NISSAN X-TRAIL 2005 Service Repair Manual

INTAKE MANIFOLD
EM-147
[YD22DDTi]
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5. Remove exhaust manifold insulator. Refer to EM-151, "EXHAUST MANIFOLD AND TURBOCHARGER" .
6. Disconnect harness connector from EGR volume control valve and water hoses.
7. Disconnect heater hose.
8. Remove EGR cooler.
9. Remove injection tube center. Refer to EM-167, "
Removal and Installation" .
CAUTION:
Be careful not to spill fuel in the engine component.
10. Remove water pipe.
11. Remove fuel hoses and fuel gallery.

To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
12. Loosen bolts and nuts in reverse order of that shown in the fig-
ure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
13. Remove EGR volume control valve from intake manifold.
CAUTION:

Handle with care avoiding any shocks.

Do not disassemble.
INSPECTION AFTER REMOVAL
Surface Distortion

Check distortion on the mounting surface with a straightedge
and feeler gauge.

If it exceeds the limit, replace intake manifold.
INSTALLATION
Following instructions below, install in the reverse order of removal.
1. Install EGR volume control valve.
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E

EM-148
[YD22DDTi]
INTAKE MANIFOLD

2. Install intake manifold.

Tighten fixing bolts and nuts in numerical order as shown in
the figure.

When stud bolts come off, install with the following torque.
3. Install water hose.

Install water hose by referring to identification marks avoiding
twisting.

When an insert stopper is not provided with the pipe, insert
the hose to the length below.

When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
4. Install remaining parts in the reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight. : 10.5 N·m (1.1 kg-m, 8 ft-lb)
PBIC0676E
: 25 - 30 mm (0.984 - 1.181 in)
PBIC2021E

CATALYST
EM-149
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-32, "
Changing Engine Coolant" .
3. Remove radiator hose (upper and lower). Refer to CO-35, "
RADIATOR" .
4. Remove cooling fan assembly. Refer to CO-37, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-35, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-45, "
THERMOSTAT AND WATER PIPING" .
7. Remove catalyst insulators.
8. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
1. Catalyst insulator 2. Gasket 3. Catalyst
4. Locking pin 5. Gusset 6. Gasket cap
7. Catalyst rear diffuser 8. Turbocharger insulator
PBIC2670E
Catalyst locking pin : Flange bolt (black)

EM-150
[YD22DDTi]
CATALYST

INSTALLATION
Note the following, and install in the reverse order of removal.

Pushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.

Assemble catalyst insulator with making clearance from catalyst.

EXHAUST MANIFOLD AND TURBOCHARGER
EM-151
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO-32, "Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
2. Remove charge air cooler. Refer to EM-144, "
Removal and Installation" .
3. Remove air duct. Refer to EM-142, "
Removal and Installation" .
4. Remove air inlet pipe.
5. Remove engine undercover.
6. Remove radiator hose (upper and lower). Refer to CO-35, "
RADIATOR" .
7. Remove cooling fan assembly. Refer to CO-37, "
DISASSEMBLY AND ASSEMBLY" .
8. Remove radiator mounting bracket and radiator. Refer to CO-35, "
Removal and Installation" .
9. Remove water inlet pipe. Refer to CO-45, "
THERMOSTAT AND WATER PIPING" .
10. Remove catalyst. Refer to EM-149, "
Removal and Installation" .
11. Remove exhaust manifold insulator.
1. EGR volume control valve 2. Gasket 3. EGR cooler
4. Air inlet pipe 5.Exhaust manifold and turbocharger
assembly6. Oil feed tube
7. Oil return hose 8. Washer 9. Eye-bolt
10. Turbocharger insulator 11. Exhaust manifold insulator 12. Air inlet pipe
PBIC3614E

EM-152
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER

12. Remove turbocharger insulator.
13. Remove oil feed tube.
14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
15. Rotate exhaust manifold and turbocharger assembly so that the rear side (EGR cooler mounting side)
faces upward. And then pull out the assembly from between the engine and the A/C piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling out the assembly.
16. Remove exhaust manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION

When a stud bolt is pulled out, tighten it to the following torque:

Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to EM-151, "
Removal and Instal-
lation" .
2. Tighten the nuts in order specified in the figure.
3. Re-tighten the nuts 1 to 4.
4. Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
JEM266G
: 14.7 N·m (1.5 kg-m, 11ft-lb)
JEM266G

