2002 NISSAN TERRANO Service Repair Manual

7. Remove piston and connecting rod assembly.
IBefore removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer to EM-71, ªCONNECTING ROD SIDE CLEARANCEº.
1) Move crankshaft pin to be removed to approximately BDC.
2) Remove connecting rod caps.
3) Using the grip of a hammer, press the piston and connecting
rod assembly out to cylinder head side.
CAUTION:
When removing the piston and connecting rod assembly, pre-
vent the big end of the connecting rod from interfering with the
oil jet.
8. Remove connecting rod bearings from connecting rods and
caps.
IKeep them by cylinder to avoid confusion.
9. Remove piston rings from pistons using piston ring expander
(multi-purpose tool).
CAUTION:
IWhen removing, prevent pistons from being damaged.
IDo not expand piston rings excessively. This may damage
the piston rings.
10. Remove pistons from connecting rods.
1) Using long nose pliers, remove snap rings.
2) Using industrial dryer, heat pistons up to 60 to 70ÉC (140 to
158ÉF).
FEM085
FEM086
FEM087
FEM088
FEM089
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-69

3) Using rod with outer diameter of 30 mm (1.18 in), press piston
pins out.
11. Remove lower cylinder block.
IThe lower cylinder block is the lower part of the cylinder block,
which works as the main bearing cap (beam) and oil pan
mounting face.
1) Remove mounting bolts for engine sub-attachment shown by
arrows in the figure.
2) Loosen and remove mounting bolts in the reverse order shown
in the figure.
3) Insert flat-bladed screwdriver into 5 locations shown by arrows
in the figure. Lift lower cylinder block evenly, and remove liquid
gasket.
CAUTION:
Prevent mating faces from being damaged.
4) When removing lower cylinder block, use slot to prevent dowel
pin from interfering with engine sub-attachment.
INo part No. is given to lower cylinder block, because it is
machined with the cylinder block.
12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder block
and lower cylinder block.
CAUTION:
Check mounting positions. Keep them to avoid confusion.
FEM090
FEM091
FEM092
FEM093
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-70

Inspection
CRANKSHAFT END PLAY
IUsing dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward, or
IUsing feeler gauge, measure crankshaft travel amount with the
lower cylinder block removed.
Standard: 0.055 - 0.140 mm (0.0022 - 0.0055 in)
Limit: 0.250 mm (0.0098 in)
IIf measured value exceeds the limit, select appropriate thrust
bearings.
Unit: mm (in)
Grade symbol Thickness of thrust bearing
A 2.275 - 2.325 (0.0896 - 0.0915)
B 2.300 - 2.350 (0.0906 - 0.0925)
C 2.325 - 2.375 (0.0915 - 0.0935)
OS 020 2.475 - 2.525 (0.0974 - 0.0994)
IOS 020 has part No. of 12280 2W215 and OS 0.20 marked on
bearing surface.
CONNECTING ROD SIDE CLEARANCE
IUsing feeler gauge, measure side clearance between connect-
ing rod and crank arm.
Standard: 0.10 - 0.22 (0.0039 - 0.0087 in)
Limit: 0.22 mm (0.0087 in)
IIf measured value exceeds the limit, replace connecting rod
and repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston pin hole inner diameter
Using inside micrometer, measure piston pin hole inner diameter.
Standard: 32.997 - 33.005 mm (1.2991 - 1.2994 in) dia.
Piston pin outer diameter
Using micrometer, measure piston pin outer diameter.
Standard: 32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
FEM094
FEM095
FEM096
FEM097
FEM098
CYLINDER BLOCKZD
EM-71

Calculation of piston to piston pin clearance
Piston pin clearance = Piston pin hole inner diameter þ Piston pin
outer diameter
Standard: þ0.003 (Tightening clearance) to 0.012 mm
(þ0.0001 to 0.0005 in)
If out of specifications, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE
IUsing feeler gauge, measure clearance between piston ring
and piston ring groove.
Unit: mm (in)
Standard Limit
Top ring 0.05 - 0.07 (0.0020 - 0.0028) 0.5 (0.020)
Second ring 0.04 - 0.08 (0.0016 - 0.0031) 0.3 (0.012)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
IAlign top ring and external surface of piston. Measure lower
side clearance of top ring with top ring pressed onto upper side
of ring groove.
IIf side clearance exceeds the limit, replace piston ring.
ICheck clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP
ICheck that cylinder bore diameter is within specifications.
Refer to EM-74, ªPISTON TO CYLINDER BORE CLEAR-
ANCEº.
IUsing piston, press piston ring to cylinder mid point, and mea-
sure end gap.
Unit: mm (in)
Standard Limit
Top ring 0.3 - 0.45 (0.0118 - 0.0177)
1.5 (0.059) Second ring 0.5 - 0.65 (0.0197 - 0.0256)
Oil ring 0.25 - 0.45 (0.0098 - 0.0177)
FEM099
FEM100
FEM101
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-72

CONNECTING ROD BEND AND TORSION
Use connecting rod aligner to check bend and torsion.
Bend limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Connecting rod big end inner diameter
Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter.
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in) dia.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL
END)
Connecting rod small end inner diameter
Use inside micrometer to measure small end inner diameter.
Standard:
33.025 - 33.038 mm (1.3002 - 1.3007 in) dia.
Piston pin outer diameter
Use micrometer to measure piston pin outer diameter.
Standard:
32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
Calculation of connecting rod bushing clearance
Connecting rod small end bushing clearance = Connecting rod
small end inner diameter þ Piston pin outer diameter
Standard:
0.025 - 0.045 mm (0.0010 - 0.0018 in)
IIf out of specifications, replace connecting rod and/or piston
and piston pin assembly.
FEM102
FEM103
FEM104
FEM098
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-73

