NISSAN X-TRAIL 2003 Service Repair Manual

ENGINE ASSEMBLY
EM-209
[YD22DDTi]
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REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate suspension member, and then separate engine and transaxle.
Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Drain engine coolant from radiator drain plug. Refer to CO-31, "
DRAINING ENGINE COOLANT" .
3. Remove the following parts.

LH/RH engine undercover

LH/RH front wheels

Battery; Refer to SC-3, "BATTERY" .

Drive belts; Refer to EM-132, "Removal and Installation" .

Air duct and air cleaner case assembly; Refer to EM-133, "Removal and Installation" .

Alternator; Refer to SC-16, "Removal and Installation" .

Radiator and cooling fan assembly; Refer to CO-34, "Removal and Installation" and CO-36, "COOL-
ING FAN" .

Charge air cooler; Refer to EM-135, "CHARGE 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
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer to EM-136,
"INTAKE MANIFOLD" .
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to EM-136,
"INTAKE MANIFOLD" .
3. Remove clutch operating cylinder from transaxle, and move it aside. Refer to MT-17, "
TRANSAXLE
ASSEMBLY" and CL-10, "OPERATING CYLINDER" .
4. Disconnect shift cable from transaxle. Refer to MT-14, "
CONTROL LINKAGE" .
Engine room RH
1. Remove engine coolant reservoir tank. Refer to CO-34, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
2. Remove propeller shaft. Refer to PR-4, "
Removal and Installation" .
3. Remove steering shaft from steering gear. Refer to PS-10, "
STEERING COLUMN" .
4. Disconnect power steering fluid cooler piping at a point between body and engine. Refer to PS-34,
"HYDRAULIC LINE" .
5. Remove ABS sensor from brake caliper. Refer to BRC-45, "
WHEEL SENSORS" (ABS), BRC-116,
"WHEEL SENSORS" (ESP/TCS/ABS).
6. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
7. Remove left and right suspensions from steering knuckle under strut. Refer to FSU-5, "
FRONT SUSPEN-
SION ASSEMBLY" .

EM-210
[YD22DDTi]
ENGINE ASSEMBLY

Removal
1. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
2. Lift with hoist and secure engine in position.

Use the manual lift table caddy (commercial service tool) 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.
3. Remove RH engine mounting insulator.
4. Pull LH engine mounting through-bolt out.
5. Remove mounting bolts at front end of center member.
6. Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "
FRONT SUSPENSION ASSEMBLY" .
7. Remove engine, transaxle and transfer assembly with suspension member and center member from vehi-
cle downward by carefully operating supporting tools.
CAUTION:

During the operation, make sure that no part interferes with body side.

Before and during this lifting, always check if any harnesses are left connected.

During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.

If necessary, support vehicle by setting a jack or equivalent tool at the rear.Slinger bolts:
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
SBIA0191E
KBIA0256E
PBIC2188E
KBIA0270E

ENGINE ASSEMBLY
EM-211
[YD22DDTi]
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8. Remove power steering oil pump with piping connected from engine. Move it aside on suspension mem-
ber. Refer to PS-34, "
HYDRAULIC LINE" .
9. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
10. Remove starter motor. Refer to SC-21, "
STARTING SYSTEM" .
11. Separate engine and transaxle. Refer to MT-17, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.

Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-208, "
ENGINE ASSEMBLY" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION

Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than
required quantity, fill to the specified level.

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working
engine oil, fuel and exhaust gas.

Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.

After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level
Fuel — Leakage —
Exhaust gas — Leakage —

EM-212
[YD22DDTi]
CYLINDER BLOCK

CYLINDER BLOCKPFP:11010
Disassembly and AssemblyEBS00ODX
PBIC2029E

CYLINDER BLOCK
EM-213
[YD22DDTi]
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DISASSEMBLY
1. Remove engine, transaxle and transfer assembly from the vehicle, then separate engine and transaxle
and transfer assembly. Refer to EM-208, "
ENGINE ASSEMBLY" .
2. Remove clutch cover and disk. Refer to CL-14, "
CLUTCH DISC,
CLUTCH COVER AND FLYWHEEL" .
3. If they need to be replaced, replace pilot bush.

Using the pilot bushing puller (special service tool), remove
the pilot bush from rear end of crankshaft.
4. Install engine to engine stand as follows.
a. Remove flywheel.
b. Secure ring gear with the ring gear stopper (special service
tool), then loosen mounting bolts with TORX socket (size: T55,
Commercial Service Tools) and remove them. As an alternative
method hold crankshaft pulley with the pulley holder (special
service tool: KV10109300) to remove flywheel.
CAUTION:

Do not disassemble flywheel.

Do not place flywheel with signal plate facing down.

When handling signal plate, take care not to damage or
scratch it.

Handle signal plate in a manner that prevents it from
becoming magnetized.
c. Install the engine sub-attachment (special service tool) to the
rear side of cylinder block.

