NISSAN X-TRAIL 2003 Electronic Repair Manual

DRIVE BELTS
EM-111
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
AIR CONDITIONER COMPRESSOR BELT
1. Remove RH splash cover (with undercover attached).
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
lRefer toEM-110, "Checking Drive Belts".
4. Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1. Loosen adjusting lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
lRefer toEM-110, "Tension Adjustment".
4. Tighten nut (C) and bolt (D) in this order.
Removal and InstallationEBS00BNZ
REMOVAL
1. Loosen each belt. Refer toEM-110, "Tension Adjustment".
2. Remove air conditioner compressor belt.
3. Remove alternator and water pump belt.
INSTALLATION
1. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer toEM-110, "
Tension Adjustment".
3. Tighten nuts and bolts provided for adjustment to the specified torque.
4. Check again that each belt tension is as specified.Nut A:
: 31 - 39 N-m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
JEM251G
Nut C:
: 19 - 24 N-m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N-m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)

EM-112
[YD22DDTi]
AIR CLEANER AND AIR DUCT
AIR CLEANER AND AIR DUCT
PFP:16500
Removal and InstallationEBS00BO7
REMOVAL
1. Remove mass air flow sensor harness clamp.
2. Remove harness connector from mass air flow sensor.
3. Remove air duct, air cleaner case/ mass air flow sensor.
lAdd marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case.
CAUTION:
Handle mass air flow sensor with following cares.
lDo not shock it.
lDo not disassemble it.
lDo not touch its sensor.
INSTALLATION
1. Attach each joint aligning marks put at removal. Screw clamps firmly.
2. Install in the reverse order of removal.
CHANGING AIR CLEANER ELEMENT
1. Remove air cleaner case.
SBIA0149E
1. Air cleaner case (upper) 2. Clamp 3. Air duct
4. Mass air flow sensor 5. Grommet 6. Air duct side
7. Mounting rubber 8. Air cleaner case (lower) 9. Air cleaner element

AIR CLEANER AND AIR DUCT
EM-113
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. Remove clips and lift up air cleaner upper case.
3. Remove air cleaner element.

EM-114
[YD22DDTi]
CHARGE AIR COOLER
CHARGE AIR COOLER
PFP:14461
Removal and InstallationEBS00BO8
REMOVAL
Remove and install with bottom bracket as an assembly
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
lBe careful not to deform core fins.
lFor cleaning procedure of charge air cooler core, refer toCO-35, "Checking Radiator".
INSTALLATION
Pay attention to identification mark color and direction when installing air inlet hoses. Refer toEM-114,
"Removal and Installation".
SBIA0150E
1. Charge air cooler cover 2. Charge air cooler 3. Gasket
4. Air inlet tube 5. Air inlet hose 6. Air inlet hose
7. Bracket

INTAKE MANIFOLD
EM-115
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00BO9
REMOVAL
WA RN ING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
2. Remove air duct. Refer toEM-112, "
Removal and Installation".
3. Remove charge air cooler and bracket. Refer toEM-114, "
Removal and Installation".
4. Remove air inlet pipes. Refer toEM-119, "
Removal and Installation"
5. Remove exhaust manifold cover.
6. Disconnect electronic EGR control valve water hoses and harness.
7. Disconnect heater hose.
SBIA0151E
1. Vacuum & fuel gallery 2. Water hose 3. Electronic EGR volume control valve
4. Gasket 5. EGR passage 6. EGR support
7. Water pipe 8. EGR tube 9. Intake manifold

