2002 NISSAN TERRANO Service Repair Manual

Crankcase Ventilation System
DESCRIPTION
In this system, blow-by gas is sucked into the air inlet pipe after oil
separation by oil separator in the rocker cover.
INSPECTION
Ventilation hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
JEF224Z
SEC692
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTIONZD30DDTi
EC-23

Injection Tube and Injection Nozzle
REMOVAL AND INSTALLATION
CAUTION:
IDo not disassemble injection nozzle assembly. If NG,
replace injection nozzle assembly.
IPlug flare nut with a cap or rag so that no dust enters the
nozzle. Cover nozzle tip for protection of needle.
Injection tube
Removal
1. Mark the cylinder Nos. to the injection tubes, then disconnect
them.
IMarking should be made at proper locations and by the
proper method, so that they are not erased by fuel, etc.
2. Remove the clamps, then disconnect the tubes one by one.
IAvoid letting leaked fuel get on the interior walls of the
engine compartment.
Take special care to prevent fuel from getting on the engine
mount insulator.
JEF237Z
JEF238Z
BASIC SERVICE PROCEDUREZD30DDTi
EC-24

Installation
IInstall the injection tubes, referring to the markings made dur-
ing removal.
IInstall the injection tubes in the order of No. 3, No. 4, No. 1, and
No. 2.
Injection nozzle oil seal
Removal
Using a tool such as a flat-bladed screwdriver, pry the flange of the
seal, then remove it.
Installation
After the injection nozzle assembly is installed, push the seal from
the cylinder head side until it contacts the flange.
IReplace the oil seal with new one when the injection nozzle
assembly is removed. (It is not necessary to replace the oil
seal when only injection tubes are removed.)
Spill tube
Installation
IAfter the spill tube is installed, check the airtightness of
the spill tube.
IAfter the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.
Injection nozzle assembly
Removal
1. Remove the nozzle support, then pull out the injection nozzle
assembly by turning it clockwise/counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the cop-
per washer inside the cylinder head.
CAUTION:
Do not disassemble the injection nozzle.
Installation
1. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.
TEST AND ADJUSTMENT
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
JEF248Z
JEF249Z
BASIC SERVICE PROCEDUREZD30DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-25

Inspection for spill tube airtightness
Before the rocker cover is installed, perform the inspection as fol-
lows.
1. Connect the handy vacuum pump to the spill hose.
2. Check that the airtightness is maintained after the negative
pressure shown below is applied.
Standard:
þ53.3 to þ66.7 kPa (þ533 to þ667 mbar, þ400 to
þ500 mmHg, þ15.75 to þ19.69 inHg)
Air bleeding of fuel piping
After the repair, bleed air in the piping by pumping the priming
pump up and down until it becomes heavy.
Injection pressure test
1. Install injection nozzle assembly to injection nozzle tester and
bleed air from flare nut.
2. Pump the tester handle slowly (one time per second) and watch
the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
19,026 kPa (190.3 bar, 194 kg/cm
2, 2,759 psi)
New
19,516 - 20,497 kPa (195.2 - 205.0 bar, 199 - 209
kg/cm
2, 2,830 - 2,972 psi)
Limit
16,182 kPa (161.8 bar, 165 kg/cm
2, 2,346 psi)
IThe injection nozzle assembly has a 2-stage pressure injection
function. However, the judgement should be made at the first
stage of the valve opening pressure.
JEF250Z
MEC991D
JEF348Y
BASIC SERVICE PROCEDUREZD30DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-26

Spray pattern test
1. Check spray pattern by pumping tester handle one full stroke
per second.
NG spray pattern:
Does not inject straight and strong (B in the fig-
ure).
Fuel drips (C in the figure).
Does not inject evenly (D in the figure).
2. If the spray pattern is not correct, replace injection nozzle
assembly.
Electronic Control Fuel Injection Pump
REMOVAL AND INSTALLATION
CAUTION:
When removing or installing the timing chain as incidental work of the fuel injection pump removal/
installation, always secure the internal mechanism of the idler gear with bolts before removing or
installing the fuel injection pump sprocket. Do not refer to the procedure for ªTIMING CHAINº in EM
section based on No. 1 cylinder compression top dead center. (Unless otherwise specified.)
JEF349Y
JEF259Z
BASIC SERVICE PROCEDUREZD30DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-27

