NISSAN X-TRAIL 2003 Service Repair Manual

CYLINDER BLOCK
EM-229
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

Piston Pin Outer Diameter
Use micrometer to measure piston pin outer diameter.
Calculation of Connecting Rod Bushing Clearance
(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter) − (Piston pin outer diameter)

If it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer to EM-223,
"HOW TO SELECT CONNECTING ROD BEARING" and/or EM-222, "HOW TO SELECT PISTON" .
CYLINDER BLOCK TOP SURFACE DISTORTION

Using scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as engine oil, scale, and car-
bon.
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.

Use straightedge and feeler gauge to check block upper surface
for six distortion.

If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER

Without installing main bearings, install main bearing caps, and
tighten bolts to the specified torque. Refer to EM-217, "
ASSEM-
BLY" .

Measure the inner diameter of main bearing housing with a bore
gauge.

If the measurement is out of the standard, replace cylinder block
and main bearing caps.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit : 0.057 mm (0.0022 in)
Limit : 0.1 mm (0.004 in)
SEM501G
Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in)
PBIC1643E

EM-230
[YD22DDTi]
CYLINDER BLOCK

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

Using bore gauge, measure cylinder inner diameters at six posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).

If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or bore the inner
wall.

Oversize piston is provided. When using oversize piston, hone
the cylinder so that the clearance between piston and cylinder
satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with over-
size piston rings.
Piston Outer Diameter
Use micrometer to measure piston outer diameter.
Calculation of Piston to Cylinder Bore Clearance

Calculate using piston outer diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diameter)

If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-222, "HOW TO SELECT PIS-
TON" .
Reboring Cylinder Bore
1. Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.Cylinder bore inner diameter
: 86.000 - 86.030 mm (3.3858 - 3.5870 in)
Wear limit
: 0.20 mm (0.008 in)
Out-of-round limit (Difference between X and y)
: 0.015 mm (0.0006 in)
Taper limit (Difference between A and C)
: 0.010 mm (0.0004 in)
JEM207G
Oversize (OS) : 0.25 mm (0.0098 in)
: 0.50 mm (0.0197 in)FEM110
Piston outer diameter
Measurement position : 11.0 mm (0.43 in)
Distance from the bottom
Standard : 85.928 - 85.962 mm
(3.3830 - 3.3843 in)
0.25 (0.0098) O/S : 86.188 - 86.202
(3.3932 - 3.3938 in)
0.50 (0.0197) O/S : 86.438 - 86.452
(3.4031 - 3.4036 in)
PBIC0125E
Specifications at room temperature [20°C (68°F)]:
Standard : 0.058 - 0.082 mm (0.0023 - 0.0032 in)
Rebore size calculation:
D = A + B – C
Where,
D: Bored diameter

CYLINDER BLOCK
EM-231
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. install main bearing caps and tighten bolts to the specified torque. Refer to EM-217, "ASSEMBLY" . This
will prevent distortion of cylinder bores.
3. Cut cylinder bore.
NOTE:

When any cylinder needs boring, all other cylinders must also be bored.

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:

Measurement should be done after cylinder bore cools down.
CRANKSHAFT JOURNAL OUTER DIAMETER

Use micrometer to measure journal outer diameter.

If out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer to EM-233, "
MAIN BEAR-
ING OIL CLEARANCE" .
CRANKSHAFT PIN OUTER DIAMETER

Use micrometer to measure crankshaft pin outer diameter.

If out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer to EM-232,
"CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT OUT-OF-ROUND AND TAPER

Using micrometer, measure each journal and pin at four points
shown in the figure.

Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.

Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.

If the measured value exceeds the limit, correct or replace crankshaft.A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
FEM114
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
PBIC0127E
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E

EM-232
[YD22DDTi]
CYLINDER BLOCK


If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-233, "
MAIN BEARING OIL CLEARANCE" and/or EM-
232, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT

Place V-block onto surface plate to support journals at both ends
of crankshaft.

Position dial gauge vertically onto No. 3 journal.

Rotate crankshaft to read needle movement on dial gauge.
(Total indicator reading)

If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement

Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer to EM-217,
"ASSEMBLY" . Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)

If clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin outer diameter to obtain specified bearing oil
clearance. Refer to EM-223, "
HOW TO SELECT CONNECTING
ROD BEARING" .
Method of Using Plastigage

Remove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.

Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.

Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft.

