check engine NISSAN X-TRAIL 2001 Service Repair Manual

GI-1
GENERAL INFORMATION
A GENERAL INFORMATION
CONTENTS
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SECTION
GENERAL INFORMATION
PRECAUTIONS .......................................................... 3
Description ............................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for NATS (NISSAN ANTI-THEFT SYS-
TEM) ........................................................................ 3
General Precautions ................................................ 4
Precautions for All Mode 4 × 4 System .................... 5
Precautions for Three Way Catalyst ......................... 5
Precautions for Fuel ................................................. 5
GASOLINE ENGINE ............................................. 5
DIESEL ENGINE ................................................... 5
Precautions for Multiport Fuel Injection System or
Engine Control System ............................................ 6
Precautions for Turbocharger (If Equipped) ............. 6
Precautions for Hoses .............................................. 6
HOSE REMOVAL AND INSTALLATION ............... 6
HOSE CLAMPING ................................................ 7
Precautions for Engine Oils ...................................... 7
HEALTH PROTECTION PRECAUTIONS ............. 7
ENVIRONMENTAL PROTECTION PRECAU-
TIONS ................................................................... 7
Precautions for Air Conditioning ............................... 7
HOW TO USE THIS MANUAL ................................... 8
Description ............................................................... 8
Terms ....................................................................... 8
Units ......................................................................... 8
Contents ................................................................... 8
Components ............................................................. 8
SYMBOLS ............................................................. 9
How to Follow Trouble Diagnoses ............................ 9
DESCRIPTION ...................................................... 9
HOW TO FOLLOW TEST GROUPS IN TROU-
BLE DIAGNOSES ............................................... 10
HARNESS WIRE COLOR AND CONNECTOR
NUMBER INDICATION ........................................ 11
KEY TO SYMBOLS SIGNIFYING MEASURE-
MENTS OR PROCEDURES ............................... 12
How to Read Wiring Diagrams ............................... 14CONNECTOR SYMBOLS ................................... 14
SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 15
DESCRIPTION .................................................... 16
Abbreviations .......................................................... 22
SERVICE INFORMATION FOR ELECTRICAL INCI-
DENT ......................................................................... 23
How to Perform Efficient Diagnosis for an Electrical
Incident ................................................................... 23
WORK FLOW ...................................................... 23
INCIDENT SIMULATION TESTS ........................ 23
CIRCUIT INSPECTION ....................................... 26
Control Units and Electrical Parts ........................
... 31
PRECAUTIONS .................................................. 31
CONSULT-II CHECKING SYSTEM .......................... 33
Description .............................................................. 33
Function and System Application ........................... 33
Nickel Metal Hydride Battery Replacement ............ 33
Checking Equipment .............................................. 34
CONSULT-II Data Link Connector (DLC) Circuit .... 34
INSPECTION PROCEDURE .............................. 34
LIFTING POINT ......................................................... 35
Special Service Tools ............................................. 35
Garage Jack and Safety Stand ............................... 35
2-pole Lift ................................................................ 36
Board-on Lift ........................................................... 37
TOW TRUCK TOWING ............................................. 38
Tow Truck Towing ................................................... 38
TOWING AN AUTOMATIC TRANSAXLE
MODEL WITH FOUR WHEELS ON GROUND ... 38
T O W I N G T H E V E H I C L E W I T H R E A R W H E E L S
R A I S E D ( W I T H F R O N T W H E E L S O N G R O U N D )
OR FRONT WHEELS RAISED ........................... 39
Vehicle Recovery (Freeing a stuck vehicle) ............ 39
TIGHTENING TORQUE OF STANDARD BOLTS .... 40
Tightening Torque Table ......................................... 40
IDENTIFICATION INFORMATION ............................ 41
Model Variation ....................................................... 41
IDENTIFICATION NUMBER ................................ 42
IDENTIFICATION PLATE .................................... 43
ENGINE SERIAL NUMBER ................................ 43

PRECAUTIONS
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●Use approved bonding agent, sealants or their equivalents when required.
●Use tools and recommended special tools where specified for safe and efficient service repairs.
●When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
●Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4 × 4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4 × 4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.
● Remove the propeller shaft.
● Use free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
●Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
●When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
●Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000P9
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
●Above –7°C (20°F) ... Summer type diesel fuel.
●Below –7°C (20°F) ... Winter type diesel fuel.
SGI234

