dimensions NISSAN X-TRAIL 2003 Electronic User Guide

EM-2
INSPECTION AFTER REMOVAL ........................ 38
Valve Clearance ...................................................... 40
INSPECTION ....................................................... 40
ADJUSTMENT .................................................... 41
TIMING CHAIN .......................................................... 43
Removal and Installation ........................................ 43
REMOVAL ........................................................... 44
INSPECTION AFTER REMOVAL ........................ 47
INSTALLATION .................................................... 48
CYLINDER HEAD ..................................................... 52
On-Vehicle Service ................................................. 52
CHECKING COMPRESSION PRESSURE ......... 52
Removal and Installation ........................................ 53
REMOVAL ........................................................... 53
INSPECTION AFTER REMOVAL ........................ 54
INSTALLATION .................................................... 54
Disassembly and Assembly .................................... 55
DISASSEMBLY ................................................... 55
ASSEMBLY ......................................................... 56
Inspection After Disassembly ................................. 56
CYLINDER HEAD DISTORTION ........................ 56
VALVE DIMENSIONS .......................................... 57
VALVE GUIDE CLEARANCE .............................. 57
VALVE GUIDE REPLACEMENT ......................... 57
VALVE SEAT CONTACT ..................................... 58
VALVE SEAT REPLACEMENT ........................... 58
VALVE SPRING SQUARENESS ......................... 60
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 60
ENGINE ASSEMBLY ................................................ 61
Removal and Installation ........................................ 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 63
INSPECTION AFTER INSTALLATION ................ 63
CYLINDER BLOCK ................................................... 64
Disassembly and Assembly .................................... 64
DISASSEMBLY ................................................... 65
ASSEMBLY ......................................................... 69
How to Select Piston and Bearing .......................... 73
DESCRIPTION .................................................... 73
HOW TO SELECT PISTON ................................. 74
HOW TO SELECT CONNCTING ROD BEARING... 74
HOW TO SELECT MAIN BEARING .................... 77
Inspection After Disassembly ................................. 80
CRANKSHAFT SIDE CLEARANCE .................... 80
CONNECTING ROD SIDE CLEARANCE ........... 81
PISTON AND PISTON PIN CLEARANCE .......... 81
PISTON RING SIDE CLEARANCE ..................... 82
PISTON RING END GAP .................................... 82
CONNECTING ROD BEND AND TORSION ....... 82
CONNECTING ROD BEARING (BIG END) ........ 83
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) ........................................... 83
CYLINDER BLOCK DISTORTION ...................... 84
INNER DIAMETER OF MAIN BEARING HOUS-
ING ...................................................................... 85
PISTON TO CYLINDER BORE CLEARANCE .... 85
OUTER DIAMETER OF CRANKSHAFT JOUR-NAL ......................................................................86
OUTER DIAMETER OF CRANKSHAFT PIN ......86
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT .................................................................87
CRANKSHAFT RUNOUT ....................................87
OIL CLEARANCE OF CONNECTING ROD
BEARING .............................................................87
OIL CLEARANCE OF MAIN BEARING ...............88
CRUSH HEIGH OF MAIN BEARING ...................88
OUTER DIAMETER OF LOWER CYLINDER
BLOCK MOUNTING BOLT ..................................88
OUTER DIAMETER OF CONNECTING ROD
BOLT ....................................................................89
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) .............................................................89
SERVICE DATA AND SPECIFICATIONS (SDS) ......90
Standard and Limit ..................................................90
GENERAL SPECIFICATIONS .............................90
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ...................................................................90
DRIVE BELTS ......................................................90
CYLINDER HEAD ................................................91
VALVE ..................................................................91
CAMSHAFT AND CAMSHAFT BEARING ...........94
CYLINDER BLOCK ..............................................94
PISTON, PISTON RING AND PISTON PIN ........95
CONNECTING ROD ............................................96
CRANKSHAFT .....................................................97
MAIN BEARING ...................................................98
CONNECTING ROD BEARING ...........................99
Tightening Torque ................................................. 100
YD22DDTi
PRECAUTIONS ....................................................... 102
Precautions for Drain Coolant ............................... 102
Precautions for Disconnecting Fuel Piping ........... 102
Precautions for Removal and Disassembly .......... 102
Precautions for Inspection, Repair and Replace-
ment ...................................................................... 102
Precautions for Assembly and Installation ............ 102
Parts Requiring Angular Tightening ...................... 102
Precautions for Liquid Gasket ............................... 103
REMOVAL OF LIQUID GASKET SEALING ...... 103
LIQUID GASKET APPLICATION PROCEDURE. 103
PREPARATION ....................................................... 104
Special Service Tools ............................................ 104
Commercial Service Tools .................................... 106
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 108
NVH Troubleshooting —Engine Noise .................. 108
Use the Chart Below to Help You Find the Cause
of the Symptom. .................................................... 109
DRIVE BELTS ..........................................................110
Checking Drive Belts .............................................110
Tension Adjustment ...............................................110
AIR CONDITIONER COMPRESSOR BELT ...... 111

