NISSAN X-TRAIL 2001 Service Workshop Manual

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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 Angular 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 ........................................ 8
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 10
NVH Troubleshooting —Engine Noise ................... 10
Use the Chart Below to Help You Find the Cause
of the Symptom. ...................................................... 11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Tension Adjustment ................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
AIR CLEANER AND AIR DUCT ............................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
CHANGING AIR CLEANER FILTER ................... 15INTAKE MANIFOLD ................................................. 16
Removal and Installation ........................................ 16
QR20DE .............................................................. 16
QR25DE .............................................................. 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
INSPECTION AFTER INSTALLATION ................ 22
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................
... 25
INSTALLATION ................................................... 25
OIL PAN AND OIL STRAINER ................................. 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
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 ........................................ 32
QR20DE .............................................................. 32
QR25DE .............................................................. 32
REMOVAL ........................................................... 33
INSTALLATION ................................................... 33
INSPECTION AFTER INSTALLATION ................ 34
ROCKER COVER ..................................................... 35
Removal and Installation ........................................ 35
REMOVAL ........................................................... 35
INSTALLATION ................................................... 36

EM-2
TIMING CHAIN .......................................................... 37
Removal and Installation ........................................ 37
REMOVAL ........................................................... 38
INSPECTION AFTER REMOVAL ........................ 41
INSTALLATION .................................................... 41
CAMSHAFT ............................................................... 46
Removal and Installation ........................................ 46
REMOVAL ........................................................... 46
INSTALLATION .................................................... 48
INSPECTION AFTER REMOVAL ........................ 51
Valve Clearance ...................................................... 53
INSPECTION ....................................................... 53
ADJUSTMENT .................................................... 54
OIL SEAL .................................................................. 56
Removal and Installation of Valve Oil Seal ............. 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 56
Removal and Installation of Front Oil Seal ............. 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 57
Removal and Installation of Rear Oil Seal .............. 57
REMOVAL ........................................................... 57
INSTALLATION .................................................... 57
CYLINDER HEAD .................................................. ... 59
On-Vehicle Service ................................................. 59
CHECKING COMPRESSION PRESSURE ......... 59
Removal and Installation ........................................ 60
REMOVAL ........................................................... 60
INSPECTION AFTER REMOVAL ........................ 61
INSTALLATION .................................................... 61
Disassembly and Assembly .................................... 62
DISASSEMBLY ................................................... 63
ASSEMBLY ......................................................... 63
Inspection After Disassembly ................................. 64
CYLINDER HEAD DISTORTION ........................ 64
VALVE DIMENSIONS .......................................... 64
VALVE GUIDE CLEARANCE .............................. 65
VALVE GUIDE REPLACEMENT ......................... 65
VALVE SEAT CONTACT ..................................... 66
VALVE SEAT REPLACEMENT ........................... 66
VALVE SPRING SQUARENESS ......................... 67
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 68
ENGINE ASSEMBLY ................................................ 69
Removal and Installation ........................................ 69
REMOVAL .......................................................
.... 69
INSTALLATION .................................................... 71
INSPECTION AFTER INSTALLATION ................ 71
CYLINDER BLOCK ................................................... 73
Disassembly and Assembly .................................... 73
DISASSEMBLY ................................................... 74
ASSEMBLY ......................................................... 78
How to Select Piston and Bearing .......................... 82
DESCRIPTION .................................................... 82
HOW TO SELECT PISTON ................................. 83
HOW TO SELECT CONNECTING ROD BEAR-
ING ...................................................................... 83HOW TO SELECT MAIN BEARING .................... 85
Inspection After Disassembly .................................. 88
CRANKSHAFT END PLAY .................................. 88
CONNECTING ROD SIDE CLEARANCE ........... 89
PISTON AND PISTON PIN CLEARANCE ........... 89
PISTON RING SIDE CLEARANCE ..................... 90
PISTON RING END GAP .................................... 90
CONNECTING ROD BEND AND TORSION ....... 91
CONNECTING ROD BEARING (BIG END) ........ 91
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) ........................................... 91
CYLINDER BLOCK DISTORTION ...................... 92
INNER DIAMETER OF MAIN BEARING HOUS-
ING ....................................................................... 93
PISTON TO CYLINDER BORE CLEARANCE .... 93
OUTER DIAMETER OF CRANKSHAFT JOUR-
NAL ...................................................................... 94
OUTER DIAMETER OF CRANKSHAFT PIN ...... 94
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ................................................................. 94
CRANKSHAFT RUNOUT .................................... 95
CONNECTING ROD BEARING OIL CLEAR-
ANCE ................................................................... 95
MAIN BEARING OIL CLEARANCE ..................... 95
MAIN BEARING CRUSH HEIGHT ...................... 96
OUTER DIAMETER OF LOWER CYLINDER
BLOCK MOUNTING BOLT .................................. 96
OUTER DIAMETER OF CONNECTING ROD
BOLT .................................................................... 96
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ............................................................. 97
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 98
Standard and Limit .................................................. 98
GENERAL SPECIFICATIONS ............................. 98
DRIVE BELTS ...................................................... 98
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ................................................................... 98
SPARK PLUG ...................................................... 98
CYLINDER HEAD ................................................ 98
VALVE .................................................................. 99
CAMSHAFT AND CAMSHAFT BEARING .........102
CYLINDER BLOCK ............................................102
PISTON, PISTON RING AND PISTON PIN .....
.103
CONNECTING ROD ..........................................104
CRANKSHAFT ...................................................105
MAIN BEARING .................................................106
CONNECTING ROD BEARING .........................107
Tightening Torque .................................................108
YD22DDTi
PRECAUTIONS .......................................................110
Precautions for Drain Engine Coolant ...................110
Precautions for Disconnecting Fuel Piping ...........110
Precautions for Removal and Disassembly ..........110
Precautions for Inspection, Repair and Replace-
ment ......................................................................110
Precautions for Assembly and Installation ............110

