NISSAN X-TRAIL 2003 Electronic Repair Manual

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-101
[QR20DE]
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Balancer unit timing chain tensioner 6.4 - 7.5 (0.65 - 0.76, 57 - 66) *2
*1 Balancer unit 1) 45.2 - 51.0 (4.6 - 5.2, 34 - 37)
2) 90°-95°(Angle tightening)
3) 0 ,(0.0 ,0)
4) 45.2 - 51.0 (4.6 - 5.2 ,34 - 37 )
5) 90°-95°(Angle tightening)
*1 Cylinder head 1) 98.1 (10.0, 72)
2) 0 (0.0, 0)
3) 34.3 - 44.1 (3.5 - 4.5, 26 - 32)
4) 75°-80°(Angle tightening)
5) 75°-80°(Angle tightening)
Flywheel (M/T)103 - 113 (10.5 - 11.5, 76 - 83)
Drive plate (A/T)103 - 113 (10.5 - 11.5 ,76 - 83)
Connecting rod bearing cap 1) 18.6 - 20.6 (1.9 - 2.1, 14 - 15)
2) 90°-95°(Angle tightening)
*1 Lower cylinder block M10 bolt 1) 36.3 - 42.2 (3.7 - 4.3, 27 - 31)
M10 bolt 2) 60°-65°(Angle tightening)
M8 bolt 3) 19.6 - 24.5 (2.0 - 2.5 , 15 - 18)
Knock sensor15.7 - 26.5 (1.6 - 2.7, 12 - 19)
Oil pressure switch12.3 - 17.2 (1.25 -1.75 , 9 - 12)
Signal plate1) 12-14(1.2-1.4,9-10)
Crankshaft position sensor (POS) 5.4 - 7.3,(0.55 - 0.75 , 48 - 64) *2

EM-102
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Drain CoolantEBS00BNO
lDrain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00BNP
lBefore starting work, make sure no fire or spark producing items are in the work area.
lRelease fuel pressure before disassembly.
lAfter disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00BNQ
lWhen instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
lExercise maximum care to avoid damage to mating or sliding surfaces.
lCover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
lMark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
lWhen loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00BNR
lBefore repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS00BNS
lUse torque wrench to tighten bolts or nuts.
lWhen tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
lReplace with new gasket, packing, oil seal or O-ring.
lThoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
lAvoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
lRelease air within route after draining coolant.
lAfter repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular TighteningEBS00BNT
lUse an angle wrench for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
lDo not use a torque value for final tightening.
lThe torque value for these parts are for a preliminary step.
lEnsure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS
EM-103
[YD22DDTi]
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Precautions for Liquid GasketEBS00BNU
REMOVAL OF LIQUID GASKET SEALING
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
lIn areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
gasket to the groove.
lAs for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the text of service manual.
lWithin five minutes of gasket application, install the mating com-
ponent.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten after the installation.
lAfter 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe
them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F

EM-104
[YD22DDTi]
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEBS00BNV
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV11105900
Engine sub-attachmentUsed with KV10106500
KV10115600
Valve oil seal driftInstalling valve oil seal
UsesideA.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV11103000
Injection pump drive gear pullerRemoving crankshaft pulley
NT042
NT028
NT799
NT603
NT605
NT676

PREPARATION
EM-105
[YD22DDTi]
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KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
PlatePreventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopperChanging valve lifter shims
ST16610001
Pilot bushing pullerRemoving crankshaft pilot bushing
KV10111100
Seal cutterRemoving steel oil pan and rear timing chain
case
WS39930000
Tube presserPressing the tube of liquid gasket
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc.
KV10109300
Pulley holdera: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia. Tool number
Tool nameDescription
NT617
NT041
NT045
NT046
NT052
NT014
NT628

EM-106
[YD22DDTi]
PREPARATION
Commercial Service Tools
EBS00BNW
KV11106010
Hexagon wrencha: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
KV11106020
Hexagon wrencha: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pina: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrencha: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrencha: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
Removing and installing mountingbolts of
fuel injection pump sprocket
KV11106060
Sprocket holderHolding fuel injection pump sprocket Tool number
Tool nameDescription
NT801
NT803
NT804
NT805
SBIA0224E
SBIA0225E

PREPARATION
EM-107
[YD22DDTi]
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Tool nameDescription
Valve seat cutter set Finishing valve seat dimensions
Piston ring compressor Installing piston assembly into cylinder bore
Piston ring expander Removing and installing piston ring
TORX socket
Standard Universal
NT048
NT044
NT030
NT807
NT808

EM-108
[YD22DDTi]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting —Engine NoiseEBS00BO5
SBIA0148E

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
EM-109
[YD22DDTi]
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Use the Chart Below to Help You Find the Cause of the Symptom.EBS00BO6
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTick in g o r
clickingCA—AB—Tappet
noiseValve clearanceEM-154
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-151EM-150
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearance (Small
end)EM-201
EM-203
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-204EM-201
EM-202
EM-202
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance (Small
end)
Connecting rod bear-
ing oil clearance (Big
end)EM-203EM-206
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-206EM-206
Front of
engine
Timin g
chain
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-158
EM-163
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-110
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-40,
"WATER
PUMP"

EM-110
[YD22DDTi]
DRIVE BELTS
DRIVE BELTS
PFP:02117
Checking Drive BeltsEBS00BNX
lBefore inspecting the engine, make sure the engine has cooled
down; wait approximately 30 minutes after the engine has been
stopped.
lVisually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.
lWhen measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
lWhen checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing the crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
lTighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00BNY
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the value specified under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with oil or cooling water etc.
lDo not twist or bend the belts with strong force.
JEM249G
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
Air conditioner compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator