NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER HEAD
EM-181
[YD22DDTi]
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3. Remove cylinder head valve guide hole.
4. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.
5. Using valve guide drift, press fit valve guides from camshaft
side, referring to the dimension shown in the figure.
6. Using valve guide reamer, perform reaming to the press-fitted
valve guides.
Valve Seat Contact
lBefore starting this check, confirm that the dimension of valve
guide and valves are as specified.
lApply red lead primer on contacting surfaces of valves seat and
of valve face to examine the conditions of contacting surfaces.
lCheck that the paint on contacting surfaces is continuous along
the entire circumference.
lIf there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace valve
seat.
Valve Seat Replacement
lWhen removing valve seat, replace it with oversized [0.5 mm (0.0020 in)] valve seat.
1. Cut valve seat to make it thin, and pull it out.Valve guide hole diameter (for service parts):
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
Projection “L” : 10.4 - 10.6 mm (0.409 - 0.417 in)
JEM156G
Reaming specifications:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)
FEM072
EMA0487D

EM-182
[YD22DDTi]
CYLINDER HEAD
2. Machine cylinder head inner diameter at valve seat installation
position.
3. Heat cylinder head to approximately 110 to 130°C(230to
266°F) in oil bath.
4. After cooling valve seats sufficiently with dry ice, press fit it to cylinder head.
CAUTION:
Do not touch the cooled valve seats directly by hand.
5. Using valve seat cutter, finish processing referring to the dimen-
sions shown in the figure.
CAUTION:
When using valve seat cutter, grasp cutter handle with both
hands, press cutter onto contacting face all around, and cut
thoroughly. If cutter is pressed unevenly or repeatedly, the
valve seat surface may be damaged.
6. Using compound, perform valve fitting.
7. Check again to make sure that contacting status is satisfactory.
For details, Refer toEM-181, "
Valve Seat Contact". Machining dimension:
Intake
30.500 - 30.516 mm (1.2008 - 1.2014 in) dia.
Exhaust
29.500 - 29.516 mm (1.1614 - 1.1620 in) dia.
SEM795A
FEM075
SBIA0197E

CYLINDER HEAD
EM-183
[YD22DDTi]
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8. Use a depth gauge to measure the distance between the mount-
ing surface of the cylinder head spring seat and the valve stem
end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace the valve seat with a
new one.
Valve Spring Sequences
Position a straightedge to valve spring, turn the spring, and measure
the maximum clearance value between top surface of spring and the
straightedge.
Valve Spring Dimensions and Valve Spring Pressure Load
Using valve spring tester, check the following.Valve seat resurface limit “L”:
Intake : 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust : 36.53 - 37.01 mm (1.4382 - 1.4571 in)
JEM253G
Limit : 1.9 mm (0.075 in)
PBIC0080E
Free length : 43.7 mm (1.720 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during
valve open: 24.82 mm (0.9772 in)
Loadwithvalve
open: 320 - 360 N
(32.65 - 36.73 kg, 71.9 - 80.9 lb)
SEM113

EM-184
[YD22DDTi]
ENGINE ASSEMBLY
ENGINE ASSEMBLY
PFP:10001
Removal and InstallationEBS00BOH
WAR NIN G:
lSituate vehicle on a flat and solid surface.
lPlace chocks at front and back of rear wheels.
lFor engines not equipped with engine slingers, attach proper slingers and bolts described in
PA R T S C ATA L O G.
CAUTION:
lAlways be careful to work safely, avoid forceful or uninstructed operations.
lDo not start working until exhaust system and coolant are cool enough.
lIf items or work required are not covered by the engine main body section, refer to the applicable
sections.
lAlways use the support point specified for lifting.
lUse either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
lFor supporting points for lifting and jacking point at rear axle, refer toGI-37, "Garage Jack and
Safety Stand".
REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle down ward.
Separate suspension member, and then separate engine and transaxle.
Preparation
SBIA0190E
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. RH engine mounting insulator
4. RH engine mounting bracket 5. Front engine mounting bracket 6. Front engine mounting insulator
7. Center member 8. LH engine mounting insulator 9. LH engine mounting bracket

ENGINE ASSEMBLY
EM-185
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1. Remove engine hood.
2. Drain coolant from radiator drain plug.
3. Remove the following parts.
lLH/RH under cover
lLH/RH front wheel
lBattery
lAuxiliary drive belt; Refer toE M - 111 , "Removal and Installation".
lAir duct and air cleaner case assembly; Refer toEM-112, "Removal and Installation".
lAlternator
lRadiator and radiator fan assembly; Refer toCO-33, "Removal and Installation".
lCharge air cooler
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
6. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
7. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
8. Remove clutch operating cylinder from transaxle, and move it aside.
9. Disconnect shift cable from transaxle.
Engine room RH
10. Remove engine coolant reservoir tank.
11. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
12. Remove exhaust front tube.
13. Remove propeller shaft.
14. Remove steering shaft from steering gear.
15. Disconnect power steering fluid cooler piping at a point between body and engine.
16. Remove ABS sensor from brake caliper.
17. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
18. Remove LH/RH suspension from steering knuckle under strut.
Removal
19. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
20. Liftwithhoistandsecuretheengineinposition.Slinger bolts:
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
SBIA0191E

