2002 NISSAN TERRANO Service Repair Manual

Disassembly
PISTON AND CRANKSHAFT
1. Remove oil filter.
2. Place engine on work stand.
3. Drain coolant and oil.
4. Remove drive belts.
5. Remove cylinder head. Refer to ªCYLINDER HEADº.
6. Remove oil pan.
7. Remove crank pulley and timing gear plate cover.
8. Remove water pump.
9. Remove timing gear case.
If the timing case is hard to remove due to liquid gasket, pry
it off with a suitable tool at the cutout section.
10. Remove injection pump gear nut.
SEM650B
NEM165
NEM170
NEM166
NEM167
ENGINE OVERHAULTD27Ti
EM-125

11. Remove injection pump gear.
12. Remove injection pump.
13. Remove idler gear and idler shaft.
14. Remove valve lifters, camshaft gear and camshaft.
15. Remove vacuum pump assembly.
16. Remove oil pump assembly.
17. Remove crankshaft gear.
18. Remove flywheel and rear plate.
19. Remove connecting rod caps.
20. Remove pistons.
21. Remove rear oil seal retainer.
22. Remove oil strainer.
SEM654B
NEM168
NEM169
SEM657B
ENGINE OVERHAULTD27Ti
Disassembly (Cont'd)
EM-126

23. Remove bearing cap and crankshaft. Loosen bearing cap nuts
in numerical order, as shown at left.
Place the bearings and caps in their proper order.
Inspection
CYLINDER BLOCK DISTORTION
1. Clean upper face of cylinder block and measure the distortion.
Standard:
Less than 0.05 mm (0.0020 in)
Limit:
0.2 mm (0.008 in)
2. If out of specification, resurface it.
CYLINDER WEAR
1. Measure cylinder bore for out-of-round and taper with a bore
gauge. If beyond the limit, rebore all 4 cylinders. Replace cyl-
inder block if necessary.
Standard inside diameter:
96.000 - 96.030 mm (3.7795 - 3.7807 in)
Refer to SDS
Wear limit:
Less than 0.20 mm (0.0079 in)
Out-of-round (X þ Y) limit:
Less than 0.020 mm (0.0008 in)
Taper (A þ B) limit:
0.20 mm (0.0079 in)
2. Check for scratches or abrasions. If abrasions are found, hone
cylinder bore.
PISTON AND PISTON PIN CLEARANCE
Check clearance between pistons and piston pins.
Clearance (A þ B):
Standard
þ0.008 to 0.007 mm (þ0.0003 to 0.0003 in)
Limit
Less than 0.1 mm (0.004 in)
NEM007
SEM038
MEM042A
NEM002
ENGINE OVERHAULTD27Ti
Disassembly (Cont'd)
EM-127

PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.00 - 0.05 mm (0.0 - 0.0020 in)
2nd ring
0.04 - 0.072 mm (0.0016 - 0.0028 in)
Oil ring
0.035 - 0.040 mm (0.0014 - 0.0016 in)
Max. limit of side clearance:
Top ring
0.5 mm (0.020 in)
2nd ring
0.3 mm (0.012 in)
Oil ring
0.15 mm (0.0059 in)
PISTON RING END GAP
Standard ring gap:
Top ring
0.25 - 0.35 mm (0.0098 - 0.0138 in)
2nd ring
0.50 - 0.75 mm (0.0197 - 0.0295 in)
Oil ring
0.25 - 0.55 mm (0.0098 - 0.0217 in)
Max. limit of ring gap:
1.5 mm (0.059 in)
BEARING CLEARANCE
Main bearing
1. Install main bearings to cylinder block and main bearing cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order and in two or three stages.
3. Measure inside diameter ªAº of main bearing.
4. Measure outside diameter ªDmº of main journal in crankshaft.
EEM117
SEM905
YEM044
YEM045
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-128

