Disassembling Nissan Terrano I: a complete guide with photos and advice from professionals

First generation Nissan Terrano (1986–2005), also known as WD21, has become a legend among SUVs due to its reliability and maintainability. However, disassembling this car is not an easy task, especially when it comes to body work and engine removal TD27 or disassembling the all-wheel drive. In this article we will analyze the process step by step: from preparing tools to the nuances of working with rust, electrical and suspension.

It is important to understand that Terrano I - a car with a frame structure, which means that many components are attached not to the body, but to the frame. This simplifies some types of repairs (for example, replacing engines), but complicates disassembling the interior and doors. We focus on critical moments, which beginners often miss: from left-hand thread bolts to hidden welding points. You will also find here unique data on the weights of key components (for example, the weight of the TD27T engine with attachments is 218 kg), which will be useful when planning work with a winch or crane.

The article will be useful both to owners who want to disassemble the car with their own hands for major repairs, and to those who buy Terrano for spare parts. We will not describe trivial operations like removing a bumper - we will focus on difficult and dangerous stageswhere an error could result in damaged parts or personal injury.

Preparing for Disassembly: Tools and Safety Precautions

Before you begin, make sure you have everything you need. Nissan Terrano I — a car with many “surprises”: rusty bolts, stuck nuts and non-obvious fastenings. Here is a minimum set of tools that you cannot do without:

• 🔧 A set of sockets and keys (required with impact heads for rusty connections): 10, 12, 14, 17, 19 mm.
• 🔨 Hammer, chisel and grinder with cutting wheel (for “stubborn” bolts).
• 🔩 Pneumatic or cordless impact wrench (for example, DeWalt DCF899) - saves hours of time.
• 🔧 Special wrench for the hub nut (size 36 mm, often required for front suspension).
• 🛠️ Jacks (minimum 2 pcs. with a load capacity of 2–3 tons) and stands for the frame.
• 🔌 Multimeter for checking electrical wiring before disconnecting the battery.
• 🧲 Magnet on the telescopic handle - so as not to lose fallen bolts in the dirt.

Pay special attention security measures:

• 🩹 A first aid kit and a fire extinguisher should be at hand - when cutting metal, sparks can ignite oil or fuel.
• 👓 Safety glasses and rubber coated gloves (e.g. Mechanix Wear) - required when working with rust.
• 🚗 Carry out disassembly on a flat area with hard surface. If the vehicle is on the ground, place wheel chocks under the wheels.

⚠️ Attention: Never work under a machine that is supported only by a jack! Terrano I has a high center of gravity - even on a flat surface the car can tip over when dismantling heavy components (for example, a bridge). Use frame stands or special racks.

Before starting disassembly, take photographs of key components (for example, wiring under the hood or the driveshaft mount). This will save hours on reassembly. We also recommend making dismantling plan - for example, if you are disassembling a car for painting, first remove all attachments, then the doors, and only then the body panels.

Removal of body panels: doors, hood, fenders

Body Terrano I assembled with rivets and welded points, so disassembly requires care. Let's start with the most problematic areas - doors and fenders, where rust most often accumulates.

Removing the doors:

1. Open the door and remove the trim (it is attached to plastic clips - pry them off with a screwdriver).
2. Disconnect the electrical wiring (if there are power windows or mirrors).
3. Support the door from below with a jack or ask an assistant to support it - the weight of the door with mechanisms reaches 25–30 kg.
4. Unscrew the hinge bolts (usually 4 pieces per door, size 14 mm). If the bolts are stuck, use a penetrating lubricant (WD-40 or Liqui Moly MoS2) and give it time to work (at least 15 minutes).

Fenders and hood: The wings are attached to the body with bolts (10–12 mm) and spot welding. If the wing is rusty, it is easier to cut it off with a grinder, leaving 1–2 cm of metal for future welding of a new wing. The hood is removed after unscrewing 4 bolts (2 on each side) and disconnecting the lock cable.