INew connecting rods are classified into 8 weight classes at
factory. The same class connecting rods are used on a engine.
Weight grade symbol Weight class g (oz)
H 1,261 - 1,264 (44.5 - 44.6)
I 1,264 - 1,267 (44.6 - 44.7)
K 1,267 - 1,270 (44.7 - 44.8)
L 1,270 - 1,273 (44.8 - 44.9)
M 1,273 - 1,276 (44.9 - 45.0)
O 1,276 - 1,279 (45.0 - 45.1)
P 1,279 - 1,282 (45.1 - 45.2)
S 1,282 - 1,285 (45.2 - 45.3)
CYLINDER BLOCK TOP SURFACE DISTORTION
IUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of oil and coolant pas-
sages.
IUse straightedge and feeler gauge to check block upper sur-
face for distortion.
Limit: 0.1 mm (0.004 in)
MAIN BEARING HOUSING INNER DIAMETER
IInstall main bearing caps without main bearings. Tighten
mounting bolts to the specified torque.
IUse bore gauge to measure main bearing housing inner diam-
eter.
Standard:
74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
IIf out of specification, replace cylinder block and lower cylinder
block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder bore inner diameter
IUsing bore gauge, measure cylinder inner diameters at 6 posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
Cylinder inner diameter (Standard):
96.000 - 96.030 mm (3.7795 - 3.7807 in) dia.
Wear limit: 0.2 mm (0.008 in)
Out-of-round limit (X - Y): 0.02 mm (0.0008 in)
Taper limit (A - C): 0.02 mm (0.0008 in)
FEM106
FEM107
FEM108
FEM109
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-74

IIf clearance exceeds the limit, or any flaws or seizures are
found on inner surface of cylinder, horn or bore the applicable
cylinder.
Piston outer diameter
Use micrometer to measure piston skirt outer diameter.
Measurement position:
10 mm (0.39 in) upper from the lower end of pis-
ton
Standard:
95.950 - 95.980 mm (3.7776 - 3.7787 in) dia.
Calculation of piston to piston bore clearance
ICalculate using piston skirt outer diameter and cylinder inner
diameter (direction X, position B).
Clearance = Cylinder inner diameter þ Piston skirt outer diam-
eter
Specifications at room temperature [20ÉC (68ÉF)]:
0.040 - 0.060 mm (0.0016 - 0.0024 in)
IIf out of specification, replace piston and piston pin assembly.
SELECTIVE PISTON COMBINATION
When using new cylinder block
IConfirm cylinder bore grade (1, 2, 3) on left upper surface of
cylinder block, and refer to ªSelective combination chartº below
to select appropriate piston.
IPart No. is given to a piston and piston pin as a set.
When re-using an old cylinder block
1. Measure cylinder block bore inner diameter.
2. Referring to ªCylinder block bore inner diameterº in ªSelective
combination chartº, select appropriate piston according to cyl-
inder bore grade.
FEM110
FEM111
FEM112
FEM113
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-75

Selective combination chart
Unit: mm (in)
q: Preferable combination
g: Allowable combination
X: NG combinationPiston grade
12
95.950 - 95.960
(3.7776 - 3.7779)95.960 - 95.970
(3.7779 - 3.7783)
Cylinder
bore grade
(Cylinder
block bore
inner
diameter)196.000 - 96.010
(3.7795 - 3.7799)qX
296.010 - 96.020
(3.7799 - 3.7803)gq
396.020 - 96.030
(3.7803 - 3.7807)gq
IPiston grade 3 (95.980/95.970) is applicable at factory only.
INew pistons are classified into 4 weight classes at factory. The
same class pistons are used on a engine.
Weight grade symbol Weight class g (oz)
E 600 - 605 (21.2 - 21.3)
F 605 - 610 (21.3 - 21.5)
G 610 - 615 (21.5 - 21.7)
H 615 - 620 (21.7 - 21.9)
CRANKSHAFT JOURNAL OUTER DIAMETER
Use micrometer to measure journal outer diameter.
Standard: 70.907 - 70.920 mm (2.7916 - 2.7921 in) dia.
CRANKSHAFT PIN OUTER DIAMETER
Use micrometer to measure pin outer diameter.
Standard: 56.913 - 56.926 mm (2.2407 - 2.2412 in) dia.
CRANKSHAFT OUT-OF-ROUND AND TAPER
IUsing micrometer, measure each journal and pin at 4 points
shown in the figure.
IOut-of-round value is indicated by difference in dimensions
between directions A and B at points 1 and 2.
ITaper value is indicated by difference in dimensions between
points 1 and 2 in directions A and B.
Out-of-round limit: 0.01 mm (0.0004 in)
Taper limit: 0.01 mm (0.0004 in)
CRANKSHAFT RUNOUT
IPlace V-block onto surface plate to support journals at both
ends of crankshaft.
IPosition dial indicator vertically onto No. 3 journal.
IRotate crankshaft to read needle movement on dial indicator.
ICrankshaft bend value is 1/2 of needle movement.
Limit: 0.03 mm (0.0012 in)
FEM114
FEM115
FEM116
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-76