2002 NISSAN TERRANO Service Repair Manual

CONNECTING ROD BEARING OIL CLEARANCE
Method by measurement
IInstall connecting rod bearings to connecting rods and caps,
and tighten connecting nuts to the specified torque. Use inside
micrometer to measure connecting rod bearing inner diameter.
Bearing clearance = Connecting rod bearing inner diameter þ
Crankshaft pin outer diameter
Standard: 0.035 - 0.077 mm (0.0014 - 0.0030 in)
IIf out of specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select appro-
priate connecting rod bearing to adjust clearance to specifica-
tions.
Refer to ªConnecting rod bearing undersize listº on the next
page.
Method using plastigage
IRemove contamination such as oil, dust completely from crank-
shaft pins and each bearing surface.
ICut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
IInstall connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
IRemove connecting rod caps and bearings, and measure plas-
tigage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in ªMethod
by measurementº.
Undersize bearing usage
IIf bearing clearance is out of specifications for connecting rod
bearings in standard size, use undersize bearings.
IWhen using undersize bearings, measure bearing inner diam-
eter with bearing installed, and grind pins to adjust clearance
to specification.
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FEM118
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-77

Connecting rod bearing undersize list
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.630 - 1.638 (0.0642 - 0.0645)
US 0.50 (0.0197) 1.755 - 1.763 (0.0691 - 0.0694)
US 0.75 (0.0295) 1.880 - 1.888 (0.0740 - 0.0743)
US 1.00 (0.0394) 2.005 - 2.013 (0.0789 - 0.0793)
CAUTION:
When grinding crank pins to use undersize bearings, avoid
damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING OIL CLEARANCE
Method by measurement
IInstall main bearings to cylinder block and bearing caps, and
tighten bearing cap bolts to the specified torque. Measure main
bearing inner diameter.
Bearing clearance = Bearing inner diameter þ Crankshaft jour-
nal outer diameter
Standard: 0.035 - 0.083 mm (0.0014 - 0.0033 in)
IIf out of specification, check main bearing housing inner diam-
eter and crankshaft journal outer diameter, and select appropri-
ate main bearing to adjust clearance to specifications.
Refer to ªMain bearing undersize listº on the next page.
Method using plastigage
IRemove contamination such as oil, dust completely from crank-
shaft journals and each bearing surface.
ICut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
IInstall main bearings to caps, and tighten connecting rod nuts
to the specified torque.
CAUTION:
Never rotate crankshaft.
IRemove bearing caps and bearings, and measure plastigage
width using scale on plastigage bag.
FEM119
FEM120
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-78

CAUTION:
If out of specification, take same action mentioned in ªMethod
by measurementº.
Undersize bearing usage
IIf bearing clearance is out of specifications for main bearings
in standard size, use undersize bearings.
IWhen using undersize bearings, measure bearing inner diam-
eter with bearing installed, and grind crank journals to adjust
clearance to specification.
Main bearing undersize list
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.130 - 2.138 (0.0839 - 0.0842)
US 0.50 (0.0197) 2.255 - 2.263 (0.0888 - 0.0891)
US 0.75 (0.0295) 2.380 - 2.388 (0.0937 - 0.0940)
US 1.00 (0.0394) 2.505 - 2.513 (0.0986 - 0.0989)
CAUTION:
When grinding crank journals to use undersize bearings,
avoid damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING CRUSH HEIGHT
ITighten bearing caps to the specified torque with main bearings
installed, and remove caps. The bearing end must then be
higher than the flat surface.
Standard: Crush height must exist.
IIf out of specification, replace main bearings.
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CYLINDER BLOCKZD
Inspection (Cont'd)
EM-79