EM-3
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EMA Parts Requiring Angular Tightening ...................... 110
Precautions For Liquid Gasket ............................. . 111
REMOVAL OF LIQUID GASKET ...................... . 111
LIQUID GASKET APPLICATION PROCEDURE . . 111
PREPARATION ........................................................112
Special Service Tools ............................................ 112
Commercial Service Tools ..................................... 115
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................116
NVH Troubleshooting —Engine Noise .................. 116
Use the Chart Below to Help You Find the Cause
of the Symptom. .................................................... 117
DRIVE BELTS ..........................................................118
Checking Drive Belts ............................................. 118
Tension Adjustment ............................................... 118
AIR CONDITIONER COMPRESSOR BELT ...... 119
ALTERNATOR AND WATER PUMP BELT ........ 119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION .................................................. 119
AIR CLEANER AND AIR DUCT ............................. 120
Removal and Installation ...................................... 120
REMOVAL ......................................................... 120
INSTALLATION ................................................. 120
CHANGING AIR CLEANER FILTER ................. 121
CHARGE AIR COOLER ......................................... 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSPECTION AFTER REMOVAL ..................... 122
INSTALLATION ................................................. 122
INTAKE MANIFOLD ............................................... 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSPECTION AFTER REMOVAL ..................... 124
INSTALLATION ................................................. 124
INSPECTION AFTER INSTALLATION ............. 125
CATALYST .............................................................. 126
Removal and Installation ...................................... 126
REMOVAL ......................................................... 126
INSTALLATION ................................................. 126
EXHAUST MANIFOLD AND TURBOCHARGER .. 127
Removal and Installation ...................................... 127
REMOVAL ......................................................... 127
INSTALLATION ................................................. 128
INSPECTION AFTER INSTALLATION ............. 128
Disassembly and Assembly ................................. 129
REMOVAL ......................................................... 129
INSPECTION AFTER REMOVAL ..................... 129
Turbocharger ........................................................ 130
ROTOR SHAFT CLEARANCE ......................... 130
ROTOR SHAFT END PLAY .............................. 130
TURBINE WHEEL ............................................. 131
COMPRESSOR WHEEL .................................. 131
WASTEGATE VALVE ACTUATOR ................... 131
TROUBLE DIAGNOSIS OF TURBOCHARGER . 132OIL PAN AND OIL STRAINER ...............................133
Removal and Installation ......................................133
REMOVAL .........................................................133
INSPECTION AFTER REMOVAL .....................135
INSTALLATION .................................................135
INSPECTION AFTER INSTALLATION ..............137
GLOW PLUG ..........................................................138
Removal and Installation ......................................138
REMOVAL .........................................................138
INSTALLATION .................................................138
VACUUM PUMP ......................................................139
Removal and Installation ......................................139
MODELS PRODUCED BEFORE MARCH 2001 .139
MODELS PRODUCED SINCE APRIL 2001 .....140
INSPECTION BEFORE REMOVAL ..................140
REMOVAL .........................................................140
INSTALLATION .................................................141
INSPECTION AFTER INSTALLATION ..............142
Disassembly and Assembly ..................................142
DISASSEMBLY .................................................142
ASSEMBLY .......................................................142
INJECTION TUBE AND FUEL INJECTOR ............144
Removal and Installation ......................................144
REMOVAL .........................................................144
INSTALLATION .................................................145
INSPECTION AFTER INSTALLATION ..............146
FUEL SUPPLY PUMP .............................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSPECTION AFTER REMOVAL .....................152
INSTALLATION .................................................152
ROCKER COVER ...................................................156
Removal and Installation ......................................156
REMOVAL .........................................................156
INSTALLATION .................................................157
INSPECTION AFTER INSTALLATION .............
.157
CAMSHAFT ............................................................158
Removal and Installation ......................................158
REMOVAL .........................................................158
INSPECTION AFTER REMOVAL .....................159
INSTALLATION .................................................162
Valve Clearance ...................................................163
INSPECTION ....................................................163
ADJUSTMENTS ................................................164
SECONDARY TIMING CHAIN ................................167
Removal and Installation ......................................167
REMOVAL .........................................................167
INSPECTION AFTER REMOVAL .....................169
INSTALLATION .................................................170
PRIMARY TIMING CHAIN ......................................172
Removal and Installation ......................................172
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................177
INSTALLATION .................................................177
CYLINDER HEAD .................................................. .182
On-Vehicle Service ...............................................182
CHECKING COMPRESSION PRESSURE .......182
Removal and Installation ......................................183
REMOVAL .........................................................183