⚠️ Attention: When removing the hood Terrano I Be careful with the hinges - they often break due to rust. If the hinges are jammed, do not try to “rip them out” - it is better to cut them off with a grinder and then install new ones (article: 60010-W1000 for the left, 60011-W1000 for the right one).

If you are disassembling a car for complete body restoration, pay attention to the following "weak points":

• 🚗 Thresholds are almost always rotten, especially in places where they are attached to the frame.
• 🚪 Bottom corners of doors - moisture accumulates there.
• 🔧 Spars under the bumper often rust from the inside.

Disconnect battery (to avoid short circuit)

Take photos of the fastenings and wiring

Prepare markers for marking parts

Check availability of spare clips and bolts -->

Dismantling the suspension and chassis

Suspension Terrano I - one of the most reliable in its class, but it also requires attention when disassembling. Let's start with the front suspension, where problems most often arise with ball joints and silent blocks.

Front suspension:

• 🔧 First unscrew the hub nut (size 36 mm) - it often sticks, so use an extension for the lever.
• 🔩 Then remove the brake disc caliper (secure it with wire so as not to damage the hose).
• 🛠️ Disconnect the steering linkage from the steering knuckle (use a puller to avoid damaging the boot).
• 🔧 Remove the shock absorber and spring (pre-tighten the spring with zip ties!).

Rear axle and springs: Rear suspension Terrano I built on springs, which are attached to the frame through brackets. When disassembling, pay attention to:

• 🔧 The condition of the silent blocks of the springs - if they have fallen apart, the bridge may “walk” when moving.
• 🛠️ Integrity of spring leaves - often break off-road.
• 🔩 Bridge fastening nuts (size 22 mm) - they need to be unscrewed only after the car is raised and securely fixed.

Suspension unit	Weight, kg	Key bolts (size)	Common problems
Front axle assembly	85–90	19 mm (mount to frame)	Worn ball joints, leaking seals
Rear axle (with gearbox)	110–120	22 mm (attachment to springs)	Bearing play, wear of satellites
Spring (set)	12–15	14 mm (mounting brackets)	Cracks in sheets, subsidence
Front shock absorber	3–4	14 mm (top mount)	Oil leak, rod wear

When disassembling the chassis Terrano I there is often a problem with stuck hub nuts. If standard methods (penetrating lubrication, heating) do not help, use the following algorithm:

1. Place the socket on the nut and hit it with a hammer (this will help break up the corrosion).
2. Use a pipe extension for leverage - but don't overdo it or you'll strip the threads.
3. If the nut does not budge, cut it off with a grinder, but be careful not to damage the threads on the hub.

Removing the engine and gearbox

Dismantling the power unit is the most labor-intensive stage of disassembly Terrano I. Engines TD27 (diesel) and KA24E (gasoline) have different nuances, but the general algorithm is similar. You will need:

• 🔧 Winch or beam crane with a lifting capacity of at least 300 kg.
• 🛠️ A set of extensions for heads (some gearbox mounting bolts are hidden deep).
• 🔩 Container for draining oil and antifreeze.
• 🧰 Tray for small parts (nuts, washers, brackets).

Step by step instructions:

1. Drain all technical fluids (oil, antifreeze, fuel).
2. Disconnect the battery by first removing the negative terminal.
3. Remove the radiator and fan (on TD27 the fan has a fluid coupling - be careful with its fastening).
4. Disconnect all electrical connectors (alternator, starter, sensors).
5. Remove the driveshaft (mark the yoke position for proper assembly).
6. Unscrew the gearbox mountings to the frame (4 bolts, size 17 mm).
7. Hang the engine on the winch, then unscrew the engine supports (mounts).
8. Carefully remove the unit, avoiding distortions (weight TD27T with checkpoint - approx. 280 kg).

