engine NISSAN X-TRAIL 2003 Electronic Repair Manual

CO-10
[QR20DE]
ENGINE COOLANT
2. Open drain plugs on cylinder block.
3. Remove reservoir tank and drain coolant.
4. Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer toCO-10,
"FLUSHING COOLING SYSTEM".
REFILLING ENGINE COOLANT
1. Install reservoir tank, radiator drain plug and cylinder block drain plug.
Apply sealant to the thread of cylinder block drain plug.
lUse Genuine Liquid Gasket or equivalent.
2. Fill radiator and reservoir tank to specified level.
lUse genuine Nissan anti-freeze coolant or equivalent mixed
with water (distilled or demineralized).
Refer toMA-17, "
RECOMMENDED FLUIDS AND LUBRI-
CANTS".
lPour coolant slowly of less than 2 (2-1/8US qt,1-3/4 lmp
qt) a minute to allow air in system to escape.
3. Warm up engine to normal operating temperature without radia-
tor cap installed.
lIf coolant overflows radiator filler hole, install filler cap.
4. Run engine at 3,000 rpm for 10 seconds and return to idle speed
with radiator cap installed.
lRepeat two or three times.
Watch coolant temperature gauge so as not to overheat the engine.
5. Stop engine and cool down to less than approximately 50°C(122°F).
lCool down using a fan to reduce the time.
lIf necessary, refill radiator up to filler neck with coolant.
6. Refill reservoir tank to MAX level line with coolant.
7. Repeat steps 5 through 7 two or more times with radiator cap installed until coolant level no longer drops.
8. Check cooling system for leaks with engine running.
9. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with
heater temperature controller set at several position between COOL and WARM.
lSound may be noticeable at heater unit.
10. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no
longer drops.
lClean excess coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator and reservoir tank with water and reinstall radiator cap.
KBIA0163E
: 7.8 - 11.8 N·m (0.8 -1.2 kg-m , 69 - 104 in-lb)
Engine coolant capacity (With reservoir tank):
Approx. 7.1 (6-1/4 Imp qt)
SMA182B
Reservoir tank:
0.6 (1/2 lmp qt )
SMA412B

ENGINE COOLANT
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2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-12
[QR20DE]
RADIATOR
RADIATOR
PFP:21400
Removal and InstallationEBS009SF
WAR NIN G:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to
allow built-up pressure to escape. Carefully remove the cap by turning it all the way.
REMOVAL
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
2. Remove air duct with air cleaner assembly.
3. Remove A/T oil cooler hose.
lInstall blind plug to avoid leakage of A/T fluid.
4. Disconnect radiator upper hose, lower hose and mounting bracket.
5. Remove radiator and radiator fan assembly
CAUTION:
lDo not damage or scratch radiator core when removing.
INSTALLATION
lReinstall any parts removed in reverse order of removal.
lCheck for coolant leaks. Refer toCO-9, "LEAK CHECK".
PBIC0237E
1 Radiator 2 Bracket 3 Mounting rubber
4 A/T oil cooler hose 5 Radiator hose (lower) 6 Radiator fan assembly
7 Reservoir tank 8 Radiator hose (upper) 9 Radiator filler cap

WATER PUMP
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WATER P UM PPFP:21020
Removal and InstallationEBS009SJ
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Water Pump Removal
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
2. Remove the following parts.
lEngine under cover
lAlternator, water pump and air compressor belt
Refer to drive beltEM-13, "
Removal and Installation".
3. Remove water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
Water Pump Housing Removal
1. Perform step 1 and 2 of “Water Pump Removal”.
2. Remove alternator.
3. Remove oil level gauge.
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
4. Remove bolts mounting water pipe.
5. Remove water pump housing.
Water Pipe Removal
1. Remove water pump housing.
KBIA0154E
1 Water pump 2 Gasket 3 Water pump housing
4 Water pipe

THERMOSTAT AND WATER CONTROL VALVE
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THERMOSTAT AND WATER CONTROL VALVEPFP:21200
Removal and InstallationEBS009SK
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Thermostat Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine cold.
2. Disconnect radiator lower hose at water inlet side.
3. Remove water inlet and thermostat.
Water Control Valve Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
2. Disconnect upper radiator hose, heater pipe and heater hose at water outlet side.
3. Remove water outlet.
4. Remove water control valve.
PBIC0239E
1 Thermostat 2 Water inlet 3 Water control valve
4 Water outlet 5 Heater hose 6 Engine coolant temperature sensor
7Heaterpipe

CO-24
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00BAU
REMOVAL AND LIQUID GASKET
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket 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 gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
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.
Occasionally, it should be applied outside the holes. Make sure
to read the 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

OVERHEATING CAUSE ANALYSIS
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Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp Symptom Check items

CO-30
[YD22DDTi]
ENGINE COOLANT
ENGINE COOLANT
PFP:KQ100
InspectionEBS00BAY
LEVEL CHECK
lCheck if the reservoir tank coolant level within MIN to MAX when
engine is cool.
lAdjust coolant if too much or too little.
LEAK CHECK
lTo check for leakage, apply pressure to the cooling system with
atester.
WAR NIN G:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine CoolantEBS00BAZ
WAR NIN G:
lTo avoid being scalded, never change the coolant when the engine is hot.
lWrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
lBe careful not to allow coolant to contact drive belts.
lCover the exhaust tube heat shield to prevent from splashing
coolant.
2. Remove reservoir tank, drain coolant, then clean reservoir tank.
SMA412B
Testing pressure
: 157 kPa (1.57bar 1.6 kg/cm2,23psi)
SLC134B
PBIC0236E

ENGINE COOLANT
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3. Open drain plugs on cylinder block and air relief plug.
4. Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer toCO-32,
"FLUSHING COOLING SYSTEM".
REFILLING ENGINE COOLANT
1. Install reservoir tank, radiator drain plug and cylinder block drain plug.
Apply sealant to the thread of cylinder block drain plug.
lUse Genuine Liquid Gasket or equivalent.
2. Fill radiator slowly with coolant until coolant spills from the air
relief plugs, then install air relief plugs.
CAUTION:
If the filling rate is too fast, this could lead to air being
mixed in the coolant. Be sure to fill the coolant slowly
according to the rate indicated above.
lReplace the copper washer of the air bleeding plug.
lUse genuine Nissan anti-freeze coolant or equivalent mixed with water (distilled or demineralized).
Refer toMA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".
lPour coolant through coolant filler neck slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
SBIA0129E
SBIA0130E
: 7.8 - 11.8 N·m (0.8 -1.2 kg-m , 69 - 104 in-lb)
Air relief plug :
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
Engine coolant capacity (With reservoir tank):
9.5 ( 8-3/8 Imp qt)
SMA182B
Reservoir tank : 0.6 (1/2 lmp qt )

CO-32
[YD22DDTi]
ENGINE COOLANT
3. Fill reservoir tank to specified level.
4. Warm up engine to normal operating temperature without radia-
tor cap installed.
lIf coolant overflows radiator filler hole, install filler cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle speed
with radiator cap installed.
lRepeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool down to less than approximately
50°C(122°F).
lCool down using a fan to reduce the time.
lIf necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 5 through 7 two or more times with radiator cap installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with
heater temperature controller set at several position between COOL and WARM.
lSound may be noticeable at heater unit.
11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no
longer drops.
lClean excess coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief flag. Fill radiator and
reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.
SMA412B