2004 NISSAN TERRANO Service Repair Manual

Removal and Installation
2 idler gears are shown in this chapter. Idler gear (A) has scissors gear, and idler gear (B) does not.
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Removal
1. Remove the engine assembly.Refer to ªENGINE REMOVALº, EM-63.
2. Place the engine on an engine stand (SST). Refer to ªCYLINDER BLOCKº, EM-67.
3. Remove the following.
I Auto tensioner bracket
I Air conditioner bracket
I Alternator bracket
I Oil tube
I Vacuum pump
I Rocker cover
I Oil pan (upper, lower)
I Injection tube
I Spill tube
I High pressure nozzle assembly
4. Remove the chain cover, timing chain and other parts in con- nection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the fig-
ure. Refer to ªTIMING CHAINº, EM-26.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
I Do not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
I Do not drop or hit the sensor.
I Store in a clean place free of iron filings, etc.
I Do not place near any magnetic equipment.
6. Remove the water pump. Refer to ªWATER PUMPº in LC section.
7. Remove the water inlet.
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8. Remove the crankshaft pulley.
ITo fix the crankshaft, clamp the bar between the drive plate
holding bolts, and set by touching the engine sub-attachment
(SST).
I As another method, set by clamping a hammer handle, etc. in
the counterweight portion of the crankshaft.
CAUTION:
I Do not damage the crankshaft.
I Make sure that no foreign objects get inside the engine.
I Do not damage or magnetize the signal detection protru-
sions of the crankshaft pulley.
I After removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.
9. Remove the gear case.
I Using the grooved places shown in the figure, remove the gear
case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a screw- driver.
CAUTION:
Do not damage the gear case.
11. Fix the internal mechanism setting bolt [part No.: 81-20620-28, screw dia.: M6, dimension below neck: 20 mm (0.79 in)] to the
bolt hole of the idler gear (A) and tighten to the specification.
: 2.5 - 3.4 N ×m (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
I Only use the genuine setting bolt, or the idler gear (A) will
be damaged.
I Do not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
I Do not remove the setting bolt from the idler gear (A) until
the timing chain and all of the parts in connection have
been installed.
I If these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit
the idler gear from being reusable.
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Removal (Cont'd)
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12. Remove the idler gears (A) and (B).
ICheck the backlash of each gear before removing. Refer to
ªBACKLASH OF EACH GEARº, ªInspectionº.
CAUTION:
I Do not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
I During removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
13. Set the fuel injection timing gear with the pulley holder (SST).
14. Remove injection pump timing gear.
15. Extract the balancer shaft taking care not to damage the inner bushes of the cylinder block.
16. Remove the fuel injection pump.
17. Remove the front plate.
Inspection
BACKLASH OF EACH GEAR
Method using a fuse wire
I Tighten the holding bolts of each gear to specification.
I Place a wire in the biting area of the teeth between the gears
to be checked, rotate the crankshaft in the operating direction
so that the wire is taken inwards.
I Measure the crushed area of the wire with a micrometer.
Method using dial gauge
ITighten the holding bolts of each gear to specification.
I Place the dial gauge on the tooth surface area of the gear to
be checked.
I With the other gear in a set position, measure the dial gauge
value while moving the gear left and right.
Standard: 0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit: 0.20 mm (0.0079 in)
I If it exceeds the limit, replace the gear and measure again.
I If it exceeds the limit again, check for the installation condition
of the gear driving parts, wear of shaft and gear, and oil clear-
ance.
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Removal (Cont'd)
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IDLER GEAR END PLAY
ITighten the holding bolts to the specification.
I Measure the clearance between the gear plate and idler gear
using a feeler gauge.
Unit: mm (in)
Standard Limit
Idler gear (A) 0.06 - 0.12
(0.0024 - 0.0047) 0.15 (0.0059)
Idler gear (B)
I If it exceeds the limit, replace the idler gear, shaft, and gear
plate.
