lock NISSAN X-TRAIL 2001 Service Service Manual

CYLINDER BLOCK
EM-89
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CONNECTING ROD SIDE CLEARANCE
●Measure side clearance between connecting rod and crankshaft
arm with feeler gauge.
●If the measured value exceeds the limit, replace the connecting
rod bearings, and measure again. If it still exceeds the limit,
replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
Measure the inner diameter of piston pin bore with an inside
micrometer.
Outer Diameter of Piston Pin
Measure outer diameter of piston pin with a micrometer.
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter
of piston pin)
●If clearance exceeds specification, replace either or both of pis-
ton/piston pin assembly and connecting rod assembly with refer-
ence to specification of each parts.
●Refer to piston selection table to replace piston/piston pin
assembly. Refer to EM-83, "
HOW TO SELECT PISTON" .
●Refer to connecting rod bearing selection table to replace con-
necting rod. Refer to EM-83, "
HOW TO SELECT CONNECTING
ROD BEARING" . Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit : 0.50 mm (0.0197 in)
KBIA0071E
Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)
PBIC0116E
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
KBIA0259E

EM-90
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CYLINDER BLOCK
NOTE:
●The connecting rod small end grade and piston pin hole (pis-
ton pin) grade are provided only for the parts installed at the
plant. For service parts, no grades can be selected. (Only 0
grade is available.)
●Refer to EM-91, "CONNECTING ROD BUSHING OIL
CLEARANCE (SMALL END)" for the values for each grade at
the plant.
●Regarding marks on piston head, Refer to EM-83, "HOW TO
SELECT PISTON" .
PISTON RING SIDE CLEARANCE
●Measure side clearance of piston ring and piston ring groove
with feeler gauge.
●If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
●Check if inner diameter of cylinder bore is within specification.
Refer to EM-93, "
PISTON TO CYLINDER BORE CLEARANCE"
.
●Insert piston ring until middle of cylinder with piston, and mea-
sure gap.
●If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.
SBIA0282E
Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0039 in)
SEM024AA
Standard:
Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring : 0.32 - 0.47 mm (0.0126 - 0.0185 in)
Oil ring : 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Limit:
Top ring : 0.54 mm (0.0213 in)
2nd ring : 0.67 mm (0.0264 in)
Oil ring : 0.95 mm (0.0374 in)
SEM822B

CYLINDER BLOCK
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CONNECTING ROD BEND AND TORSION
●Check with connecting rod aligner.
●If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter using an
inside micrometer.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
Measure inner diameter of bushing.Bend
Limit:
0.15 mm (0.0059 in) per 100 mm (3.94 in) length.
To r s i o n
Limit:
0.30 mm (0.0118 in) per 100 mm (3.94 in) length.
SEM003F
SEM038F
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)
PBIC0119E
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E

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CYLINDER BLOCK
Outer Diameter of Piston Pin
Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of con-
necting rod small end) – (Outer diameter of piston pin)
●If the measured value exceeds the standard, replace the con-
necting rod assembly and/or piston and piston pin assembly.
●If replacing the piston and piston pin assembly, refer to the “Pis-
ton Selection Table” to select the piston corresponding to the
applicable bore grade of the cylinder block to be used. Refer to
EM-83, "
HOW TO SELECT PISTON" .
Factory installed parts grading:
Service parts apply only to grade 0.
Unit: mm (in)
CYLINDER BLOCK DISTORTION
●Using a scraper, remove gasket on the cylinder block surface,
and also remove engine oil, scale, carbon, or other contamina-
tion.
CAUTION:
Be careful not to allow gasket flakes to enter the engine oil
or engine coolant passages.
●Measure the distortion on the block upper face at some different
points in 6 directions.
●If out of the distortion limit, replace the cylinder block.Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
SBIA0282E
Grade 0 1
Connecting rod small end
inner diameter 20.000 - 20 .0 06
(0.7874 - 0.7876) 20.006 - 20.012
(0.7876 - 0.7879)
Piston pin outer diameter 19.989 - 19.995
(0.7870 - 0.7872) 19.995 - 20. 001
(0.7872 - 0.7874)
Piston pin bore diameter 19.993 - 19.999
(0.7871- 0.7874) 19.999 - 20.005
(0.7874 - 0.7876)
KBIA0259E
Limit: 0.1 mm (0.004 in)
PBIC0121E

CYLINDER BLOCK
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INNER DIAMETER OF MAIN BEARING HOUSING
●Install the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
●Using a bore gauge, measure the inner diameter of the main
bearing housing.
●If out of the standard, replace the cylinder block and lower cylin-
der block assembly.
NOTE:
These components cannot be replaced as a single unit because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
●Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C) (Y is in longitudinal direction of engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
B position.
●If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or re-bore the cylinder.
●An oversize piston is provided. When using an oversize piston, re-bore the cylinder so that the clearance
of the piston cylinder satisfies the standard.
●When using an oversize piston, use it for all cylinders with oversize piston rings.
Outer Diameter of Piston
●Measure piston skirt diameter.
●Measure point (Distance from the top): 42 mm (1.65 in)Standard: 58.944 - 58.967 mm (2.3206 - 2.3215 in)
PBIC0269E
Standard inner diameter:
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
Less than 0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
Less than 0.01 mm (0.0004 in)
Oversize (OS): 0.2 mm (0.008 in)
SBIA0284E
Standard: 88.980 - 89.010 mm (3.5031 - 3.5043 in)
PBIC0125E