EM-186
[YD22DDTi]
ENGINE ASSEMBLY
lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
21. Remove RH engine mounting insulator.
22. Pull LH engine mounting through-bolt out.
23. Remove mounting bolts at front end of center member.
24. Remove front suspension member mounting bolts and nuts.
25. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
26. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
27. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
28. Remove starter motor.
29. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lBefore starting engine, bleed air from fuel piping. Refer toFL-16, "Air Bleeding".
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
KBIA0256E
KBIA0257E
KBIA0270E

ENGINE ASSEMBLY
EM-187
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lBleed air from passages in pipes and tubes of applicable lines.

EM-188
[YD22DDTi]
CYLINDER BLOCK
CYLINDER BLOCK
PFP:11010
Disassembly and AssemblyEBS00BPQ
SBIA0198E

CYLINDER BLOCK
EM-189
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CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove engine assembly from the vehicle, then separate engine and transaxle. Refer toEM-184,
"ENGINE ASSEMBLY".
2. Remove clutch cover and disk. Refer toCL-15, "
CLUTCH DISC,
CLUTCH COVER AND FLYWHEEL".
3. If they need to be replaced, replace pilot bushing.
lUsing pilot bushing puller, remove the bushing from rear edge
of crankshaft.
4. Install engine to engine stand as follows.
a. Remove flywheel.
b. Secure ring gear with ring gear stopper, then loosen mounting
bolts with TORX bit (size: Q6T55 E9, Commercial Service Tools)
and remove them. As an alternative method hold the crankshaft
pulley with a pulley holder (SST) to remove the flywheel.
CAUTION:
Do not disassemble flywheel.
c. Install engine sub-attachment to the rear side of cylinder block.
lAlign knock pins on cylinder block with pin holes on attach-
ment to install.
NOTE:
Installation bolts are part of engine sub-attachment.
d. Install engine attachment.
NOTE:
Use commercially available M12 (0.47 in) mounting bolts and
nuts (4 sets) with strength grade of 9T (minimum).
1. Rear oil seal retainer 2. Oil pressure switch 3. Coppet washer
4. Oil jet relief valve 5. Cylinder block 6. Top ring
7. Second ring 8. Oil ring 9. Oil jet
10. Piston pin 11. Snap ring 12. Piston
13. Main bearing 14. Thrust bearing 15. Connecting rod
16. Key 17. Connecting rod bearing 18. Connecting rod cap
19. Connecting rod nut 20. Main bearing 21. Crankshaft
22. Main bearing cap 23. Pilot bush 24. Flywheel
25. Drain plug 26. Rear oil seal
SEM500G
SBIA0199E
JEM192G

EM-190
[YD22DDTi]
CYLINDER BLOCK
e. Hoist engine and install it to the engine stand.
NOTE:
It is possible to set engine sub-attachment and engine attach-
ment to engine stand at first, then install engine later.
lCommercial engine stand can be used.
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
5. Drain engine oil and coolant from inside engine.
6. Remove the following parts and related parts. (Only major parts are listed.)
lIntake manifold collector and intake manifold (Refer toEM-115, "Removal and Installation".)
lExhaust manifold (Refer toEM-119, "Removal and Installation".)
lRocker cover (Refer toEM-147, "Removal and Installation").
lInjection tube and fuel injector (Refer toEM-135, "Removal and Installation".)
lOil pan and oil strainer (Refer toEM-125, "Removal and Installation".)
lWater pump (Refer toCO-40, "Removal and Installation".)
lThermostat and water piping (Refer toCO-42, "Removal and Installation".)
lVacuum pump and vacuum pipe (Refer toEM-131, "Removal and Installation".)
lSecondary timing chain (Refer toEM-158, "Removal and Installation")
lPrimary timing chain (Refer toEM-163, "Removal and Installation".)
lElectronic control fuel supply pump (Refer toEM-138, "Removal and Installation".)
lCamshaft (Refer toEM-149, "Removal and Installation".)
lCylinder head (Refer toEM-174, "Removal and Installation".)
lOil cooler (Refer toLU-25, "Removal and Installation".)
lAccessory, accessory bracket and mount brackets
7. Remove fuel supply pump bracket.
8. Remove rear oil seal retainer.
JEM193G
PBIC0085E