2004 NISSAN TERRANO engine

For details of values (q1toq10), refer to EM-87, ªValve Seatº in
ªSERVICE DATA AND SPECIFICATIONS (SDS)º.
VALVE SPRING RIGHT ANGLE
Position a straightedge to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring
and the straightedge Limit: 2.4 mm (0.094 in)
VALVE SPRING FREE LENGTH AND COMPRESSIVE
LOAD
Using valve spring tester, check the following.Free length: 55.43 mm (2.1823 in)
Installation height: 40.8 mm (1.6063 in)
Installation load: 180 - 206 N (18.4 - 21.0 kg, 40.6 -
46.3 lb)
Height at valve open: 32.3 mm (1.2717 in)
Load at valve open: 336 - 372 N (34.3 - 37.9 kg, 75.6 -
83.6 lb)
Assembly
1. Install valve guides, referring to EM-60, ªVALVE SEATREPLACEMENTº.
2. Install valve seats, referring to EM-60, ªVALVE SEAT CON- TACTº.
3. Using valve oil seal drift (SST), install valve oil seals referring to the dimension shown in the figure.
I The figure shows the dimension before valve spring seats are
installed.
4. Install valve spring seats.
5. Install valves.
I Install the valves with bigger openings to intake valve side.
I Note that valve layout here is different from that of conventional
the engine.
YEM035
FEM077
FEM078
FEM079
CYLINDER HEADZD
Inspection (Cont'd)
EM-61
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Precautions
IDo not perform operation unless it is perfectly safe.
I Do not start operation unless the exhaust system and coolant
are cooled down.
I Lift the engine at the designated support points only.
I Perform operations for the items other than the engine body,
referring to the applicable sections.
I Refer to MT section and AT section for rear mount.
Removal
IAfter removing transmission, hoist the engine and remove it.
Preparation
1. Drain coolant from radiator drain plugs.
2. Remove the following parts.
IEngine hood
I Undercover
I Under protector
I Battery
I Intercooler
I Radiator shroud
I Radiator
I Accessory belt
I Cooling fan
I Exhaust front tube
YEM032
ENGINE REMOVALZD
EM-63
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Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.
5. Disconnect harness connectors from alternator and air com-pressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor and inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.
Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix it to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move har- nesses to the side of the vehicle.
Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and removerear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount mem- bers to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to trans- mission.
Removal operation
19. Remove air conditioner high pressure pipes at the rear of theengine room.
I This is due to some inconvenience in the rear slinger installa-
tion.
20. Install the engine slingers (standard service part) to front-left and rear-right.
:25-28N ×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
FEM082
ENGINE REMOVALZD
Removal (Cont'd)
EM-64
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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:
I While performing operation, check that all necessary wires
and pipes are disconnected.
I Avoid 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.
I While 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.
I Start the engine, and check that there is no abnormal noise or
vibration.
I Warm 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
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Selection Procedure for Selective Part
Combination
LocationSelective part combination ItemMethod
Cylinder block - piston Piston and piston assembly
(Part No. is given to a piston and piston pin as a set.) Piston grade (Piston outer
diameter) Refer to ªSelective combination
chartº.
IIdentification grade stamped on each part represents initial
dimension of new part. This grade will not be applied to a
reused part.
I Measure correct dimensions of a reused or modified part, then
refer to ªSelective combination chartº in this manual to identify
the grade.
I Refer to the applicable pages for measurement method for
each part, standards for reuse, and selecting method for selec-
tive part combination.
Disassembly
1. Remove engine assembly from vehicle.
Refer to EM-63, ªENGINE REMOVALº.
2. Remove pilot bushing from flywheel using pilot bearing puller (SST), if necessary (M/T model).
3. Install engine to engine stand (SST).
1) Remove flywheel (M/T model) or drive plate (A/T model).
I Using ring gear stopper (SST), secure ring gear, and remove
mounting bolts.
CAUTION:
Do not disassemble flywheel.
I Flywheel has a two-piece structure. When being pressed
forward/backward, or twisted in rotating direction, transmission-
side mass will be moved with audible sound. This is not a
problem.
2) Remove pilot converter (A/T model) and rear plate.
SEM364G
YEM043
CYLINDER BLOCKZD
EM-67
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3) Install engine sub-attachment (SST) to the rear side of cylinderblock.
I Align knock pin on cylinder block with pin hole on attachment
to install engine sub-attachment.
I Mounting bolts are provided with engine sub-attachment.
4) Install engine attachment (SST).
I Use 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).
I Engine 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.)
I Accessory belt
I Catalytic converter
I Turbocharger
I Exhaust manifold
I Injection tube
I Intake manifold
I Rocker cover
I Oil pan (upper/lower)
I Water pump
I Thermostat and water pipes
I Vacuum pump
I Injection tube
I Timing chain
I Electronic high pressure fuel injection pump
I Timing gear
I High pressure injection nozzle assembly
I Camshaft
I Cylinder head
I Oil cooler
I Accessory and accessory brackets
6. Remove rear oil seal and retainer assembly.
I Insert flat-bladed screwdriver between lower cylinder block and
rear oil seal retainer to remove the assembly.
I No part No. is given to oil seal.
FEM083
FEM084
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-68
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3) Using rod with outer diameter of 30 mm (1.18 in), press pistonpins out.
11. Remove lower cylinder block.
I The lower cylinder block is the lower part of the cylinder block,
which works as the main bearing cap (beam) and oil pan
mounting face.
1) Remove mounting bolts for engine sub-attachment shown by arrows in the figure.
2) Loosen and remove mounting bolts in the reverse order shown in the figure.
3) Insert flat-bladed screwdriver into 5 locations shown by arrows in the figure. Lift lower cylinder block evenly, and remove liquid
gasket.
CAUTION:
Prevent mating faces from being damaged.
4) When removing lower cylinder block, use slot to prevent dowel pin from interfering with engine sub-attachment.
I No part No. is given to lower cylinder block, because it is
machined with the cylinder block.
12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Check mounting positions. Keep them to avoid confusion.
FEM090
FEM091
FEM092
FEM093
CYLINDER BLOCKZD
Disassembly (Cont'd)
EM-70
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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
I Using 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.
I Use straightedge and feeler gauge to check block upper sur-
face for distortion.
Limit: 0.1 mm (0.004 in)
MAIN BEARING HOUSING INNER DIAMETER
I Install main bearing caps without main bearings. Tighten
mounting bolts to the specified torque.
I Use bore gauge to measure main bearing housing inner diam-
eter.
Standard: 74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
I If 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
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