2004 NISSAN TERRANO engine

Removal and Installation
CAUTION:
As the internal mechanism of the idler gear must first of all,
and always, be set by a bolt when removing the timing chain
before removing the fuel injection pump and timing gear, fol-
low the procedures on EM-38, ªRemoval of timing chain after
setting idler gearº, ªElectronic controlled fuel injection pumpº.
IThis chapter will deal with the summary of removing the timing
chain before removing the camshaft and cylinder head.
Removal
1. Remove the following parts.
IEngine cover
I Intercooler
I Air inlet pipe
I Throttle body
I Rocker cover
I Spill tube
I Coolant (Drain)
I Radiator upper hose
I Water outlet
I Radiator shroud
I Cooling fan
I Auxiliary belt
I Vacuum pipe
I Vacuum pump
YEM028
TIMING CHAINZD
EM-26
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6. Remove the timing chain slack guide.
7. Remove the timing chain with cam sprocket.
ILoosen the cam sprocket holding bolt by fixing the hexagonal
portion of the intake manifold side camshaft with a spanner, etc.
I If the spill tube is not removed, fix the hexagonal portion of the
exhaust manifold side camshaft.
CAUTION:
Do not loosen the holding bolt by using the tension of the
chain.
8. Remove the timing chain tension guide.
Installation
1. Install the timing chain tension guide.
2. Install the cam sprocket and the timing chain together.
I Install by aligning the sprocket and timing chain match marks.
I Tighten the cam sprocket holding bolt by fixing the hexagonal
portion of the camshaft.
CAUTION:
Do not tighten in the holding bolt using the tension of the
chain.
3. Install the timing chain slack guide.
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Do not over-tighten.
4. Install the chain tensioner.
1) With the chain tensioner in the position shown in the figure (with the plunger on the outer side), temporarily tighten the holding
bolt.
2) Press the plunger into the tensioner body while pressing on the clips which prevent the plunger from returning.
3) Install the upper side holding bolt while holding the plunger down with your finger and rotating it 180 degrees.
4) Tighten the holding bolt to the specified torque.
5. Install the chain cover.
1) Before installing chain cover, remove all traces of liquid gasket from mating surface using a scraper.
2) Apply a continuous bead of liquid gasket to chain cover.
I Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach chain cover to gear case within 5 minutes after coating.
c. Wait at least 30 minutes before refilling engine oil or start- ing engine.
SEM335G
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TIMING CHAINZD
Removal (Cont'd)
EM-28
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Removal and Installation
IThis engine will have a different valve arrangement from nor-
mal DOHC 4-valve type engines. As both camshafts on this
engine have intake and exhaust cams, in this chapter they are
named as follows:
Camshaft (Right side): Intake manifold side camshaft
Camshaft (Left side): Exhaust manifold side camshaft
I The same parts are used for the right and left sides.
I Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
Removal
1. Set the No. 1 cylinder at TDC, then remove the chain case,
timing chain and other parts in connection. Refer to ªTIMING
CHAINº, EM-26.
2. Remove the cam gear.
I Loosen the cam gear installation bolt by fixing the hexagonal
portion of the camshaft.
I The idler gear cannot be removed at this point as the gear case
is in the way. (The cylinder head can be removed as a single
unit.)
SEM350G
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CAMSHAFTZD
EM-30
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3. Remove injection tube and injection nozzle assembly. Refer toEC section, ªInjection Tube and Injection Nozzleº in ªBASIC
SERVICE PROCEDUREº.
4. Remove the camshaft.
I Place distinguishing marks on the right and left sides with paint.
I Loosen and remove the installation bolt in reverse order shown
in the figure.
5. Remove the adjusting shim and valve lifter.
I Remove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
Inspection
VISUAL CHECK OF CAMSHAFT
ICheck the camshaft for one sided wear or scratches.
I Replace the camshaft if there are abnormalities.
CAMSHAFT RUNOUT
IPrepare V-block on a flat surface and secure camshaft journals
No. 1 and No. 5.
I Set the dial gauge vertically on journal No. 3.
I Rotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)
HEIGHT OF CAM NOSE
Measure by using a micrometer. Standard:Intake40.468 - 40.508 mm (1.5932 - 1.5948 in)
Exhaust 40.830 - 40.870 mm (1.6075 - 1.6091 in)
CAMSHAFT OIL CLEARANCE
Measure by using a micrometer. Cam journal outer diameter:Standard29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
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CAMSHAFTZD
Removal (Cont'd)
EM-31
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VALVE LIFTER BORE DIAMETER
Measure the bore diameter of the cylinder head valve lifter with an
inside micrometer.Standard: 34.495 - 34.515 mm (1.3581 - 1.3589 in) dia.
VALVE LIFTER CLEARANCE CALCULATIONS
Clearance = Valve lifter bore diameter þ Valve lifter outer diameterStandard: 0.030 - 0.060 mm (0.0012 - 0.0024 in)
If it exceeds the standard value, refer to the outer diameter and
bore diameter standard values and replace valve lifter and/or cyl-
inder head.
