PROJECT REPORT FOR NATIONAL

CERTIFICATE IN AUTOMOTIVE
MECHANICS (NCAM)

PROJECT TITLE: Maintenance and Repair of Nissan Mistral TD27B Diesel

STUDENT NAME: Munduni Collins

REG. NO: [ ]

INSTITUTION: Omugo Technical School

ENGINE MODEL: Nissan TD27B 2.7L Diesel Engine

VEHICLE: Nissan Mistral (1994-1998)

SUPERVISOR: Barack Hedgehog

REPORT PERIOD: APRIL - JULY

A PROJECT REPORT SUBMITTED TO UGANDA VOCATIONAL AND TECHNICAL

ASSESMENT BOARD (UVTAB) FOR THE AWARD OF NATIONAL CERTIFICATE IN
AUTOMOTIVE MECHANICS AT OMUGO TECHNICAL SCHOOL.

ACADEMIC YEAR (2026- 2027)

DECLARATION

I declare that all the information contained in this project report is personal effort which was done
practically at the work place and has never been submitted to any Institution, university or to any awarding
body for any academic award.

Name: ……………………………………………………………………….

Sign: ………………………………………………………………………….

Date: ………………………………………………………………………
APPROVAL

I Mr. ……………………………………..Approve that this person has carried out real life project on
welding of chairs and it is ready for the submission to Uganda Vocational and Technical Assessment Board
(UVTAB) the awarding body.

Sign: ……………………………………………………..

Date: …………………………………………………….
DEDICATION

I dedicate this work to my fellow students, my beloved father and mother for their financial support
towards my studies and to Mr. ……………………..my beloved instructor
ACKNOWLEGEMENT

I appreciate the almighty God for the precious gift of life and his sufficient grace that he enabled me
financially to pay my tuition.

I am here also to appreciate the principal of omugo technical school for allowing us to carry out my project
work and also our lecturers for their assistance towards the completion of my project work. I also generally
thank all my friends who assisted me on the weaker areas that I couldn’t manage alone.
1.0 INTRODUCTION

This project report documents the maintenance and repair procedures carried out on a Nissan Mistral
TD27B diesel engine at Omugo Technical School. The Nissan Mistral, also known as the Nissan Terrano II in
some markets, was produced from 1993 to 1998 and features the 2.7-litre diesel engine from Nissan's TD
series family. The TD27B is a 4-cylinder, in-line, overhead valve (OHV) diesel engine with a displacement of
2664 cc, producing approximately 100 horsepower at 4000 rpm.

This project was undertaken to develop practical skills in diesel engine diagnosis, disassembly, inspection,
and reassembly in accordance with the requirements for the National Certificate in Automotive
Mechanics. The work was performed following factory service manual specifications and standard
workshop safety procedures.

1.1 Project Objectives

The specific objectives of this project were to:

1. Diagnose engine faults and determine necessary repair procedures

2. Dismantle the TD27B engine following correct removal sequence

3. Inspect and measure engine components to determine serviceability

4. Carry out repairs and replacements as required

5. Reassemble the engine to factory specifications

6. Perform functional tests after reassembly

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2.0 ENGINE SPECIFICATIONS
2.1 TD27B Engine Technical Data
Specification Details

Engine Type 4-cylinder in-line diesel

Displacement 2664 cc

Bore x Stroke 96.0 mm x 92.0 mm

Compression Ratio 21.9:1

Power Output 100 PS (74 kW) at 4000 rpm

Torque 220 Nm at 2000 rpm

Fuel System VE-type distributor injection pump

Cooling System Water-cooled, with thermostat

Lubrication Pressurized with oil pump and full-flow filter

Turbocharger Garrett or IHI (varies by version)

Oil Capacity 6.2 L (including filter)

2.2 Engine Identification

The TD27B engine used in the Nissan Mistral was produced in several variants:

· TD27B – Non-turbo or naturally aspirated version

· TD27BETI – Turbocharged and intercooled version (1996-1998, 125-131 HP)

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3.0 DIAGNOSTIC PROCEDURES
3.1 Initial Assessment
Before commencing maintenance work, a thorough diagnostic procedure was carried out to identify
engine faults and establish the scope of work required.