EM-116
[YD22DDTi]
INTAKE MANIFOLD
8. Remove EGR tube.
9. Remove vacuum hose.
10. Remove injection tube. Refer toEM-135, "
Removal and Installa-
tion".
11. Remove water pipe.
12. Remove fuel hose.
lTo prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
13. Loosen bolts and nuts in the reverse order of that shown in the
figure.
CAUTION:
Do not disassemble or adjust swirl control valve.
14. Remove electronic EGR control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
lConnect vacuum handy pump to actuator, and apply vacuum to close swirl control valve.
lCheck distortion on the mounting surface with a straightedge
and feeler gauge.
Swirl Control Valve
lConnect vacuum handy pump to actuator, confirm that rod
moves smoothly in accordance with the amount of vacuum
applied and vacuum is maintained.
INSTALLATION
Following instructions below, install in reverse order of removal.
1. Install EGR vacuum control valve.
lHandle with care avoiding any shocks.
SBIA0152E
SBIA0153E
Limit : 0.1 mm (0.004 in)
SBIA0154E
Vacuum reference value (Approx.)
At start of rod movement
: – 8.0 Kpa (– 80 mbar, – 60 mmHg, – 2.36 inHg)
At end of rod movementApprox.
: –26.7Kpa(–267bar,–200mmHg,–7.87inHg)
SBIA0155E

INTAKE MANIFOLD
EM-117
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
lDo not disassemble or adjust.
2. Install intake manifold.
lTighten fixing bolts and nuts in numerical order as shown in the figure.
lWhen stud bolts come off, install with the following torque..
3. Install water hose.
lInstall water hose by referring to identification marks avoiding
twisting.
lWhen an insert stopper is not provided with the pipe, insert
the hose up to dimension A. When the pipe is shorter than
dimension A, insert hose fully until it reaches the end.
lWhen an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
lWhen marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
4. Install remaining parts in reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer toFL-16,
"Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Dimension A : 25 - 30 mm (0.984 - 1.181 in)
SBIA0156E

EM-118
[YD22DDTi]
CATALYST
CATALYST
PFP:20905
Removal and InstallationEBS00BOA
REMOVAL
1. Remove engine under cover.
2. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
3. Remove radiator upper hose.
4. Remove radiator fan. Refer toCO-33, "
Removal and Installation".
5. Remove radiator mount bracket and radiator.
6. Remove water inlet pipe.
7. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
8. Remove catalyst.
CAUTION:
Do not disassemble.
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
INSTALLATION
Install in reverse order of removal.
lPushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
SBIA0157E
1. Insulator 2. Catalyst 3. Catalyst rear diffuser
4. Gasket
Catalyst locking pin : Flange bolt (black)
Insulator mounting bolt : Washer bolt (silver or yellow)

EXHAUST MANIFOLD AND TURBOCHARGER
EM-119
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00BOB
REMOVAL
1. Drain engine coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove charge air cooler. Refer toEM-114, "
Removal and Installation".
3. Remove air duct and air inlet pipe. Refer toEM-112, "
Removal and Installation".
4. Remove engine under cover.
5. Remove radiator upper hose.
6. Remove radiator fan. Refer toCO-34, "
Disassembly and Assembly Radiator Fan".
7. Remove radiator mount bracket and radiator. Refer toCO-33, "
Removal and Installation".
8. Remove water inlet pipe.
9. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
10. Remove catalyst. Refer toEM-118, "
Removal and Installation".
11. Remove exhaust manifold cover.
12. Remove insulator.
13. Each wiring and piping (disconnect/move)
SBIA0158E
1. Electronic EGR control valve 2. Gasket 3. EGR tube
4. Air inlet pipe 5.Exhaust manifold & turbocharger
assembly6. Oil return hose
7. Turbo insulator 8. Exhaust manifold insulator 9. Air inlet pipe

EM-120
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
14. Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
15. Rotate the exhaust manifold and turbocharger assembly so that
the rear side (EGR tube mounting side) faces upward. And then
pull out the assembly from between the engine and the air con-
ditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling
out the assembly.
INSTALLATION
lWhen a stud bolt is pulled out, tighten it to the following torque:
lTighten the exhaust manifold mounting nuts in the following procedure:
1. Tighten the nuts in the order specified in the figure.
2. Re-tighten the nuts 1 to 4.
3. Install the gasket so that the alignment protrusion faces the No.
4port.
4. Install in reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
JEM266G
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
JEM266G