Belt NISSAN X-TRAIL 2003 Service Repair Manual

MODEL T30 SERIES
2004NISSANEUROPES.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.
A GENERAL INFORMATION
B ENGINE
C TRANSMISSION/TRANSAXLE
D DRIVELINE/AXLE
E SUSPENSION F BRAKES
G STEERING H RESTRAINTS
I BODY
J AIR CONDITIONER
K ELECTRICAL
L MAINTENANCE
M INDEXGI General Information
EM Engine Mechanical
LU Engine Lubrication System
CO Engine Cooling System
EC Engine Control System
FL Fuel System
EX Exhaust System
ACC Accelerator Control System
CL Clutch
MT Manual Transaxle
AT Automatic Transaxle
TF Transfer
PR Propeller Shaft
RFD Rear Final Drive
FAX Front Axle
RAX Rear Axle
FSU Front Suspension
RSU Rear Suspension
WT Road Wheels & Tires
BR Brake System
PB Parking Brake System
BRC Brake Control System
PS Power Steering System
SB Seat Belts
SRS Supplemental Restraint System (SRS)
BL Body, Lock & Security System
GW Glasses, Window System & Mirrors
RF Roof
EI Exterior & Interior
IP Instrument Panel
SE Seat
ATC Automatic Air Conditioner
MTC Manual AIr Conditioner
SC Starting & Charging System
LT Lighting System
DI Driver Information System
WW Wiper, Washer & Horn
BCS Body Control System
LAN LAN System
AV Audio Visual, Navigation & Telephone System
PG Power Supply, Ground & Circuit Elements
MA Maintenance
IDX Alphabetical Index
QUICK REFERENCE INDEX
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GI-1
GENERAL INFORMATION
A GENERAL INFORMATION
CONTENTS
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GI
SECTION GI

GENERAL INFORMATION
PRECAUTIONS .......................................................... 3
Description ............................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for NATS (NISSAN ANTI-THEFT SYS-
TEM) ........................................................................ 3
General Precautions ................................................ 4
Precautions for All Mode 4 × 4 System .................... 5
Precautions for Three Way Catalyst ......................... 5
Precautions for Fuel ................................................. 5
GASOLINE ENGINE ............................................. 5
DIESEL ENGINE ................................................... 5
Precautions for Multiport Fuel Injection System or
Engine Control System ............................................ 6
Precautions for Turbocharger (If Equipped) ............. 6
Precautions for Hoses .............................................. 6
HOSE REMOVAL AND INSTALLATION ............... 6
HOSE CLAMPING ................................................ 7
Precautions for Engine Oils ...................................... 7
HEALTH PROTECTION PRECAUTIONS ............. 7
ENVIRONMENTAL PROTECTION PRECAU-
TIONS ................................................................... 7
Precautions for Air Conditioning ............................... 7
HOW TO USE THIS MANUAL ................................... 8
Description ............................................................... 8
Terms ....................................................................... 8
Units ......................................................................... 8
Contents ................................................................... 8
Components ............................................................. 9
SYMBOLS ............................................................. 9
How to Follow Trouble Diagnoses .......................... 10
DESCRIPTION .................................................... 10
HOW TO FOLLOW TEST GROUPS IN TROU-
BLE DIAGNOSES ............................................... 10
HARNESS WIRE COLOR AND CONNECTOR
NUMBER INDICATION ........................................ 11
KEY TO SYMBOLS SIGNIFYING MEASURE-
MENTS OR PROCEDURES ............................... 12
How to Read Wiring Diagrams ............................... 14CONNECTOR SYMBOLS ................................... 14
SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 15
DESCRIPTION .................................................... 16
Abbreviations .......................................................... 22
SERVICE INFORMATION FOR ELECTRICAL INCI-
DENT ......................................................................... 23
How to Perform Efficient Diagnosis for an Electrical
Incident ................................................................... 23
WORK FLOW ...................................................... 23
INCIDENT SIMULATION TESTS ........................ 23
CIRCUIT INSPECTION ....................................... 26
Control Units and Electrical Parts ........................... 31
PRECAUTIONS .................................................. 31
CONSULT-II CHECKING SYSTEM .......................... 33
Description .............................................................. 33
Function and System Application ........................... 33
Nickel Metal Hydride Battery Replacement ............ 33
Checking Equipment .............................................. 34
CONSULT-II Start Procedure .................................. 34
CONSULT-II Data Link Connector (DLC) Circuit .... 35
INSPECTION PROCEDURE .............................. 35
LIFTING POINT ......................................................... 36
Special Service Tools ............................................. 36
Garage Jack and Safety Stand ............................... 36
2-Pole Lift ............................................................... 37
Board-On Lift .......................................................... 38
TOW TRUCK TOWING ............................................. 39
Tow Truck Towing ................................................... 39
TOWING AN AUTOMATIC TRANSAXLE
MODEL WITH FOUR WHEELS ON GROUND ... 39
TOWING THE VEHICLE WITH REAR WHEELS
RAISED (WITH FRONT WHEELS ON GROUND)
OR FRONT WHEELS RAISED ........................... 40
Vehicle Recovery (Freeing a Stuck Vehicle) ........... 40
TIGHTENING TORQUE OF STANDARD BOLTS .... 41
Tightening Torque Table ......................................... 41
IDENTIFICATION INFORMATION ............................ 42
Model Variation ....................................................... 42
IDENTIFICATION NUMBER ................................ 43
IDENTIFICATION PLATE .................................... 44