Align knock pins on cylinder block with pin holes on attach-
ment to install.
NOTE:
Installation bolts are part of engine sub-attachment.
d. Install the engine stand shaft (special service tool).
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. Cylinder block 3. Oil pressure switch
4. Fuel pump bracket 5. Oil level gauge guide 6. Top ring
7. Second ring 8. Oil ring 9. Oil jet
10. Piston pin 11. Snap ring 12. Piston
13. Main bearing upper 14. Thrust bearing 15. Connecting rod
16. Key 17. Connecting rod bearing 18. Connecting rod cap
19. Connecting rod nut 20. Main bearing lower 21. Crankshaft
22. Main bearing cap bolt 23. Main bearing cap 24. Pilot bush
25. Flywheel 26. Copper washer 27. Oil jet relief valve
28. Drain plug 29. Rear oil seal
SEM500G
PBIC2406E
JEM192G

EM-214
[YD22DDTi]
CYLINDER BLOCK

e. Hoist engine and install it to the engine stand (special service
tool).
NOTE:
It is possible to set engine sub-attachment and engine stand
shaft to the engine stand at first, then install engine later.

Widely use 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 engine coolant from inside engine. Refer to LU-21, "
Changing Engine Oil" .
6. Drain engine coolant by removing drain plug from inside of
engine.
7. Remove the following parts and related parts. (Only major parts are listed.)

Intake manifold (Refer to EM-136, "Removal and Installation" .)

Exhaust manifold and turbocharger (Refer to EM-141, "Removal and Installation" .)

Rocker cover (Refer to EM-168, "Removal and Installation" .)

Fuel injector (Refer to EM-157, "Removal and Installation" .)

Oil pan and oil strainer (Refer to EM-147, "Removal and Installation" .)

Water pump (Refer to CO-42, "WATER PUMP" .)

Thermostat and water piping (Refer to CO-44, "THERMOSTAT AND WATER PIPING" .)
JEM193G
PBIC0085E
PBIC2439E

CYLINDER BLOCK
EM-215
[YD22DDTi]
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Vacuum pump (Refer to EM-153, "Removal and Installation" .)

Secondary timing chain (Refer to EM-180, "Removal and Installation" .)

Primary timing chain (Refer to EM-185, "Removal and Installation" .)

Fuel pump (Refer to EM-161, "Removal and Installation" .)

Camshaft (Refer to EM-170, "Removal and Installation" .)

Cylinder head (Refer to EM-197, "Removal and Installation" .)

Oil cooler (Refer to LU-28, "OIL COOLER" .)

Accessory, accessory bracket and mount brackets
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.

Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.

Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
11. Remove piston and connecting rod assembly.

Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-226, "
CONNECT-
ING 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 piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.
12. Remove connecting rod bearings from connecting rods and
caps.

Keep them by cylinder to avoid confusion.
13. Remove piston rings from pistons using the piston ring expander
(commercial service tool).
CAUTION:

When removing, prevent pistons from being damaged.

Do not expand piston rings excessively. This may dam-
age piston rings.
JEM195G
FEM086
JEM196G

EM-216
[YD22DDTi]
CYLINDER BLOCK

14. Remove pistons from connecting rods.
a. Using the snap ring pliers, remove snap rings.
b. Using the industrial use 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.
15. Remove main bearing cap bolts.

With a TORX socket (size: E14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in reverse
order of that shown in the figure and remove them.

Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-226, "
CRANKSHAFT END PLAY" .
16. Remove main bearing caps.

Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
19. Remove oil jet.
JEM197G
PBIC0089E
EMM0072D
JEM200G
JEM201G

CYLINDER BLOCK
EM-217
[YD22DDTi]
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20. Remove oil jet relief valve.
ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
2. Install oil jet relief valve.
3. Install oil jet.

Align 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 engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.

Install thrust bearings with oil groove facing to crankshaft arm
(outside).
c. Being careful with the direction, install main bearings.

Install 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.

While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.

Align stopper notches on bearings to install them.

Make sure 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.

Make sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.

Identify 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.

Main 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 to EM-
234, "MAIN BEARING CAP BOLT DEFORMATION" .
PBIC0389E
JEM224G
JEM213G
JEM225G

EM-218
[YD22DDTi]
CYLINDER BLOCK

8. With the TORX socket (size: E14, commercial service tool),
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 all bolts in 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 degrees to 95 degrees [target: 90 degrees].
(angle tightening)
CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angular tightening. Avoid tightening
based on visual checks alone.

After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.

Check crankshaft end play. Refer to EM-226, "CRANKSHAFT
END PLAY" .
9. Check the outer diameter of connecting rod bolts. Refer to EM-
234, "CONNECTING ROD BOLT DEFORMATION" .
10. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.

Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.

Using the industrial use dryer, heat pistons up to approx. 60 to
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.

Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.

Refer to above step a for precaution on snap ring installation.

After installation, check connecting rods for smooth move-
ment.
11. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.: 25 - 30 N·m (2.5 - 3.1 kg-m, 18 - 22 ft-lb)
JEM200G
JEM226G
PBIC0089E
MBIA0024E