EM-4
INSPECTION AFTER REMOVAL ......................184
INSTALLATION ..................................................185
Disassembly and Assembly ..................................187
DISASSEMBLY .................................................187
ASSEMBLY .......................................................188
INSPECTION AFTER DISASSEMBLY ..............188
ENGINE ASSEMBLY ..............................................193
Removal and Installation ......................................193
REMOVAL .........................................................194
INSTALLATION ..................................................195
INSPECTION AFTER INSTALLATION ..............196
CYLINDER BLOCK .................................................197
Disassembly and Assembly ..................................197
DISASSEMBLY .................................................198
ASSEMBLY .......................................................202
How to Select Piston and Bearing ........................206
DESCRIPTION ..................................................206
HOW TO SELECT PISTON ...............................206
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................207
HOW TO SELECT MAIN BEARING ..................208
Inspection After Disassembly ...............................210
CRANKSHAFT END PLAY ................................210
CONNECTING ROD SIDE CLEARANCE .........210
PISTON TO PISTON PIN CLEARANCE ...........210
PISTON RING SIDE CLEARANCE ...................211
PISTON RING END GAP ..................................211
CONNECTING ROD BEND AND TORSION .....212
CONNECTING ROD BIG END INNER DIAME-
TER ...................................................................212
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .........................................212
CYLINDER BLOCK TOP SURFACE DISTOR-TION ..................................................................213
MAIN BEARING HOUSING INNER DIAMETER .213
PISTON TO CYLINDER BORE CLEARANCE ..214
CRANKSHAFT JOURNAL OUTER DIAMETER .215
CRANKSHAFT PIN OUTER DIAMETER ..........215
CRANKSHAFT OUT-OF-ROUND AND TAPER .215
CRANKSHAFT RUNOUT ..................................216
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................216
MAIN BEARING OIL CLEARANCE ...................216
MAIN BEARING CRUSH HEIGHT ....................217
MAIN BEARING CAP BOLT DEFORMATION ...217
CONNECTING ROD BOLT DEFORMATION ....217
OIL JET ..............................................................218
OIL JET RELIEF VALVE ....................................218
MOVEMENT AMOUNT OF FLYWHEEL ...........218
SERVICE DATA AND SPECIFICATIONS (SDS) ....220
Standard and Limit ...............................................
.220
GENERAL SPECIFICATIONS ...........................220
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................220
DRIVE BELTS ....................................................220
CYLINDER HEAD ..............................................221
VALVE ................................................................221
CAMSHAFT AND CAMSHAFT BEARING .........225
CYLINDER BLOCK ............................................225
PISTON, PISTON RING AND PISTON PIN ......226
CONNECTING ROD ..........................................227
CRANKSHAFT ...................................................227
AVAILABLE MAIN BEARING .............................228
AVAILABLE CONNECTING ROD BEARING .....228
MISCELLANEOUS COMPONENTS ..................228
Tightening Torque .................................................229

