NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-71
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9. Restart tightening of lower cylinder block bolts with the following
procedure.
NOTE:
Step “a ”and “b” have been completed before installation of rear
oil seal (step 7).
a. Step “a” has been completed before installation of rear oil seal.
b. Step “b” has been completed before installation of rear oil seal.
c. Tighten M10 bolts to 60 to 65°(target: 60°) in order from 1to 10.
d. Tighten M8 ( in) bolts to 19.6 to 24.5 N·m (2.0 to 2.5 kg-m, 15 to
18 ft-lb) in order from 11 to 22.
CAUTION:
In step “c”, use an angle wrench (special service tool) or
protractor to check tightening angle. Do not make judgment
by visual inspection.
lAfter installing mounting bolts, make sure that crankshaft
can be rotated smoothly by hand.
lWipe off completely any protruding liquid gasket on front side
of engine.
lCheck crankshaft side clearance. Refer toEM-80, "CRANK-
SHAFT SIDE CLEARANCE".
10. Install the piston to the connecting rod.
a. Usingasnapringpliers,installthesnapringtothegroovesof
the piston rear side.
lInsert it fully into groove to install.
b. Install the piston to the connecting rod.
lUsing an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 C°(140 to 158°F)]. From the front to the rear, insert the piston
pin into the piston and the connecting rod.
lAssemble so that the front mark on the piston crown and the
oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown in the figure.
c. Install the snap rings to the front of the piston.
lAfter installing, check that the connecting rod moves
smoothly.
11. Using a piston ring expander, install the piston rings.
CAUTION:
Be careful not to damage the piston.
lPosition each ring with the gap as shown in the figure refer-
ring to the piston front mark.
lInstall the top ring and the second ring with the stamped sur-
face facing upward.
KBIA0063E
KBIA0065E
PBIC0099E
Stamped mark : 1E (top ring)
: 2A (second ring)
PBIC0100E

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12. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
lWhen installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
lWhen installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
lCheck the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft.
lPosition the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
lApply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
lMatch the cylinder position with the cylinder No. on the con-
necting rod to install.
lUsing a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.
14. Install the connecting rod cap.
lMatch the stamped cylinder number marks on the connecting
rodwiththoseonthecaptoinstall.
15. Tighten the connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of the connecting rod
bolts.
b. Tighten bolts to 18.6 to 20.6 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
c. Put mating (with paint) on each bolt and connecting rod cap, all
in the same direction (when using a protractor).
d. Then tighten all bolts 90 to 95 degrees clockwise (target: 90
degrees) (Angle tightening).
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.
lAfter tightening the bolt, make sure that the crankshaft rotates smoothly.
lCheck the connecting rod side clearance. Refer toEM-81, "CONNECTING ROD SIDE CLEARANCE".
PBIC0266E
PBIC0267E
KBIA0067E
KBIA0068E

CYLINDER BLOCK
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16. Install flywheel (M/T models) or drive plate (A/T models).
lInstall drive plate, reinforcement plate and pilot converter as
showninfigure.
lUsing drift of 33 mm (1.30 in) in diameter, push pilot converter
into the end of crankshaft.
17. Install knock sensor.
lMake sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor.
lInstall sensor with connector facing lower left by 45°as show.
lDo not tighten the mounting bolts while holding the connector.
lMake sure that the knock sensor does not interfere with other-
parts.
CAUTION:
If any impact by dropping is applied to the knock sensor,
replace it with new one.
18. Install crankshaft position (POS) sensor.
19. Install followings in reverse order of removal.
How to Select Piston and BearingEBS009R9
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.
lThe identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
lFor reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
lFor details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
KBIA0075E
KBIA0069E
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end inner
diameter and crankshaft pin
outer diameter determine con-
necting rod bearing selection.
Between cylinder block to pis-
tonPiston and piston pin assembly
Thepistonisavailabletogether
with piston pin as an assembly.Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
*Between piston to connecting
rod———

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HOW TO SELECT PISTON
When New Cylinder Block is Used:
lCheck the cylinder bore grade on rear left side of cylinder block, and select a piston of the same grade.
lIf there is a corrected stamp mark on the cylinder block, use it as
a correct reference.
When Cylinder Block is Reused:
1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”. Select the piston of the same grade.
Piston Selection Table
Unit: mm (in)
NOTE:
lThe piston is available together with piston pin as an assembly.
lThe piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected. (Only 0 grade is available.)
HOW TO SELECT CONNCTING ROD BEARING
When New Connecting Rod and Crankshaft are Used:
1. Apply big end inside diameter grade stamped on connecting rod
side face to the row in the “Connecting Rod Bearing Selection
Table”.
KBIA0070E
KBIA0259E
Grade number (Mark) 1 2 (or no mark) 3
Inner diameter of cylinder bore 89.000-89.010 (3.5039-3.5043) 89.010-89.020 (3.5043-3.5047) 89.020-89.030 (3.5047-3.5051)
Outer diameter of piston 88.980-88.990 (3.5031-3.5035) 88.990-89.000 (3.5035-3.5039) 89.000-89.010 (3.5039-3.5043)
KBIA0067E