REMOVAL
1. Remove the following:
IEngine coolant draining
ICharge air cooler
IAir inlet pipe
IThrottle body
IRocker cover
IOil level gauge guide
IEGR cooler
IEGR guide tube
IEGR volume control solenoid valve
IFuel hose
IInjection tube
IRadiator upper hose
IRadiator shroud
ICooling fan
IDrive belt
IVacuum pipe
IVacuum pump
2. Move the power steering pump.
3. Remove the harness connector from the fuel injection pump.
IAfter pulling the connector stopper all the way back, remove the
connector.
IWhen the stopper is pulled all the way back, the interlocked-
connector will come off.
As for installation, when the connector is pushed all the way
forward until the stopper locks, the interlocked-connector is
inserted.
4. Remove the fuel injection pump rear bracket.
5. Remove the chain cover.
IRemove the installation bolts A, B, and C shown in the figure
(left).
CAUTION:
During chain cover removal, seal the opening to prevent for-
eign objects from getting into the engine.
6. Fix the internal mechanism of the idler gear (scissors gear
structure).
a. Remove the plug on the front side of the gear case.
b. While turning the crankshaft pulley clockwise, check the tight-
ening bolt hole of the idler gear internal mechanism through the
plug hole.
IConduct the visual check using a mirror.
IWhen checking, note that there are 2 other holes (with no
thread) beside the tightening bolt hole on the idler gear.
JEF260Z
JEF261Z
JEF262Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-28

c. Install the tightening bolt [Part No.: 81-20620-28, thread diam-
eter: M6, under head: 20 mm (0.79 in), pitch: 1.0 mm (0.039 in)]
to the idler gear tightening bolt hole, and tighten to the speci-
fied torque:
: 2.5 - 3.4 N×m (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
ITo protect the idler gear from damage, do not use the sub-
stitute part for the tightening bolt.
IHereafter, do not turn the crankshaft to avoid hitting tight-
ening bolt head against the gear case.
IDo not remove the idler gear tightening bolt before instal-
lations of the timing chain and related parts are completed.
7. Make mating marks on the cam sprocket, fuel injection pump
sprocket, and timing chain with paint.
8. Make mating marks on the fuel injection pump gear and idler
gear with paint.
9. Remove the chain tensioner.
(1) Loosen the upper and lower installation bolts.
(2) While holding the chain tensioner by hand, remove the upper
installation bolt to release the spring tension.
(3) Remove the lower installation bolt first, and then the chain ten-
sioner.
ISince the chain tensioner does not have a mechanism to pre-
vent the plunger pop-out, watch out for the fall of the plunger
and spring. (Return prevention mechanism is available.)
10. Remove the timing chain slack guide.
11. Remove the cam sprocket and timing chain at the same time.
IMake mating marks on each sprocket and timing chain.
IHold the hexagon head of the camshaft on the exhaust mani-
fold side, and loosen the cam sprocket installation bolt.
CAUTION:
Do not loosen the installation bolt using a chain tension.
12. Remove the fuel injection pump sprocket and gear as an
assembly.
IFix the fuel injection pump gear with the pulley holder (SST),
and loosen the installation bolt for removal.
ITry not to move the pump shaft when removing.
IConnect the sprocket and gear with a dowel pin, and tighten
them together with the installation bolt.
JEF263Z
JEF264Z
JEF265Z
JEF266Z
JEF267Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-29

13. Make the mating marks on the fuel injection pump flange and
front plate with paint.
14. Remove installation bolts first, and then fuel injection pump
toward the rear side of the engine.
IWhen the fuel injection pump is stationary, it can still be
retained by the dowel without all bolts.
CAUTION:
Do not disassemble or adjust the fuel injection pump.
INSTALLATION
IThe injection timing adjustment to correct the installation angle
deviation is not necessary. Install the pump in the proper posi-
tion according to the dowel and installation bolts.
1. Install the fuel injection pump from the rear side of the engine.
IMatch the dowel of the spacer to the dowel hole of the pump
side for installation.
IReplace the seal washer of the installation bolt with a new one.
2. Align the mating marks of the fuel injection pump flange and
front plate, and then adjust the approximate flange position.
IEach hole [6 mm (0.24 in) dia.] is used as a reference point for
the fuel injection pump flange, fuel injection pump gear, and fuel
injection pump sprocket.
IOnly during removal/installation at No. 1 cylinder compression
top dead center, can the hole [6 mm (0.24 in) dia.] of the pump
body be aligned.
3. Install the fuel injection pump sprocket and gear as an assem-
bly.
IAlign the mating marks of the idler gear and fuel injection pump
gear properly.
4. Tighten the installation bolt of the fuel injection pump sprocket.
IFix the fuel injection pump gear with the pulley holder (SST),
and tighten the installation bolt.
CAUTION:
Before tightening the installation bolt, check again that the
mating marks of the idler gear and fuel injection pump gear are
aligned.
JEF268Z
JEF269Z
JEF270Z
JEF271Z
JEF267Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-30