NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-201
[YD22DDTi]
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PISTON TO PISTON PIN CLEARANCE
Piston Pin Hole Inner Diameter
Using inside micrometer, measure piston pin hole inner diameter.
Piston Pin Outer Diameter
Using micrometer, measure piston pin outer diameter.
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin hole inner diameter)-(Piston pin outer diameter)
lIf clearance is exceeds specification, replace either or both piston/piston pin assembly.
PISTON RING SIDE CLEARANCE
lUsing feeler gauge, measure clearance between piston ring and
piston ring groove.
Unit: mm (in)
lAlign top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.
lIf side clearance exceeds the limit, replace piston ring.
lCheck clearance again. If side clearance still exceeds the limit,
replace piston.Standard : 27.997 - 28.005 mm (1.1022 - 1.1026 in) dia.
PBIC0116E
Standard : 27.994 - 28.000 mm (1.1021 - 1.1024 in)dia .
PBIC0117E
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
Item Standard Limit
Top ring 0.120 - 0.180 (0.0047 - 0.0071) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
FEM100

EM-202
[YD22DDTi]
CYLINDER BLOCK
PISTON RING END GAP
lCheck that cylinder bore diameter is within specifications.
Refer toEM-204, "
PISTON TO CYLINDER BORE CLEAR-
ANCE".
lUsing piston, press piston ring to cylinder mid point, and mea-
sure end gap.
Unit: mm (in)
CONNECTING ROD BEND AND TORSION
Use connecting rod aligner to check bend and torsion.
CONNECTING ROD BIG END INNER DIAMETER
lInstall connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter.
Item Standard Limit
Top ring 0.20 - 0.35 (0.0079 - 0.0138)
1.0 (0.039) 2nd ring 0.39 - 0.54 (0.0154 - 0.0213)
Oil ring 0.25 - 0.50 (0.0098 - 0.0197)
FEM101
Bend limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
Torsion limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
SEM038F
SEM003F
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in) dia.
PBIC0119E

CYLINDER BLOCK
EM-203
[YD22DDTi]
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CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Connecting Rod Small End Inner Diameter
Use inside micrometer to measure small end inner diameter.
Piston Pin Outer Diameter
Use micrometer to measure piston pin outer diameter.
Calculation of Connecting Rod Bushing Clearance
(Connecting rod small end bushing clearance) = (Connecting rod small end inner diameter)-(Piston pin outer
diameter)
lIf out of specifications, replace connecting rod and/or piston and piston pin assembly. Refer toEM-198,
"HOW TO SELECT CONNECTING ROD BEARING".
CYLINDER BLOCK TOP SURFACE DISTORTION
lUsing scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of oil and coolant pas-
sages.
lUse straightedge and feeler gauge to check block upper surface
for distortion.Standard : 28.026 - 28.038 mm (1.1034 - 1.1039 in) dia.
PBIC0120E
Standard : 27.994 - 28.000 mm (1.1021 - 1.1024 in) dia.
PBIC0117E
Standard : 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit : 0.057 mm (0.0022 in)
Limit : 0.04 mm (0.0016 in)
SEM501G

EM-204
[YD22DDTi]
CYLINDER BLOCK
MAIN BEARING HOUSING INNER DIAMETER
lWithout installing main bearings, install main bearing caps, and
tighten bolts to the specified torque.
lMeasure the inner diameter of main bearing housing with a bore
gauge.
lIf the measurement is out of the specified range, replace cylin-
der block and main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
lUsing bore gauge, measure cylinder inner diameters at 6 posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y).
lIf clearance exceeds the limit, or any flaws or seizures are found
on inner surface of cylinder, horn or bore the applicable cylinder
or redore all cylinder.
Piston Outer Diameter
Use micrometer to measure piston skirt outer diameter.
Calculation of Piston to Piston Bore Clearance
lCalculate using piston skirt outer diameter and cylinder inner diameter (direction X, position B).
(Clearance) = (Cylinder inner diameter)-(Piston skirt outer diameter) Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
JEM214G
Cylinder inner diameter:
Standard : 86.000 - 86.030 mm
(3.3858 - 3.5870 in) dia.
Wear limit : 0.07 mm (0.0028 in)
Out-of-round limit (X - Y) : 0.015 mm (0.0006 in)
Taper limit (A - B - C) : 0.010 mm (0.0004 in)
JEM207G
FEM110
Piston skirt diameter:
Measurement position : 48.83 mm (1.9224 in)
Distance from the top
Standard : 85.925 - 85.955 mm
(3.3829 - 3.3841 in) dia.
0.25 (0.0098) O/S : 86.175 - 86.205 )
(3.3927 - 3.3939
0.50 (0.0197) O/S : 86.425 - 86.455
(3.4026 - 3.4036)
Specifications at room temperature [20°C(68°F)]:
0.065 - 0.085 mm (0.0026 - 0.0033 in)
PBIC0125E

