NISSAN X-TRAIL 2003 Electronic Repair Manual

ENGINE ASSEMBLY
EM-61
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ENGINE ASSEMBLYPFP:10001
Removal and InstallationEBS009R7
WA RN ING:
lSituate vehicle on a flat and solid surface.
lPlace chocks at front and back of rear wheels.
lFor engines not equipped with engine slingers, attach proper slingers and bolts described in
PA R T S C ATA L O G.
CAUTION:
lAlways be careful to work safely, avoid forceful or uninstructed operations.
lDo not start working until exhaust system and coolant are cool enough.
lIf items or work required are not covered by the engine main body section, refer to the applicable
sections.
lAlways use the support point specified for lifting.
lUseeither2-polelifttypeorseparatetypeliftasbestyoucan.Ifboard-ontypeisusedfor
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
lFor supporting points for lifting and jacking point at rear axle, refer toGI-37, "Garage Jack and
Safety Stand".
REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle down ward.
Separate suspension member, and then separate engine and transaxle.
Preparation
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1 Rear engine mounting insulator 2 Rear engine mounting bracket 3 RH engine mounting insulator
4 RH engine mounting bracket 5 Front engine mounting bracket 6 Front engine mounting insulator
7 Center member 8 LH engine mounting insulator 9 LH engine mounting bracket

EM-62
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ENGINE ASSEMBLY
1. Release fuel pressure. Refer toEC-34, "FUEL PRESSURE RELEASE"(WITH EURO-OBD),EC-399,
"FUEL PRESSURE RELEASE"(WITHOUT EURO-OBD).
2. Remove engine hood.
3. Drain coolant from radiator drain plug.
4. Remove the following parts.
lLH/RH under cover
lLH/RH Front wheel
lBattery
lAuxiliary drive belt; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt Auto- tensioner".
lAir duct and air cleaner case assembly; Refer toEM-15, "Removal and Installation".
lAlternator
lRadiator and radiator fan assembly; Refer toCO-12, "RADIATOR".
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
7. Disconnect fuel hose, and plug it to prevent fuel from draining. Refer toEM-17, "
INTAKE MANIFOLD"
8. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
9. Disconnect select cable from transaxle (A/T models).
10. Remove clutch operating cylinder from transaxle, and move it aside (M/T models).
11. Disconnect shift cable from transaxle (M/T models).
Engine room RH
12. Remove engine coolant reservoir tank.
13. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
14. Remove exhaust front tube.
15. Remove propeller shaft.
16. Remove steering shaft from steering gear.
17. Disconnect power steering fluid cooler piping at a point between body and engine.
18. Remove ABS sensor from brake caliper.
19. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
20. Remove LH/RH suspension from steering knuckle under strut.
Removal
21. Install engine slingers into front left of cylinder head and rear right of cylinder head.
lUse alternator bracket mounting bolt holes for the frontside.
22. Lift with hoist and secure the engine in position.Slinger bolts:
Front: 51.0 - 64.7 N·m (5.2 - 6.6 kg-m, 38 - 47 ft-lb)
Rear: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
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ENGINE ASSEMBLY
EM-63
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lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
lPut a piece of wood or something similar as the support-
ing surface, secure a completely stable condition.
23. Remove RH engine mounting insulator.
24. Pull LH engine mounting through-bolt out.
25. Remove mounting bolts at front end of center member.
26. Remove front suspension member mounting bolts and nuts.
27. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
28. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
29. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
30. Remove starter motor.
31. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
lBleed air from passages in pipes and tubes of applicable lines.
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EM-64
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CYLINDER BLOCK
CYLINDER BLOCK
PFP:11010
Disassembly and AssemblyEBS009R8
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1 Cylinder block 2 O-ring 3 Crankshaft position sensor (POS)
4 Knock sensor 5 Oil pressure switch 6 Lower cylinder block
7 Lower cylinder block bolt 8 Snap ring 9 Connecting rod
10 Connecting rod bearing 11 Connecting rod bearing cap 12 Connecting rod bolt
13 Piston 14 Oil ring 15 Second ring
16 Top ring 17 Piston pin 18 Thrust bearing
19 Main bearing upper 20 Crankshaft 21 Main bearing lower
22 Rear oil seal 23 Pilot convertor 24 Signal plate
25 Drive plate 26 Reinforce plate 27 Flywheel