3.2 Common Faults Identified on TD27B Engines

Based on diagnostic checks and reference to common issues reported with the TD27B engine, the
following problem areas were investigated:

Fuel System Issues:

· Hard starting, especially in cold conditions

· Rough idling and hunting (fluctuating RPM)

· Black smoke under load

· Poor fuel economy

Potential causes investigated included:

· Fuel filter contamination

· Injector nozzle wear or blockage

· Injection pump timing issues

· Air in fuel system

· Glow plug failure

Engine Mechanical Issues:

· Excessive oil consumption

· Blow-by / excessive crankcase pressure

· Engine overheating

· Unusual engine noises (knocking, rattling)

Potential causes investigated included:

· Piston ring wear

· Cylinder bore wear

· Head gasket failure

· Cooling system faults

· Valve seat recession or damage

3.3 Diagnostic Tools and Equipment Used

Tool/Equipment Purpose

1. Multimeter Electrical circuit testing

2. Compression tester Cylinder compression measurement
3. Dial gauge Measuring runout and end play
4. Feeler gauges Measuring clearances
5. Micrometers Component measurement
6. Vernier callipers General dimensional measurement
7. timing light Injection timing verification

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4.0 ENGINE REMOVAL AND DISASSEMBLY

4.1 Pre-Removal Procedure
1. Engine accessories (alternator, power steering pump, air conditioning compressor) were removed
following the service manual sequence

2. Battery was disconnected (negative terminal first)

3. Engine coolant and engine oil were drained

4. Fuel lines were disconnected and capped

5. Transmission mounting bolts were removed

6. Engine mounts were disconnected

4.2 Engine Removal

The engine was lifted from the vehicle using a suitable hoist technique, following the procedures specified
in the Nissan TD series service manual.

4.3 Engine Disassembly Sequence

The engine was dismantled following the manufacturer's recommended sequence:

1. Intake and exhaust manifolds removed

2. Cylinder head removed (following correct bolt loosening sequence)

3. Valve train dismantled

4. Timing gear inspected

5. Pistons and connecting rods removed

6. Crankshaft inspected

7. Oil pump and lubrication system components removed

8. Engine block cleaned and prepared for inspection

Important: All bolts loosened in the correct order to prevent warping of components, particularly the
cylinder head.

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5.0 COMPONENT INSPECTION AND MEASUREMENT
5.1 Cylinder Bore Inspection
Cylinder bores were measured for ovality and taper at three positions:

· Top of bore

· Middle of bore

· Bottom of bore

Measurements were taken in both the horizontal and vertical directions to determine wear patterns.

Note: If cylinder taper exceeds 0.05 mm, reboring is recommended.

5.2 Cylinder Head Inspection

The cylinder head was inspected for:

· Flatness (warpage)

· Cracks

· Valve seat condition

· Valve guide wear

· Valve stem clearance

Valve Clearance Specifications (TD27B):

· Intake valve clearance (cold): 0.30 mm

· Exhaust valve clearance (cold): 0.35 mm

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6.0 REPAIR AND MAINTENANCE PROCEDURES

6.1 Cylinder Head Service
Valve Seat Grinding:

The valve seats were ground using the correct 45-degree and 60-degree angle grinders. After grinding, the
valves were lapped to ensure proper sealing.

Operation Performed:
1. Valve seat inspected for pitting or damage

2. 45-degree seat ground to remove imperfections

3. 60-degree angle ground to adjust seat width

4. Valves lapped with grinding paste

5. Valve spring tension tested

6.2 Injection System Service

Injector Overhaul:

The injectors were removed and tested for:

1. Opening pressure

2. Spray pattern

3. Leakage

Procedure followed:

1. Injectors removed from cylinder head

2. Injector nozzles inspected for wear/carbon buildup

3. Nozzle opening pressure tested (reference: 180-185 bar)

4. Spray pattern observed and documented

5. Injector nozzles replaced if necessary

6. New copper gaskets installed on reassembly

Fuel Injection Pump Inspection:

The VE-type injection pump was inspected for:

· Timing verification

· Leakage from seals

· Fuel cutoff solenoid operation

· Throttle position sensor adjustment (if equipped)

6.3 Cooling System Service

Water Pump Inspection:

· Water pump removed and inspected for bearing play and seal integrity

· Coolant drained and replaced

· Thermostat tested for proper opening temperature (82°C)

· Radiator flushed to remove debris and scale

6.4 Oil System Service
Oil Pump Inspection:

· Oil pump removed and inspected for wear between gears and housing

· Oil pump clearance measured (standard clearance: 0.05-0.12 mm)

· Oil pressure relief valve checked

· Oil cooler inspected for clogging

Lubrication System Flush:

The lubrication system was flushed and filled with SAE 10W-40 diesel engine oil (following Ravanol VDL
5W40 or similar specification).

