2004 NISSAN TERRANO check engine

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
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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
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(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.
SEM995B
SEM110C
NEM172
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-134
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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)
SEM987B
SEM034
SEM999B
SEM670B
ENGINE OVERHAULTD27Ti
Inspection (Cont'd)
EM-136
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ENGINE LUBRICATION &COOLING SYSTEMS
SECTION
LC
CONTENTS
ZD
PRECAUTIONS AND PREPARATION ............................2
Liquid Gasket Application Procedure ..........................2
Special Service Tools ..................................................2
ENGINE LUBRICATION SYSTEM ..................................3
Lubricating Circuit ........................................................3
Oil Pressure Check......................................................4
Oil Pump ......................................................................5
Oil Jet........................................................................\
...7
Oil Cooler .....................................................................8
ENGINE COOLING SYSTEM ..........................................9
Cooling Circuit .............................................................9
System Check............................................................10
Water Pump ............................................................... 11
Thermostat .................................................................12
Water Outlet ...............................................................13
Radiator .....................................................................14
Cooling Fan (Crankshaft driven) ...............................15
EGR Cooler ...............................................................16
SERVICE DATA AND SPECIFICATIONS (SDS) ..........17
Engine Lubrication System ........................................17
Engine Cooling System .............................................17 TD27TiPREPARATION
..............................................................18
PRECAUTION ................................................................19
ENGINE LUBRICATION SYSTEM ................................20
Lubrication Circuit ......................................................20
Oil Pressure Check....................................................21
Oil Pump ....................................................................22
Oil Filter Bracket ........................................................24
Oil Cooler ...................................................................25
Oil Jet........................................................................\
.26
ENGINE COOLING SYSTEM ........................................27
Cooling Circuit ...........................................................27
System Inspection .....................................................28
Water Pump ...............................................................29
Thermostat .................................................................31
Radiator .....................................................................32
Cooling Fan ...............................................................33
SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
Engine Lubrication System ........................................34
Engine Cooling System .............................................34
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Oil Pressure Check
WARNING:
IBe careful not to burn yourself, as the engine and oil may
be hot.
I Oil pressure check should be done in ªNeutralº gear posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.
3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
Engine speed
rpm Approximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed 2,000
4,000 More than 147 (1.47, 1.5, 21)
More than 539 (5.39, 5.5, 78)
More than 736 (7.36, 7.5, 107)
If difference is extreme, check oil passage and oil pump.
6. Install oil pressure switch with sealant. Oil pressure switch:
:13-17N ×m (1.25 - 1.75 kg-m ,9-12ft-lb)
SLC694A
JLC362B
ENGINE LUBRICATION SYSTEMZD
LC-4
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OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer gear radial clearanceq10.114 - 0.200
(0.0045 - 0.0079)
Inner gear to outer gear tip clearance q
2Less than 0.180 (0.0071)
Body to inner gear axial clearance q
30.05 - 0.09
(0.0020 - 0.0035)
Body to outer gear axial clearance q
40.050 - 0.105
(0.0020 - 0.0041)
Inner gear to brazed portion of housing
clearance q
5
0.045 - 0.091
(0.0018 - 0.0036)
Regulator valve to oil pump cover
clearance q
6
0.040 - 0.097
(0.0016 - 0.0038)
I If the tip clearance ( q2) exceeds the limit, replace gear set.
I If body to gear clearances ( q
1,q3,q4,q5) exceed the limit,
replace oil pump body assembly.
REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve spring.
3. Coat regulator valve with engine oil. Check that it falls smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.
4. Check regulator valve to oil pump cover clearance. Clearance:q
6: 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump cover.
JLC365B
JLC366B
JLC367B
SLC369B
ENGINE LUBRICATION SYSTEMZD
Oil Pump (Cont'd)
LC-6
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OIL PRESSURE RELIEF VALVE AND BYPASS VALVE
INSPECTION (For oil cooler)
1. Inspect oil pressure relief valve for movement, cracks andbreaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with suitable tool.
Install a new valve in place by tapping it.
2. Check oil pressure relief valve to oil cooler housing clearance. Clearance:q
C: 0.032 - 0.068 mm (0.0013 - 0.0027 in)
If it exceeds the limit, replace oil cooler housing.
Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on.
INSPECTION (For piston)
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod and make sure that cut-off valve moves smoothly with proper
repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with a wire if necessary.
When installing oil jet, align oil jet's boss with hole on cylin-
der block. Oil jet:
:30-39N ×m (3.0 - 4.0 kg-m, 22 - 28 ft-lb)
SLC371B
SLC385B
FEM124
FEM125
ENGINE LUBRICATION SYSTEMZD
Oil Pump (Cont'd)
LC-7
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