2004 NISSAN TERRANO service

Greasing Steering Linkage ........................................44
Ventilation Air Filter ....................................................44
Body ........................................................................\
...45
Checking Body Corrosion ..........................................47SERVICE AND SPECIFICATIONS (SDS)
.....................48
Engine Maintenance ..................................................48
Chassis and Body Maintenance ................................49
CONTENTS(Cont'd)
MA-2
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Shown below are Pre-delivery Inspection items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
lRadiator coolant level and coolant hose connections for leaks
l Battery fluid level, specific gravity and conditions of battery terminals
l Drive belts tension
l Fuel filter for water or dust, and fuel lines and connections for leaks
l Engine oil level and oil leaks
l Brake and clutch reservoirs fluid level and fluid lines for leaks
l Windshield and rear window washer and headlamp cleaner reservoir fluid level
l Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
lRemove front spring/strut spacer (if applicable)
l Operation of all instruments, gauges, lights and accessories
l Operation of horn(s), wiper and washer
l Steering lock for operation
l Check air conditioner for gas leaks
l Front and rear seats, and seat belts for operation
l All moldings, trims and fittings for fit and alignment
l All windows for operation and alignment
l Hood, tailgate, door panels for fit and alignment
l Latches, keys and locks for operation
l Weatherstrips for adhesion and fit
l Headlamp aiming
l Tighten wheel nuts (Inc. inner nuts if applicable)
l Tire pressure (Inc. spare tire)
l Check front wheels for toe-in
l Install clock/voltmeter/room lamp fuse (if applicable)
l Install deodorizing filter to air conditioner (if applicable)
l Remove wiper blade protectors (if applicable)
UNDER BODY
lManual transmission/transaxle, transfer and differential gear oil level
l Brake and fuel lines and oil/fluid reservoirs for leaks
l Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
l Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
lClutch operation
l Parking brake operation
l Service brake operation
l Automatic transmission/transaxle shift timing and kickdown (if applicable)
l Steering control and returnability
l Engine performance
l Squeaks and rattles
ENGINE OPERATING AND HOT
lAdjust idle speed
l Automatic transmission/transaxle fluid level (if applicable)
l Engine idling and stop knob operation
FINAL INSPECTION
lInstall necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
l Inspect for interior and exterior metal and paint damage
l Check for spare tire, jack, tools (wheel check) and literature
l Wash, clean interior and exterior
PRE-DELIVERY INSPECTION ITEMS
MA-3
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General maintenance includes those items which should be checked during normal day-to-day operation of
the vehicle. They are essential if the vehicle is to continue functioning correctly. Owners can perform the
checks and inspections themselves, or they can be carried out by a NISSAN dealer.
ItemReference pages
OUTSIDE THE VEHICLE
The maintenance items listed here should be checked periodically, unless otherwise specified.
Tires Check the pressure with a gauge weekly when at a service station, including the spare,
and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive
wear. Ð
Windshield wiper blades Check for cracks or wear if not functioning correctly. Ð
Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door
function correctly. Also ensure that all latches lock securely. Lubricate if necessary. Make sure
that the secondary latch prevents the hood from opening when the primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication more
often. MA-45
Tire rotation Tires should be rotated every 5,000 km (3,000 miles). MA-43
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when per-
forming periodic maintenance, cleaning the vehicle etc.
Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other lights
are all operating correctly and installed securely. Also check headlight aim. Ð
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are
functioning correctly. Ð
Steering wheel Check that it has the specified play. Check for changes in the steering
operation, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in) Ð
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for
cuts, fraying, wear of damage. MA-46
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. MA-22
Engine oil level Check the level after parking the vehicle (on level ground) and turning off the
engine. MA-21
Brake and clutch fluid level Make sure that the brake fluid level is between the ªMAXº and
ªMINº lines on the reservoir. MA-36/MA-40
Battery Check the fluid level in each cell. It should be between the ªMAXº and ªMINº lines. Ð
GENERAL MAINTENANCE
MA-4
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Pinch the rubber cap located under the cyclone air cleaner assem-
bly to remove dust.
Checking Injection Nozzle
WARNING:
When using nozzle tester, do not allow fuel sprayed from
nozzle to contact your hand or body, and make sure that your
eyes are properly protected with goggles.
1. Check initial injection pressure by pumping tester handle onetime per second.Initial injection pressure: Used Nozzle12,259 - 12,749 kPa
(122.6 - 127.5 bar, 125 - 130 kg/cm
2,
1,778 - 1,849 psi)
New Nozzle 12,749 - 13,730 kPa
(127.5 - 137.3 bar, 130 - 140 kg/cm
2,
1,849 - 1,991 psi)
I Always check initial injection pressure before installing
new nozzle.
