2004 NISSAN TERRANO Service Repair Manual

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
http://vnx.su/

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
http://vnx.su/

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
http://vnx.su/

5. Calculate main bearing clearance.Main bearing clearance = A þ DmStandard0.035 - 0.083 mm (0.0014 - 0.0033 in)
Limit Less than 0.15 mm (0.0059 in)
CONNECTING ROD BEARING (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Apply oil to the thread portion of bolts and seating surface of
nuts.
3. Measure inside diameter ªAº of bearing.
4. Measure outside diameter ªDpº of pin journal in crankshaft.
5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = A þ DpStandard0.035 - 0.077 mm
(0.0014 - 0.0030 in)
Limit Less than 0.15 mm (0.0059 in)
CONNECTING ROD BEND AND TORSION
Bend and torsion: Limit0.15 mm (0.0059 in)
per 200 mm (7.87 in) length
CONNECTING ROD BUSHING CLEARANCE (Small end)
1. Measure inside diameter ªAº of connecting rod small end bush- ings.
YEM046
EM133
YEM047
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-129
http://vnx.su/

2. Measure outside diameter ªDº of piston pin.
3. Calculate connecting rod small end bushing clearance.Connecting rod small end bushing clearance = A þ DStandard0.025 - 0.043 mm (0.0010 - 0.0017 in)
Limit 0.15 mm (0.0059 in)
REPLACEMENT OF CONNECTING ROD BUSHING
(Small end)
1. Drive in the small end bushing until it is flush with the end sur- face of the rod.
Be sure to align the oil holes.
2. After driving in the small end bushing, ream the bushing. Small end bushing inside diameter:Finished size30.025 - 30.038 mm (1.1821 - 1.1826 in)
CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or cracks. If faults are minor, correct with fine emery paper.
2. Check journals and pins with a micrometer for taper and out- of-round.Out-of-round (X þ Y): StandardLess than 0.01 mm (0.0004 in)
Limit 0.02 mm (0.0008 in)
Taper (A þ B): StandardLess than 0.01 mm (0.0004 in)
Limit 0.02 mm (0.0008 in)
3. Check crankshaft runout. Runout (Total Indicator Reading)Standard0 - 0.03 mm (0 - 0.0012 in)
Limit 0.10 mm (0.0039 in)
SEM416B
EM715
SEM662B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-130
http://vnx.su/

RESURFACING OF CRANKSHAFT JOURNAL AND
CRANK PIN
When using undersize main bearings and connecting rod bearings,
the crankshaft journals or crank pins must be finished to match the
bearings.R: Crank journal 3.0 mm (0.118 in)Crank pin 3.5 mm (0.138 in)
CAUTION:
I At the same time make sure that the surface width does not
increase.
I Do not attempt to cut counterweight of crankshaft.
PILOT BUSHING REPLACEMENT
1. Pull out bushing with Tool.
2. Insert pilot bushing until distance between flange end and
bushing is specified value.Distance: Approx. 5.6 - 6.0 mm (0.220 - 0.236 in)
FLYWHEEL RUNOUT
Runout (Total Indicator Reading):Less than 0.15 mm (0.0059 in)
FRONT PLATE
Check front plate for warpage. If not within the limit, make flat or
replace front plate. Warpage limit:0.2 mm (0.008 in)
SEF692A
SEM413
NEM181
SEM059A
SEM668B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-131
http://vnx.su/

GEAR TRAIN
Camshaft drive gear, injection pump drive gear, oil pump gear,
idler gear, crankshaft gear and vacuum pump gear.
1. If gear tooth and key have scratches or are excessively worn,replace gear and key.
2. Check gear train backlash before disassembling and after assembling.
Method A (Using dial gauge)
Method B (Using fuse wire)
If beyond the limit, replace gear. Backlash:Standard0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit 0.20 mm (0.0079 in)
IDLER GEAR BUSHING CLEARANCE
1. Measure idler gear shaft outer diameter.
2. Measure idler gear bushing inner diameter.
3. Calculate idler gear bushing clearance. Bushing oil clearance:Standard0.025 - 0.061 mm (0.0010 - 0.0024 in)
Limit 0.20 mm (0.0079 in)
IDLER GEAR END PLAY
Measure idler gear end play between gear plate and gear. Idler gear end play:Standard0.03 - 0.14 mm (0.0012 - 0.0055 in)
Limit Less than 0.3 mm (0.012 in)
NEM186
NEM187
SEM666B
SEM705
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-132
http://vnx.su/

REPLACEMENT OF IDLER GEAR BUSHING
1. Use a suitable tool to replace bushing.
2. Ream idler gear bushing.Finished size:42.00 - 42.02 mm (1.6535 - 1.6543 in)
Idler gear shaft
Install idler gear shaft so that oil hole of shaft faces upward.
CAMSHAFT AND CAMSHAFT BUSHING
Camshaft bushing clearance
Measure inside diameter of camshaft bushing (A) and outside
diameter of camshaft journal (B) with a suitable gauge. Clearance between camshaft and bushing (A þ B):Standard0.020 - 0.109 mm
(0.0008 - 0.0043 in)
Limit Less than 0.15 mm (0.0059 in)
REPLACING CAMSHAFT BUSHING
1. Remove welch plug. Using Tool, remove camshaft bushings from the cylinder block.
Some bushings must be broken in order to remove.
2. Using Tool, install camshaft bushings as follows:
(1) Install camshaft bushings in the order of ªrearº, ª4thº, ª3rdº, ª2ndº and ªfrontº. All bushings must be installed from the front.
(2) Face the cutout upward and toward the front of the engine dur- ing installation.
SEM706
SEM669B
NEM171
SEM993B
SEM686B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-133
http://vnx.su/