2004 NISSAN TERRANO Service Repair Manual

(3) Rear camshaft bushing.Align the cutout of rear bushing with knock pin of replacer bar
before installation.
Insert rear bushing with replacer bar into the cylinder block.
Install guide plate with bolt holes (on the ªTDº mark side) fac-
ing upper side of cylinder block. Tighten bolts.
Drive replacer bar until the alignment mark on replacer bar is
aligned with the end of replacer guide.
Remove replacer set.
After installation, check that oil hole in camshaft bushing are
aligned with oil hole in cylinder block.
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(4) 4th, 3rd and 2nd camshaft bushings.Install in the same manner as rear camshaft bushing.
(5) Front camshaft bushing. Using 1st bushing adapter, position front camshaft bushing so
that oil hole in cylinder block is aligned with oil hole in bushing.
The camshaft bushing of the front side must be inserted at 0.5
mm (0.020 in) from the extreme front of cylinder block.
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3. Check camshaft bushing clearance.
4. Install new welch plug with a drift.
Apply liquid sealer.When setting 4th through 2nd bushings on replacer bar, tape
the bar to prevent movement.
CAMSHAFT ALIGNMENT
1. Check camshaft journal and cam surface for cracks, wear ordamage.
If fault is beyond limit, replace.
2. Check camshaft runout at center journal. If runout is greater than specified limit, repair or replace cam-
shaft.Camshaft runout
(Total indicator reading): StandardLess than 0.02 mm (0.0008 in)
Limit Less than 0.06 mm (0.0024 in)
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3. Measure camshaft end play between locating plate and gear.If beyond the specified limit, replace camshaft locating plate.Camshaft end play: Standard0.08 - 0.28 mm (0.0031 - 0.0110 in)
Limit Less than 0.5 mm (0.020 in)
4. Measure camshaft cam height. If beyond the specified limit, replace camshaft.Cam height: StandardIntake41.570 mm (1.6366 in)
Exhaust 41.900 mm (1.6496 in)
Limit IntakeLess than 41.20 mm (1.6220 in)
Exhaust Less than 41.40 mm (1.6299 in)
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Assembly
PISTON
1. Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap cor-responding to each cylinder. Care should be taken to avoid
a wrong combination including bearing.
b. When inserting piston pin in connecting rod, heat piston with a heater or hot water [approximately 60 to 70ÉC (140
to 158ÉF)] and apply engine oil to pin and small end of
connecting rod.
c. After assembling, ascertain that piston swings smoothly.
2. Install piston assembly.
CAUTION:
a. Stretch the piston rings just enough to fit them in the pis- ton grooves.
b. Be sure the manufacturer's mark faces upward.
c. Install No. 1 piston ring (oil ring) in such a way that its gap faces the direction of engine front, as shown in illustration
at left; and then install 2nd and top rings so that their gap
is positioned at 120É one to another.
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing isreused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however lower bearings do not.
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(2) Apply engine oil to crankshaft journal and pin and install crank-shaft.
(3) Install main bearings caps.
a) Install main bearing cap with the lowest number facing the front of vehicle.
b) Apply engine oil to main bearing cap and cylinder block contact surfaces.
c) Install rear oil seal assembly. Apply engine oil to contact surface of rear end oil seal and crankshaft.
(4) Install crankshaft thrust washer at the 4th journal from front.
Install thrust washer so that oil groove can face crankshaft.
(5) Tighten bearing cap bolts gradually in stages, starting from two to three separate stages, from center bearing and moving out-
ward in sequence.
(6) Measure crankshaft free end play at No. 4 bearing. Crankshaft free end play:Standard0.060 - 0.25 mm (0.0024 - 0.0098 in)
Limit 0.4 mm (0.016 in)
If beyond the limit, replace No. 4 main bearing thrust washer. Refer to SDS.
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2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
IBe careful not to scratch cylinder wall with connecting rod.
I Apply engine oil to cylinder wall, piston and bearing.
I The leaf type combustion chamber on piston head must be
facing toward the fuel pump side.
(2) Install connecting rod bearing caps.
3. Measure connecting rod side clearance. Connecting rod side clearance:Standard0.10 - 0.32 mm (0.0039 - 0.0126 in)
Limit 0.32 mm (0.0126 in)
If beyond the limit, replace connecting rod and/or crankshaft.
4. Install oil strainer and oil pan.
5. Install all removed parts.
GEAR TRAIN
1. Set No. 1 piston at its Top Dead Center.
2. Align each gear mark and install gears.
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TIMING GEAR CASE
Installation
1. Before installing timing gear case, remove all traces of liquidgasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of front
plate.
2. Apply a continuous bead of liquid gasket to mating surface of timing gear case and install the two rubber seals as shown.
I Be sure liquid gasket is 2.5 to 3.5 mm (0.098 to 0.138 in)
wide.
I Attach timing gear case to front plate within 20 minutes
after coating.
I Wait at least 30 minutes before refilling engine coolant or
starting engine.
I use Genuine Liquid Gasket or equivalent.
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