NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-81
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CONNECTING ROD SIDE CLEARANCE
lMeasure side clearance between connecting rod and crankshaft
arm with feeler gauge.
lIf the measured value exceeds the limit, replace the connecting
rod bearings, and measure again. If it still exceeds the limit,
replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
lMeasure the inner diameter of piston pin bore with an inside
micrometer.
OuterDiameterofPistonPin
lMeasure outer diameter of piston pin with a micrometer.
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter
of piston pin)
lIf clearance exceeds specification, replace either or both of pis-
ton/piston pin assembly and connecting rod assembly with refer-
ence to specification of each parts.
lRefer to piston selection table to replace piston/piston pin
assembly. Refer toEM-74, "
HOW TO SELECT PISTON".
lRefer to connecting rod bearing selection table to replace con-
necting rod. Refer toEM-74, "
HOW TO SELECT CONNCTING
ROD BEARING". Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit : 0.50 mm (0.0197 in)
KBIA0071E
Standard : 19.993 - 20.005 mm (0.7871 - 0.7876 in)
PBIC0116E
Standard : 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
KBIA0259E

EM-82
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CYLINDER BLOCK
NOTE:
lThe connecting rod small end grade and piston pin hole (piston
pin) grade are provided only for the parts installed at the plant.
For service parts, no grades can be selected. (Only 0 grade is
available.)
lRefer toEM-83, "CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END)"for the values for each grade at the plant.
lRegarding marks on piston head, Refer toEM-74, "HOW TO
SELECT PISTON".
PISTON RING SIDE CLEARANCE
lMeasure side clearance of piston ring and piston ring groove
with feeler gauge.
lIf out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
lCheck if inner diameter of cylinder bore is within specification.
Refer toEM-85, "
PISTON TO CYLINDER BORE CLEARANCE"
.
lInsert piston ring until middle of cylinder with piston, and mea-
sure gap.
lIf out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.
CONNECTING ROD BEND AND TORSION
lCheck with connecting rod aligner.
KBIA0067E
Standard:
Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring 0.11 mm (0.0043 in)
2nd ring 0.10 mm (0.0039 in)
SEM024AA
Standard:
Top ring 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring 0.32 - 0.47 mm (0.0126 - 0.0185 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Limit:
Topring 0.54mm(0.0213in)
2nd ring 0.67 mm (0.0264 in)
Oilring 0.95mm(0.0374in)
SEM822B

CYLINDER BLOCK
EM-83
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lIf it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
lInstall the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter
usinganinsidemicrometer.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
lMeasure inner diameter of bushing.Bend:
Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Tor s i on :
Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
SEM003F
SEM038F
Standard : 48.000 - 48.013 mm (1.8898 - 1.8903 in)
PBIC0119E
Standard : 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E

EM-84
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CYLINDER BLOCK
Outer Diameter of Piston Pin
lMeasure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of con-
necting rod small end) – (Outer diameter of piston pin)
lIf the measured value exceeds the standard, replace the con-
necting rod assembly and/or piston and piston pin assembly.
lIf replacing the piston and piston pin assembly, refer to the “Pis-
ton Selection Table” to select the piston corresponding to the
applicable bore grade of the cylinder block to be used. Refer to
EM-74, "
HOW TO SELECT PISTON".
Factory installed parts grading:
lService parts apply only to grade 0.
Unit: mm (in)
CYLINDER BLOCK DISTORTION
lUsing a scraper, remove gasket on the cylinder block surface,
and also remove oil, scale, carbon, or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter the oil or cool-
ant passages.
lMeasure the distortion on the block upper face at some different
points in 6 directions.
lIf out of the distortion limit, replace the cylinder block.Standard : 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
KBIA0067E
Grade 0 1
Connecting rod small end
inner diameter20.000 - 20.006
(0.7874 - 0.7876)20.006 - 20.012
(0.7876 - 0.7879)
Piston pin outer diameter19.989 - 19.995
(0.7870 - 0.7872)19.995 - 20. 001
(0.7872 - 0.7874)
Piston pin bore diameter19.993 - 19.999
(0.7871- 0.7874)19.999 - 20.005
(0.7874 - 0.7876)
KBIA0259E
Limit : 0.1 mm (0.004 in)
PBIC0121E

