NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-191
[YD22DDTi]
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lInsert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
9. Remove rear oil seal from rear oil seal retainer.
lPunch out with a flat-bladed screwdriver.
lBe careful not to damage rear oil seal retainer.
10. Remove piston and connecting rod assembly.
lBefore removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer toEM-200, "
CONNECTING ROD SIDE CLEARANCE".
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION:
When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.
11. Remove connecting rod bearings from connecting rods and
caps.
lKeep them by cylinder to avoid confusion.
12. Remove piston rings from pistons using piston ring expander.
CAUTION:
lWhen removing, prevent pistons from being damaged.
lDo not expand piston rings excessively. This may dam-
age the piston rings.
13. Remove pistons from connecting rods.
a. Using long nose pliers, remove snap rings.
JEM195G
FEM086
JEM196G
JEM197G

EM-192
[YD22DDTi]
CYLINDER BLOCK
b. Using industrial dryer, heat pistons up to 60 to 70°C (140 to
158°F).
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
14. Remove main bearing cap bolts.
lWith a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.
lBefore loosening main bearing cap bolts, measure crankshaft
side clearance. Refer toEM-200, "
CRANKSHAFT SIDE
CLEARANCE".
15. Remove main bearing caps.
lUsing main bearing cap bolts, remove by rocking bearing cap
back and forth.
16. Remove crankshaft.
17. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
lCheck the correct installation locations of removed parts.
Store them so they do not get mixed up.
18. Remove oil jet.
19. Remove oil jet relief valve.
PBIC0089E
EMM0072D
JEM200G
JEM201G

CYLINDER BLOCK
EM-193
[YD22DDTi]
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ASSEMBLY
1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase and cylinder bore to remove foreign matter.
2. Install oil jet relief valve.
3. Install oil jet.
lAlign knock pin on back of oil jet with hole on block when
installing oil jet.
4. Install main bearings and thrust bearings.
a. Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
lInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
c. Being careful with the direction, install main bearings.
lInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
lWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them
completely.
lAlign stopper notches on bearings to install them.
lCheck that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
5. Install crankshaft to cylinder block.
lMake sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
lIdentify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
lMain bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
7. Check the main bearing cap bolts for deformation.
Refer toEM-207, "
MAIN BEARING CAP BOLT DEFORMA-
TION".
PBIC0389E
JEM224G
JEM213G
JEM225G

EM-194
[YD22DDTi]
CYLINDER BLOCK
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90°to 95°[target: 90°].
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
lCheck crankshaft end side clearance. Refer toEM-200,
"CRANKSHAFT SIDE CLEARANCE".
9. Check the outer diameter of connecting rod bolts. Refer toEM-
207, "CONNECTING ROD BOLT DEFORMATION".
10. Install pistons to connecting rod.
a. Using long nose pliers, install snap rings to grooves on piston rear side.
lFit snap rings correctly into grooves.
b. Install pistons to connecting rods.
lUsing industrial dryer, heat pistons up to approx. 60 to 70°C(140to158°F) until piston pin can be
pressed down by finger touch. Then insert piston pins into piston and connecting rod from front side of
piston toward rear.
lAssemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being
positioned as shown in the figure.
c. Install snap rings to front side of pistons.
lRefertoabovestepaforprecautiononsnapringinstallation.
lAfter installation, check connecting rods for smooth move-
ment.
11. Use piston ring expander to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
lInstall top ring and second ring with stamped surfaces facing
upward.
lInstall rings so that three closed gap position 120°apart one
another.
lClosed gaps do not need to face in a specific directions, as long as each are positioned 120°apart.
JEM200G
JEM226G
JEM227G
Identification stamp:
To p r i n g : A E
Second ring : AE2
JEM228G

CYLINDER BLOCK
EM-195
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12. Install connecting rod bearings to connecting rods and caps.
lWhile installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces,
but clean them completely.
lAlign stoppers on connecting rod bearings with connecting
rod stopper notches to install connecting rod bearings.
13. Install piston and connecting rod assembly to crankshaft.
lMove crankshaft pin to be assembled to BDC.
lAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
lUsing piston ring compressor, install piston and connecting
rod assembly with front mark on piston crown facing toward
the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.
14. Install connecting rod caps and mounting nuts.
lAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
lMake sure that the front mark on connecting rod cap faces
towards the front of the engine.
15. Tighten connecting rod nuts according to the following proce-
dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N·m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120°to 125°[target: 120°]. (angular tightening)
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening nuts, check that crankshaft rotates smoothly.
JEM229G
JEM230G
JEM227G
JEM231G

EM-196
[YD22DDTi]
CYLINDER BLOCK
lCheck connecting rod side clearance. Refer toEM-200,
"CONNECTING ROD SIDE CLEARANCE".
16. Force fit rear oil seal into rear oil seal retainer.
lUsing a drift [105 mm (4.13 in) dia.], force fit so that the
dimension is as specified in the figure.
lAvoid inclined fitting. Force fit perpendicularly.
17. Install rear oil seal and retainer assembly.
lApply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
18. Press fit pilot bushing into flywheel.
lUsing drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
19. Install fuel supplypump bracket.
lAlign the bracket with the dowel pins on the block to install.
lThe two bolts used for dowel pins have a longer shanks than
the other two.
20. Install parts to the engine in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of
assembly.
22. Install flywheel.
lHolding ring gear with ring stopper (SST), tighten securing
bolts with TORX bit (size: Q6T55 E9, Commercial Service
Tool).
lTighten bolts uniformly in a crisscross manner.
JEM232G
JEM233G
JEM234G
SBIA0200E