EM-6
[QR20DE]
PRECAUTIONS
Precautions for Liquid Gasket
EBS009QJ
REMOVAL OF LIQUID GASKET SEALING
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
lIn 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-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface 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 gasket without breaks to the specified location with the
specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
gasket to the groove.
lAs for the bolt holes, normally apply the gasket inside the holes.
If specified, it should be applied outside the holes. Make sure to
read the text of service manual.
lWithin five minutes of gasket application, install the mating com-
ponent.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten after the installation.
lAfter 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe
them.
PBIC0275E
PBIC0003E
EMA0622D
SEM164F

PREPARATION
EM-9
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
Tool number
Tool name Description
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)
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
PBIC0198E
NT628
ZZA0010D
S-NT047
S-NT048
S-NT030

CYLINDER HEAD
EM-57
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
VA LV E D I M EN S IO N S
Check dimensions of each valve. For dimensions, refer to SDSEM-
91, "VA LV E"
VALVE GUIDE CLEARANCE
Perform this inspection before removing valve guide.
1. Make sure that the valve stem diameter is within the specification.
2. Push the valve out by approx. 15 mm (0.59 in) toward the combustion chamber side to measure the
valve's run-out volume (in the direction of dial gauge) with dial gauge.
3. The half of the run-out volume accounts for the valve guide clearance.
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized (0.2 mm, 0.008 in) valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C(230
to 266°F) by soaking in heated oil.
2. Driveoutvalveguidewithapress[undera20kN(2ton,2.2US
ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
SEM188A
Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
PBIC0077E
SEM008A
SEM931C

EM-58
[QR20DE]
CYLINDER HEAD
3. Ream cylinder head valve guide hole.
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illus-
tration.
6. Using valve guide reamer, apply reamer finish to valve guide.
VA LV E S E AT C O N TA C T
lAfter confirming that the dimensions of valve guides and valves
are within specifications, perform this procedure.
lApply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.
lCheck if the contact area band is continuous all around the cir-
cumference.
lIf not, grind to adjust valve fitting and check again. If the contact-
ing surface still has N.G conditions even after the re-check,
replace valve seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized (0.5 mm, 0.020 in) valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this.Valve guide hole diameter (for service parts)
Intake and exhaust
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
PBIC0078E
Standard
Intake and exhaust : 6.000- 6.018 mm (0.2362- 0.2369
in)
SEM932C
EMA0487D

CYLINDER HEAD
EM-59
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. Ream cylinder head recess diameter for service valve seat.
lBe sure to ream in circles concentric to the valve guide center.
lThis will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat
into cylinder head.
CAUTION:
Avoid directly to touching cold valve seats.
5. Using valve seat cutter set or valve seat grinder, finish the seat
to the specified dimensions.
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
Grind to obtain the dimensions indicated in figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.Oversize [0.5 mm (0.020 in)]
Intake : 37.000 - 37.016 mm (1.4567 - 1.4573 in)
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
SEM795A
SEM008A
SEM934C
Standard
D1 dia. : 33.5 mm (1.3189 in)
D2 dia. : 35.1 - 35.3 mm (1.382 - 1.390 in)
D3 dia. : 39.0 - 39.2 mm (1.535 - 1.543 in)
D4 dia. : 28 mm (1.10 in)
D5 dia. : 29.9 - 30.1 mm (1.177- 1.185 in)
D6 dia. : 33.5 - 33.7mm (1.319 - 1.327 in)
SBIA0226E