PRECAUTIONS
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PRECAUTIONSPFP:00001
DescriptionEAS000FN
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EAS000P8
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for NATS (NISSAN ANTI-THEFT SYSTEM)EAS000FP
NATS will immobilize the engine if someone tries to start it without the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.

When NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.

When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-
II operation manual, NATS.
Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly con-
fidential to maintain the integrity of the anti-theft function.

When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to
receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS.

When failing to start the engine first time using the key of NATS, start as follows.
1. Leave the ignition key in "ON" position for approximately 5 seconds.
2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds.
3. Repeat step 1 and 2 again.
4. Restart the engine while keeping the key separate from any others on key-chain.

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
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ENGINE MECHANICAL
QR
PRECAUTIONS .......................................................... 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET .......................... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting — Engine Noise ................... 11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Changing Air Cleaner Filter .................................... 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
INTAKE MANIFOLD ................................................. 17
Removal and Installation (QR20DE) ...................... 17REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
INSPECTION AFTER INSTALLATION ................ 19
Removal and Installation (QR25DE) ...................... 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
OIL PAN AND OIL STRAINER ................................. 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 27
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 28
IGNITION COIL ......................................................... 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
SPARK PLUG ........................................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSPECTION AFTER REMOVAL ....................... 30
INSTALLATION ................................................... 31
FUEL INJECTOR AND FUEL TUBE ........................ 32
Removal and Installation (QR20DE) ...................... 32
REMOVAL ........................................................... 32
INSTALLATION ................................................... 34
INSPECTION AFTER INSTALLATION ................ 36
Removal and Installation (QR25DE) ...................... 37
REMOVAL ........................................................... 37
INSTALLATION ................................................... 39
INSPECTION AFTER INSTALLATION ................ 41

