2004 NISSAN TERRANO radiator

CHECKING RADIATOR CAP
Apply pressure to radiator cap (side with pressure valve) with cap
tester to see if it is satisfactory.Radiator cap relief pressure:108 - 128 kPa
(1.08 - 1.28 bar, 1.1 - 1.3 kg/cm
2, 16 - 18 psi)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage. Testing pressure:157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
CAUTION:
Use of higher pressure than the specified value may cause
damage to radiator.
Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs.
REPLACING FUEL FILTER
1. Disconnect harness connector and drain fuel.
2. Remove fuel filter using band-type filter wrench.
3. Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off imme-
diately. Be specially careful not to spill fuel on engine mount
insulator.
SLC613
SMA871B
JMA110D
DMA011
SMA111D
ENGINE MAINTENANCEZD
Checking Cooling System (Cont'd)
MA-33
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Engine Maintenance
INSPECTION AND ADJUSTMENT
Drive belt deflection
Unit: mm (in)
Used belt deflectionDeflection of
new belt
Limit Deflection after
adjustment
Engine TD27Ti TD27Ti TD27Ti
Alternator 20
(0.79) 11-13
(0.43 - 0.51) 9-11
(0.35 - 0.43)
Air conditioner 12
(0.47) 6 - 7.5
(0.236 - 0.295) 5 - 6.5
(0.197 - 0.256)
Power steering
oil pump 15
(0.59) 8 - 9.5
(0.315 - 0.374) 7 - 8.5
(0.276 - 0.335)
Applied pushing
force 98 N (10 kg, 22 lb)
Oil capacity (Refill capacity)
TD27Ti engine
Unit:
(Imp qt)
With oil filter change 6.2 (5-1/2)
Without oil filter change 5.5 (4-7/8)
ZD30DDTi engine
Unit: (Imp qt)
With oil filter change 6.7 (5-7/8)
Without oil filter change 6.2 (5-1/2)
Cooling system check
TD27Ti engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
ZD30DDTi engine
Unit: kPa (bar, kg/cm2, psi)
Cooling system testing pressure 157 (1.57, 1.6, 23)
Radiator cap relief pressure 108 - 128
(1.08 - 1.28, 1.1 - 1.3, 16 - 18)
Coolant capacity (Refill capacity)
Unit: (Imp qt)
Engine TD27TiZD30DDTi
Without reservoir tank 10 (8-3/4) 10.6 (9-3/8)
Reservoir tank 0.8 (3/4) 0.75 (5/8)
Valve clearance (Hot)
Unit: mm (in)
Engine TD27Ti
Intake 0.25 (0.0098)
Exhaust
Injection nozzle
Unit: kPa (bar, kg/cm2, psi)
Engine TD27Ti
Initial injection pressure
New 12,259 - 12,749 (122.6 - 127.5, 125 -
130, 1,778 - 1,849)
Used 12,749 - 13,730 (127.5 - 137.3, 130 -
140, 1,849 - 1,991)
Idle speed
Unit: rpm
Engine TD27Ti
With A/C 850 50
Without A/C 700 50
SERVICE AND SPECIFICATIONS (SDS)
MA-48
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Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT
Clutch
Unit: mm (in)
Vehicle modelAll
Pedal free height RHD
210 - 220
(8.27 - 8.66) LHD
227 - 237
(8.94 - 9.33)
Pedal free play 1.0 - 3.0 (0.039 - 0.118)
Pedal free travel 155 - 160 (6.10 - 6.30)
Front axle and front suspension
(Unladen)*1
Unit: degree
Model H/T VAN H/T WAGON
Camber 0É30¢  30¢
Caster 0É29¢ 30¢ 0É30¢ 30¢ 0É30¢ 30¢
Kingpin inclination 12É37¢
Toe-in
A-B mm (in) 3.5 - 5.5
(0.14 - 0.22) 3-5
(0.12 - 0.20) 3-5
(0.12 - 0.20)
Front wheel turning
angle (degrees) (Full turn)*2
Inside 34É27¢
Outside 33É38¢
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
Brake
Disc brake mm (in)
LD28VA
PadStandard thickness 15.5 (0.610)
Minimum thickness 2.0 (0.079)
Rotor Standard thickness 2.60 (0.1024)
Minimum thickness 24.0 (0.945)
Drum brake mm (in)
LT28 LiningStandard thicknessLeading 8.95 (0.3524)
Trailing 3.95 (0.1555)
Minimum thickness 1.52 (0.0598)
Drum Standard diameter 280 (11.02)
Maximum diameter 282 (11.10)
Pedal mm (in) RHD LHD
Free height 196 - 206
(7.7 - 8.1) 210 - 220
(8.3 - 8.7)
Free play 1.0 - 3.0 (0.039 - 0.118)
Full stroke 137.7 - 148.7
(5.42 - 5.85) 142.5 - 152.5
(5.61 - 6.00)
Parking brake Number of notches [at pulling
force 196 N (20 kg, 44 lb)] 9-10
Wheel runout
Unit: mm (in)
Wheel typeSteel Aluminum
16² x7J 16 ²x7J
Radial runout limit 0.5 (0.020) 0.3 (0.012)
Lateral runout limit 0.8 (0.031) 0.3 (0.012)
Wheel bearing
Axial end play limit mm (in) 0
SERVICE AND SPECIFICATIONS (SDS)
MA-49
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Removal and Installation
REMOVAL
1. Remove the following parts.
IRadiator under side
I Radiator shroud
I Cooling fan
I Chain cover front side
I A/T cooler hose (Disconnect)
I Vacuum hose
I Intercooler cover (When removing vacuum tank)
2. Remove the installation bolts and pull the vacuum pump from the engine front directly.
3. If it is difficult to remove from the spline shaft connection, tap lightly with a plastic hammer.
SEM320G
SEM321G
VACUUM PUMPZD
EM-24
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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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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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Removal
1. Set No. 1 cylinder at TDC on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block andradiator.
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
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6. Install rocker cover.
IBe sure to tighten bolts in the order shown in the illustration.
I When 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
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