EM-60
[QR20DE]
CYLINDER HEAD
VALVE SPRING SQUARENESS
Set try square along the side of valve spring and rotate the spring.
Measure the maximum clearance between the top face of spring and
try square.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
Check valve spring pressure with valve spring seat installed at spec-
ified spring height.
CAUTION:
Do not remove valve spring seat.Limit : More than 1.9 mm (0.0748 in)
PBIC0080E
Standard: INTAKE EXHAUST
Free height 44.84-45.34 mm
(1.7654-1.7850
in)45.28-45.78 mm
(1.7827-1.8024 in)
Installation
height35.30 mm (1.390
in)35.30 mm (1.390
in)
Installation
load151-175 N (15.4-
17.8 kg, 34-39 lb)151-175 N (15.4-
17.8 kg, 34-39 lb)
Height during
valve open24.94 mm
(0.9819 in)26.39 mm (1.0390
in)
Load with
valve open358-408 N (36.5-
41.6 kg, 80-92 lb)325-371 N (33.1-
37.8 kg, 73-83 lb)
Identification
colorBlue Yellow
SEM113

CYLINDER BLOCK
EM-75
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. Apply pin diameter grade stamped on crankshaft front side to
the column in the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column
in the “Connecting Rod Bearing Selection Table”. selective-fit
service parts table.
4. Apply the symbol obtained to connecting rod bearing grade table
to select.
When Crankshaft and Connecting Rod are Reused:
1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin
individually.
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table” selective-fit service
parts table.
3. The following steps are same as in Step 3 or later in “When New Connecting Rod and Crankshaft are
Used”.
KBIA0073E

CYLINDER BLOCK
EM-87
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
lUsing a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
lOut-of-round is indicated by the difference in dimensions
between X and Y at A and B.
lTaper is indicated by the difference in dimension between A and
BatXandY.
CRANKSHAFT RUNOUT
lPlace a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
lPlace a dial gauge straight up on the No. 3 journal.
lWhile rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)
OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
lInstall 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)
lIf clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer toEM-74, "
HOW
TO SELECT CONNCTING ROD BEARING".
Method of Using Plastigauge
lRemove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
lCut a plastigauge slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
lInstall the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
lRemove the connecting rod cap and bearings, and using the
scale on the plastigauge bag, measure the plastigauge width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the method by
calculation.Limit:
Out-of-round (X– Y) : 0.005 mm (0.0002in)
Taper (A – B) : 0.005 mm (0.0002in)
PBIC0128E
Limit: : 0.10 mm (0.004 in)
PBIC0271E
Standard : 0.028 - 0.045 mm (0.0011 - 0.0018 in)
Limit : 0.10 mm (0.0039in)
PBIC0119E
EM142

EM-88
[QR20DE]
CYLINDER BLOCK
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
lInstall 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)
lIf the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter
and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer toEM-77,
"HOW TO SELECT MAIN BEARING".
Method of Using Plastigauge
lRemove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
lCut a plastigauge slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
lTighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
lRemove the bearing cap and bearings, and using the scale on
the plastigauge bag, measure the plastigauge width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in “the method by calculation.”
CRUSH HEIGH OF MAIN BEARING
lWhen the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
lIf the standard is not met, replace main bearings.
OUTER DIAMETER OF LOWER CYLINDER BLOCK MOUNTING BOLT
lPerform only with M10 (0.39 in) bolts.
lMeasure outer diameters (d1, d2) at two positions shown in the figure.
lMeasure d2 at a point within block A.
lWhen the value of d1- d2 exceeds the limit (a large difference in
dimensions), replace the bolt with a new one.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 :0.1mm (0.004in)
EM142
Standard : There must be crush height
SEM502G
Limit : 0.13 mm (0.0051 in) or more.
PBIC0272E