engine NISSAN TERRANO 2004 Service Manual Online

Removal
1. Remove the engine assembly.Refer to ªENGINE REMOVALº, EM-63.
2. Place the engine on an engine stand (SST). Refer to ªCYLINDER BLOCKº, EM-67.
3. Remove the following.
I Auto tensioner bracket
I Air conditioner bracket
I Alternator bracket
I Oil tube
I Vacuum pump
I Rocker cover
I Oil pan (upper, lower)
I Injection tube
I Spill tube
I High pressure nozzle assembly
4. Remove the chain cover, timing chain and other parts in con- nection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the fig-
ure. Refer to ªTIMING CHAINº, EM-26.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
I Do not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
I Do not drop or hit the sensor.
I Store in a clean place free of iron filings, etc.
I Do not place near any magnetic equipment.
6. Remove the water pump. Refer to ªWATER PUMPº in LC section.
7. Remove the water inlet.
SEM376G
TIMING GEARZD
EM-39
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8. Remove the crankshaft pulley.
ITo fix the crankshaft, clamp the bar between the drive plate
holding bolts, and set by touching the engine sub-attachment
(SST).
I As another method, set by clamping a hammer handle, etc. in
the counterweight portion of the crankshaft.
CAUTION:
I Do not damage the crankshaft.
I Make sure that no foreign objects get inside the engine.
I Do not damage or magnetize the signal detection protru-
sions of the crankshaft pulley.
I After removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.
9. Remove the gear case.
I Using the grooved places shown in the figure, remove the gear
case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a screw- driver.
CAUTION:
Do not damage the gear case.
11. Fix the internal mechanism setting bolt [part No.: 81-20620-28, screw dia.: M6, dimension below neck: 20 mm (0.79 in)] to the
bolt hole of the idler gear (A) and tighten to the specification.
: 2.5 - 3.4 N ×m (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
I Only use the genuine setting bolt, or the idler gear (A) will
be damaged.
I Do not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
I Do not remove the setting bolt from the idler gear (A) until
the timing chain and all of the parts in connection have
been installed.
I If these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit
the idler gear from being reusable.
FEM050
YEM030
FEM052
SEM377G
TIMING GEARZD
Removal (Cont'd)
EM-40
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2. Using Tool, remove balancer shaft rear bearing from engine.
3. Install the rear and front balancer shaft bearings.
IInstall from the cylinder block hole to the rear journal and then
the front journal.
I Install the groove of the balancer shaft bearing facing the front
and the under right direction.
(Align the guide plate and bar knock pin and then force in the
balancer shaft bearing.)
I Align the balancer shaft bearing groove with the knock pin of
the bar (SST) and install the balancer shaft bearing.)
I On rear journals, so the bearing does not get out of position,
wrap tape around the bar.
SEM381G
SEM382G
SEM383G
EMV0514D
TIMING GEARZD
Inspection (Cont'd)
EM-44
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4. Install the front oil seal to the gear case.
IApply engine oil to the fitting side.
I Evenly insert the front oil seal using a drift [outer dia.: approx.
64 mm (2.52 in)] completely.
CAUTION:
Make sure the oil seal does not spill off the end side of the gear
case.
5. Install the gear case.
1) Before installing gear case, remove all traces of liquid gasket from mating surface using a scraper.
2) Align gasket with dowel and install.
3) Install the O-rings to the gear case.
I The O-ring at the top position shown in the figure can be
installed in during cylinder head installation.
4) Apply a continuous bead of liquid gasket to gear case.
I Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach gear case to cylinder block within 5 minutes after coating.
c. Wait at least 30 minutes before refilling engine oil or start- ing engine.
FEM043
FEM044
SEM353G
FEM045
TIMING GEARZD
Installation (Cont'd)
EM-47
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CRANKSHAFT FRONT OIL SEAL
1. Remove the front cover. Refer to ªTIMING GEARº.
2. Remove front oil seal with a suitable tool.
3. Apply engine oil to new oil seal and install oil seal using a suit-able tool.
CRANKSHAFT REAR OIL SEAL
1. Remove oil pan assembly. Refer to EM-22, ªOIL PANº.
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove oil seal retainer assembly.
5. Apply a continuous bead of liquid gasket to rear oil sealretainer.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach oil seal retainer to cylinder block within five min- utes after coating.
c. Wait at least 30 minutes before refilling engine oil or start- ing engine.
d. Use Genuine Liquid Gasket or equivalent.
SEM358G
FEM044
SLC822
FEM053
OIL SEAL REPLACEMENTZD
EM-51
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5. Remove cylinder head assembly.