Assembly
1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase, and cylinder bore to remove foreign matter.
2. Install main bearings and thrust bearings.
1) Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
2) Install thrust bearings on both sides of No. 4 housing on cylin-
der block.
IInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
3) Being careful with the direction, install main bearings.
IInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the lower cylinder block side.
IWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them com-
pletely.
IAlign stopper notches on bearings to install them.
ICheck that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
3. Install crankshaft to cylinder block.
IWhile rotating crankshaft by hand, check for smooth rotation.
4. Install lower cylinder block.
IApply a continuous bead of liquid gasket to lower cylinder block
as shown in the figure.
IUsing slots on engine sub-attachment, install the lower cylinder
block to the cylinder block, avoiding interference of dowel pins.
5. Tighten lower cylinder mounting bolts to the torque shown
below in 3 consecutive steps in the order shown in the figure.
Unit: N×m (kg-m, ft-lb)
Main bolt (Nos. 1 - 10) Sub-bolt (Nos. 11 - 20)
1st 20 (2.0, 14) 98 (10, 72)
2nd 98 (10, 72) 20 (2.0, 14)
3rd 167 - 176 (17 - 18, 123 - 130) 40 - 46 (4.0 - 4.7, 29 - 33)
ISub-bolt No. 17 has shorter length than that of other sub-bolts.
FEM126
FEM127
FEM128
FEM092
CYLINDER BLOCKZD
EM-80

6. Install mounting bolts for engine sub-attachment shown by
arrows in the figure.
IAfter tightening bolts to the specified torque, check crankshaft
for smooth rotation.
ICheck crankshaft end play.
Refer to EM-71, ªCRANKSHAFT END PLAYº.
7. Install pistons to connecting rod.
1) Using long nose pliers, install snap rings to grooves on piston
rear side.
IFit snap rings correctly into grooves.
2) Install pistons to connecting rods.
IUsing industrial dryer, heat pistons up to approx. 60 to 70ÉC
(140 to 158ÉF) until piston pin can be pressed down by finger
touch. Then insert piston pins into piston and connecting rod
from front side of piston toward rear.
IAssemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
3) Install snap rings to front side of pistons.
IRefer to above 1) for precaution on snap ring installation.
IAfter installation, check connecting rods for smooth movement.
8. Use piston ring expander (multi-purpose tool) to install piston
rings.
CAUTION:
When installing, prevent piston from being damaged.
IInstall top ring and second ring with stamped surfaces facing
upward.
Identification stamp:
Top ring: R
Second ring: RN
9. Install connecting rod bearings to connecting rods and caps.
IWhile installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces, but
clean them completely.
IAlign stoppers on connecting rod bearings with connecting rod
stopper notches to install connecting rod bearings.
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CYLINDER BLOCKZD
Assembly (Cont'd)
EM-81

10. Install piston and connecting rod assembly to crankshaft.
IMove crankshaft pin to be removed to BDC.
IAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
IUsing piston ring compressor (multi-purpose tool), install piston
and connecting rod assembly with front mark on piston crown
facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, prevent
the big end of connecting rod from interfering with oil jet.
11. Install connecting rod caps and mounting nuts.
IAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
IAfter tightening nuts, check crankshaft for smooth rotation.
ICheck connecting rod side clearance.
Refer to EM-71, ªCONNECTING ROD SIDE CLEARANCEº.
12. Install rear oil seal and retainer assembly.
IApply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
13. Press fit pilot bushing into flywheel (M/T model).
1) Using drift with outer diameter of 35 mm, press fit spacer until
it is in contact with the flywheel to prevent displacement at
removal.
2) Using drift with outer diameter of 20 mm, press fit pilot bushing
by the length shown in the figure.
14. Install rear plate.
15. Install removed parts to engine in the reverse order of disas-
sembly.
16. Remove engine from engine stand.
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SEM366G
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-82

17. Install flywheel (M/T model) or drive plate (A/T model).
IInstall pilot converter, drive plate, and reinforcing plate in direc-
tion shown in the figure.
IUsing the same method as disassembly, secure crankshaft and
tighten mounting bolts.
ITighten mounting bolts for flywheel or drive plate in order
shown in the figure.
FEM137
FEM138
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-83

General Specifications
Cylinder arrangementIn-line 4
Displacementcm
3(cu in) 2,953 (180.19)
Bore and strokemm (in) 96 x 102 (3.78 x 4.02)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil1
Number of main bearings5
Compression ratio17.9
Compression Pressure
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Compression pressureStandard 2,942 (29.42, 30.0, 427)
Minimum 2,452 (24.52, 25.0, 356)
Differential limit between cylinders 294 (2.94, 3.0, 43)
Cylinder Head
Unit: mm (in)
Standard Limit
Head surface distortion Less than 0.05 (0.0020) 0.2 (0.008)
SEM368G
Valve
VA LV E
Unit: mm (in)
FEM067
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-84