IDLER GEAR OIL CLEARANCE
IMeasure the inner diameter (d1) of the idler gear shaft.
Standard: Idler gear (A)43.000 - 43.020 mm (1.6929 - 1.6937 in) dia.
Idler gear (B) 28.600 - 28.620 mm (1.1260 - 1.1268 in) dia.
I Measure the outer diameter (d2) of the idler shaft.
Standard: Idler gear (A)42.959 - 42.975 mm (1.6913 - 1.6919 in) dia.
Idler gear (B) 28.567 - 28.580 mm (1.1247 - 1.1252 in) dia.
I Calculate the oil clearance.
Clearance = d1 þ d2
Unit: mm (in)
Standard Limit
Idler gear (A) 0.025 - 0.061
(0.0010 - 0.0024) 0.2 (0.0079)
Idler gear (B) 0.020 - 0.053
(0.0008 - 0.0021)
I If it exceeds the limit, refer to each standard specification and
replace the idler gear and/or shaft.
BALANCER SHAFT END PLAY
IMeasure the clearance between the plate and gear using a
feeler gauge.
Standard: 0.07 - 0.22 mm (0.0028 - 0.0087 in)
I If it exceeds the specification, replace the balancer shaft
assembly.
I As the gears are press-fitted, there are no setting for individual
parts.
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Inspection (Cont'd)
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BALANCER SHAFT OIL CLEARANCE
Outer diameter of balancer shaft journal
Measure the outer diameter of the balancer shaft journal with a
micrometer.Standard:Front side50.875 - 50.895 mm (2.0029 - 2.0037 in) dia.
Rear side 50.675 - 50.695 mm (1.9951 - 1.9959 in) dia.
Inner diameter of balancer shaft bearing
Measure the inner diameter of the balancer shaft bearing using a
bore gauge. Standard:Front side50.940 - 51.010 mm (2.0055 - 2.0083 in) dia.
Rear side 50.740 - 50.810 mm (1.9976 - 2.0004 in) dia.
Oil clearance calculations
Oil clearance = Bearing inner diameter þ Journal outer diameter Standard: 0.045 - 0.135 mm (0.0018 - 0.0053 in)
Limit: 0.180 mm (0.0071 in)
BALANCER SHAFT BEARING REMOVAL AND
INSTALLATION
1. Remove balancer shaft front bearing.
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2. Using Tool, remove balancer shaft rear bearing from engine.
3. Install the rear and front balancer shaft bearings.
IInstall from the cylinder block hole to the rear journal and then
the front journal.
I Install the groove of the balancer shaft bearing facing the front
and the under right direction.
(Align the guide plate and bar knock pin and then force in the
balancer shaft bearing.)
I Align the balancer shaft bearing groove with the knock pin of
the bar (SST) and install the balancer shaft bearing.)
I On rear journals, so the bearing does not get out of position,
wrap tape around the bar.
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Inspection (Cont'd)
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IMake an alignment mark 11.0 0.8 mm (0.433 0.031 in) from
the bar No. 2 engraved line with a marker pen. This alignment
mark q
Bwill be the point to where the rear bearing is pushed.
I Insert the bar with the bearing installed into the cylinder block
and install the guide plate (SST).
I Align the guide plate with the ZD engraving and install the bolts.
CAUTION:
Use a washer of the same thickness used on the front plate to
prevent the guide plate from bending.
I Push the engraved bar alignment mark q
Bto the same position
of the guide plate tip q
A.
I After all the journals have been installed, make sure that all the
journal and cylinder block oil holes are aligned.
4. Install the front balancer shaft bearing.
I Align the journal and cylinder block oil holes.
I Use a drift (SST) to force in the tip of the journal to 8.0 0.3 mm
(0.315 0.012 in) inside the cylinder block.
I After installing the journal, make sure that the journal and cyl-
inder block oil holes are aligned.
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Inspection (Cont'd)
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