
Alternator 20
(0.79) 11-13
(0.43 - 0.51) 9-11
(0.35 - 0.43)
Air conditioner 12
(0.47) 6 - 7.5
(0.236 - 0.295) 5 - 6.5
(0.197 - 0.256)
Power steering
oil pump 15
(0.59) 8 - 9.5
(0.315 - 0.374) 7 - 8.5
(0.276 - 0.335)
Applied pushing
force 98 N (10 kg, 22 lb)
Oil capacity (Refill capacity)
TD27Ti engine
Unit:
(Imp qt)
With oil filter change 6.2 (5-1/2)
Without oil filter change 5.5 (4-7/8)
ZD30DDTi engine
Unit: (Imp qt)
With oil filter change 6.7 (5-7/8)
Without oil filter change 6.2 (5-1/2)
Cooling system check
TD27Ti engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
ZD30DDTi engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 108 - 128
(1.08 - 1.28, 1.1 - 1.3, 16 - 18)
Coolant capacity (Refill capacity)
Unit: (Imp qt)
Engine TD27TiZD30DDTi
Without reservoir tank 10 (8-3/4) 10.6 (9-3/8)
Reservoir tank 0.8 (3/4) 0.75 (5/8)
Valve clearance (Hot)
Unit: mm (in)
Engine TD27Ti
Intake 0.25 (0.0098)
Exhaust
Injection nozzle
Unit: kPa (bar, kg/cm2, psi)
Engine TD27Ti
Initial injection pressure
New 12,259 - 12,749 (122.6 - 127.5, 125 -
130, 1,778 - 1,849)
Used 12,749 - 13,730 (127.5 - 137.3, 130 -
140, 1,849 - 1,991)
Idle speed
Unit: rpm
Engine TD27Ti
With A/C 850 50
Without A/C 700 50
SERVICE AND SPECIFICATIONS (SDS)
MA-48
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Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT
Clutch
Unit: mm (in)
Vehicle modelAll
Pedal free height RHD
210 - 220
(8.27 - 8.66) LHD
227 - 237
(8.94 - 9.33)
Pedal free play 1.0 - 3.0 (0.039 - 0.118)
Pedal free travel 155 - 160 (6.10 - 6.30)
Front axle and front suspension
(Unladen)*1
Unit: degree
Model H/T VAN H/T WAGON
Camber 0É30¢  30¢
Caster 0É29¢ 30¢ 0É30¢ 30¢ 0É30¢ 30¢
Kingpin inclination 12É37¢
Toe-in
A-B mm (in) 3.5 - 5.5
(0.14 - 0.22) 3-5
(0.12 - 0.20) 3-5
(0.12 - 0.20)
Front wheel turning
angle (degrees) (Full turn)*2
Inside 34É27¢
Outside 33É38¢
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
Brake
Disc brake mm (in)
LD28VA
PadStandard thickness 15.5 (0.610)
Minimum thickness 2.0 (0.079)
Rotor Standard thickness 2.60 (0.1024)
Minimum thickness 24.0 (0.945)
Drum brake mm (in)
LT28 LiningStandard thicknessLeading 8.95 (0.3524)
Trailing 3.95 (0.1555)
Minimum thickness 1.52 (0.0598)
Drum Standard diameter 280 (11.02)
Maximum diameter 282 (11.10)
Pedal mm (in) RHD LHD
Free height 196 - 206
(7.7 - 8.1) 210 - 220
(8.3 - 8.7)
Free play 1.0 - 3.0 (0.039 - 0.118)
Full stroke 137.7 - 148.7
(5.42 - 5.85) 142.5 - 152.5
(5.61 - 6.00)
Parking brake Number of notches [at pulling
force 196 N (20 kg, 44 lb)] 9-10
Wheel runout
Unit: mm (in)
Wheel typeSteel Aluminum
16² x7J 16 ²x7J
Radial runout limit 0.5 (0.020) 0.3 (0.012)
Lateral runout limit 0.8 (0.031) 0.3 (0.012)
Wheel bearing
Axial end play limit mm (in) 0
SERVICE AND SPECIFICATIONS (SDS)
MA-49
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ENGINE MECHANICAL
SECTION
EM
CONTENTS
ZD
PRECAUTIONS ...............................................................3
Parts Requiring Angular Tightening .............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION ................................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................8
NVH Troubleshooting Chart - Engine Noise ...............9
MEASUREMENT OF COMPRESSION PRESSURE ....10
INTERCOOLER ............................................................. 11
Removal and Installation ........................................... 11
INTAKE MANIFOLD ......................................................12
Removal and Installation ...........................................12
Inspection...................................................................13
CATALYST AND TURBOCHARGER ............................14
Removal and Installation ...........................................14
Inspection...................................................................15
EXHAUST MANIFOLD ..................................................18
Removal and Installation ...........................................18
Inspection...................................................................19
ROCKER COVER ..........................................................20
Removal and Installation ...........................................20
OIL PAN & OIL STRAINER ...........................................22
Removal and Installation ...........................................22
VACUUM PUMP ............................................................24
Removal and Installation ...........................................24
TIMING CHAIN ..............................................................26
Removal and Installation ...........................................26
Removal .....................................................................26
Installation ..................................................................28
CAMSHAFT ...................................................................30
Removal and Installation ...........................................30
Removal .....................................................................30
Inspection...................................................................31
Installation ..................................................................33 VALVE CLEARANCE INSPECTIONS AND
ADJUSTMENTS