CYLINDER BLOCK
EM-85
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INNER DIAMETER OF MAIN BEARING HOUSING
lInstall the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
lUsing a bore gauge, measure the inner diameter of the main
bearing housing.
lIf out of the standard, replace the cylinder block and lower cylin-
der block assembly.
NOTE:
These components cannot be replaced as a single unit because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
lUsing a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C)(Y is in longitudinal direction of engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at B
position.
lIf the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or rebore the inner wall.
lAn oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance
of the piston cylinder satisfies the standard.
OuterDiameterofPiston
lMeasure piston skirt diameter.Standard : 58.944 - 58.967 mm (2.3206 - 2.3215 in)
PBIC0269E
KBIA0151E
Standard inner diameter:
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)
Over size (OS) : 0.2 mm (0.008 in)
Standard : 88.980 - 89.010 mm (3.5031 - 3.5043 in)
PBIC0125E

EM-86
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CYLINDER BLOCK
lMeasure point (Distance from the top): 42 mm (1.65 in)
Piston to Cylinder Bore Clearance
lCalculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).
lIf it exceeds the limit, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.
3. Cut cylinder bores.
lWhen any cylinder needs boring, all other cylinders must also be bored.
lDo not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter
at a time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
lMeasurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
lMeasure outer diameter of crankshaft journals.
OUTER DIAMETER OF CRANKSHAFT PIN
lMeasure outer diameter of crankshaft pin.Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 54.955 - 54.979 mm (2.1636 - 2.1645 in)
Standard : 44.956 - 44.974 mm (1.7699-1.7706 in)
PBIC0270E

CYLINDER BLOCK
EM-87
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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
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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

CYLINDER BLOCK
EM-89
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OUTER DIAMETER OF CONNECTING ROD BOLT
lMeasure outer diameter (d) at position shown in the figure.
lWhen “d ” exceeds the limit (when it becomes thinner), replace
the bolt with a new one.
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
NOTE:
lInspection for double mass flywheel only.
lDo not disassembly double mass flywheel.
Flywheel Deflection
lMeasure deflection of flywheel contact surface to the clutch with a dial gauge.
lMeasure deflection at 210 mm (8.27 in) dia.
lWhen measured value exceeds the limit, replace it with a new
one.
Movement Amount in Radial (rotation) Direction
lCheck the movement amount in the following procedure.
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
lTighten bolt at a force of 9.8 N·m (1kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1kg-m, 87 in-lb) in each direction, and
mark the movement amount on the mass on the transmission
side.
4. Measure dimensions of movement amounts A and B on circum-
ference of the flywheel on the transmission side.
lWhen measured value is outside the standard, replace flywheel.Limit : 7.75 mm (0.3051in) or less.
PBIC0273E
Standard : 0.45mm (0.0177in)or less
Limit : 1.3mm (0.051in) or less
PBIC0274E
Standard : 28.3mm (1.114in) or less
KBIA0297E

EM-90
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS009RB
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Cylinder arrangement4.in-line
Displacementcm
3(cu in
)1,998 (121.92)
Bore and stroke mm (in) 89.0x 80.3 (3.504 x 3.161)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Compression ratio9.9
Compression pressure
kPa (bar, kg/cm
2,psi)/250rpmStandard 1.19 (11.9, 12.1, 173)
Minimum 0.99 (9.9, 10.1, 144)
Differential limit between cylinders 0.1 (1.0, 1.0, 14)
Valve timing
Unit: degree
ab cde f
212 244 0 64 3 29
PBIC0187E
Limit
Surface distortionIntake manifold collec tor 0.1 (0.004)
Intake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Tension of drive belts Auto adjustment by auto-tensioner