HOW TO USE THIS MANUAL
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GITurn ignition switch from “OFF” to
“ON” position.Drive vehicle.
Turn ignition switch from “ON” to
“OFF” position.Disconnect battery negative cable.
Do not start engine, or check with
engine stopped.Depress brake pedal.
Start engine, or check with engine run-
ning.Release brake pedal.
Apply parking brake. Depress accelerator pedal.
Release parking brake. Release accelerator pedal.
Check after engine is warmed up suffi-
ciently.Pin terminal check for SMJ type ECM
and TCM connectors.
For details regarding the terminal
arrangement, refer to the “ELEC-
TRICAL UNITS” electrical reference
page at the end of the manual. Voltage should be measured with a
voltmeter.
Circuit resistance should be measured
with an ohmmeter.
Current should be measured with an
ammeter.
Procedure with CONSULT-II
Procedure without CONSULT-II Symbol Symbol explanation Symbol Symbol explanation

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
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SERVICE INFORMATION FOR ELECTRICAL INCIDENTPFP:00000
How to Perform Efficient Diagnosis for an Electrical IncidentEAS000G6
WORK FLOW
INCIDENT SIMULATION TESTS
Introduction
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-
lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:
●Vehicle vibration
SGI838
STEP DESCRIPTION
STEP 1Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHATVehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).
WHENDate, Time of Day, Weather Conditions, Frequency.
WHERERoad Conditions, Altitude and Traffic Situation.
HOWSystem Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Incident Simulation Tests”.
STEP 3Get the proper diagnosis materials together including:
●Power Supply Routing
●System Operation Descriptions
●Applicable Service Manual Sections
●Check for any Service Bulletins
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness
Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad-
vertently created a new incident during your diagnosis or repair steps.

GI-24
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
●Heat sensitive
●Freezing
●Water intrusion
●Electrical load
●Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
Vehicle Vibration
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
CONNECTORS & HARNESS
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
HINT
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
SENSORS & RELAYS
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
ENGINE COMPARTMENT
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
●Connectors not fully seated.
●Wiring harness not long enough and is being stressed due to engine vibrations or rocking.
●Wires laying across brackets or moving components.
●Loose, dirty or corroded ground wires.
●Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
BEHIND THE INSTRUMENT PANEL
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
SGI839

CONSULT-II CHECKING SYSTEM
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CONSULT-II CHECKING SYSTEMPFP:00000
DescriptionEAS000G8
●CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the
vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various
kinds of diagnostic tests.
●Refer to “CONSULT-II Software Operation Manual” for more information.
Function and System Application EAS000G9
x:Applicable
*1: Nissan Anti-Theft System
Nickel Metal Hydride Battery Replacement EAS000GA
CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following:
WARNING:
Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another bat-
tery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if
mistreated. Do not recharge, disassemble or dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regulations.
Diagnostic test
modeFunction
ENGINE
A/T
AIR BAG
ABS
ABS (Including ESP)
ALL MODE 4WD
NATS*1
Work supportThis mode enables a technician to adjust some devices faster and more accu-
rately by following the indications on CONSULT-II.x- -- x- -
Self-diagnostic
resultsSelf-diagnostic results can be read and erased quickly. x x x x x x x
Trouble diagnos-
tic recordCurrent self-diagnostic results and all trouble diagnostic records previously
stored can be read.--x----
Data monitor Input/Output data in the ECM can be read. x x - x x x -
Active testDiagnostic Test Mode in which CONSULT-II drives some actuators apart from the
ECMs and also shifts some parameters in a specified range.x- -xx- -
DTC confirmationThe results of SRT (System Readiness Test) and the self-diagnosis status/result
can be confirmed.x------
DTC work sup-
portSelect the operating condition to confirm Diagnosis Trouble Codes. -x-----
ECM part number ECM part number can be read. x x - x x x -
ECU discrimi-
nated No.Classification number of a replacement ECU can be read to prevent an incorrect
ECU from being installed.--x----
Function testConducted by CONSULT-II instead of a technician to determine whether each
system is “OK” or “NG”.xxxxx - -
Control unit ini-
tializationAll registered ignition key IDs in NATS components can be initialized and new
IDs can be registered.------x
Self-function
checkECM checks its own NATS communication interface. - - - - - - x

GI-46
TERMINOLOGY
Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
A
EM
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