2004 NISSAN TERRANO engine

OIL SEAL INSTALLING DIRECTION
IWhen installing a new front or rear oil seal, make sure its
mounting direction is correct.
CRANKSHAFT FRONT OIL SEAL
1. Remove protecting cover.
2. Remove radiator shroud.
3. Remove cooling fan.
4. Remove drive belts.
5. Remove crank pulley.
6. Remove crankshaft oil seal.
IBe careful not to damage sealing surfaces of crankshaft.
7. Coat new oil seal with engine oil and install it in place.
CRANKSHAFT REAR OIL SEAL
1. Dismount transmission.
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove oil seal retainer assembly, then remove oil seal.
I Be careful not to damage sealing surfaces of crankshaft.
5. Coat new oil seal with engine oil and install it in place.
SEM715A
SEM644B
SEM217B
OIL SEAL REPLACEMENTTD27Ti
EM-118
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Removal and Installation
Turbocharger should not be disassembled.
1. Drain engine coolant.
2. Remove the following:
IAir duct and intercooler components
I Heat shield plates
I Exhaust front tube
I Oil tubes
I Water 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
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EEM097E
ENGINE REMOVALTD27Ti
EM-123
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WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completelycooled off.
d. For safety during subsequent steps, the tension of wires should be slackened against the engine.
e. Be sure to hoist engine in a safe manner.
f. For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be careful not to strike adjacent parts,
especially, brake lines and brake master cylinder.
I In hoisting the engine, always use engine slingers in a safe
manner.
ENGINE REMOVALTD27Ti
EM-124
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Disassembly
PISTON AND CRANKSHAFT
1. Remove oil filter.
2. Place engine on work stand.
3. Drain coolant and oil.
4. Remove drive belts.
5. Remove cylinder head. Refer to ªCYLINDER HEADº.
6. Remove oil pan.
7. Remove crank pulley and timing gear plate cover.
8. Remove water pump.
9. Remove timing gear case.
If the timing case is hard to remove due to liquid gasket, pry
it off with a suitable tool at the cutout section.
10. Remove injection pump gear nut.
SEM650B
NEM165
NEM170
NEM166
NEM167
ENGINE OVERHAULTD27Ti
EM-125
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11. Remove injection pump gear.
12. Remove injection pump.
13. Remove idler gear and idler shaft.
14. Remove valve lifters, camshaft gear and camshaft.
15. Remove vacuum pump assembly.
16. Remove oil pump assembly.
17. Remove crankshaft gear.
18. Remove flywheel and rear plate.
19. Remove connecting rod caps.
20. Remove pistons.
21. Remove rear oil seal retainer.
22. Remove oil strainer.
SEM654B
NEM168
NEM169
SEM657B
ENGINE OVERHAULTD27Ti
Disassembly (Cont'd)EM-126
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23. Remove bearing cap and crankshaft. Loosen bearing cap nutsin numerical order, as shown at left.
Place the bearings and caps in their proper order.
Inspection
CYLINDER BLOCK DISTORTION
1. Clean upper face of cylinder block and measure the distortion. Standard:Less than 0.05 mm (0.0020 in)
Limit: 0.2 mm (0.008 in)
2. If out of specification, resurface it.
CYLINDER WEAR
1. Measure cylinder bore for out-of-round and taper with a bore gauge. If beyond the limit, rebore all 4 cylinders. Replace cyl-
inder block if necessary.Standard inside diameter: 96.000 - 96.030 mm (3.7795 - 3.7807 in)
Refer to SDS
Wear limit: Less than 0.20 mm (0.0079 in)
Out-of-round (X þ Y) limit: Less than 0.020 mm (0.0008 in)
Taper (A þ B) limit: 0.20 mm (0.0079 in)
2. Check for scratches or abrasions. If abrasions are found, hone cylinder bore.
PISTON AND PISTON PIN CLEARANCE
Check clearance between pistons and piston pins. Clearance (A þ B):Standard0.002 to 0.012 mm (0.0001 to 0.0005 in)
Limit Less than 0.1 mm (0.004 in)
NEM007
SEM038
MEM042A
NEM002
ENGINE OVERHAULTD27Ti
Disassembly (Cont'd)
EM-127
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PISTON RING SIDE CLEARANCE
Side clearance:Top ring0.00 - 0.05 mm (0.0 - 0.0020 in)
2nd ring 0.04 - 0.072 mm (0.0016 - 0.0028 in)
Oil ring 0.02 - 0.055 mm (0.0008 - 0.0022 in)
Max. limit of side clearance: Top ring0.50 mm (0.0197 in)
2nd ring 0.30 mm (0.0118 in)
Oil ring 0.15 mm (0.0059 in)
PISTON RING END GAP
Standard ring gap: Top ring0.25 - 0.40 mm (0.0098 - 0.0157 in)
2nd ring 0.40 - 0.55 mm (0.0157 - 0.0217 in)
Oil ring 0.25 - 0.55 mm (0.0098 - 0.0217 in)
Max. limit of ring gap: 1.5 mm (0.059 in)
BEARING CLEARANCE
Main bearing
1. Install main bearings to cylinder block and main bearing cap.
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order and in two or three stages.
3. Measure inside diameter ªAº of main bearing.
4. Measure outside diameter ªDmº of main journal in crankshaft.
EEM117
SEM905
YEM044
YEM045
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-128
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