CYLINDER BLOCK
EM-205
[YD22DDTi]
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lIf out of specification, replace piston and piston pin assembly. Refer toEM-197, "HOW TO SELECT PIS-
TON".
Reboring cylinder
1. Determine cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.
2. install main bearing caps and tighten bolts to specified torque. This will prevent distortion of cylinder
bores.
3. Cut cylinder bore.
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 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.
CRANKSHAFT JOURNAL OUTER DIAMETER
Use micrometer to measure journal outer diameter.
CRANKSHAFT PIN OUTER DIAMETER
Use micrometer to measure pin outer diameter.
CRANKSHAFT OUT-OF-ROUND AND TAPER
lUsing micrometer, measure each journal and pin at 4 points
shown in the figure.
lOut-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
lTaper value is indicated by difference in dimensions between
points A and B in directions X and Y.Rebore size calculation:
D=A+B–C
Where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in) dia.
FEM114
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in) dia.
Out-of-round:
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
Ta p e r :
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
SEM316A

EM-206
[YD22DDTi]
CYLINDER BLOCK
CRANKSHAFT RUNOUT
lPlace V-block onto surface plate to support journals at both ends
of crankshaft.
lPosition dial indicator vertically onto No. 3 journal.
lRotate crankshaft to read needle movement on dial indicator.
(Total indicator reading)
CONNECTING ROD BEARING OIL CLEARANCE
Method by measurement
lInstall connecting rod bearings to connecting rods and caps, and
tighten connecting nuts to the specified torque. Use inside
micrometer to measure connecting rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter)-
(Crankshaft pin outer diameter)
lIf out of specifications, check connecting rod big end inner diam-
eter and crankshaft pin outer diameter, and select appropriate
connecting rod bearing to adjust clearance to specifications.
Refer toEM-198, "
HOW TO SELECT CONNECTING ROD
BEARING".
Method using plastigage
lRemove contamination such as oil, dust completely from crank-
shaft pins and each bearing surface.
lCut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
lInstall connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
lRemove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in “Method by measurement”.
MAIN BEARING OIL CLEARANCE
Method by measurement
lInstall main bearings to the cylinder block and bearing cap, and tighten the bolts to the specified torque.
Then, measure the inner diameter of the main bearings.
(Bearing clearance) = (Bearing inner diameter)-(Crankshaft journal outer diameter)
lIf out of specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to specifications. Refer toEM-199, "
HOW TO
SELECT MAIN BEARING". Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.031 - 0.061 mm (0.0012 - 0.0024 in)
PBIC0119E
EM142
Standard : 0.039 - 0.066 mm (0.0015 - 0.0026 in)

CYLINDER BLOCK
EM-207
[YD22DDTi]
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Method using plastigage
lRemove contamination such as oil and dust completely from
crankshaft journals and each bearing surface.
lCut plastigage slightly shorter than bearing width. place it in
crankshaft turning direction, avoiding oil holes.
lInstall main bearings and bearing cap and tighten to the speci-
fied torque.
CAUTION:
Never rotate crankshaft.
lRemove main bearings and bearings, and measure plastigage
width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in “Method by measurement”.
lInstall main bearings to the cylinder block and bearing cap, and tighten the bolts to the specified torque.
Then, measure the inner diameter of the main bearings.
MAIN BEARING CRUSH HETIGH
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 out of specification, replace main bearings.
MAIN BEARING CAP BOLT DEFORMATION
lMeasure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
lWhen the necked point is identified at a point other than where
specified, measure at the point as d2.
lCalculate the difference between d1 and d2.
CONNECTING ROD BOLT DEFORMATION
lInstall nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on
the bolt.
lIf the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.
lIf a necked point is identified, measure at that point.
lIf the measurement exceeds the limit, replace connecting rod
bolts and nuts.
PBIC0131E
Standard : Crush height must exist.
SEM502G
Limit : 0.13 mm (0.0051 in)
JEM219G
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit : 8.75 mm (0. 3445 in) dia.
JEM220G

EM-208
[YD22DDTi]
CYLINDER BLOCK
OIL JET
lCheck nozzle for deformation and damage.
lBlow compressed air from nozzle, and check for clogs.
lIf it out of the standard, replace oil jet.
OIL JET RELIEF VALVE
lUsing a clean plastic stick, press check valve in oil jet relief
valve. Make sure that valve moves smoothly with proper reac-
tion force.
lIf it is out of the standard, replace oil jet relief valve.
MOVEMENT AMOUNT OF FLYWHEEL
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 flywheel 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.Standard : Deformation and damage.
JEM221G
Standard
: Valve moves smoothly with proper reaction force.
JEM222G
Standard : 0.45mm (0.0177 in) or less
Limit : 1.3mm (0.051 in)
PBIC0274E

CYLINDER BLOCK
EM-209
[YD22DDTi]
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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.Standard : 26.2 mm (1.031 in) or lessKBIA0297E

EM-210
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00BPO
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
Unit: mm (in)
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3(cu in)2,184 (133.27)
Bore and stroke Unit: mm (in) 86 x 94 (3.39 x 3.70)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.0
Compression pressure
Unit:kPa(bar,kg/cm
2,psi)/200rpmStandard 2,893 (28.9, 29.5, 419)
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
224 212 2 30 -2 46
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied*
New Adjusted Limit for re-adjusting
Air conditioner compressor
belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator & water pump
belt9.0 - 10.5
(0.354 - 0.413)11 . 0 - 1 2 . 5
(0.433 - 0.492)16.5 (0.650)