ILoosen and remove mounting bolts in the reverse order shown
in the figure.
I Lift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
I Do not drop the O-ring located between the front of cylin-
der head and the rear of gear case into the engine.
I Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head, or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.
I For glow plug removal, the following shall be noted.
CAUTION:
I To avoid breakage, do not remove glow plug unless nec-
essary.
I Perform continuity test with glow plug installed.
I Keep glow plug from any impact. (Replace if dropped from
a height 10 cm (3.94 in) or higher.)
I Do not use air impact wrench.
6. Remove idler gear.
CAUTION:
While removing idler gear, keep the rear of idler gear facing up
to prevent idler shaft from falling.
Inspection
CYLINDER HEAD BOLT DEFORMATION (ELONGATION)
I Using micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.
I If the necking point can be identified, set it as measuring point
d2.
I Calculate the difference between d1 and d2.
Limit: 0.15 mm (0.0059 in)
IDLER GEAR END PLAY
I Tighten mounting bolts to the specified torque.
I Using feeler gauge, measure the clearance between gear plate
and idler gear.
Standard: 0.07 - 0.14 mm (0.0028 - 0.0055 in)
Limit: 0.2 mm (0.0079 in)
I If the measured value exceeds the limit value, replace idler
gear, shaft, and gear plate.
FEM055
SEM379G
FEM056
CYLINDER HEADZD
Removal (Cont'd)
EM-53
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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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6) Once again, tighten bolts at the angle of 90 to 95É (target is95É). (Angle tightening)
CAUTION:
Perform the following procedure to check turning angle of
angle tightening, and do not judge by visual check.
ANGLE TIGHTENING PROCEDURE
With protractor
I Make counter marks on the bolt head of cylinder head and cyl-
inder head surface with paint, and check the turning angle.
With angle wrench (SST)
ICheck the turning angle using angle indicator of angle wrench.
6. Loosen gear case mounting bolts which were tightened in 3) of procedure 4, retighten them to the specified torque.
7. Install glow plug.
I 2 different types (manufacturers) of glow plugs are provided in
parallel. (Refer to the figure for identification.)
I Do not install 2 different types of glow plugs in the engine. Make
sure that the same glow plugs are installed.
I Using reamer, remove the carbon adhering to the installation
hole of glow plug, and install glow plug.
FEM063
FEM064
CYLINDER HEADZD
Installation (Cont'd)
EM-56
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For details of values (q1toq10), refer to EM-87, ªValve Seatº in
ªSERVICE DATA AND SPECIFICATIONS (SDS)º.
VALVE SPRING RIGHT ANGLE
Position a straightedge to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring
and the straightedge Limit: 2.4 mm (0.094 in)
VALVE SPRING FREE LENGTH AND COMPRESSIVE
LOAD
Using valve spring tester, check the following.Free length: 55.43 mm (2.1823 in)
Installation height: 40.8 mm (1.6063 in)
Installation load: 180 - 206 N (18.4 - 21.0 kg, 40.6 -
46.3 lb)
Height at valve open: 32.3 mm (1.2717 in)
Load at valve open: 336 - 372 N (34.3 - 37.9 kg, 75.6 -
83.6 lb)
Assembly
1. Install valve guides, referring to EM-60, ªVALVE SEATREPLACEMENTº.
2. Install valve seats, referring to EM-60, ªVALVE SEAT CON- TACTº.
3. Using valve oil seal drift (SST), install valve oil seals referring to the dimension shown in the figure.
I The figure shows the dimension before valve spring seats are
installed.
4. Install valve spring seats.
5. Install valves.
I Install the valves with bigger openings to intake valve side.
I Note that valve layout here is different from that of conventional
the engine.
YEM035
FEM077
FEM078
FEM079
CYLINDER HEADZD
Inspection (Cont'd)
EM-61
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Precautions
IDo not perform operation unless it is perfectly safe.
I Do not start operation unless the exhaust system and coolant
are cooled down.
I Lift the engine at the designated support points only.
I Perform operations for the items other than the engine body,
referring to the applicable sections.
I Refer to MT section and AT section for rear mount.
Removal
IAfter removing transmission, hoist the engine and remove it.
Preparation
1. Drain coolant from radiator drain plugs.
2. Remove the following parts.
IEngine hood
I Undercover
I Under protector
I Battery
I Intercooler
I Radiator shroud
I Radiator
I Accessory belt
I Cooling fan
I Exhaust front tube
YEM032
ENGINE REMOVALZD
EM-63
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