2002 NISSAN TERRANO engine

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

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.
FEM091
FEM131
FEM132
FEM133
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.
FEM134
FEM131
FEM053
SEM366G
CYLINDER BLOCKZD
Assembly (Cont'd)
EM-82

Parts Requiring Angular Tightening
ISome important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
IIf these parts are tightened using a torque setting method, dis-
persal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
IAlthough the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
ITo assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
IBefore tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
IThe bolts and nuts which require the angular-tightening method
are as follows:
(1) Cylinder head bolts
(2) Connecting rod cap nuts
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface and
grooves, and then completely clean any oil stains from
these portions.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
IBe sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (oil pan).
IBe sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perimeter.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant.
SEM371C
PRECAUTIONSTD27Ti
EM-95

Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST0501S000*
Engine stand assembly
q
1ST05011000
Engine stand
q
2ST05012000
Base
Disassembling and assembling
KV10106500*
Engine attachment
KV11103200*
Engine sub-attachment
q1KV10109210*
Valve spring
compressor
q
2KV10111200*
Adapter
Disassembling and assembling valve
components
KV10107900*
Valve oil seal puller
Disassembling valve oil seal
KV11103400
Valve oil seal drift
Installing valve oil seal
ST11033000*
Valve guide drift
Removing valve guide
PREPARATIONTD27Ti
EM-96

*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV11103900*
Valve guide drift
Installing valve guide
q
1K V 111 0 111 0
Valve seat remover
q
2KV11103610
Adapter (Intake)
q
3KV11103620
Adapter (Exhaust)
Removing valve seat
q
1ST15243000
Valve seat drift
q
2KV11103810
Adapter (Intake)
q
3KV11103820
Adapter (Exhaust)
Installing valve seat
EM03470000*
Piston ring compressor
Installing piston into cylinder
KV111033S0
Engine stopper
q
1KV11103310
Stopper plate
q
2KV10105630
Stopper gear
Preventing crankshaft from rotating
ST16610001*
Pilot bushing puller
Removing pilot bushing
PREPARATIONTD27Ti
Special Service Tools (Cont'd)
EM-97

q1Intake manifold
q
2Oil cooler
q
3Injection pump drive gearq
4Dust cover
q
5Engine revolution sensor
q
6Air conditioner compressorq
7Idler pulley
q
8Electronic injection pump
NEM324
ENGINE COMPONENTS Ð Outer PartsTD27Ti
EM-100