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2. Apply pin diameter grade stamped on crankshaft front side to
the column in the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column
in the “Connecting Rod Bearing Selection Table”. selective-fit
service parts table.
4. Apply the symbol obtained to connecting rod bearing grade table
to select.
When Crankshaft and Connecting Rod are Reused:
1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin
individually.
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table” selective-fit service
parts table.
3. The following steps are same as in Step 3 or later in “When New Connecting Rod and Crankshaft are
Used”.
KBIA0073E

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Connecting “Rod Bearing Selection Table”.
Connecting “Rod Bearing Grade Table”.
Under size Bearings Usage Guide
lWhen the specified oil clearance is not obtained with standard size connecting rod bearings, use under
size (US) bearings.
lWhen using under size bearing, measure the bearing inner diameter with bearing installed, and grind the
crankshaft pin so that the oil clearance satisfies the standard.
KBIA0147E
Grade0123
Upper / Lower thickness
mm (in)1.499 / 1.495
(0.0590 / 0.0589)1.503 / 1.499
(0.0592 / 0.0590)1.507 / 1.503
(0.0593 / 0.0592)1.511 / 1.507
(0.0595 / 0.0593)
Identification color Black Brown Green Yellow

CYLINDER BLOCK
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Bearing under size table
Unit: mm (in)
CAUTION:
In grinding the crankshaft pin to use under size bearings, keep
the fillet R (All crankshaft pins).
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used:
1. “Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block.
lIf there is a corrected stamp mark on the cylinder block, use it
as a correct reference.
2. Apply journal diameter grade stamped on crankshaft front side
to column in “Main Bearing Selection Table”.
3. Find sign at crossing of row and column in “Main Bearing Selection Table”.
CAUTION:
lThere are two main bearing selection tables. One is for odd-numbered journals (1, 3 and 5) and
the other is for even-numbered journals (2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to “Main Bearing Grade Table” to select.
NOTE:
lService parts is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused:
1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Apply measurement in above step 1 to “Main Bearing Selection Table”.
3. Follow step 3 and later in “When new cylinder block and crankshaft are used”.
Size Thickness
US 0.25 (0.0098) 1.624 - 1.632 (0.0639 - 0.0643)
KBIA0148E
KBIA0070E
KBIA0073E

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Main Bearing Selection Table (No.1,3 and No.5 journals)
KBIA0149E

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Main Bearing Selection Table (No.2 and 4 journals)
Main Bearing Grade Table (All Journals)
Unit: mm (in)
KBIA0150E
Grade number ThicknessIdentification color
(UPR / LWR)Remarks
0 1.973 - 1.976 (0.0777 - 0.0778) Black
Grade and color are the same
for upper and lower bearings. 1 1.976 - 1.979 (0.0778 - 0.0779) Brown
2 1.979 - 1.982 (0.0779- 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow
4 1.985 - 1.988 (0.0781 - 0.0783) Blue
5 1.988 - 1.991 (0.0783 - 0.0784) Pink
6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White

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Use Undersize Bearing Usage Guide
lUse undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
lWhen using undersize (US) bearing, measure the bearing inner diameter with bearing installed, and grind
journal until oil clearance falls within specification.
Bearing undersize table
Unit: mm (in)
CAUTION:
Keep fillet R when grinding crankshaft journal in order to use
undersize bearing (All journals).
Inspection After DisassemblyEBS009RA
CRANKSHAFT SIDE CLEARANCE
lUsing a dial gauge, measure the clearance between the thrust
bearings and the crankshaft arm when the crankshaft is moved
fully forward or backward.
lIf the measured value exceeds the limit, replace the thrust bear-
ings, and measure again. If it still exceeds the limit, replace the
crankshaft also.
01UPR 1.973 - 1.976 (0.0777 - 0.0778)
Black / Brown
Grade and color are different
for upper and lower bearings. LWR 1.976 - 1.979 (0.0778 - 0.0779)
12UPR 1.976 - 1.979 (0.0778 - 0.0779)
Brown / Green
LWR 1.979 - 1.982 (0.0779 - 0.0780)
23UPR 1.979 - 1.982 (0.0779- 0.0780)
Green / Yellow
LWR 1.982 - 1.985 (0.0780 - 0.0781)
34UPR 1.982 - 1.985 (0.0780 - 0.0781)
Ye l l o w / B l u e
LWR 1.985 - 1.988 (0.0781 - 0.0783)
45UPR 1.985 - 1.988 (0.0781 - 0.0783)
Blue / Pink
LWR 1.988 - 1.991 (0.0783 - 0.0784)
56UPR 1.988 - 1.991 (0.0783 - 0.0784)
Pink / Purple
LWR 1.991 - 1.994 (0.0784 - 0.0785)
67UPR 1.991 - 1.994 (0.0784 - 0.0785)
Purple / White
LWR 1.994 - 1.997 (0.0785 - 0.0786) Grade number ThicknessIdentification color
(UPR / LWR)Remarks
Size Thickness
US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832)
KBIA0148E
Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in)
Limit : 0.30 mm (0.0118 in)
PBIC0268E