EM-2 ROCKER COVER ..................................................... 42
Removal and Installation ........................................ 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
TIMING CHAIN .......................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSPECTION AFTER REMOVAL ........................ 48
INSTALLATION .................................................... 49
CAMSHAFT ............................................................... 53
Removal and Installation ........................................ 53
REMOVAL ........................................................... 53
INSPECTION AFTER REMOVAL ........................ 55
INSTALLATION .................................................... 58
Valve Clearance ...................................................... 61
INSPECTION ....................................................... 61
ADJUSTMENT .................................................... 62
OIL SEAL .................................................................. 64
Removal and Installation of Valve Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 64
Removal and Installation of Front Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 65
Removal and Installation of Rear Oil Seal .............. 65
REMOVAL ........................................................... 65
INSTALLATION .................................................... 65
CYLINDER HEAD ..................................................... 67
On-Vehicle Service ................................................. 67
CHECKING COMPRESSION PRESSURE ......... 67
Removal and Installation ........................................ 68
REMOVAL ........................................................... 68
INSPECTION AFTER REMOVAL ........................ 69
INSTALLATION .................................................... 69
Disassembly and Assembly .................................... 71
DISASSEMBLY ................................................... 71
ASSEMBLY ......................................................... 72
Inspection After Disassembly ................................. 73
VALVE DIMENSIONS .......................................... 73
VALVE GUIDE CLEARANCE .............................. 73
VALVE GUIDE REPLACEMENT ......................... 74
VALVE SEAT CONTACT ..................................... 75
VALVE SEAT REPLACEMENT ........................... 75
VALVE SPRING SQUARENESS ......................... 77
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 77
ENGINE ASSEMBLY ................................................ 78
Removal and Installation ........................................ 78
REMOVAL ........................................................... 78
INSTALLATION .................................................... 81
INSPECTION AFTER INSTALLATION ................ 81
CYLINDER BLOCK ................................................... 82
Disassembly and Assembly .................................... 82
DISASSEMBLY ................................................... 83
ASSEMBLY ......................................................... 87
How to Select Piston and Bearing .......................... 92
DESCRIPTION .................................................... 92
HOW TO SELECT PISTON ................................. 92
HOW TO SELECT CONNECTING ROD BEAR-ING ....................................................................... 93
HOW TO SELECT MAIN BEARING .................... 95
Inspection After Disassembly .................................. 99
CRANKSHAFT END PLAY .................................. 99
CONNECTING ROD SIDE CLEARANCE ........... 99
PISTON TO PISTON PIN OIL CLEARANCE ....... 99
PISTON RING SIDE CLEARANCE ...................100
PISTON RING END GAP ..................................100
CONNECTING ROD BEND AND TORSION .....101
CONNECTING ROD BIG END DIAMETER ......101
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................101
CYLINDER BLOCK DISTORTION ....................102
MAIN BEARING HOUSING INNER DIAMETER .103
PISTON TO CYLINDER BORE CLEARANCE ..103
CRANKSHAFT MAIN JOURNAL DIAMETER ...104
CRANKSHAFT PIN JOURNAL DIAMETER ......105
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ...............................................................105
CRANKSHAFT RUNOUT ..................................105
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................105
MAIN BEARING OIL CLEARANCE ...................106
MAIN BEARING CRUSH HEIGHT ....................107
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................107
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ...........................................107
CONNECTING ROD BOLT OUTER DIAMETER .107
FLYWHEEL DEFLECTION (M/T MODELS) ......108
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ...........................................................108
SERVICE DATA AND SPECIFICATIONS (SDS) ....109
Standard and Limit ................................................109
GENERAL SPECIFICATIONS ...........................109
DRIVE BELT ......................................................109
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................109
SPARK PLUG ....................................................109
CYLINDER HEAD ..............................................109
VALVE ................................................................110
CAMSHAFT AND CAMSHAFT BEARING .........113
CYLINDER BLOCK ............................................114
PISTON, PISTON RING AND PISTON PIN ......115
CONNECTING ROD ..........................................116
CRANKSHAFT ...................................................116
MAIN BEARING .................................................118
CONNECTING ROD BEARING .........................119
Tightening Torque .................................................119
YD22DDTi
PRECAUTIONS .......................................................122
Precautions for Draining Engine Coolant ..............122
Precautions for Disconnecting Fuel Piping ...........122
Precautions for Removal and Disassembly ..........122
Precautions for Inspection, Repair and Replace-
ment ......................................................................122
Precautions for Assembly and Installation ............122

