2002 NISSAN TERRANO Service Repair Manual

REMOVAL
1. Remove the following parts.
IDrain engine coolant. Refer to MA section, ªChanging Engine
Coolantº.
IRemove engine cover. Refer to the figure at left.
IRemove intercooler.
IRemove air hose (on throttle body side).
IRemove injection tube.
IRemove or relocate wires/harnesses and tubes/pipes.
2. Remove intake manifold in the reverse order of that shown in
the figure.
Inspection
Clean surface of intake manifold.
Use a reliable straightedge and feeler gauge to check the flatness
of intake manifold surface.
Intake manifold surface flatness:
Limit 0.2 mm (0.008 in)
INSTALLATION
1. Tighten intake manifold in the numerical order shown in the
figure.
:25-28N×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
2. Install in the reverse order of removal.
SEM293G
SEM294G
INTAKE MANIFOLDZD
Removal and Installation (Cont'd)
EM-13

Removal and Installation
REMOVAL
1. Remove the following parts.
IUndercover
IUnder guard
IEngine coolant (drain)
Refer to MA section, ªChanging Engine Coolantº.
IExhaust front tube
Refer to FE section, ªRemoval and Installationº, ªEXHAUST
SYSTEMº.
IRemove wires, harnesses, tubes and pipes.
YEM038
SEM296G
CATALYST AND TURBOCHARGERZD
EM-14

2. Remove catalyst.
CAUTION:
Do not disassemble catalyst.
Inspection
TURBOCHARGER
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and intercooler
Exhaust side: Between turbocharger and catalytic
converter
Rotor shaft
ICheck that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
ICheck that the rotor shaft is not loose when it is moved verti-
cally or horizontally.
Standard value for rotor shaft oil clearance:
0.086 - 0.177 mm (0.0034 - 0.0070 in)
SEM297G
SEM298G
CATALYST AND TURBOCHARGERZD
Removal and Installation (Cont'd)
EM-15

Rotor shaft end play
Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.
Standard: 0.044 - 0.083 mm (0.0017 - 0.0033 in)
Turbine wheel
ICheck that there is no oil adhesion.
ICheck that there is no carbon accumulation.
ICheck that blades of the turbine wheel are not bent or broken.
ICheck that the turbine wheel does not interfere with the turbine
housing.
Compressor wheel
ICheck that there is no oil adhesion inside the air inlet.
ICheck that the compressor wheel does not interfere with the
compressor housing.
ICheck that the wheel is not bent or broken.
VNT control actuator
IConnect the handy pump to the actuator, and check that the rod
strokes smoothly in compliance with the following pressure.
IFirst, apply the inspection negative pressure of about þ66.7
kPa (þ667 mbar, þ500 mmHg, 19.69 inHg), and then measure
the values while reducing the negative pressure to 0.
Standard (Vacuum pressure/rod stroke amount):
þ46.9 1.3 kPa (þ469 13 mbar, þ352 10 mmHg,
þ13.86 0.39 inHg)/0.2 mm (0.008 in)
þ30.8 0.7 kPa (þ308 7 mbar, þ231 5 mmHg,
þ9.09 0.20 inHg)/5.0 mm (0.197 in)
Approximately þ22.7 kPa (þ227 mbar, þ170 mmHg,
þ6.69 inHg)/Rod stroke end
SEM299G
SEM300G
SEM310G
SEM311G
CATALYST AND TURBOCHARGERZD
Inspection (Cont'd)
EM-16

Trouble diagnosis of turbocharger
Preliminary check:
Check that the VNT control valve system has no malfunction. Refer
to EC section, ªECM Terminals and Reference Valueº in ªTROUBLE
DIAGNOSIS Ð GENERAL DESCRIPTIONº.
ICheck that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
IAsk the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
IReplace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
IIf no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item
meets each inspection result)
Oil leak-
ageSmoke NoiseInsuffi-
cient
power/
accel-
eration
failure
Turbine wheelOil leaks.g
gg
Carbon is accumulated.g
qq
Friction with housing.gq
q
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contami-
nated by oil.qq
Friction with housing.gqq
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor shaft
is rotated by your fingertips.ggq
The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing.ggqg
Oil return portCarbon or sludge is accumulated in the
waste oil hole.g
gg
Operation of VNT control actuatorIThe actuator does not operate
smoothly when vacuum pressure is
gradually applied.
IStroke amount is not in compliance
with the vacuum pressure.q
: Large possibility
q: Medium possibility
g: Small possibility
INSTALLATION
1. Install catalyst.
:29-39N×m (2.9 - 3.3 kg-m, 21 - 23 ft-lb)
Place the protruding area of the gasket between the turbocharger
and the exhaust outlet upwards, and install the lipped side to the
turbocharger side. Refer to the figure, EM-14.
2. Install in the reverse order of removal.
CATALYST AND TURBOCHARGERZD
Inspection (Cont'd)
EM-17

Removal and Installation
REMOVAL
1. Remove the following parts.
IRefer to ªPREPARATIVE WORKº in ªCATALYST AND
TURBOCHARGERº, EM-14.
IRemove catalytic converter.
IRemove turbocharger.
2. Loosen nuts holding the exhaust manifold in the reverse order
of that shown in the figure.
YEM040
SEM313G
EXHAUST MANIFOLDZD
EM-18

Inspection
EXHAUST MANIFOLD
Check distortion on mounting surface with straightedge and feeler
gauge.
Limit: 0.2 mm (0.008 in)
INSTALLATION
1. Tighten exhaust manifold holding nuts in the numerical order
shown in the figure.
:40-44N×m (4.0 - 4.5 kg-m, 29 - 32 ft-lb)
NOTE:
Install gasket so that the protruding tab (mark for correct
installation) is positioned on the side of No. 1 port (front side).
Refer to component structure diagram on the previous page.
2. Install in the reverse order of removal.
FEM034
EXHAUST MANIFOLDZD
EM-19

Removal and Installation
REMOVAL
1. Remove the following parts.
IEngine cover
IIntercooler
IAir inlet pipe
IThrottle body
IWires, harnesses, tubes and pipes
2. Loosen holding bolts in the reverse order of that shown in the
figure and remove.
3. Remove rocker cover to the direction of glow plug tilt.
4. Remove glow plug oil seals.
SEM315G
SEM316G
ROCKER COVERZD
EM-20