CYLINDER BLOCK
EM-197
[YD22DDTi]
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How to Select Piston and BearingEBS00BPR
DESCRIPTION
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.
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select the piston of the same grade.
lThe part No. of piston is specified together with the piston pin as
an assembly.
When Re-using an Old Cylinder Block
1. Measure cylinder block bore inner diameter.
2. Referring to “Cylinder block bore inner diameter” in “Piston
Selection Table”, determine the bore grade.
3. Select the piston of the same grade.
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 bearing and
crankshaft pin outer diameter
determine connecting rod bear-
ing 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)
JEM208G
SBIA0201E

EM-198
[YD22DDTi]
CYLINDER BLOCK
Piston Selection Table
Unit: mm (in)
HOW TO SELECT CONNECTING ROD BEARING
When Using a New Crankshaft and Connecting Rod
1. Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft.
2. Select the connecting rod bearings of the same grade.
lThere is no grading for the inner diameter of the big end of the
connecting rod.
When Re-using the Removed Crankshaft and Connecting Rod
1. Measure the inner diameter of the big end of the connecting rod and make sure it is within the specified
range.
2. Measure the outer diameter of the crankshaft pin.
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” of the table below.
4. Choose the bearings of the same grade.
Selection Table of connecting Rod BearinC
Unit: mm (in)
Under Size Bearing Usage
lIf bearing clearance is out of specifications for connecting rod bearings in standard size, use under size
bearings.
lWhen using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Grade (punched) 1 2 3
Cylinder bore
inner diameter86.000 - 86.010(3.3858 - 3.3862) 86.010 - 86.020(3.3862 - 3.3866) 86.020 - 86.030(3.3866 - 3.3870)
Piston outer
diameter85.925 - 85.935(3.3829 - 3.3833) 85.935 - 85.945(3.3833 - 3.3837) 85.945 - 85.955(3.3837 - 3.3841)
JEM215G
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin outer diameter Grade (punched) 0 (no punching)
51.968 - 51.974
(2.0460 - 2.0462)0
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 0
1.492 - 1.496
(0.0587 - 0.0589)
0.031 - 0.061
(0.0012 - 0.0024)
Black
51.961 - 51.968
(2.0457 - 2.0460)1
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 1
1.496 - 1.500
(0.0589 - 0.0591)
0.031 - 0.061
(0.0012 - 0.0024)
Brown
51.954 - 51.961
(2.0454 - 2.0457)2
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 2
1.500 - 1.504
(0.0591 - 0.0592)
0.031 - 0.061
(0.0012 - 0.0024)
Green

CYLINDER BLOCK
EM-199
[YD22DDTi]
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Connecting Rod Bearing Under Size lLst
Unit: mm (in)
CAUTION:
When grinding the crankshaft journal to use an under size bear-
ing, avoid damaging the fillet R.
HOW TO SELECT MAIN BEARING
When Using a New Cylinder Block and Crankshaft
1. Identify the bearing housing grade (No. 0, 1, or 2) on LH surface
at the rear of the cylinder block, and locate the applicable grade
on the “Grade” row in the table below.
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of
the crankshaft, and locate the applicable grade under the
“Grade” column on the table.
3. Themainbearingtobeused(STD0toSTD4)canbelocated
in the cell where the row and column cross.
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing hous-
ing.
2. Locate the applicable cell where the measurement falls, on
“Inner diameter of Cylinder block main bearing housing” row on
the table.
3. Measure the outer diameter of the crankshaft journal.
4. Locate the applicable cell where the measurement falls, under
“Crankshaft journal outer diameter” column on the table.
5. Themainbearingtobeused(STD0toSTD4)canbelocatedin
the cell where the row and column cross.
Main Bearing Grade Table
Unit: mm (in) Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)JEM216G
JEM208G
JEM215G
Inner diameter of Cylinder block main bearing housing66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft journal
outer diameterGrade
(punched)012
62.967 - 62.975
(2.4790 - 2.4793)0
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
Red or BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green

EM-200
[YD22DDTi]
CYLINDER BLOCK
Under Size Bearing Usage
lIf bearing clearance is out of specifications for connecting rod bearings in standard size, use under size
bearings.
lWhen using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to specification.
Main Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding crank journals to use undersize bearings, keep
corners radius of fillet. (All journals)
Inspection After DisassemblyEBS00CU2
CRANKSHAFT SIDE CLEARANCE
lUsing dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward.
lIf the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
CONNECTING ROD SIDE CLEARANCE
lUsing feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.
lIf measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
62.959 - 62.967
(2.4787 - 2.6790)1
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
62.951 - 62.959
(2.4784 - 2.4787)2
lBearing grade No.
lBearing thickness
lOil clearance
lIdentification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
Size Thickness
US 0.25(0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
JEM202G
Standard : 0.200 - 0.350(0.0079 - 0.0138 in)
Limit : 0.4 mm (0.0157 in)
JEM203G