PRECAUTIONS
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1
●Before starting work, make sure no fire or spark producing items are in the work area.
●Release fuel pressure before disassembly.
●After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2
●When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
●Exercise maximum care to avoid damage to mating or sliding surfaces.
●Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
●Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
●When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ
●Use torque wrench to tighten bolts or nuts to specification.
●When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
●Replace with new gasket, packing, oil seal or O-ring.
●Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
●Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
●Release air within route when refilling after draining coolant.
●Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then mark sure that there are no leaks at fuel line connections.
●After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular TighteningEBS00KN5
●Use an angle wrench for the final tightening of the following engine parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
●Do not use a torque value for final tightening.
●The torque value for these parts are for a preliminary step.
●Ensure thread and seat surfaces are clean and coated with engine oil.

EM-6
[QR]
PRECAUTIONS
Precautions For Liquid Gasket
EBS00MRW
REMOVAL OF LIQUID GASKET
●After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
●In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
●Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
●If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
●As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
●Within five minutes of liquid gasket application, install the mat-
ing component.
●If the liquid gasket protrudes, wipe it off immediately.
●Do not retighten after the installation.
●After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEBS00L7N
Tool number
To o l n a m eDescription
K V 1 0 1111 0 0
Seal cutterRemoving oil pan and timing chain case
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV10115300
Engine sub-attachment
KV10116200
Valve spring compressor
1. KV10115900
AttachmentDisassembling valve mechanism
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc.
KV10117100
Heated oxygen sensor wrenchLoosening or tightening heated oxygen
sensors with 22 mm (0.87 in) hexagon nut
S-NT046
NT042
NT028
ZZA1078D
NT022
S-NT014
NT379

EM-8
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PREPARATION
Commercial Service Tools
EBS00L7O
KV10107902
Valve oil seal pullerRemoving valve oil seal
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
ST16610001
Pilot bushing pullerRemoving crankshaft pilot bushing
WS39930000
Tube presserPressing the tube of liquid gasket Tool number
Tool nameDescription
S-NT011
S-NT603
S-NT044
S-NT045
S-NT052
Tool nameDescription
Quick connector release Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
Pulley holderCrankshaft pulley removing and installing
a: 68 mm (2.68 in)
b: 8 mm (0.31 in)
PBIC0198E
NT628

PREPARATION
EM-9
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Crank pullerCrankshaft pulley removing
Spark plug wrench Removing and installing spark plug
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia. To o l n a m eDescription
ZZA0010D
S-NT047
S-NT048
S-NT030
S-NT015
S-NT016

EM-10
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting —Engine NoiseEBS00L7P
PBIC0276E