secure NISSAN X-TRAIL 2003 Electronic Service Manual

EC-382
[QR (WITHOUT EURO-OBD)]
PRECAUTIONS
lDo not disassemble ECM.
lIf a battery terminal is disconnected, the memory will return
to the ECM value.
The ECM will now start to self-control at its initial value.
Engine operation can vary slightly when the terminal is dis-
connected. However, this is not an indication of a problem.
Do not replace parts because of a slight variation.
lWhen connecting ECM harness connector, fasten it
securely with a lever as far as it will go as shown at right.
lWhen connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
lSecurely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
lKeep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control sys-
tem malfunctions due to receiving external noise, degraded
operation of ICs, etc.
lKeep engine control system parts and harness dry.
lBefore replacing ECM, perform “ECM Terminals and Refer-
ence Value” inspection and make sure ECM functions prop-
erly. Refer toEC-427
.
lHandle mass air flow sensor carefully to avoid damage.
lDo not disassemble mass air flow sensor.
lDo not clean mass air flow sensor with any type of deter-
gent.
lDo not disassemble electric throttle control actuator.
lEven a slight leak in the air intake system can cause seri-
ous problems.
lDo not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
SEF707Y
SEF908W
PBIB0090E
MEF040D

EC-656
[YD]
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EBS008RR
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WAR NIN G:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
PrecautionsEBS00317
lBefore connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative
battery terminal. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.
lDo not disassemble ECM.
lWhen connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
lSecurely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to IC's.
lKeep engine control system harness at least 10cm (4 in)
away from adjacent harness, to prevent engine control sys-
tem malfunctions due to receiving external noise, degraded
operation of IC's, etc.
lKeep engine control system parts and harness dry.
SEF289H
PBIB0378E
SEF291H

DRIVE BELTS
EM-13
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS009QO
WA RN ING:
Be sure to perform when the engine is stopped.
lMake sure that the stamp mark of auxiliary drive belt auto-tensioner is within the usable range.
NOTE:
lCheck the automatic tensioner indication when the engine is cold.
lWhen the new drive belt is installed, the range should be A.
lVisually check entire belt for wear, damage or cracks.
lIf the indicator is out of allowable use range or belt is damaged, replace the belt.
Tension AdjustmentEBS009QP
lBelt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.
Removal and InstallationEBS009QQ
REMOVAL
1. Remove front RH engine side cover.
2. With box wrench, and while securely holding the hexagonal part
in pulley center of automatic tensioner, move the wrench handle
in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
3. Insert a rod approximately 6mm (0.24in) in diameter through the
rear of engine into holding boss to fix tensioner pulley.
lLeave tensioner pulley arm locked until belt is installed again.
4. Loosen auxiliary drive belt from water pump pulley in sequence,
and remove it.
INSTALLATION
1. With box wrench, and while securely holding the hexagonal part in pulley center of automatic tensioner,
move the wrench handle in the direction of arrow [loosening direction of tensioner].
CAUTION:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
PBIC0256E
KBIA0088E

EM-30
[QR20DE]
FUEL INJECTOR AND FUEL TUBE
INSTALLATION
1. Install O-rings to fuel injector paying attention to the items below.
lLubricate O-rings by smearing new engine oil.
lBe careful not to scratch it with a tool or fingernails during installation. Also be careful not to twist
or stretch O-ring. If O-ring was stretched while it is attached, do no insert it into fuel tube immedi-
atly.
2. Install fuel injector to fuel tube with the following procedure.
lInsert clip into clip mounting groove on fuel injector.
lInsert clip so that projection A of fuel injector matches notch A of
the clip.
lDo not reuse clip. Replace it with a new one.
lBe careful to keep clip from interfering with O-ring. If interfer-
ence occurs, replace O-ring.
3. Insert fuel injector into fuel tube with clip attached.
lInsertitwhilematchingittotheaxialcenter.
lInsert fuel injector so that projection B of fuel injector matches
notch B of the clip.
lMake sure that fuel tube flange is securely fixed in flange fixing
groove on clip.
lMake sure that installation is complete by checking that fuel
injector does not rotate or come off.
4. Install fuel tube assembly with the following procedure.
a. Insert the tip of each fuel injector into intake manifold.
b. Tighten mounting bolts in two steps in the numerical order
shown in the figure.
5. Install intake manifold collector. Refer toEM-17, "
INTAKE MANI-
FOLD".
6. Connect fuel hose. Refer toEM-17, "
INTAKE MANIFOLD".
7. Install all removed parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
lCheck connections for fuel leakage.
1. Start the engine, and run it for a few minutes with engine at idle.
2. Stop the engine, and check for fuel leakage both visually and by odor of gasoline.
NOTE:
Use mirrors for checking on invisible points.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
KBIA0240E
1st step: 9.3 - 10.8 N·m (0.95 - 1.1 kg-m, 0.7 - 0.8 ft-lb)
2nd step: 20.6 - 26.5 N·m (2.1 - 2.7 kg-m, 16 - 19 ft-lb)
KBIA0239E

