NISSAN X-TRAIL 2001 Service Repair Manual

AIR CLEANER AND AIR DUCT
EM-121
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CHANGING AIR CLEANER FILTER
1. Remove air cleaner case.
2. Remove clips and lift up air cleaner upper case.
3. Remove air cleaner filter.

EM-122
[YD22DDTi]
CHARGE AIR COOLER
CHARGE AIR COOLER
PFP:14461
Removal and InstallationEBS00LRE
REMOVAL
Remove and install with bottom bracket as an assembly
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
●Be careful not to deform core fins.
●For cleaning procedure of charge air cooler core, refer to CO-34, "Checking Radiator".
INSTALLATION
Pay attention to identification mark color and direction when installing air inlet hoses. Refer to EM-122,
"Removal and Installation" .
PBIC1236E
1. Charge air cooler cover 2. Charge air cooler 3. Gasket
4. Air inlet tube 5. Air inlet hose 6. Air inlet hose
7. Bottom bracket

INTAKE MANIFOLD
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INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00LRF
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
1. Drain engine coolant. Refer to CO-29, "
Changing Engine Coolant" .
2. Remove air duct. Refer to EM-120, "
Removal and Installation" .
3. Remove charge air cooler and bracket. Refer to EM-122, "
Removal and Installation" .
4. Remove air inlet pipes. Refer to EM-127, "
Removal and Installation" .
5. Remove exhaust manifold cover.
6. Disconnect electronic EGR control valve water hoses and harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
PBIC0675E
1. Vacuum & fuel gallery 2. Water hose 3. Electronic EGR volume control valve
4. Gasket 5. EGR passage 6. EGR support
7. Water pipe 8. EGR Cooler 9. Intake manifold

EM-124
[YD22DDTi]
INTAKE MANIFOLD
9. Remove vacuum hose.
10. Remove injection tube. Refer to EM-144, "
Removal and Installa-
tion" .
11. Remove water pipe.
12. Remove fuel hose.
●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.
13. Loosen bolts and nuts in the reverse order of that shown in the
figure.
CAUTION:
Do not disassemble or adjust swirl control valve.
14. Remove electronic EGR volume control valve from intake mani-
fold.
INSPECTION AFTER REMOVAL
Surface Distortion
Check distortion on the mounting surface with a straightedge and
feeler gauge.
INSTALLATION
Following instructions below, install in reverse order of removal.
1. Install electronic EGR volume control valve.
●Handle with care avoiding any shocks.
●Do not disassemble or adjust.
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.
PBIC0982E
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)

INTAKE MANIFOLD
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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 up to dimension A. When the pipe is shorter than
dimension A, insert hose fully until it reaches the end.
●When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
●When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
4. Install remaining parts in reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer to FL-16,
"Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.Dimension A : 25 - 30 mm (0.984 - 1.181 in)
SBIA0156E

EM-126
[YD22DDTi]
CATALYST
CATALYST
PFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-29, "
Changing Engine Coolant" .
3. Remove radiator upper and lower hoses.
4. Remove radiator fan. Refer to CO-33, "
Disassembly and Assembly Radiator Fan" .
5. Remove radiator mount bracket and radiator. Refer to CO-32, "
Removal and Installation" .
6. Remove water inlet pipe.
7. Remove insulators.
8. Disconnect exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
INSTALLATION
Install in 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.
SBIA0157E
1. Catalyst insulator 2. Catalyst 3. Catalyst rear diffuser
4. Gasket
Catalyst locking pin : Flange bolt (black)

EXHAUST MANIFOLD AND TURBOCHARGER
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO-29, "Changing Engine Coolant" .
2. Remove charge air cooler. Refer to EM-122, "
Removal and Installation" .
3. Remove air duct and air inlet pipe. Refer to EM-120, "
Removal and Installation" .
4. Remove engine undercover.
5. Remove radiator upper and lower hoses.
6. Remove radiator fan. Refer to CO-33, "
Disassembly and Assembly Radiator Fan" .
7. Remove radiator mount bracket and radiator. Refer to CO-32, "
Removal and Installation" .
8. Remove water inlet pipe.
9. Disconnect exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
10. Remove catalyst. Refer to EM-126, "
Removal and Installation" .
11. Remove exhaust manifold cover.
12. Remove insulator.
13. Each wiring and piping (disconnect/move)
PBIC1228E
1. Electronic EGR volume control valve 2. Gasket 3. EGR Cooler
4. Air inlet pipe 5.Exhaust manifold & turbocharger
assembly6. Oil return hose
7. Turbo insulator 8. Exhaust manifold insulator 9. Air inlet pipe

EM-128
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
14. Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
15. Rotate the 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 air
conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when
pulling out the assembly.
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. Tighten the nuts in the order specified in the figure.
2. Re-tighten the nuts 1 to 4.
3. Install the gasket so that the alignment protrusion faces the No.
4 port.
4. Install in reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
JEM266G
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
JEM266G

EXHAUST MANIFOLD AND TURBOCHARGER
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Disassembly and AssemblyEBS00LRI
REMOVAL
1. 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.
2. When a stud bolt is pulled out, tighten it to the following torque:
INSPECTION AFTER REMOVAL
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
PBIC0679E
1. Exhaust manifold 2. Gasket 3. Oil inlet tube
4. Water tube 5. Turbocharger 6. Oil outlet tube
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
Limit : 0.3 mm (0.012 in)
JEM267G

EM-130
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
Turbocharger
EBS00LRJ
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 failure:
ROTOR SHAFT CLEARANCE
●Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
●Check that the rotor shaft is not loose when it is moved vertically
or horizontally.
Measure looseness with a dial gauge inserting its measuring rod
through oil drain hole of turbocharger.
ROTOR SHAFT END PLAY
Place a dial gauge at the rotor shaft end in the axial direction to mea-
sure the end play.
SEM269G
Suction side : Between turbocharger and air cleaner
Exhaust side : Between turbocharger and catalyst
Standard : 0.068 - 0.096 mm (0.0027 - 0.0038 in)
SEM270G
Standard : 0.026 - 0.084 mm (0.0010 - 0.0033 in)
SEM271G