NISSAN X-TRAIL 2003 Electronic Repair Manual

PRIMARY TIMING CHAIN
EM-171
[YD22DDTi]
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12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
lApply a continuous bead of Genuine Liquid Gasket or equiv-
alent as shown in the figure. Refer toEM-103, "
Precautions
for Liquid Gasket".
lApply liquid gasket on oil pump-side surface.
13. Install oil pump.
a. Apply a continuous bead of Genuine Liquid Gasket or equiva-
lent on locations shown in the figure. Refer toEM-103, "
Precau-
tions for Liquid Gasket".
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
b. Install oil pump drive spacer to crankshaft.
lInstall with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
d. Install oil pump.
lWhen installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
lWhen installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM143G
JEM144G
JEM145G
JEM133G

EM-172
[YD22DDTi]
PRIMARY TIMING CHAIN
14. Check gaps on upper oil pan mounting surface.
lUsing straightedge and feeler gauge, measure gaps between
the locations of the following parts:
lIf the measured value is out of the above range, install again.
15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST).
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with one
of the punched marks on the bolt.
e. Tighten fixing bolt another 60°-66°[target: 60°(turn by one
notch)].
16. Install secondary timing chain and the associated parts.
Refer toEM-161, "
INSTALLATION".
17. Install in the reverse order of removal hereafter.Oil pump and rear chain case:
Standard : – 0.14 to 0.14 mm (– 0.0055 to 0.0055 in)
Rear chain case and cylinder block:
Standard : – 0.25 to 0.13 mm (– 0.0098 to 0.0051 in)
JEM146G
JEM147G

CYLINDER HEAD
EM-173
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CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00BPL
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer toEC-672,
"Basic Inspection".
lDo not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove the following parts.
lCharge air cooler (Refer toEM-114, "Removal and Installation".)
5. To prevent fuel from being injected during inspection, remove
fuel supply pump fuse [ENG CONT (20A)] from fuse box on the
left side of engine compartment.
lAmong marks on fuse box, [ENG CONT 3 (20A)] is for fuel
supply pump fuse.
6. Remove glow plugs from all the cylinders. Refer toEM-130,
"Removal and Installation".
CAUTION:
lBefore removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
lCarefully remove glow plugs to prevent any damage or
breakage.
lHandle with care to avoid applying any shock to glow plugs.
7. Install adapter to installation holes of glow plugs and connect
compression gauge for diesel engine.
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
lAlways use a fully-charged battery to obtain specified engine
speed.
Unit:kPa(bar,kg/cm2, psi)/rpm
lWhen engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
lIf engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
lIf compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying oil, piston ring may be worn or damaged.
Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying oil, valve may be malfunctioning. Check valve for mal-
function. If contact malfunction is found, replace valve or valve seat.
lIf compression pressure in adjacent two cylinders is low after applying oil, pressure may be leaking
from gasket. In this case, replace cylinder head gasket.
SBIA0192E
:18-21N·m(1.8-2.2kg-m,13-15ft-lb)
Standard MinimumDifference limit between
cylinders
2,893 (28.9, 29.5, 419)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
SEM112G

EM-174
[YD22DDTi]
CYLINDER HEAD
10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuel supply pump fuse [ENG CONT (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for items of self-diagnosis.
Removal and InstallationEBS00BPM
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove drain coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove the following parts:
lCharge air cooler (Refer toEM-114, "Removal and Installation".)
lRocker cover (Refer toEM-147, "Removal and Installation".)
lAir cleaner and air duct (Refer toEM-112, "Removal and Installation".)
lVacuum pump (Refer toEM-131, "Removal and Installation".)
lInjection tube, spill tube and fuel injector (Refer toEM-135, "Removal and Installation".)
lIntake manifold (Refer toEM-115, "Removal and Installation".)
lExhaust manifold (Refer toEM-119, "Removal and Installation".)
lSecondary timing chain (Refer toEM-158, "Removal and Installation".)
lCamshaft (Refer toEM-149, "Removal and Installation".)
SBIA0193E
1. Glow plug 2. Cylinder head assembly 3. Cylinder head bolt
4. Thermal transmitter 5. Engine coolant temperature sensor 6. Gasket
7. Water outlet 8. Glow plate

CYLINDER HEAD
EM-175
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3. Remove cylinder head assembly.
lLoosen and remove mounting bolts in the reverse order
showninthefigure.
lLift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head, or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.
lFor glow plug removal, the following shall be noted.
CAUTION:
lTo avoid breakage, do not remove glow plug unless necessary.
lPerform continuity test with glow plug installed.
lKeep glow plug from any impact. (Replace if dropped from a height 10 cm (3.94 in) or higher.)
lDo not use air impact wrench.
INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation
lUsing micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.
lIf the necking point can be identified, set it as measuring point
d2.
lCalculate the difference between d1 and d2.
lIf out of the limit, replace cylinder head bolt.
Cylinder Head-to-block Difference Check
lAfter installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head.
lIf the difference is out of the range, check fitting of dowel pins
and cylinder head.
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
JEM149G
Limit : 0.15 mm (0.0059 in)
JEM171G
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)
JEM172G

