seats NISSAN X-TRAIL 2003 Electronic Repair Manual

ATC-122
DUCTS AND GRILLES
Foot Duct
EJS000V5
1. Remove the heater & cooling unit. Refer toATC-115, "HEATER
&COOLING UNIT ASSEMBLY".
2. Remove the foot duct.
Floor ductEJS000V6
1. Remove the front seats.
2. Remove the instrument lower center panel.
3. Remove the front floor duct.
4. Peel back the floor trim to a point where the floor duct is visible.
5. Remove the mounting screw and clip from the rear floor duct.
6. Remove the rear floor duct.
RJIA0069E
RJIA0070E
RJIA0071E

FRONT DISC BRAKE
BR-23
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3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.
INSTALLATION
CAUTION:
lRefill with new brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe oil and grease on the trailing arm washer seats and cali-
per assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lDo not reuse the copper washer for union bolts.
lSecurely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer toBR-10, "
Bleeding Brake System".
Caliper Disassembly and AssemblyEF S0 00 CK
DISASSEMBLY
WA RN ING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots.
SBR979B
BRB0032D

REAR DISC BRAKE
BR-29
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Caliper Removal and InstallationEFS00180
REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing
brake pedal.
3. Remove brake hose connected to caliper assembly and union
bolts. Remove brake hose from caliper assembly.
4. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
5. Remove disc rotor.
INSTALLATION
CAUTION:
lRefill with new brake fluid “ DOT 3 or DOT 4”.
lNever reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and caliper assembly mounting surface.
Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lDo not reuse the copper washer for union bolts.
lSecurely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer toBR-10, "
Bleeding Brake System".
Caliper Disassembly and AssemblyEFS00181
DISASSEMBLY
WA RN ING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Remove caliper assembly from vehicle.
2. Remove sliding pin from cylinder body. Then remove pads,
shims, shim covers, and pad retainers from caliper assembly.
3. Remove sliding pin boots from torque member.
4. Using a slotted screwdriver (as shown in the figure), remove pis-
ton seals.
SBR656
SBR028A

BR-32
REAR DISC BRAKE
4. Fix piston boot with retaining ring.
CAUTION:
lBe sure boot is securely engaged in groove on cylinder
body.
lDo not reuse retaining ring.
5. Connect sliding pins and sliding pin boots to torque member.
6. Connect torque member to axle assembly and tighten mounting
bolts to specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and torque
member mounting surface. Install torque member to axle
assembly.
7. Connect pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque.
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer toBR-10, "
Bleeding Brake
System"
SFIA0158E

DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MIS-
FIRE
EC-209
[QR (WITH EURO-OBD)]
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5.CHECK IGNITION SPARK
1. Disconnect ignition coil assembly from rocker cover.
2. Connect a known good spark plug to the ignition coil assembly.
3. Place end of spark plug against a suitable ground and crank engine.
4. Check for spark.
OK or NG
OK >> GO TO 6.
NG >> Check ignition coil, power transistor and their circuits.
Refer toEC-334, "
IGNITION SIGNAL".
6.CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
OK or NG
OK >> GO TO 7.
NG >> Repair or replace spark plug(s) with standard type
one(s). For spark plug type, refer toMA-25, "
Checking
and Changing Spark Plugs".
7.CHECK COMPRESSION PRESSURE
Check compression pressure. Refer toEM-52, "
CHECKING COMPRESSION PRESSURE".
OK or NG
OK >> GO TO 8.
NG >> Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
8.CHECK FUEL PRESSURE
1. Install all removed parts.
2. Release fuel pressure to zero. Refer toEC-34, "
FUEL PRESSURE RELEASE".
3. Install fuel pressure gauge and check fuel pressure. Refer toEC-34, "
FUEL PRESSURE CHECK".
OK or NG
OK >> GO TO 9.
NG >> Follow the construction of "FUEL PRESSURE CHECK".
SEF575Q
SEF156I
Standard:
1,190 kPa (11.9 bar, 12.1 kg/cm2, 172 psi)/250
rpm
Minimum:
990 kPa (9.9 bar, 10.1 kg/cm
2, 144 psi)/250 rpm
Difference between each
cylinder:98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)/250 rpm
At idle: Approx. 350 kPa (3.5 bar, 3.7 kg/cm
2,51psi)

