NISSAN X-TRAIL 2005 Service Repair Manual

CYLINDER BLOCK
EM-237
[YD22DDTi]
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7. 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.
8. Check the main bearing cap bolts for deformation. Refer to EM-254, "
MAIN BEARING CAP BOLT
DEFORMATION" .
9. 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. (angle tightening)
CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angle 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-245, "CRANKSHAFT
END PLAY" .
10. Check the outer diameter of connecting rod bolts. Refer to EM-
254, "CONNECTING ROD BOLT DEFORMATION" .
11. 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.
JEM225G
: 27 N·m (2.8 kg-m, 20 ft-lb)
JEM200G
JEM226G
PBIC0089E

EM-238
[YD22DDTi]
CYLINDER BLOCK


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.
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.

Install top ring and second ring with punched mark surfaces
facing upward.

Install rings so that three closed gap position 120 degrees
apart one another.

Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
13. Install connecting rod bearing to connecting rod and cap.

While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.

Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
14. Install piston and connecting rod assembly to crankshaft.

Move crankshaft pin to be assembled to BDC.

Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.

Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.

Using the piston ring compressor (special service tool) or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:

When removing piston and connecting rod assembly,
prevent the big end of connecting rod from interfering with oil jet.

Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference
of the connecting rod big end.
MBIA0024E
Punched mark:
Top ring : RTop
Second ring : R2nd
JEM228G
JEM229G
PBIC1619E

CYLINDER BLOCK
EM-239
[YD22DDTi]
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15. Install connecting rod caps and mounting nuts.

Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.

Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
16. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
c. Loosen completely.
d. Tighten bolts.
e. Tighten 120 degrees. (angle tightening)

Always use either the angle wrench (special service tool)
or protractor during angle tightening. Avoid tightening
based on visual checks alone.

After tightening nuts, make sure that crankshaft rotates
smoothly.

Check connecting rod side clearance. Refer to EM-246,
"CONNECTING ROD SIDE CLEARANCE" .
17. Press fit rear oil seal into rear oil seal retainer.

Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.

Avoid inclined fitting. Force fit perpendicularly.
MBIA0024E
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
: 0 N·m (0 kg-m, 0 in-lb)
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
JEM231G
JEM232G

EM-240
[YD22DDTi]
CYLINDER BLOCK

18. Install rear oil seal retainer to cylinder block.

Apply new engine oil to the oil and dust seal lips.

Apply liquid gasket to rear oil seal retainer using the tube
presser (special service tool: WS39930000) as shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
19. Press fit pilot bush into crankshaft.

Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bush until it stops.
20. Install fuel pump bracket.

Align the bracket with the dowel pins on cylinder block to
install.

The two bolts used for dowel pins have a longer shanks than
the other two.
21. Install parts to engine in the reverse order of disassembly.
22. Remove engine from engine stand in the reverse order of assembly.
23. Install flywheel.

When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin
hole.
CAUTION:
If these are not aligned correctly, engine runs roughly
and “MI” turns on.
JEM233G
JEM234G
PBIC2329E
PBIC2538E

CYLINDER BLOCK
EM-241
[YD22DDTi]
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There is a mating mark on the clutch cover side, Refer it dur-
ing installation.

Holding ring gear with the ring stopper (special service tool),
tighten securing bolts with TORX bit (size: T55, Commercial
Service Tool).

Tighten bolts uniformly in a crisscross manner.

Apply engine oil to bolt threads and seat surfaces.
How to Select Piston and BearingEBS00ODY
DESCRIPTION

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
PBIC2495E
PBIC2406E
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft main jour-
nal grade (outer diameter of
main journal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin journal
diameter determine connecting
rod bearing selection.
Between cylinder block to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston skirt diam-
eter)Piston grade = cylinder bore
grade (inner diameter of bore)

EM-242
[YD22DDTi]
CYLINDER BLOCK

HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.