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CYLINDER BLOCK
Piston to Cylinder Bore Clearance
●Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).
●If it exceeds the limit, replace piston/piston pin assembly.
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.
3. Cut cylinder bores.
●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 in diame-
ter at a time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
●Measurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
Measure outer diameter of crankshaft journals.
OUTER DIAMETER OF CRANKSHAFT PIN
Measure outer diameter of crankshaft pin.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
●Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
●Out-of-round is indicated by the difference in dimensions
between X and Y at A and B.
●Taper is indicated by the difference in dimension between A and
B at X and Y.Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
Re-bored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.
Standard: 44.956 - 44.974 mm (1.7699-1.7706 in) dia.
PBIC0270E
Limit:
Out-of-round (X– Y) : Less than 0.005 mm (0.0002 in)
Taper (A – B) : Less than 0.005 mm (0.0002 in)
PBIC0128E

CYLINDER BLOCK
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CRANKSHAFT RUNOUT
●Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
●Place a dial gauge straight up on the No. 3 journal.
●While rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)
CONNECTING ROD BEARING OIL CLEARANCE
Method of Measurement
●Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod bolts to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) –
(Outer diameter of crankshaft pin)
●If out of specifications, check connecting rod big end inner diam-
eter and crankshaft pin outer diameter, and select appropriate
connecting rod bearing to adjust clearance to specifications.
Refer to EM-83, "
HOW TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
●Remove engine oil and dust on the crankshaft pin and the sur-
faces of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in “Method of Mea-
surement”.
MAIN BEARING OIL CLEARANCE
Method of Measurement
●Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
●If out of specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to specifications. Refer to EM-85, "
HOW TO
SELECT MAIN BEARING" . Limit: Less than 0.05 mm (0.002 in)
PBIC0271E
Standard : 0.028 - 0.045 mm (0.0011 - 0.0018 in)
Limit : 0.10 mm (0.0039 in)
PBIC0119E
EM142
Standard
No. 1, 3 and 5 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in)
No. 2 and 4 journals : 0.018 - 0.028 mm (0.0007 - 0.0011 in)
Limit : 0.1 mm (0.004 in)

EM-96
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CYLINDER BLOCK
Method of Using Plastigage
●Remove engine oil and dust on the crankshaft journal and the
surfaces of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in “Method of Measurement”.
MAIN BEARING CRUSH HEIGHT
●When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
●If the standard is not met, replace main bearings.
OUTER DIAMETER OF LOWER CYLINDER BLOCK MOUNTING BOLT
●Perform only with M10 (0.39 in) bolts.
●Measure outer diameters (d1, d2) at two positions shown in the figure.
●Measure d2 at a point within block A.
●When the value of d1- d2 exceeds the limit (a large difference in
dimensions), replace the bolt with a new one.
OUTER DIAMETER OF CONNECTING ROD BOLT
●Measure outer diameter (d) at position shown in the figure.
●When “d ” exceeds the limit (when it becomes thinner), replace
the bolt with a new one.
EM142
Standard: There must be crush height.
SEM502G
Limit: 0.13 mm (0.0051 in) or more.
SBIA0285E
Limit: 7.75 mm (0.3051 in) or less.
SBIA0286E

CYLINDER BLOCK
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MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
NOTE:
●Inspection for double mass flywheel only.
●Do not disassembly double mass flywheel.
Flywheel Deflection
●Measure deflection of flywheel contact surface to the clutch with a dial gauge.
●Measure deflection at 210 mm (8.27 in) dia.
●When measured value exceeds the limit, replace it with a new
one.
Movement Amount in Radial (rotation) Direction
Check the movement amount in 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 dimensions of movement amounts A and B on circum-
ference of the flywheel on the transaxle side.
●When measured value is outside the standard, replace fly-
wheel.Standard : 0.45 mm (0.0177 in) or less.
Limit : 1.3 mm (0.051 in) or less.
SBIA0287E
Standard: 28.3 mm (1.114 in) or less.
PBIC1263E

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SERVICE DATA AND SPECIFICATIONS (SDS)
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
CYLINDER BLOCK
Unit: mm (in) Item Standard
Camshaft runout [TIR] (Total indicator reading) Less than 0.04 (0.0016)
Cam height “A”Intake 45.665 - 45.855 (1.7978 - 1.8053)
ExhaustQR20DE 42.825 - 43.015 (1.6860 - 1.6935)
QR25DE 43.975 - 44.165 (1.7313 - 1.7388)
Outer diameter of camshaft journalNo. 1 27.935 - 27.955 (1.0998 - 1.1006)
No. 2, 3, 4 and 5 23.435 - 23.455 (0.9226 - 0.9234)
Inner diameter of camshaft bracketNo. 1 28.000 - 28.021 (1.1024 - 1.1032)
No. 2, 3, 4 and 5 23.500 - 23.521 (0.9252 - 0.9260)
Camshaft journal clearance 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft end play0.115 - 0.188 (0.0045 - 0.0074)
Camshaft sprocket runout [TIR] (Total indicator reading) Less than 0.15 (0.0059)
SEM671
Surface flatness Limit 0.1 (0.004)
Cylinder boreInner diameterStandardGrade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.2 (0.008)
Out-of-round (X − Y) Less than 0.015 (0.0006)
Ta p e r ( C− A) Less than 0.01 (0.0004)
PBIC0281E