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EMA
Parts Requiring Angle Tightening ......................... 122
Precautions For Liquid Gasket ............................. 123
REMOVAL OF LIQUID GASKET ...................... 123
LIQUID GASKET APPLICATION PROCEDURE . 123
PREPARATION ....................................................... 124
Special Service Tools ........................................... 124
Commercial Service Tools .................................... 127
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 129
NVH Troubleshooting — Engine Noise ................ 129
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 130
DRIVE BELTS ......................................................... 131
Checking Drive Belts ............................................ 131
Tension Adjustment .............................................. 131
A/C COMPRESSOR BELT ............................... 132
ALTERNATOR AND WATER PUMP BELT ....... 132
Removal and Installation ...................................... 132
REMOVAL ......................................................... 132
INSTALLATION ................................................. 132
AIR CLEANER AND AIR DUCT ............................. 133
Removal and Installation ...................................... 133
REMOVAL ......................................................... 133
INSTALLATION ................................................. 133
CHANGING AIR CLEANER FILTER ................. 134
CHARGE AIR COOLER ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSPECTION AFTER REMOVAL ..................... 135
INSTALLATION ................................................. 135
INTAKE MANIFOLD ............................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSPECTION AFTER REMOVAL ..................... 137
INSTALLATION ................................................. 137
INSPECTION AFTER INSTALLATION ............. 138
CATALYST .............................................................. 139
Removal and Installation ...................................... 139
REMOVAL ......................................................... 139
INSTALLATION ................................................. 140
EXHAUST MANIFOLD AND TURBOCHARGER .. 141
Removal and Installation ...................................... 141
REMOVAL ......................................................... 141
INSTALLATION ................................................. 142
INSPECTION AFTER INSTALLATION ............. 142
Disassembly and Assembly ................................. 143
DISASSEMBLY ................................................. 143
ASSEMBLY ....................................................... 143
INSPECTION AFTER DISASSEMBLY ............. 143
Turbocharger ........................................................ 144
ROTOR SHAFT CLEARANCE ......................... 144
ROTOR SHAFT END PLAY .............................. 144
TURBINE WHEEL ............................................. 145
COMPRESSOR WHEEL .................................. 145
TURBOCHARGER BOOST CONTROL ACTU-
ATOR ................................................................ 145
TROUBLE DIAGNOSIS OF TURBOCHARGER . 146OIL PAN AND OIL STRAINER ...............................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSPECTION AFTER REMOVAL .....................149
INSTALLATION .................................................149
INSPECTION AFTER INSTALLATION ..............151
GLOW PLUG ..........................................................152
Removal and Installation ......................................152
REMOVAL .........................................................152
INSTALLATION .................................................152
VACUUM PUMP ......................................................153
Removal and Installation ......................................153
INSPECTION BEFORE REMOVAL ..................153
REMOVAL .........................................................153
INSTALLATION .................................................154
INSPECTION AFTER INSTALLATION ..............155
Disassembly and Assembly ..................................155
DISASSEMBLY .................................................155
ASSEMBLY .......................................................156
INJECTION TUBE AND FUEL INJECTOR ............157
Removal and Installation ......................................157
REMOVAL .........................................................157
INSTALLATION .................................................159
INSPECTION AFTER INSTALLATION ..............160
FUEL PUMP ............................................................161
Removal and Installation ......................................161
REMOVAL .........................................................161
INSPECTION AFTER REMOVAL .....................165
INSTALLATION .................................................165
ROCKER COVER ...................................................168
Removal and Installation ......................................168
REMOVAL .........................................................168
INSTALLATION .................................................169
INSPECTION AFTER INSTALLATION ..............169
CAMSHAFT ............................................................170
Removal and Installation ......................................170
REMOVAL .........................................................170
INSPECTION AFTER REMOVAL .....................171
INSTALLATION .................................................174
Valve Clearance ...................................................175
INSPECTION ....................................................175
ADJUSTMENTS ................................................177
SECONDARY TIMING CHAIN ................................180
Removal and Installation ......................................180
REMOVAL .........................................................180
INSPECTION AFTER REMOVAL .....................182
INSTALLATION .................................................182
PRIMARY TIMING CHAIN ......................................185
Removal and Installation ......................................185
REMOVAL .........................................................187
INSPECTION AFTER REMOVAL .....................190
INSTALLATION .................................................190
CYLINDER HEAD ...................................................196
On-Vehicle Service ...............................................196
CHECKING COMPRESSION PRESSURE .......196
Removal and Installation ......................................197
REMOVAL .........................................................197
INSPECTION AFTER REMOVAL .....................198

