2002 NISSAN TERRANO engine coolant

21. Hook hoists to slingers to secure the position.
22. Remove installation nuts for left and right engine mount insula-
tors.
23. While adjusting position frequently, hoist and remove the
engine.
CAUTION:
IWhile performing operation, check that all necessary wires
and pipes are disconnected.
IAvoid interference with parts on the vehicle.
Installation
Install the engine in the reverse order of the removal procedure.
IKeep each mount insulator from oil adherence and damage.
IWhile keeping each mount insulator free from twisting, tighten
mounting bolts and nuts for the engine mount.
Inspection
IBefore starting the engine, check coolant level and grease
amount, and if necessary, refill them to the specified level.
IStart the engine, and check that there is no abnormal noise or
vibration.
IWarm up the engine to the sufficient temperature, and check
that there is no leakage of coolant, greases, fuel, or exhaust
gas.
YEM042
ENGINE REMOVALZD
Removal (Cont'd)
EM-65

3) Install engine sub-attachment (SST) to the rear side of cylinder
block.
IAlign knock pin on cylinder block with pin hole on attachment
to install engine sub-attachment.
IMounting bolts are provided with engine sub-attachment.
4) Install engine attachment (SST).
IUse commercially available M12 mounting bolts and nuts (4
sets) with strength grade of 9T (minimum).
5) Hoist engine and install it to the engine stand (SST).
IEngine attachment and engine sub-attachment can be installed
to engine stand before engine installation.
4. Drain engine oil and coolant from engine.
5. Remove the following parts and related parts. (Only major parts
are listed.)
IAccessory belt
ICatalytic converter
ITurbocharger
IExhaust manifold
IInjection tube
IIntake manifold
IRocker cover
IOil pan (upper/lower)
IWater pump
IThermostat and water pipes
IVacuum pump
IInjection tube
ITiming chain
IElectronic high pressure fuel injection pump
ITiming gear
IHigh pressure injection nozzle assembly
ICamshaft
ICylinder head
IOil cooler
IAccessory and accessory brackets
6. Remove rear oil seal and retainer assembly.
IInsert flat-bladed screwdriver between lower cylinder block and
rear oil seal retainer to remove the assembly.
INo part No. is given to oil seal.
FEM083
FEM084
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-68

INew connecting rods are classified into 8 weight classes at
factory. The same class connecting rods are used on a engine.
Weight grade symbol Weight class g (oz)
H 1,261 - 1,264 (44.5 - 44.6)
I 1,264 - 1,267 (44.6 - 44.7)
K 1,267 - 1,270 (44.7 - 44.8)
L 1,270 - 1,273 (44.8 - 44.9)
M 1,273 - 1,276 (44.9 - 45.0)
O 1,276 - 1,279 (45.0 - 45.1)
P 1,279 - 1,282 (45.1 - 45.2)
S 1,282 - 1,285 (45.2 - 45.3)
CYLINDER BLOCK TOP SURFACE DISTORTION
IUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of oil and coolant pas-
sages.
IUse straightedge and feeler gauge to check block upper sur-
face for distortion.
Limit: 0.1 mm (0.004 in)
MAIN BEARING HOUSING INNER DIAMETER
IInstall main bearing caps without main bearings. Tighten
mounting bolts to the specified torque.
IUse bore gauge to measure main bearing housing inner diam-
eter.
Standard:
74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
IIf out of specification, replace cylinder block and lower cylinder
block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder bore inner diameter
IUsing bore gauge, measure cylinder inner diameters at 6 posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
Cylinder inner diameter (Standard):
96.000 - 96.030 mm (3.7795 - 3.7807 in) dia.
Wear limit: 0.2 mm (0.008 in)
Out-of-round limit (X - Y): 0.02 mm (0.0008 in)
Taper limit (A - C): 0.02 mm (0.0008 in)
FEM106
FEM107
FEM108
FEM109
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-74

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

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

Removal
1. Set No. 1 cylinder at TDC on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block and
radiator.
3. Remove air cleaner and intercooler components.
4. Remove the following parts:
Ð Water temperature connectors
Ð Throttle chamber vacuum hoses
Ð EGR valve vacuum hose
Ð Connectors located on the intake manifold
Ð Connector located on the thermostat housing
Ð Heater tubes
Ð Connectors of the injection pump
5. Remove alternator adjusting bolt.
6. Disconnect exhaust manifold from front exhaust tube.
7. Remove turbocharger oil and water tubes.
8. Remove turbocharger bracket bolts.
9. Disconnect radiator outlet hose and thermostat housing water
inlet hose.
10. Remove fuel injection tube assembly and spill tube.
11. Remove injection nozzle holder from first cylinder with a spe-
cial tool (KV119E0030). Remove injection nozzles from cylin-
ders 2, 3 and 4 using a deep socket wrench.
12. Remove thermostat housing bolts shown at left.
13. Remove rocker cover and ventilation hose.
14. Remove rocker shaft with rocker arms.
15. Remove push rods.
16. Remove cylinder head bolts in numerical order and remove
cylinder head.
Head warpage or cracking could result from removing in incor-
rect order.
EEM092
SEM621B
EEM103
SEM623B
CYLINDER HEADTD27Ti
EM-105

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

Removal and Installation
Turbocharger should not be disassembled.
1. Drain engine coolant.
2. Remove the following:
IAir duct and intercooler components
IHeat shield plates
IExhaust front tube
IOil tubes
IWater tubes
3. Remove turbocharger from exhaust manifold.
4. Remove turbocharger bracket bolts.
Inspection
Condition 1: Low engine power
Probable cause Corrective action
Air leak at the connection of compressor housing and suc-
tion hose/inlet tube, or inlet and intake manifold.
ECorrect the connection.
Exhaust gas leak at the connection of turbine housing and
exhaust manifold, connecting tube or exhaust outlet.
ECorrect the connection or replace gasket.
By-pass valve is stuck in open position.E
Replace turbocharger assembly.
Stuck or worn journal or bearing.E
Broken shaft.E
Sludge on back of turbine wheel.E
Broken turbine wheel.E
Condition 2: Excessively high engine power
Probable cause Corrective action
Disconnected or cracked rubber hose of by-pass valve
controller.
ECorrect or replace rubber hose.
By-pass valve is stuck in closed position.E
Replace turbocharger assembly.
Controller diaphragm is broken.E
TURBOCHARGERTD27Ti
EM-119