CYLINDER BLOCK
EM-65
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CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, and separate transaxle from engine. Refer toEM-
61, "ENGINE ASSEMBLY".
2. Mount engine on an engine stand with the following procedure.
a. Remove oil cooler on right side of cylinder block.
b. Install engine sub-attachment to right side of cylinder block.
lDo not use bolt hole at the upper right looking from bolt inser-
tion side.
lMachine a bolt hole at the lower right of the engine sub-
attachment looking from bolt insertion side.Refer to the figure.
c. Lift engine, and mount it onto the engine stand.
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EM-66
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CYLINDER BLOCK
lA commercial engine stand can be used.
NOTE:
lThis example is an engine stand for holding at transaxle
mounting side with the flywheel or drive plate removed.
3. Drain engine oil and coolant from inside of engine.
4. Remove the following components and associated parts.
lExhaust manifold and three way catalyst assembly; Refer to
EM-22, "
Removal and Installation".
lIntake manifold collector; Refer toEM-17, "Removal and
Installation".
lIntake manifold and fuel tube assembly; Refer toEM-17,
"Removal and Installation".
lIgnition coil; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lOil pan and oil strainer; Refer toEM-24, "Removal and Installation".
lFront cover, timing chain and balancer unit; Refer toEM-43, "Removal and Installation".
lCamshaft; Refer toEM-33, "Removal and Installation".
lCylinder head; Refer toEM-53, "Removal and Installation".
5. Remove knock sensor.
CAUTION:
Carefully handle the sensor avoiding shocks.
6. Remove crankshaft position sensor (POS).
CAUTION:
lAvoid impacts such as a dropping.
lDo not disassemble.
lKeep it away from metal particles.
lDo not place sensor close to magnetic materials.
7. Remove flywheel (M/T models) or drive plate (A/T models). Fix crankshaft with a stopper plate, and
remove mounting bolts.
Torx bit (size T55) : Flywheel (M/T models)
Torx socket (size E20): Drive plate (A/T models)
CAUTION:
lBe careful not to damage contact surface for the clutch
disc of the flywheel.
NOTE:
lThe flywheels, two block construction, allows movement in
response to transmission side pressure, or when twisted in its
rotational direction. Therefore, some amount of noise is nor-
mal.
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CYLINDER BLOCK
EM-67
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8. Remove pilot converter using Tool or suitable tool. (A/T models)
NOTE:
M/T models have no pilot push.
9. Remove the piston and connecting rod assembly.
a. Position the crankshaft pin corresponding to the connecting rod
to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and con-
necting rod assembly out to the cylinder head side.
lBefore removing the piston and connecting rod assembly,
check the connecting rod side clearance. Refer toEM-81,
"CONNECTING ROD SIDE CLEARANCE".
10. Remove the connecting rod bearings.
CAUTION:
lWhen removing them, note the installation position. Keep them in the correct order.
11. Remove the piston rings form the piston.
lUse a piston ring expander.
CAUTION:
lWhen removing the piston rings, be careful not to dam-
age the piston.
lBe careful not to damage piston rings by expanding them
excessively.
lBefore removing the piston rings, check the piston ring
side clearance. Refer toEM-82, "
PISTON RING SIDE
CLEARANCE".
12. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers, remove the snap ring.
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EM-68
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CYLINDER BLOCK
b. Heat piston to 60 to 70°C(140to158°F) with drier or equivalent.
c. Push out piston pin with stick of outer diameter approximately 19
mm (0.75in).
13. Remove lower cylinder block mounting bolts.
lLoosen them in the reverse order shown in the figure, and
remove them.
lUse Torx socket (size E14) for bolts 1 to 10.
lBefore loosening lower cylinder block mounting bolts, mea-
sure crankshaft side clearance. Refer toEM-80, "
CRANK-
SHAFT SIDE CLEARANCE".
14. Remove lower cylinder block.
lUsing Tool (Seal cutter), cut liquid gasket off, and remove it
from cylinder block.
CAUTION:
lBe careful not to damage the mounting surface.
15. Remove crankshaft.
CAUTION:
lBe careful not damage or deform the signal plate
mounted on the crankshaft.
lWhen setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between the signal
plate and the floor surface.
lDo not remove signal plate unless it is necessary to do
so.
NOTE:
When removing or installing signal plate, use Torx bit size T30.
16. Pull rear oil seal out from rear end of crankshaft.
NOTE:
When replacing rear oil seal without removing cylinder block, use a screwdriver to pull it out from between
crankshaft and block.
CAUTION:
Be careful not to damage the crankshaft and cylinder block.
17. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
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CYLINDER BLOCK
EM-69
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CAUTION:
Identify installation positions, and store them without mixing them up.
ASSEMBLY
1. Fully air-blow the coolant and oil passages in the cylinder block, the cylinder bore and the crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to the cylinder block.
lApply liquid gasket.
Use Genuine Liquid Gasket or equivalent.
lReplace the copper washers with new ones.
3. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the lower cylinder block.
b. Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block.
lInstall the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
c. Install the main bearings paying attention to the direction.
lThe main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
lOnly the main bearing (on the cylinder block) for No. 3 journal
has different specifications.
lBefore installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
lWhen installing, align the bearing stopper to the notch.
lEnsuretheoilholesoncylinderblockandthoseonthecorre-
sponding bearing are aligned.
4. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
lDowel pins of crankshaft and signal plate are provided as a
set for each.
5. Install the crankshaft to the cylinder block.
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EM-70
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CYLINDER BLOCK
lWhile turning the crankshaft by hand, check that it turns smoothly.
6. Install the lower cylinder block.
lApply genuine liquid gasket or equivalent to positions shown
in the figure.
NOTE:
Cylinder block and lower cylinder block are machined together.
Neither of them can be replaced as a single unit.
CAUTION:
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly.
7. Tighten lower cylinder block mounting bolts in the numerical
order in the figure by following the procedure below.
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten M10(0.39in) bolts in order from 1 to 10 with tightening
torqu 36.3 to 42.2N·m (3.7 to 4.3 kg-m, 27 to 31 ft-lb).
NOTE:
There are two more processes to complete the tightening of
mounting bolts(See step 9). However stop precesure here to
install rear oil seal.
8. Install rear oil seal.
CAUTION:
Complete this step within approximately 5 minutes after liq-
uid gasket is applied to the lower cylinder block.
lPress oil seal between cylinder block and crankshaft with a
suitable drift.
lBe careful not to touch the grease on the oil seal lip.
lBe careful not to cause scratches or burrs when pressing in
the oil seal.
lPress in rear oil seal to the position shown in the figure.
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