Installation
1. Install the valve lifter and adjusting shim.
I Make sure that these are installed in the same position as
before the removal process.
2. Install the camshaft.
I Follow the distinguishing marks that were placed on in the
removal process.
I Face the key in the direction shown in the figure.
3. Install the camshaft bracket.
I Refer to the camshaft bracket upper side journal No. and install.
I Looking from the exhaust manifold side (left side of engine),
install in the direction that the journal number can be read cor-
rectly.
I Place baffle plate onto upper face of No. 1 camshaft bracket,
and tighten together.
4. Tighten the installation bolts in numerical order in the figure.
1) Tighten to 10 to 14 N ×m (1.0 to 1.5 kg-m, 8 to 10 ft-lb).
I Make sure that the thrust portion of the camshaft is fitted prop-
erly in the head installation side.
2) Tighten to 20 to 23 N ×m (2.0 to 2.4 kg-m, 15 to 17 ft-lb).
FEM019
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CAMSHAFTZD
Inspection (Cont'd)
EM-33
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Inspection
IWhen the camshaft or parts in connection with valves are
removed or replaced, and a fault has occurred (poor starting,
idling, or other faults) due to the misadjustment of the valve
clearance, inspect as follows.
I Inspect and adjust when the engine is cool (at normal tempera-
ture).
I Be careful of the intake and exhaust valve arrangement. (The
valve arrangement is different from that in a normal engine.)
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
1. Remove the following parts.
I Intercooler cover
I Intercooler
I Rocker cover
2. Set the No. 1 cylinder at TDC.
1) Rotate the crankshaft pulley clockwise, and align the TDC mark of the crankshaft pulley with the timing indicator of the TDC
sensor bracket.
2) Confirm that the cam nose of the No. 1 cylinder and the knock pin of the cam sprocket is in the position shown in the figure.
I Rotate the crankshaft pulley again if not in the position shown
in the figure.
3. While referring to the figure, measure the valve clearance in the circled area of the table below.
Measuring point No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDC qqq q
I
The injection order is 1-3-4-2.
I Measure the valve clearance using a JIS high grade feeler
gauge when the engine is cool (at normal temperature).
Standard: Intake and exhaust0.35 0.05 mm (0.0138 0.0020 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft clock- wise once.
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SEM342G
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VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
EM-35
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5. While referring to the figure, measure the valve clearance in thecircled area of the table below.
Measuring point No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDC qq qq
6. If the valve clearance is outside the specification, adjust as fol-
lows.
Adjustments
IRemove the adjusting shim for parts which are outside the
specified valve clearance.
1. Remove the spill tube.
2. Extract the engine oil on the upper side of the cylinder head (for the air gun used in step 7).
3. Rotate the crankshaft to face the cam for adjusting shims that are to be removed upward.
4. Grip the camshaft with camshaft pliers (SST), the using the camshaft as a support point, push the adjusting shim downward
to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, or the outer cir-
cumference of the valve lifter.
5. With the valve spring in a compressed state, remove the cam- shaft pliers (SST) by securely setting the outer circumference
of the valve lifter with the end of the lifter stopper (SST).
I Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the camshaft
will be damaged.
6. Move the rounded hole of the adjusting shim to the front with a very thin screwdriver.
I When the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 with the end of the lifter stopper
(SST) touching the adjusting shim.
7. Remove the adjusting shim from the valve lifter by blowing air through the rounded hole of the shim with an air gun.
CAUTION:
To prevent any remaining oil from being blown around, thor-
oughly wipe the area clean and wear protective goggles.
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VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Inspection (Cont'd)
EM-36
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8. Remove the adjusting shim by using a magnetic hand.
9. Measure the thickness of the adjusting shim using a microme-ter.
I Measure near the center of the shim (the part that touches the
cam).
10. Select the new adjusting shim from the following methods. Calculation method of the adjusting shim thickness:
t=t
1+(C1þC2)
t = Adjusting shim thickness
t
1= Thickness of the removed shim
C
1= Measured valve clearance
C
2= Specified valve clearance
[when the engine is cool (at normal temperature)] 0.35 mm (0.0138 in)
I New adjusting shims have the thickness stamped on the rear
side.
Stamped Shim thickness mm (in)
2.35
2.40 .
.
.
3.05 2.35 (0.0925)
2.40 (0.0945)
.
.
.
3.05 (0.1201)
I The thickness of the adjusting shim ranges from 2.35 to 3.05
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm
(0.0020 in). There are 15 types of shims available.
11. Fix the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve lifter.
12. Compress the valve spring using the camshaft pliers and remove the lifter stopper (SST).
13. Rotate the crankshaft 2 to 3 times by hand.
14. Confirm that the valve clearance is within the specification.
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VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Adjustments (Cont'd)
EM-37
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