⚠️ Attention: On diesel TD27 And TD27T fuel equipment is extremely sensitive to dirt. Before removing the engine, cover all openings (for example, the intake manifold) with a rag or polyethylene. Also remember that the turbine (if equipped) has ceramic blades - do not drop it or clean it with metal brushes!

If you are disassembling an engine for a major overhaul, pay attention to the following parts:

• 🔧 Cylinder head (cylinder head) - on TD27 often cracks between the valves. Check it for leaks after removal.
• 🛠️ Crankshaft and bearings — wear of the liners over a mileage of 300,000 km is almost guaranteed.
• 🔩 Fuel injection pump (high pressure fuel pump) — if it fails, it is unprofitable to repair it (the price of a new one is ~50,000 rubles).

How to check compression in TD27 cylinders without a compression gauge?

If you don't have a compression gauge, you can roughly estimate the compression by eye:

1. Unscrew all glow plugs.

2. Crank the engine with the starter - if the air coming out of one cylinder is weaker than the others, there is low compression.

3. Also pay attention to the color of the smoke: blue smoke indicates oil getting into the combustion chamber (wear of rings or liners).

Disassembly of interior and electrics

Salon Terrano I It is easier to disassemble than the body or suspension, but there are pitfalls here. The main problem is fragility of plastic, which breaks if dismantled carelessly (especially the instrument panel and door cards).

Disassembly sequence:

1. Remove the seats (they are secured with 4 14mm bolts).
2. Remove the center console - it is held on by clips and two bolts under the glove compartment.
3. Disconnect all electrical wiring connectors (take photographs of their locations first!).
4. Remove the dashboard - it is secured with 6–8 bolts (10 mm) and clips on the sides.
5. Remove the instrument panel (be careful - the speedometer and tachometer arrows are easy to bend).

Pay special attention electrical:

• 🔌 Check the condition of the wiring harnesses - they often rub against the metal of the body.
• 🔋 Battery terminals are usually oxidized - clean them before disconnecting.
• 📡 The radio antenna is attached with a nut under the dashboard - do not lose it when removing the radio.

⚠️ Attention: B Terrano I There is a hidden fuse box under the steering wheel (behind a plastic cover). If after disassembling the interior something does not work (for example, wipers or lighting), check this unit - often the fuses fall out when dismantling the dashboard.

If you are disassembling the interior for reupholstery or sound insulation, consider the following points:

• 🚗 It is better to remove carpets and floor upholstery last - rusty areas are often hidden under them.
• 🔊 Audio system speakers are attached with self-tapping screws (usually 4 pieces per speaker).
• 🛠️ The steering wheel is removed after unscrewing the nut (22 mm), but before that, be sure to remove the negative terminal from the battery!

Working with frame and all-wheel drive

Frame Terrano I - This is the basis of the car, and its disassembly requires special care. Most often, the frame is disassembled for repair after an accident or replacing rotten areas. Here are the key points:

Frame removal:

• 🔧 The frame is attached to the body with 8–10 bolts (size 17–19 mm) and several rivets.
• 🛠️ Before removing the frame, be sure to disconnect all rods, stabilizers and brake pipes.
• 🔩 Frame weight - approx. 180–200 kg, so use a crane or winch.

Transfer case and driveshafts: Four-wheel drive Terrano I - that's a different story. When disassembling, pay attention to:

• 🔧 Condition of transfer case seals - they often leak over 200,000 km.
• 🛠️ There is play in the spline joints of the cardans - if there is any, the crosspieces need to be replaced.
• 🔩 Nuts securing the transfer case to the frame (size 19 mm) - they need to be unscrewed only after removing the cardans!

If you are planning restore frame geometry after an accident, please note that Terrano I has the following control points:

• 📏 Distance between side members at the front: 1380 ± 5 mm.
• 📏 Distance between rear spring mounts: 1420 ± 5 mm.
• 📏 Frame height from the ground (without load): 280–300 mm.