Do not disassemble injection nozzle assembly. Entrust disas-
sembly or adjustment to BOSCH service shop.
2. Check spray pattern by pumping tester handle 4 to 6 times or more per second.
a. If main spray angle is within 30 degrees as shown, injec- tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from the main spray (pattern B).
3. If spray is not correct, clean injection nozzle tip or replace it.
I For details, refer to INJECTION NOZZLE ASSEMBLY in EC
section.
NMA063
EF792A
SEF079S
ENGINE MAINTENANCETD
Cleaning and Replacing Air Cleaner Filter (Dry
paper type) (Cont'd)
MA-25
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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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TIGHTENING TORQUE
UnitN×m kg-m ft-lb
Clutch Pedal stopper lock nut 12 - 15 1.2 - 1.5 8.7 - 10.8
Master cylinder push rod
lock nut 8 - 11 0.8 - 1.1 5.8 - 8.0
Manual transmission Drain and filler plugsFS5R30A 25 - 34 2.5 - 3.5 18 - 25
Differential carrier Drain and filler plugsR180A 39 - 59 4 - 6 28.8 - 43.5
H233B 59 - 98 6 - 10 43.5 - 72.3
Front axle and front suspen-
sion Tie-rod lock nut 60 - 70 6.1 - 7.1 44.3 - 51.6
Brake system Air bleeder valve 7 - 9 0.7 - 0.9 5.1 - 6.5
Wheel and tire
Wheel nut 118 - 147 12.0 - 15.0 87.0 -
108.4
SERVICE AND SPECIFICATIONS (SDS)
Chassis and Body Maintenance (Cont'd)
MA-50
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ENGINE MECHANICAL
SECTION
EM
CONTENTS
ZD
PRECAUTIONS ...............................................................3
Parts Requiring Angular Tightening .............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION ................................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................8
NVH Troubleshooting Chart - Engine Noise ...............9
MEASUREMENT OF COMPRESSION PRESSURE ....10
INTERCOOLER ............................................................. 11
Removal and Installation ........................................... 11
INTAKE MANIFOLD ......................................................12
Removal and Installation ...........................................12
Inspection...................................................................13
CATALYST AND TURBOCHARGER ............................14
Removal and Installation ...........................................14
Inspection...................................................................15
EXHAUST MANIFOLD ..................................................18
Removal and Installation ...........................................18
Inspection...................................................................19
ROCKER COVER ..........................................................20
Removal and Installation ...........................................20
OIL PAN & OIL STRAINER ...........................................22
Removal and Installation ...........................................22
VACUUM PUMP ............................................................24
Removal and Installation ...........................................24
TIMING CHAIN ..............................................................26
Removal and Installation ...........................................26
Removal .....................................................................26
Installation ..................................................................28
CAMSHAFT ...................................................................30
Removal and Installation ...........................................30
Removal .....................................................................30
Inspection...................................................................31
Installation ..................................................................33 VALVE CLEARANCE INSPECTIONS AND
ADJUSTMENTS
.............................................................35
Inspection...................................................................35
Adjustments ...............................................................36
TIMING GEAR ...............................................................38
Removal and Installation ...........................................38
Removal .....................................................................39
Inspection...................................................................41
Installation ..................................................................46
OIL SEAL REPLACEMENT ..........................................50
CYLINDER HEAD ..........................................................52
Removal and Installation ...........................................52
Removal .....................................................................52
Inspection...................................................................53
Installation ..................................................................54
Disassembly...............................................................57
Inspection...................................................................58
Assembly ...................................................................61
ENGINE REMOVAL .......................................................63
Precautions ................................................................63
Removal .....................................................................63
Installation ..................................................................65
Inspection...................................................................65
CYLINDER BLOCK .......................................................66
Selection Procedure for Selective Part
Combination ...............................................................67
Disassembly...............................................................67
Inspection...................................................................71
Assembly ...................................................................80
SERVICE DATA AND SPECIFICATIONS (SDS) ..........84
General Specifications ...............................................84
Compression Pressure ..............................................84
Cylinder Head ............................................................84
Valve ........................................................................\
..84
Valve Seat..................................................................87
Camshaft and Camshaft Bearing ..............................89
Cylinder Block ............................................................90
Piston, Piston Ring and Piston Pin ...........................90
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