Remove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.031 - 0.061 mm (0.0012 - 0.0024 in)
PBIC1642E
EM142

CYLINDER BLOCK
EM-233
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

MAIN BEARING OIL CLEARANCE
Method by Measurement

Install main bearings to cylinder block and bearing cap, and
tighten the bolts to the specified torque. Refer to EM-217,
"ASSEMBLY" . Then, measure the inner diameter of main bear-
ings.
(Bearing clearance) = (Bearing inner diameter) − (Crankshaft
journal outer diameter)

If out of the standard, check main bearing housing inner diame-
ter and crankshaft journal outer diameter, and select appropriate
main bearing to adjust clearance to specifications. Refer to EM-
224, "HOW TO SELECT MAIN BEARING" .
Method of Using Plastigage

Remove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.

Cut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.

Install main bearings and bearing cap and tighten to the speci-
fied torque. Refer to EM-217, "
ASSEMBLY" for the tightening
procedure.
CAUTION:
Do not rotate crankshaft.

Remove main bearings and bearing caps, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.
CRUSH HEIGHT OF MAIN BEARING

When bearing cap is removed after being tightened to the speci-
fied torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-217, "
ASSEMBLY" .

If out of the standard, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING

When connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-217,
"ASSEMBLY" .

If out of the standard, replace connecting rod bearings.Standard : 0.039 - 0.066 mm (0.0015 - 0.0026 in)
PBIC1644E
EM142
Standard : There must be crush height.
SEM502G
Standard : There must be crush height.
PBIC1646E

EM-234
[YD22DDTi]
CYLINDER BLOCK

MAIN BEARING CAP BOLT DEFORMATION

Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.

When the necked point is identified at a point other than where
specified, measure at the point as d2.

Calculate the difference between d1 and d2.

If it exceeds the limit, replace main bearing cap bolt.
CONNECTING ROD BOLT DEFORMATION

Install nuts to connecting rod bolts. Make sure that the nut can
be screwed smoothly on bolt threads by hand to the last thread
on the bolt.

If the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.

If a necked point is identified, measure at that point.

If it exceeds the limit, replace connecting rod bolts and nuts.
OIL JET

Check nozzle for deformation and damage.

Blow compressed air from nozzle, and check for clogs.

If out of the standard, replace oil jet.
OIL JET RELIEF VALVE

Using clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force.

If out of the standard, replace oil jet relief valve.Limit : 0.13 mm (0.0051 in)
JEM219G
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit : 8.75 mm (0. 3445 in) dia.
JEM220G
Standard : No deformation and no damage.
JEM221G
Standard:
Valve moves smoothly with proper reaction force.
JEM222G

CYLINDER BLOCK
EM-235
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

FLYWHEEL DEFLECTION

Measure the deflection of flywheel contact surface to clutch with
a dial indicator.

Measure the deflection at 210 mm (8.27 in) dia.

If measured value is out of the standard, replace flywheel.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL
CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction

Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.

If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.

Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side.

If measured value is out of the standard, replace flywheel.Standard : 0.45 mm (0.0177 in) or less.
PBIC2646E
Standard : 1.3 mm (0.051 in) or less
Standard: 26.2 mm (1.031 in) or less.
PBIC1263E

EM-236
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00ODZ
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
Unit: mm (in)
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3 (cu in)2,184 (133.27)
Bore and stroke Unit: mm (in) 86 x 94 (3.39 x 3.70)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.7
Compression pressure
Unit: kPa (bar, kg/cm
2 , psi)/200 rpmStandard 2,991 (29.9, 30.5, 434)
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
224 212 2 30 -2 46
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied*
New Adjusted Limit for re-adjusting
A/C compressor belt4 - 5
(0.16 - 0.20)6 - 7
(0.24 - 0.28)8.5 (0.335)
Alternator and water pump belt9.0 - 10.5
(0.354 - 0.413)11.0 - 12.5
(0.433 - 0.492)16.5 (0.650)

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-237
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*: Approximately 80°C (176°F) Item Standard Limit
Cylinder head distortion Less than 0.03 (0.0012) 0.1 (0.004)
JEM204G
Valve head diameter “D”Intake 28.0 - 28.3 (1.102 - 1.114)
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Valve length “L”Intake 106.72 (4.2016)
Exhaust 106.36 (4.1874)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α”Intake
45 degrees 15′ - 45 degrees 45′
Exhaust
Valve margin “T”Intake 1.38 (0.0543)
Exhaust 1.48 (0.0583)
Valve margin “T” limitMore than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
SEM188
Item Cold Hot* (Reference data)
Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)

EM-238
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

Available Shims
Stamped mark Thickness mm (in)
2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858)
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882)
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921)
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
2.40 2.40 (0.0954)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961)
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000)
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024)
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063)
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
SEM512G