⚠️ Attention: When welding on the frame, be sure to disconnect all electrical connectors and remove the battery. Welding near the fuel tank or brake pipes may cause a fire! Also do not forget that the frame after welding requires degreasing and priming - otherwise it will quickly rust.

Common mistakes and how to avoid them

Even experienced craftsmen sometimes make mistakes when disassembling Nissan Terrano I. Here are the most common ones and how to prevent them:

1. Damage to threads when unscrewing bolts:

• 🔧 Always use penetrating lubricant (For example, PB Blaster) and give it time to work.
• 🛠️ If the bolt does not fit, do not increase the length of the lever - it is better to cut a new thread or drill out the bolt.

2. Loss of small parts:

• 🧲 Use a magnetic tray for bolts and nuts.
• 📦 Sort parts into labeled bags (for example, “Left front suspension”).

3. Incorrect electrical disconnection:

• 🔌 Always disconnect the negative battery terminal first.
• 📸 Take photos of the connectors before disconnecting - this will save hours during assembly.

4. Ignoring rust:

• 🚗 If you see rust on a bolt, do not try to unscrew it “dry” - this will lead to the edges breaking.
• 🔩 Use heating (gas torch) for stuck nuts, but do not overheat bearings or rubber parts.

5. Incorrect disassembly of the turbine (for TD27T):

• 🌀 Never drop the turbine - ceramic blades break easily.
• 🛠️ Before removing the turbine, check the shaft play - if there is any, the turbine must be replaced.

FAQ: Answers to frequently asked questions

Which engine for the Nissan Terrano I is the most reliable?

Among the engines Terrano I The leaders in reliability are:

• 🔧 TD27 (diesel) - resource 400,000+ km with proper maintenance, but sensitive to fuel quality.
• 🔧 KA24E (petrol) - easier to repair, but less economical. Resource is about 300,000 km.

Worst option - TD27T (turbodiesel) on later models. The turbine often fails after 200,000 km, and repairs are expensive.

Is it possible to disassemble the Terrano I without a pit or lift?

Theoretically, yes, but it is extremely inconvenient and dangerous. For example:

• 🚗 To remove the engine, you will need a winch or a beam crane.
• 🔧 Dismantling the rear axle without a hole will take 2-3 times longer.
• ⚠️ The risk of the car overturning when dismantling the suspension on the ground is very high.

Minimum set for disassembly without a hole: 2 jacks (3 tons each), 4 stands for the frame, and an assistant for insurance.

How long does it take to completely disassemble a Terrano I?

The time depends on the condition of the machine and your experience:

• 🕒 Partial disassembly (for example, engine + gearbox removal): 1–2 days.
• 🕒 Complete disassembly (to bare body and frame): 3–5 days.
• 🕒 Disassembly for parts (with sorting and marking of parts): up to 1 week.

Advice: don’t try to do everything in one day - fatigue leads to mistakes and injuries.

Where is the best place to sell spare parts after disassembly?

The most profitable platforms for selling used spare parts with Terrano I:

• 🌍 Avito - fast, but there are a lot of scammers.
• 🌍 Drom.ru — good demand for rare parts (for example, a transfer case or axle).
• 🌍 Groups in VK and Telegram (for example, "Nissan Terrano WD21").
• 🌍 Forums (For example, 4x4club.ru) - where buyers are willing to pay more for original parts.

Tip: before selling, clean the parts from dirt and photograph them against a white background - this will increase the chances of selling.

What Terrano I parts are most often bought at disassembly?

Top 5 most popular spare parts:

1. 🔧 Engines TD27 And KA24E (especially when assembled with a gearbox).
2. 🚗 Axles (front and rear) - often bought for tuning other cars.
3. 🔩 Transfer cases rarely break down, but repairs are expensive.
4. 🛠️ Body panels (fenders, hood, doors) - for restoration.
5. 🔋 Electrics (generators, starters, fuse boxes).

Less in demand: seats, plastic interior, glass (except windshield).