EM-4 INSTALLATION ..................................................199
Disassembly and Assembly ..................................201
DISASSEMBLY .................................................201
ASSEMBLY .......................................................202
INSPECTION AFTER DISASSEMBLY ..............203
ENGINE ASSEMBLY ..............................................208
Removal and Installation ......................................208
REMOVAL .........................................................209
INSTALLATION ..................................................211
INSPECTION AFTER INSTALLATION ..............211
CYLINDER BLOCK .................................................212
Disassembly and Assembly ..................................212
DISASSEMBLY .................................................213
ASSEMBLY .......................................................217
How to Select Piston and Bearing ........................222
DESCRIPTION ..................................................222
HOW TO SELECT PISTON ...............................222
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................223
HOW TO SELECT MAIN BEARING ..................224
Inspection After Disassembly ...............................226
CRANKSHAFT END PLAY ................................226
CONNECTING ROD SIDE CLEARANCE .........226
PISTON TO PISTON PIN CLEARANCE ...........226
PISTON RING SIDE CLEARANCE ...................227
PISTON RING END GAP ..................................227
CONNECTING ROD BEND AND TORSION .....228
CONNECTING ROD BIG END INNER DIAME-
TER ...................................................................228
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................228
CYLINDER BLOCK TOP SURFACE DISTOR-TION ..................................................................229
MAIN BEARING HOUSING INNER DIAMETER .229
PISTON TO CYLINDER BORE CLEARANCE ..230
CRANKSHAFT JOURNAL OUTER DIAMETER .231
CRANKSHAFT PIN OUTER DIAMETER ..........231
CRANKSHAFT OUT-OF-ROUND AND TAPER .231
CRANKSHAFT RUNOUT ..................................232
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................232
MAIN BEARING OIL CLEARANCE ...................233
CRUSH HEIGHT OF MAIN BEARING ..............233
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................233
MAIN BEARING CAP BOLT DEFORMATION ...234
CONNECTING ROD BOLT DEFORMATION ....234
OIL JET ..............................................................234
OIL JET RELIEF VALVE ....................................234
FLYWHEEL DEFLECTION ................................235
MOVEMENT AMOUNT OF FLYWHEEL ...........235
SERVICE DATA AND SPECIFICATIONS (SDS) ....236
Standard and Limit ................................................236
GENERAL SPECIFICATIONS ...........................236
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................236
DRIVE BELTS ....................................................236
CYLINDER HEAD ..............................................237
VALVE ................................................................237
CAMSHAFT .......................................................241
CYLINDER BLOCK ............................................241
PISTON, PISTON RING AND PISTON PIN ......242
CONNECTING ROD ..........................................243
CRANKSHAFT ...................................................243
AVAILABLE MAIN BEARING .............................244
AVAILABLE CONNECTING ROD BEARING .....244
MISCELLANEOUS COMPONENTS ..................244
Tightening Torque .................................................245

EM-12
[QR]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00L7Q
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-61
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-56EM-55
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-99
EM-101
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-104EM-100
EM-100
EM-101
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-101EM-105
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-106EM-105
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-48
EM-44
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-20,
"WATER
PUMP"

DRIVE BELTS
EM-13
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00KN7
WARNING:
Be sure to perform this step when the engine is stopped.

Make sure that the indicator (single line notch on fixed side) of drive belt auto-tensioner is within the pos-
sible use range (between three line notches on moving side).
NOTE:

Check the drive belt auto-tensioner indicator (single line notch on fixed side) when engine is cold.

When new drive belt is installed, the indicator (single line notch on fixed side) should be within the
range “A” in the figure.

Visually check entire belt for wear, damage or cracks.

If the indicator (single line notch on fixed side) is out of the possible use range or belt is damaged, replace
drive belt.
Tension AdjustmentEBS00KN8
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationEBS00KN9
REMOVAL
1. Remove splash guard on RH undercover.
2. With box wrench, and while securely holding the hexagonal part
in center of drive belt auto-tensioner pulley, move the wrench
handle in the direction of arrow (loosening direction of ten-
sioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
3. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of the retaining boss to fix
drive belt auto-tensioner pulley.
4. Loosen drive belt from water pump pulley in sequence, and
remove it.
PBIC1234E
PBIC2169E

EM-14
[QR]
DRIVE BELTS

INSTALLATION
1. With box wrench, and while securely holding the hexagonal part in center of drive belt auto-tensioner pul-
ley, move the wrench handle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off.
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole of
retaining boss to fix drive belt auto-tensioner pulley.
3. Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally.
CAUTION:
Confirm belt is completely set to pulleys.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator is within the range of possible use. Refer to EM-13, "
Checking
Drive Belts" .
Removal and Installation of Drive Belt Auto-TensionerEBS00KNA
REMOVAL
1. Remove splash guard on RH undercover.
2. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
3. Remove drive belt auto-tensioner.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
When installing drive belt auto-tensioner, be careful not to damage water pump pulley.
1. Drive belt auto-tensioner 2. Water pump pulley
PBIC2170E