2002 NISSAN TERRANO Service Repair Manual

5. Stake exhaust valve seat at five places with punch.
When staking valve seat, select different places than those
staked before.
6. Cut or grind valve seat using suitable tool at the specified
dimensions. Refer to SDS.
7. After cutting, lap valve seat with a lapping compound.
8. Check contact condition of valve seat.
COMBUSTION CHAMBER
Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER
Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot be
damaged.
2. Install combustion chamber.
IIdentification of combustion chambers
Identification mark
(on combustion chamber)Outer diameter ªDº
mm (in)
2 37 (1.46)
(1) Cool combustion chamber with dry ice for approximately 5 to 10
minutes.
WARNING:
Do not touch cooled combustion chamber with bare hands.
SEM087
NEM161
EEM116
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-109

(2) Align combustion chamber knock pin with cylinder head notch,
and drive in combustion chamber with a soft hammer.
3. Check amount of protrusion of combustion chamber.
Protrusion:
Standard
Less than 0.10 mm (0.0039 in)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to SDS.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
VALVE SPRING SQUARENESS
Out-of-square ªSº:
Less than 2.0 mm (0.079 in)
VALVE SPRING PRESSURE
Refer to SDS.
SEM634B
SEM188A
SEM635B
EM113
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-110

VALVE LIFTER AND PUSH ROD
Valve lifter
1. Check valve lifters for excessive wear on the surfaces.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:
Standard
0.030 - 0.073 mm (0.0012 - 0.0029 in)
Limit
Less than 0.20 mm (0.0079 in)
Valve lifter outer diameter ªAº:
Standard
25.960 - 25.970 mm (1.0220 - 1.0224 in)
Cylinder block valve lifter hole diameter ªBº:
Standard
26.000 - 26.033 mm (1.0236 - 1.0249 in)
Push rod
1. Inspect push rod for excessive wear on the surfaces.
2. Replace if worn or damaged beyond repair.
3. Check push rod for bend using a dial gauge.
Maximum allowable bend
(Total indicator reading):
Less than 0.5 mm (0.020 in)
ROCKER SHAFT AND ROCKER ARM
1. Check valve rockers, brackets and rocker shafts for scoring,
wear or distortion. Replace if necessary.
SEM636B
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-111

2. Check clearance between valve rockers and rocker shaft. If
specified clearance is exceeded, replace affected valve rockers
or shaft.
Specified clearance:
Limit
Less than 0.15 mm (0.0059 in)
Rocker shaft outer diameter ªAº:
Standard
19.979 - 20.000 mm (0.7866 - 0.7874 in)
Rocker arm inner diameter ªBº:
Standard
20.014 - 20.035 mm (0.7880 - 0.7888 in)
3. Check rocker shaft bend at its center. If bend is greater than
specified limit, replace rocker shaft.
Rocker shaft bend
(Total indicator reading):
Limit
Less than 0.3 mm (0.012 in)
MEASURING CYLINDER HEAD TO VALVE DISTANCE
Measure distance from cylinder head surface to intake and exhaust
valves. If specified distance is exceeded, replace valve(s) or valve
seat(s).
Specified distance:
Standard
Intake
0.79 - 1.19 mm
(0.0311 - 0.0469 in)
Exhaust
0.80 - 1.20 mm
(0.0315 - 0.0472 in)
Limit
Less than 1.75 mm (0.0689 in)
for intake and exhaust valves
SEM027
SEM028
SEM026
CYLINDER HEADTD27Ti
Inspection (Cont'd)
EM-112

Assembly
1. Assemble rocker shaft component parts.
IIdentification of rocker arms
Identification mark
(on rocker arm)For use with
B Intake valve
C Exhaust valve
2. Install valve component parts.
IAlways use new valve oil seal. Refer to ªVALVE STEM OIL
SEALº.
IIntake and exhaust valve springs are interchangeable.
3. Assemble all removed parts in reverse order of disassembly.
SEM637B
EEM093
CYLINDER HEADTD27Ti
EM-113

Installation
1. Install cylinder head gasket.
IIdentification of cylinder head gaskets
Identification cut hole
(on cylinder head gasket)Inner diameter ªdº
mm (in)
Ð97 + 0.3
(3.82 + 0.012 in)
a. When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as
follows:
(1) Measure piston projection.
ISet each piston at its Top Dead Center. With piston held in that
position, measure its projections at two points.
ICalculate the average value of the two measurements.
IDetermine the amount of projection of the other three pistons.
(2) Select suitable cylinder head gasket which conforms to the
largest amount of projection of the four pistons.
Unit: mm (in)
Average value piston
projectionsGasket thicknessGasket grade
numberPart
no.
Less than 0.368 (0.0145)1.20 0.05
(0.047 0.002)211044
0W800
0.368 - 0.418 (0.0145 - 0.0165)1.25 0.05
(0.049 0.002)311044
0W801
More than 0.418 (0.0165)1.30 0.05
(0.051 0.002)411044
0W802
Make sure that No. 1 piston is at TDC on its compression
stroke.
NEM162
EEM104
CYLINDER HEADTD27Ti
EM-114

2. Install cylinder head.
ICylinder head identification mark
3. Apply oil to threaded portion and seat surface of bolts and
tighten cylinder head bolts using Tool.
CAUTION:
ITightening procedure
1st: Tighten bolts to 39 - 44 N×m
(4.0 - 4.5 kg-m, 29 - 33 ft-lb)
2nd: Tighten bolts to 54 - 59 N×m
(5.5 - 6.0 kg-m, 40 - 43 ft-lb)
3rd:
(1) Mark exhaust side of cylinder head and cylin-
der head bolts with paint as shown.
(2) Turn all bolts 90   10 degrees clockwise.
(3) Check that paint mark of each bolt is facing
the front of the vehicle.
4. Apply engine oil and install push rods.
5. Install rocker shaft assembly.
Adjust intake and exhaust valve clearance carefully.
Refer to MA section in order to accomplish valve adjustment.
NEM179
SEM641B
SEM580C
SEM642B
CYLINDER HEADTD27Ti
Installation (Cont'd)
EM-115

6. Install rocker cover.
IBe sure to tighten bolts in the order shown in the illustration.
IWhen replacing rocker cover gasket, bend slit of rocker cover
baffle plate a little to hold the gasket. Do not twist gasket.
7. Install glow plugs and glow plate.
8. Install new top nozzle gasket and injection nozzle.
9. Install thermostat housing bolts shown at left.
10. Install spill tube and injection tube.
Spill tube nut:
:39-49N×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Injection tubes:
:20-25N×m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
11. Connect thermostat housing water inlet hose and radiator hose.
12. Install all removed parts in reverse order of removal.
13. After assembling all disassembled parts, fill radiator and engine
with new coolant up to filler opening.
Refer to MA section.
NEM163
SEM618B
EEM103
SEM621B
CYLINDER HEADTD27Ti
Installation (Cont'd)
EM-116