The part No. of piston is specified together with piston pin as
an assembly.
When Re-using Old Cylinder Block
1. Measure cylinder bore inner diameter. Refer to EM-250, "Cylinder Bore Inner Diameter" .
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
3. Select piston of the same grade.
Piston Selection Table
Unit: mm (in)
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
When Using New Crankshaft and Connecting Rod
1. Identify the pin journal diameter grade (No. 0, 1, or 2) on front
surface of crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
PBIC2589E
MBIA0025E
Grade (punched) 1 2 3
Cylinder bore
inner diameter86.000 - 86.010 (3.3858 - 3.3862) 86.010 - 86.020 (3.3862 - 3.3866) 86.020 - 86.030 (3.3866 - 3.3870)
Piston skirt diam-
eter85.928 - 85.942 (3.3830 - 3.3835) 85.938 - 85.952 (3.3834 - 3.3839) 85.948 - 85.962 (3.3838 - 3.3843)
PBIC2590E

CYLINDER BLOCK
EM-243
[YD22DDTi]
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When Re-using the Removed Crankshaft and Connecting Rod
1. Measure the inner diameter of the big end of connecting rod and make sure it is within the specified
range. Refer to EM-248, "
CONNECTING ROD BIG END INNER DIAMETER" .
2. Measure the outer diameter of the crankshaft pin journal. Refer to EM-251, "
CRANKSHAFT PIN JOUR-
NAL DIAMETER" .
3. Determine the crankshaft pin journal grade by comparing the measurement with the values under the col-
umn “Crankshaft pin journal diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
Selection Table of connecting Rod Bearing
Unit: mm (in)
Unit: mm (in)
Under Size Bearing Usage

If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under
size bearings.

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Connecting Rod Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding the crankshaft pin journal to use an under size
bearing, avoid damaging the fillet R.
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.492 - 1.496 (0.0587 - 0.0589) STD 0 Black
51.961 - 51.968 (2.0457 - 2.0460) 1 1.496 - 1.500 (0.0589 - 0.0591) STD 1 Brown
51.954 - 51.961 (2.0454 - 2.0457) 2 1.500 - 1.504 (0.0591 - 0.0592) STD 2 Green
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
PBIC2200E

EM-244
[YD22DDTi]
CYLINDER BLOCK

HOW TO SELECT MAIN BEARING
When Using New Cylinder Block and Crankshaft
1. Identify the main bearing housing grade (No. 0, 1, or 2) on LH
surface at the rear of the cylinder block, and locate the applica-
ble grade on the “Grade” row in the “Main Bearing Grade Table”.
2. Identify the main journal grade (No. 0, 1, or 2) on the front sur-
face of crankshaft, and locate the applicable grade under the
“Grade” column in the “Main Bearing Grade Table”.
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-249, "MAIN BEARING
HOUSING INNER DIAMETER" .
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft main journal. Refer to EM-251, "
CRANKSHAFT MAIN JOUR-
NAL DIAMETER" .
4. Locate the applicable cell where the measurement falls, under “Crankshaft main journal diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Main Bearing Grade Table
Unit: mm (in)
PBIC2589E
PBIC2590E
Inner diameter of Cylinder block main bearing housing66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft main
journal diameterGrade
(punched)012
62.967 - 62.975
(2.4790 - 2.4793)0

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green

CYLINDER BLOCK
EM-245
[YD22DDTi]
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Under Size Bearing Usage

If bearing clearance is out of the specifications for main bearings in standard size, use under size bear-
ings.

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to the specification.
Main Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding crankshaft main journals to use under size bear-
ings, keep corners radius of fillet R.
Inspection After DisassemblyEBS00ODP
CRANKSHAFT END PLAY

Using dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward.

If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
62.959 - 62.967
(2.4787 - 2.6790)1

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Ye l l o w
62.951 - 62.959
(2.4784 - 2.4787)2

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Ye l l o wSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
PBIC2200E
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
PBIC2377E

EM-246
[YD22DDTi]
CYLINDER BLOCK

CONNECTING ROD SIDE CLEARANCE

Using feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.

If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.
Piston Pin Outer Diameter
Using micrometer, measure piston pin outer diameter.
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)

If out of the standard, replace piston/piston pin assembly.

When replacing piston and piston pin assembly, refer to EM-250, "PISTON TO CYLINDER BORE
CLEARANCE" .
NOTE:
Piston is available together with piston pin as assembly.Standard : 0.20 - 0.35 (0.0079 - 0.0138 in)
Limit : 0.40 mm (0.0157 in)
JEM203G
Standard : 28.003 - 28.009 mm (1.1025 - 1.1027 in)
PBIC0116E
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)