EM-176
[YD22DDTi]
CYLINDER HEAD
1. Install cylinder head gasket.
lCylinder head gasket to be installed is selected by its thick-
ness through the following procedure.
–When replacing gasket alone
• Install a gasket with same thickness as that of the one
removed.
• Identify the thickness of gasket by the number of cut-outs and
holes on the rear RH side.
*: Measured with head bolts tightened
• Gasket thickness can be identified at the location shown in
the figure by the numbers of cut-outs and holes before
removal.
–When the following parts have been repaired/replaced:
lWith cylinder block upper surface and/or crankshaft pin journal ground
lWith cylinder block, pistons, connecting rods, and/or crankshaft replaced
a. Set piston at a point close to TDC.
b. Set a dial gauge at the location as shown in the figure. Turning crankshaft gradually, set the gauge scale
to “0” where the piston protrusion is maximized.
c. Move the dial gauge stand so that the tip of dial gauge can contact the cylinder block. Read the difference.
d. Measure at two locations per cylinder, that is eight locations for four cylinders. Select gasket based on the
maximum protrusion of eight measurements.
Gasket thickness* mm (in) Number of cut-outs Number of holes
0.900 (0.0354) 1 No
0.925 (0.0364) 2 No
0.950 (0.0374) 3 No
0.975 (0.0384) 1 Yes
1.000 (0.0394) 2 Yes
1.025 (0.0404) 3 YesJEM168G
JEM169G
JEM170G
Piston protrusion mm (in) Gasket thickness* mm (in)Identification
Number of cut-outs Number of holes
Less than 0.255 (0.0100) 0.900 (0.0354) 1 No

CYLINDER HEAD
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*: Measured with head bolts tightened
2. Apply a continuous bead of Genuine Liquid Gasket or equivalent
on the surface shown in the figure.
A: Apply bead so that it does not protrude into oil passage. Refer
toEM-103, "
Precautions for Liquid Gasket".
B: Miniimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
3. Install cylinder head assembly.
lTighten bolts in numerical order as shown in the figure
according to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten bolts to 29 to 38 N·m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).
c. Tighten 180°to 185°[target: 180°] (angular tightening).
d. Loosen completely to 0 N·m (0 kg-m, 0 in-lb) in the reverse order
of that shown in the figure.
e. Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
f. Tighten 90°to 95°[target: 90°] (angular tightening)
g. Tighten another 90°to 95°[target: 90°] (angular tightening).
lWhen an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.
4. Install glow plug.
lTo avoid damage, glow plugs should be removed only
when required.
lHandle with care to avoid applying shock. When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.
lBefore installing, remove carbon depositing on mounting hole of glow plug with a reamer.
5. Install engine coolant temperature sensor and thermal transmitter.
Less than 0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 2 No
Less than 0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 3 No
Less than 0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 1 Yes
Less than 0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 2 Yes
More than 0.355 (0.0140) 1.025 (0.0404) 3 Yes
JEM167G
JEM149G
JEM166G

EM-178
[YD22DDTi]
CYLINDER HEAD
Disassembly and Assembly
EBS00BPN
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
lCheck the installation positions, and keep them to avoid being
confused.
2. Remove valve.
lUsing valve spring compressor, compress valve spring. Using
magnetic hand, remove valve collets.
3. Remove valve spring retainers and valve springs.
4. Remove valves as pressing valve stems toward combustion
chamber.
lBefore removing the valve, check the valve guide clearance.
Refer toEM-180, "
Valve Guide Clearance".
lCheck installation positions, and keep them to avoid being
confused.
NOTE:
Refertothefigureforintakeandexhaustvalvepositions.
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.
SBIA0194E
SBIA0195E
SBIA0196E

CYLINDER HEAD
EM-179
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5. Remove valve oil seals using valve oil seal puller.
6. Remove valve spring seats.
7. Before removing valve spring seats, perform valve seat contact
check. Refer toEM-181, "
Va l v e S e a t C o n ta ct".
8. Before removing valve guides, perform valve guide clearance
check. Refer toEM-180, "
Valve Guide Clearance".
ASEMBLY
1. Install valve guides. Refer toEM-180, "Valve Guide Clearance".
2. Install valve seats. Refer toEM-181, "
Valve Seat Replacement".
3. Using valve oil seal drift, install valve oil seals referring to the
dimension shown in the figure.
lDifferent parts are used for valve location, Identify by the rub-
ber color.
4. Install valve spring seats.
5. Install valves.
lInstall the valves with bigger outer diameter to intake valve
side.
lNote that valve layout here is different from that of conventional engine.
6. Install valve spring.
lWhen installing valve spring, make sure that a smaller pitch
side (identification paint-applied side) faces the cylinder head.
7. Install valve spring retainers.
8. Using valve spring compressor, compress valve springs.
Then install valve collets using magnetic hand.
lAfter installing valve collets, tap the stem end using a plastic
hammer, and check the installation status.
9. Install valve lifters and adjusting shims to the same positions as
before.
INSPECTION AFTER DISASSEMBLY
Cylinder Head Distortion
Using straightedge and feeler gauge, check the bottom of the cylin-
der head for distortion.
JEM153G
For intake : Black
For exhaust : Brown
JEM165G
Identification color : Yellow
FEM080
Limit : 0.04 mm (0.0016 in)
SEM496G

EM-180
[YD22DDTi]
CYLINDER HEAD
Valve Dimension
Check dimensions of each valve. For dimensions, refer to SDS,EM-
211, "Va l v e".
Whenvalveheadhasbeenworndownto1mm(0.039in)inmargin
thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
Valve Guide Clearance
lPerform the inspection before removing valve guides.
lCheck that the valve stem diameter is within specifications.
lPush valve approximately 25 mm (0.98 in) toward combustion
chamber, move valve toward dial indicator to measure valve
movement.
lValve guide clearance is 1/2 of movement on dial indicator.
lIf the measured value exceeds the limit, replace valve guide.
Valve Guide Replacement
lWhen removing valve guide, replace it with oversized [0.2 mm
(0.0008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.
2. Using valve guide drift, tap valve guides out from the combus-
tion chamber side.
SEM188A
Standard:
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Limit:
Intake : 0.08 mm (0.0031 in)
Exhaust : 0.10 mm (0.0039 in)
PBIC0414E
SEM008A
SEM931C