EXHAUST MANIFOLD AND TURBOCHARGER
EM-153
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Disassembly and AssemblyEBS00LRI
DISASSEMBLY

After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
ASSEMBLY

When a stud bolt is pulled out, tighten it to the following torque:
1. Exhaust manifold 2. Gasket 3. Oil feed tube
4. Turbocharger 5. Washer 6. Eye- bolt
PBIC3613E
Exhaust manifold side
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
Catalyst side
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
Air inlet side
: 11.3 N·m (1.2 kg-m, 8 ft-lb)

EM-154
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER

INSPECTION AFTER DISASSEMBLY
Surface Distortion

Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.

If it exceeds the limit, replace exhaust manifold.
TurbochargerEBS00LRJ
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
ROTOR SHAFT CLEARANCE

Make sure that the rotor shaft rotates smoothly without any
resistance when it is rotated by your fingertips.

Make sure that the rotor shaft is not loose when it is moved ver-
tically or horizontally.

Measure looseness with a dial indicator inserting its measuring
rod through oil drain hole of turbocharger.

Replace turbocharger if out of standard.Limit : 0.3 mm (0.012 in)
JEM267G
PBIC2532E
Suction side : Between turbocharger and air cleaner
Exhaust side : Between turbocharger and catalyst
Standard : 0.086 - 0.117 mm (0.0034 - 0.0046 in)
PBIC0727E

EXHAUST MANIFOLD AND TURBOCHARGER
EM-155
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ROTOR SHAFT END PLAY

Place a dial indicator at the rotor shaft end in the axial direction
to measure the end play.

Replace turbocharger if out of standard.
TURBINE WHEEL

Make sure that there is no engine oil adhesion.

Make sure that there is no carbon accumulation.

Make sure that blades of turbine wheel are not bent or broken.

Make sure that turbine wheel does not interfere with turbine
housing.

If anything above is found, replace turbocharger.
COMPRESSOR WHEEL

Make sure that there is no engine oil adhesion inside the air
inlet.

Make sure that compressor wheel does not interfere with com-
pressor housing.

Make sure that compressor wheel is not bent or broken.

If anything above is found, replace turbocharger.
TURBOCHARGER BOOST CONTROL ACTUATOR

Connect the handy vacuum pump to the actuator, and make
sure that the rod strokes smoothly in compliance with the follow-
ing pressure.

Pressure to be applied at actuator part to move rod end as fol-
lows:

Replace turbocharger if out of standard.Standard : 0.036 - 0.090 mm (0.0014 - 0.0035 in)
PBIC2643E
PBIC0729E
PBIC0730E
Standard (Pressure/rod stroke amount):
:– 52.0 to – 54.6 kPa (– 520 to – 546 mbar, – 390 to– 410
mmHg, – 15.4 to – 16.1 inHg)/0.2 mm (0.0079 in)
: – 32.0 to – 40.0 kPa (– 320 to – 400 mbar, – 240 to –
300 mmHg, – 9.45 to – 11.8 inHg)/5.0 mm (0.197 in)
PBIC0941E

EM-156
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER

TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:

Make sure that the engine oil level is between “MIN” and “MAX” of the oil level gauge. (When engine oil
amount is more than “MAX”, engine oil flows into the inlet duct through blow-by gas passage, and turbo-
charger is misjudged malfunction.)

Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.

Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.

If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
A: Large possibility
B: Medium possibility
C: Small possibilityInspection item Inspection resultSymptom
(when each inspection item meets each inspection result)
Engine oil
leakageSmoke NoiseInsufficient power/accel-
eration malfunction
Turbine wheelEngine oil leaks C A C C
Carbon is accumulated C A B B
Friction with housing C B A B
Blades are bent or broken — — A A
Compressor wheelInside the air inlet is seriously con-
taminated by engine oil.BB— —
Friction with housing C B A B
Blades are bent or broken — — A A
After checking both turbine and
compressor, inspect rotor shaft
end play.There is resistance when the rotor
shaft is rotated by your fingertips.—CC B
The rotor shaft sometimes does not
rotate by your fingertips.——— A
There is too much play in the bear-
ing.CCB C
Oil return portCarbon or sludge is accumulated in
the waste oil hole.CAC C