CYLINDER HEAD
EM-59
[QR20DE]
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2. Ream cylinder head recess diameter for service valve seat.
lBe sure to ream in circles concentric to the valve guide center.
lThis will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat
into cylinder head.
CAUTION:
Avoid directly to touching cold valve seats.
5. Using valve seat cutter set or valve seat grinder, finish the seat
to the specified dimensions.
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
Grind to obtain the dimensions indicated in figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.Oversize [0.5 mm (0.020 in)]
Intake : 37.000 - 37.016 mm (1.4567 - 1.4573 in)
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
SEM795A
SEM008A
SEM934C
Standard
D1 dia. : 33.5 mm (1.3189 in)
D2 dia. : 35.1 - 35.3 mm (1.382 - 1.390 in)
D3 dia. : 39.0 - 39.2 mm (1.535 - 1.543 in)
D4 dia. : 28 mm (1.10 in)
D5 dia. : 29.9 - 30.1 mm (1.177- 1.185 in)
D6 dia. : 33.5 - 33.7mm (1.319 - 1.327 in)
SBIA0226E

EM-72
[QR20DE]
CYLINDER BLOCK
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 HEAD
EM-173
[YD22DDTi]
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CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00BPL
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer toEC-672,
"Basic Inspection".
lDo not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove the following parts.
lCharge air cooler (Refer toEM-114, "Removal and Installation".)
5. To prevent fuel from being injected during inspection, remove
fuel supply pump fuse [ENG CONT (20A)] from fuse box on the
left side of engine compartment.
lAmong marks on fuse box, [ENG CONT 3 (20A)] is for fuel
supply pump fuse.
6. Remove glow plugs from all the cylinders. Refer toEM-130,
"Removal and Installation".
CAUTION:
lBefore removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
lCarefully remove glow plugs to prevent any damage or
breakage.
lHandle with care to avoid applying any shock to glow plugs.
7. Install adapter to installation holes of glow plugs and connect
compression gauge for diesel engine.
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
lAlways use a fully-charged battery to obtain specified engine
speed.
Unit:kPa(bar,kg/cm2, psi)/rpm
lWhen engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
lIf engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
lIf compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying oil, piston ring may be worn or damaged.
Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying oil, valve may be malfunctioning. Check valve for mal-
function. If contact malfunction is found, replace valve or valve seat.
lIf compression pressure in adjacent two cylinders is low after applying oil, pressure may be leaking
from gasket. In this case, replace cylinder head gasket.
SBIA0192E
:18-21N·m(1.8-2.2kg-m,13-15ft-lb)
Standard MinimumDifference limit between
cylinders
2,893 (28.9, 29.5, 419)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
SEM112G

CYLINDER HEAD
EM-179
[YD22DDTi]
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5. Remove valve oil seals using valve oil seal puller.
6. Remove valve spring seats.
7. Before removing valve spring seats, perform valve seat contact
check. Refer toEM-181, "
Va l v e S e a t C o n ta ct".
8. Before removing valve guides, perform valve guide clearance
check. Refer toEM-180, "
Valve Guide Clearance".
ASEMBLY
1. Install valve guides. Refer toEM-180, "Valve Guide Clearance".
2. Install valve seats. Refer toEM-181, "
Valve Seat Replacement".
3. Using valve oil seal drift, install valve oil seals referring to the
dimension shown in the figure.
lDifferent parts are used for valve location, Identify by the rub-
ber color.
4. Install valve spring seats.
5. Install valves.
lInstall the valves with bigger outer diameter to intake valve
side.
lNote that valve layout here is different from that of conventional engine.
6. Install valve spring.
lWhen installing valve spring, make sure that a smaller pitch
side (identification paint-applied side) faces the cylinder head.
7. Install valve spring retainers.
8. Using valve spring compressor, compress valve springs.
Then install valve collets using magnetic hand.
lAfter installing valve collets, tap the stem end using a plastic
hammer, and check the installation status.
9. Install valve lifters and adjusting shims to the same positions as
before.
INSPECTION AFTER DISASSEMBLY
Cylinder Head Distortion
Using straightedge and feeler gauge, check the bottom of the cylin-
der head for distortion.
JEM153G
For intake : Black
For exhaust : Brown
JEM165G
Identification color : Yellow
FEM080
Limit : 0.04 mm (0.0016 in)
SEM496G

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