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7.0 REASSEMBLY PROCEDURE

7.1 Engine Assembly Sequence

Engine reassembly was performed in the reverse order of disassembly, following the service manual
torque specifications and sequence:

1. Cylinder head installed and torqued in correct sequence

2. Valve train installed and clearances adjusted

3. Timing checked and set

4. Intake and exhaust manifolds installed

5. Accessories reinstalled

7.2 Critical Torque Specifications

Bolt/Fastener Torque (Nm) Sequence

Cylinder Head Bolts 98-108 Nm 5-stage sequence

Main Bearing Caps 78-88 Nm 4-stage sequence

Connecting Rod Bolts 40-45 Nm 2-stage sequence

Flywheel Bolts 98-108 Nm 4-stage sequence

7.3 Injection Timing Setting

The injection pump timing was set using the appropriate timing marks and a dial gauge. For the TD27B
engine:

· Static injection timing: 12°-14° BTDC at idle

· Timing gauge was used to verify TDC and injection point

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8.0 POST-REPAIR TESTS AND COMMISSIONING

8.1 Pre-Start Checks

Before starting the engine, the following were verified:

1. All fluids at correct levels (engine oil, coolant)

2. Fuel system bled of air

3. Battery connected

4. All electrical connections secure

5. No tools or debris left in engine bay

8.2 Engine Start and Run-Up

The engine was started and run at various RPM to check for:

· Unusual noises or vibrations

· Oil pressure (minimum 2.0 bar at idle, 3.0-4.0 bar at 2000 rpm)

· Coolant temperature (normal 80-90°C)

· Exhaust emissions and smoke

· Idle speed (700-800 RPM)

· Response to throttle

8.3 Post-Repair Inspection

After running the engine to operating temperature, the following were rechecked:

· All fasteners retorqued (after thermal expansion)

· All fluid levels topped up

· No leaks (coolant, oil, fuel)

· Valve clearances rechecked after running-in

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9.0 FAULT SUMMARY AND MAINTENANCE PLAN
9.1 Faults Identified and Rectified
No. Faulty Component Fault Description Maintenance Action

1 [Component] [Fault Description] [Action Taken]

2 [Component] [Fault Description] [Action Taken]

3 [Component] [Fault Description] [Action Taken]

9.2 Recommended Future Maintenance Schedule

For TD27B Engine:

· Oil and filter change: Every 5,000 km or 6 months

· Fuel filter replacement: Every 10,000 km

· Valve clearance adjustment: Every 10,000 km

· Injection nozzle check: Every 20,000 km

· Timing belt/chain inspection: Every 50,000 km

· Coolant replacement: Every 40,000 km

10.0 SAFETY CONSIDERATIONS

Throughout the project, the following safety procedures were strictly observed:

1. Correct personal protective equipment (PPE) worn at all times

2. Proper lifting techniques using suitable equipment

3. Lockout/tagout procedures during engine disassembly

4. Safe disposal of fluids and waste materials

5. Clean and organized work area

6. Correct tool selection for each procedure

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11.0 CONCLUSION

The maintenance and repair of the Nissan Mistral TD27B diesel engine was successfully completed at
Omugo Technical School. The TD27B engine proved to be a robust and relatively straightforward diesel
unit to work on, requiring attention to specific areas such as the fuel injection system and cooling system,
which are critical for reliable diesel engine operation.

The project successfully developed practical skills in:

· Systematic fault diagnosis on diesel engines

· Precise component measurement and inspection

· Correct disassembly and reassembly procedures

· Use of special service tools and equipment

· Adherence to manufacturer specifications

The engine was returned to serviceable condition following the completion of necessary repairs and
adjustments.

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12.0 REFERENCES

1. Nissan Motor Company Ltd (1989). TD Series Diesel Engine Factory Service Manual Supplement. Nissan
Staff Publication

2. Elsbett (1996). Nissan Mistral TD27BETI Conversion Kit Specifications. [online] Available at:
[Link] [Accessed: 2026]

3. Ravenol (2026). Nissan Mistral 2.7 D/TD 4WD Engine Oil Specifications. [online] Available at:
[Link] [Accessed: 2026]

4. Omugo Technical School. National Certificate in Automotive Mechanics Course Materials (Module 3)
13.0 APPENDICES

valve grinding checking for leakage

disconnecting the vehicle accessories disconnecting the engine from the frame

from the engine.

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