height adjustment NISSAN TERRANO 2004 Service Repair Manual

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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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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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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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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Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.Pedal height ªHº:LHD: 227 - 237 mm (8.94 - 9.33 in)
RHD: 210 - 220 mm (8.27 - 8.66 in)
2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut.Pedal free play ªAº: 1.0 - 3.0 mm (0.039 - 0.118 in)
YCL009
INSPECTION AND ADJUSTMENT
CL-5
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Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
ISet Tools and check height and unevenness of diaphragm
spring.
Diaphragm spring height ªAº: 36.5 - 38.5 mm (1.437 - 1.516 in)
I Check thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammer-
ing on rivets for a slight cracking noise. Replace clutch cover
assembly if necessary.
I Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
I Check pressure plate and clutch disc contact surface for defor-
mation or damage. Replace if necessary.
I Adjust unevenness of diaphragm spring with Tool.
Uneven limit: 0.7 mm (0.028 in)
FLYWHEEL INSPECTION
ICheck contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
I Check flywheel runout.
Runout (Total indicator reading): Refer to EM section. (Inspection Ð CYLINDER
BLOCK)
SCL503
SCL504
SCL468
CLUTCH DISC AND CLUTCH COVER
CL-12
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General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch controlHydraulic
CLUTCH MASTER CYLINDER
Inner diametermm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
EngineTD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness) 250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load 7.0 - 7.4 (0.276 - 0.291)
Under a load of 5,884 N (600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27TiZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHDRHD
Pedal height* 227 - 237
(8.94 - 9.33) 210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis) 1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27TiZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head 0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center) 120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc) 1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine
TD27TiZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14
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PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION
PD
CONTENTS
PREPARATION ................................................................2
PROPELLER SHAFT ......................................................5
On-Vehicle Service ......................................................6
Removal and Installation .............................................7
Inspection.....................................................................7
Disassembly.................................................................7
Assembly .....................................................................8
ON-VEHICLE SERVICE ................................................10
Front Oil Seal Replacement
(Front final drive: R180A) ..........................................10
Front Oil Seal Replacement
(Rear final drive: C200) .............................................10
REMOVAL AND INSTALLATION (Front final drive
- R180A) ........................................................................\
.12
Removal .....................................................................12
Installation ..................................................................12
REMOVAL AND INSTALLATION (Rear final drive
- C200) ........................................................................\
...13
Removal .....................................................................13
Installation ..................................................................13
FRONT FINAL DRIVE (R180A) ....................................14
DISASSEMBLY (R180A) ...............................................15
Pre-inspection ............................................................15
Final Drive Housing ...................................................15
Differential Case ........................................................18
Extension Tube and Differential Side Shaft ..............19
INSPECTION (R180A) ...................................................20
Ring Gear and Drive Pinion ......................................20
Differential Case Assembly........................................20
Bearing.......................................................................20
ADJUSTMENT (R180A) ................................................21 Drive Pinion Height ....................................................21
Side Bearing Preload.................................................24
Tooth Contact.............................................................27
ASSEMBLY (R180A) .....................................................28
Extension Tube and Differential Side Shaft ..............28
Differential Case ........................................................29
Final Drive Housing ...................................................30
REAR FINAL DRIVE (C200) .........................................35
Air Breather................................................................36
DISASSEMBLY (C200) ..................................................37
Pre-inspection ............................................................37
Differential Carrier......................................................38
Differential Case ........................................................40
INSPECTION (C200) .....................................................42
Ring Gear and Drive Pinion ......................................42
Differential Case Assembly........................................42
Bearing.......................................................................42
LIMITED SLIP DIFFERENTIAL (C200) .........................43
Preparation for Disassembly .....................................43
Disassembly...............................................................44
Inspection...................................................................44
Adjustment .................................................................45
Assembly ...................................................................47
ADJUSTMENT (C200) ...................................................49
Drive Pinion Height ....................................................49
Tooth Contact.............................................................52
ASSEMBLY (C200) ........................................................53
Differential Carrier......................................................53
SERVICE DATA AND SPECIFICATIONS (SDS) ..........57
Propeller Shaft ...........................................................57
Final Drive..................................................................58
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To avoid confusion while calculating bearing shims, it is absolutely
necessary to stay with the metric system. If you measure anything
in inches, the results MUST be converted to the metric system.
Drive Pinion Height
1. First prepare Tools for pinion height adjustment.
q
1Height gauge (ST31211000)
q
2Dummy shaft (ST31212000)
q
3Collar
q
4Feeler gauge
q
5Dummy shaft spacer (ST31851000)
q
6Stopper (ST31852000)
q
7Preload gauge (ST3127S000)
I Use a collar which has the specifications shown at left.
2. To simplify the job, make a chart, like the one below, to orga- nize your calculations.
LETTERS HUNDREDTHS OF
A MILLIMETER
H: Head number
D¢ : Figure marked on dummy shaft
S: Figure marked on height gauge
N: Measuring clearance
3. Write the following numbers down in the chart.
H: Head number
SPD633
SPD753
SPD542
ADJUSTMENT (R180A)
PD-21
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