lock NISSAN TERRANO 2004 Service Manual PDF

REPLACEMENT OF IDLER GEAR BUSHING
1. Use a suitable tool to replace bushing.
2. Ream idler gear bushing.Finished size:42.00 - 42.02 mm (1.6535 - 1.6543 in)
Idler gear shaft
Install idler gear shaft so that oil hole of shaft faces upward.
CAMSHAFT AND CAMSHAFT BUSHING
Camshaft bushing clearance
Measure inside diameter of camshaft bushing (A) and outside
diameter of camshaft journal (B) with a suitable gauge. Clearance between camshaft and bushing (A þ B):Standard0.020 - 0.109 mm
(0.0008 - 0.0043 in)
Limit Less than 0.15 mm (0.0059 in)
REPLACING CAMSHAFT BUSHING
1. Remove welch plug. Using Tool, remove camshaft bushings from the cylinder block.
Some bushings must be broken in order to remove.
2. Using Tool, install camshaft bushings as follows:
(1) Install camshaft bushings in the order of ªrearº, ª4thº, ª3rdº, ª2ndº and ªfrontº. All bushings must be installed from the front.
(2) Face the cutout upward and toward the front of the engine dur- ing installation.
SEM706
SEM669B
NEM171
SEM993B
SEM686B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-133
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(3) Rear camshaft bushing.Align the cutout of rear bushing with knock pin of replacer bar
before installation.
Insert rear bushing with replacer bar into the cylinder block.
Install guide plate with bolt holes (on the ªTDº mark side) fac-
ing upper side of cylinder block. Tighten bolts.
Drive replacer bar until the alignment mark on replacer bar is
aligned with the end of replacer guide.
Remove replacer set.
After installation, check that oil hole in camshaft bushing are
aligned with oil hole in cylinder block.
SEM995B
SEM110C
NEM172
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-134
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(4) 4th, 3rd and 2nd camshaft bushings.Install in the same manner as rear camshaft bushing.
(5) Front camshaft bushing. Using 1st bushing adapter, position front camshaft bushing so
that oil hole in cylinder block is aligned with oil hole in bushing.
The camshaft bushing of the front side must be inserted at 0.5
mm (0.020 in) from the extreme front of cylinder block.
NEM173
SEM001C
EEM105
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-135
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Assembly
PISTON
1. Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap cor-responding to each cylinder. Care should be taken to avoid
a wrong combination including bearing.
b. When inserting piston pin in connecting rod, heat piston with a heater or hot water [approximately 60 to 70ÉC (140
to 158ÉF)] and apply engine oil to pin and small end of
connecting rod.
c. After assembling, ascertain that piston swings smoothly.
2. Install piston assembly.
CAUTION:
a. Stretch the piston rings just enough to fit them in the pis- ton grooves.
b. Be sure the manufacturer's mark faces upward.
c. Install No. 1 piston ring (oil ring) in such a way that its gap faces the direction of engine front, as shown in illustration
at left; and then install 2nd and top rings so that their gap
is positioned at 120É one to another.
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing isreused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however lower bearings do not.
NEM174
NEM175
NEM182
NEM176
ENGINE OVERHAULTD27Ti
EM-138
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(2) Apply engine oil to crankshaft journal and pin and install crank-shaft.
(3) Install main bearings caps.
a) Install main bearing cap with the lowest number facing the front of vehicle.
b) Apply engine oil to main bearing cap and cylinder block contact surfaces.
c) Install rear oil seal assembly. Apply engine oil to contact surface of rear end oil seal and crankshaft.
(4) Install crankshaft thrust washer at the 4th journal from front.
Install thrust washer so that oil groove can face crankshaft.
(5) Tighten bearing cap bolts gradually in stages, starting from two to three separate stages, from center bearing and moving out-
ward in sequence.
(6) Measure crankshaft free end play at No. 4 bearing. Crankshaft free end play:Standard0.060 - 0.25 mm (0.0024 - 0.0098 in)
Limit 0.4 mm (0.016 in)
If beyond the limit, replace No. 4 main bearing thrust washer. Refer to SDS.
SEM674B
SEM057
SEM675B
SEM677B
SEM063
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-139
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REAR PLATE
Installation
1. Before installing rear plate, remove all traces of liquid gasketfrom mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of cyl-
inder block.
2. Apply a continuous bead of liquid gasket to mating surface of cylinder block.
3. Fit the rear plate into the cylinder block and apply liquid gasket in the area indicated by discontinuous line.
4. After the transmission is installed, apply liquid gasket in the area indicated by arrows.
5. Install all removed parts.
EEM109
EEM110
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-142
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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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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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Liquid Gasket Application Procedure
a. Use a scraper to remove all traces of old liquid gasket frommating surfaces and grooves. Also, completely clean any oil
from these areas.
b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.)
IFor oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
c. Apply liquid gasket around the inner side of bolt holes (unless otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and engine coolant.
Special Service Tools*: Special tool or commercial equivalent
Tool number
Tool name Description
ST25051001*
Oil pressure gauge
NT558
Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25
kg/cm
2, 356 psi)
ST25052000*
Hose
NT559
Adapting oil pressure gauge
to cylinder block
EG17650301
Radiator cap tester
adapter
NT564
Adapting radiator cap tester
to radiator filler neck and reser-
voir tank cap
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
SEM164F
AEM080
PRECAUTIONS AND PREPARATIONZD
LC-2
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OIL PRESSURE RELIEF VALVE AND BYPASS VALVE
INSPECTION (For oil cooler)
1. Inspect oil pressure relief valve for movement, cracks andbreaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with suitable tool.
Install a new valve in place by tapping it.
2. Check oil pressure relief valve to oil cooler housing clearance. Clearance:q
C: 0.032 - 0.068 mm (0.0013 - 0.0027 in)
If it exceeds the limit, replace oil cooler housing.
Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on.
INSPECTION (For piston)
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod and make sure that cut-off valve moves smoothly with proper
repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with a wire if necessary.
When installing oil jet, align oil jet's boss with hole on cylin-
der block. Oil jet:
:30-39N ×m (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
SLC371B
SLC385B
FEM124
FEM125
ENGINE LUBRICATION SYSTEMZD
Oil Pump (Cont'd)
LC-7
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