.............................................................35
Inspection...................................................................35
Adjustments ...............................................................36
TIMING GEAR ...............................................................38
Removal and Installation ...........................................38
Removal .....................................................................39
Inspection...................................................................41
Installation ..................................................................46
OIL SEAL REPLACEMENT ..........................................50
CYLINDER HEAD ..........................................................52
Removal and Installation ...........................................52
Removal .....................................................................52
Inspection...................................................................53
Installation ..................................................................54
Disassembly...............................................................57
Inspection...................................................................58
Assembly ...................................................................61
ENGINE REMOVAL .......................................................63
Precautions ................................................................63
Removal .....................................................................63
Installation ..................................................................65
Inspection...................................................................65
CYLINDER BLOCK .......................................................66
Selection Procedure for Selective Part
Combination ...............................................................67
Disassembly...............................................................67
Inspection...................................................................71
Assembly ...................................................................80
SERVICE DATA AND SPECIFICATIONS (SDS) ..........84
General Specifications ...............................................84
Compression Pressure ..............................................84
Cylinder Head ............................................................84
Valve ........................................................................\
..84
Valve Seat..................................................................87
Camshaft and Camshaft Bearing ..............................89
Cylinder Block ............................................................90
Piston, Piston Ring and Piston Pin ...........................90
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Connecting Rod .........................................................91
Crankshaft..................................................................92
Available Main Bearing ..............................................92
Available Connecting Rod Bearing............................93
Miscellaneous Components.......................................94TD27Ti
PRECAUTIONS.............................................................95
Parts Requiring Angular Tightening ...........................95
Liquid Gasket Application Procedure ........................95
PREPARATION ..............................................................96
Special Service Tools ................................................96
Commercial Service Tools .........................................99
ENGINE COMPONENTS - Outer Parts .....................100
ENGINE COMPONENTS - Internal Parts ..................102
COMPRESSION PRESSURE......................................103 Measurement of Compression Pressure .................103
CYLINDER HEAD ........................................................104 Removal ...................................................................105
Disassembly.............................................................106
Inspection.................................................................107
Assembly ................................................................. 113
Installation ................................................................ 114
OIL SEAL REPLACEMENT ........................................ 117
TURBOCHARGER ....................................................... 119
Removal and Installation ......................................... 119
Inspection................................................................. 119
ENGINE REMOVAL .....................................................123
ENGINE OVERHAUL ..................................................125
Disassembly.............................................................125
Inspection.................................................................127
Assembly .................................................................138
SERVICE DATA AND SPECIFICATIONS (SDS) ........143
General Specifications .............................................143
Inspection and Adjustment ......................................144
CONTENTS(Cont'd)
EM-2
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