5. Calculate main bearing clearance.
Main bearing clearance = A þ Dm
Standard
0.035 - 0.087 mm (0.0014 - 0.0034 in)
Limit
Less than 0.15 mm (0.0059 in)
CONNECTING ROD BEARING (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Apply oil to the thread portion of bolts and seating surface of
nuts.
3. Measure inside diameter ªAº of bearing.
4. Measure outside diameter ªDpº of pin journal in crankshaft.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = A þ Dp
Standard
0.035 - 0.081 mm
(0.0014 - 0.0032 in)
Limit
Less than 0.15 mm (0.0059 in)
CONNECTING ROD BEND AND TORSION
Bend and torsion:
Limit
0.15 mm (0.0059 in)
per 200 mm (7.87 in) length
CONNECTING ROD BUSHING CLEARANCE (Small end)
1. Measure inside diameter ªAº of connecting rod small end bush-
ings.
YEM046
EM133
YEM047
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-129

2. Measure outside diameter ªDº of piston pin.
3. Calculate connecting rod small end bushing clearance.
Connecting rod small end bushing clearance = A þ D
Standard
0.025 - 0.045 mm (0.0010 - 0.0018 in)
Limit
0.15 mm (0.0059 in)
REPLACEMENT OF CONNECTING ROD BUSHING
(Small end)
1. Drive in the small end bushing until it is flush with the end sur-
face of the rod.
Be sure to align the oil holes.
2. After driving in the small end bushing, ream the bushing.
Small end bushing inside diameter:
Finished size
30.025 - 30.038 mm (1.1821 - 1.1826 in)
CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or
cracks. If faults are minor, correct with fine emery paper.
2. Check journals and pins with a micrometer for taper and out-
of-round.
Out-of-round (X þ Y):
Standard
Less than 0.01 mm (0.0004 in)
Limit
0.02 mm (0.0008 in)
Taper (A þ B):
Standard
Less than 0.01 mm (0.0004 in)
Limit
0.02 mm (0.0008 in)
3. Check crankshaft runout.
Runout (Total Indicator Reading)
Standard
0 - 0.03 mm (0 - 0.0012 in)
Limit
0.10 mm (0.0039 in)
SEM416B
EM715
SEM662B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-130

RESURFACING OF CRANKSHAFT JOURNAL AND
CRANK PIN
When using undersize main bearings and connecting rod bearings,
the crankshaft journals or crank pins must be finished to match the
bearings.
R: Crank journal 3.0 mm (0.118 in)
Crank pin 3.5 mm (0.138 in)
CAUTION:
IAt the same time make sure that the surface width does not
increase.
IDo not attempt to cut counterweight of crankshaft.
PILOT BUSHING REPLACEMENT
1. Pull out bushing with Tool.
2. Insert pilot bushing until distance between flange end and
bushing is specified value.
Distance:
Approx. 5.6 - 6.0 mm (0.220 - 0.236 in)
FLYWHEEL RUNOUT
Runout (Total Indicator Reading):
Less than 0.15 mm (0.0059 in)
FRONT PLATE
Check front plate for warpage. If not within the limit, make flat or
replace front plate.
Warpage limit:
0.2 mm (0.008 in)
SEF692A
SEM413
NEM181
SEM059A
SEM668B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-131

GEAR TRAIN
Camshaft drive gear, injection pump drive gear, oil pump gear,
idler gear, crankshaft gear and vacuum pump gear.
1. If gear tooth and key have scratches or are excessively worn,
replace gear and key.
2. Check gear train backlash before disassembling and after
assembling.
Method A (Using dial gauge)
Method B (Using fuse wire)
If beyond the limit, replace gear.
Backlash:
Standard
0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit
0.20 mm (0.0079 in)
IDLER GEAR BUSHING CLEARANCE
1. Measure idler gear shaft outer diameter.
2. Measure idler gear bushing inner diameter.
3. Calculate idler gear bushing clearance.
Bushing oil clearance:
Standard
0.025 - 0.061 mm (0.0010 - 0.0024 in)
Limit
0.20 mm (0.0079 in)
IDLER GEAR END PLAY
Measure idler gear end play between gear plate and gear.
Idler gear end play:
Standard
0.03 - 0.14 mm (0.0012 - 0.0055 in)
Limit
Less than 0.3 mm (0.012 in)
NEM186
NEM187
SEM666B
SEM705
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-132