CAMSHAFT
EM-35
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c. Secure hexagonal part of camshaft with a tool such as a span-
ner. Loosen camshaft sprocket mounting bolts and remove the
camshaft sprockets.
CAUTION:
lDo not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
NOTE:
lChain tension holding work is not necessary. Crank sprocket
and timing chain do not disconnect structurally while front cover
is attached.
8. Loosen mounting bolts in the reverse order shown in the figure,
and remove camshaft brackets and camshafts.
lRemove No.1 camshaft bracket by slightly tapping it with a
soft tool such as a plastic hammer.
9. Remove valve lifter.
lCheck mounting positions, and store them without mixing
them up.
INSTALLATION
1. Install valve lifter.
lInstall them in the same positions they were in prior to removal.
2. Install camshaft.
lDistinction between intake and exhaust camshafts is performed with a difference of shapes of rear end.
Intake : Signal plate shape for camshaft position (PHASE) sensor.
Exhaust : Cone end shape.
lInstall camshafts so that knock pins on the front side are posi-
tioned as shown in the figure.
KBIA0049E
KBIA0245E
KBIA0246E
KBIA0051E

EM-44
[QR20DE]
TIMING CHAIN
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove the parts listed below.
lEngine hood
lUndercover
lPCV hose
lIgnition coil; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lEngine coolant reservoir tank
lAuxiliary drive belt; Refer toEM-13, "Removal and Installation".
lAlternator
lAuxiliary drive belt auto-tensioner; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt
Auto- tensioner".
lExhaust front tube; Refer toEX-2, "EXHAUST SYSTEM".
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Move power steering pump with piping connected, and secure it to vehicle side temporarily.
5. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
lTo avoid power steering fluid leakage, temporarily fix reservoir tank vertically.
6. Suspend engine with a hoist, and support the engine posture.
For installation of engine slingers, refer toEM-61, "
ENGINE ASSEMBLY"
7. Remove RH engine mount insulator.
8. Remove center member and rear engine mounting bracket.
9. Drain engine oil.
10. Remove oil pan upper and lower, and oil strainer. Refer toEM-24, "
Removal and Installation".
11. Remove Intake valve timing control cover.
a. Loosen bolts in reverse order shown in the figure.
b. Remove the cover using Tool (Seal cutter).
12. Pull chain guide between camshaft sprockets out through front
cover.
13. Set No.1 cylinder at TDC on its compression stroke with the fol-
lowing procedure.
a. Rotate crankshaft pulley clockwise and align mating marks to
timid indicator on front cover.
KBIA0085E
KBIA0190E

EM-46
[QR20DE]
TIMING CHAIN
15. Remove front cover with following procedure.
a. Loosen mounting bolts in the reverse order shown in the figure,
and remove them.
b. Using a seal cutter, remove front cover.
CAUTION:
lBe careful not to damage mounting surface.
16. If front oil seal needs to be replaced, lift it with a screwdriver,
and remove it.
17. Remove timing chain with the following procedure.
a. Push in tensioner plunger. lnsert a stopper pin into hole on ten-
sioner body to fix chain tensioner and remove it.
lUse wire of 0.5mm (0.02in) in diameter as a stopper pin.
b. Secure hexagonal part of camshaft with a tool such as a span-
ner. Loosen camshaft sprocket mounting bolts and remove the
camshaft sprockets.
CAUTION:
lDo not rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and pis-
ton.
18. Remove chain slack guide, tension guide, timing chain and oil
pump drive spacer.
KBIA0083E
KBIA0048E
KBIA0049E

TIMING CHAIN
EM-47
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19. Remove timing chain tensioner for balancer unit with the follow-
ing procedure.
a. Lift tensioner lever up, and release rachet claw for return proof.
b. Push tensioner sleeve in, and hold it.
c. Matching the hole on lever with the one on body, insert a stopper
pin to secure tensioner sleeve.
d. Remove timing chain tensioner for balancer unit.
20. Remove timing chain for balancer unit and crankshaft sprockets.
21. Loosen mounting bolts in reverse order shown in the figure, and
remove balancer unit.
lUse Torx socket (size E14)
CAUTION:
lDo not disassemble balancer unit.
INSPECTION AFTER REMOVAL
Timing Chain
Check timing chain for cracks or serious wear. If a malfunction is
detected, replace it.
Balancer Unit mounting bolt outer diameter.
lMeasure outer diameters (d1, d2) at the two positions shown in
the figure.
lMeasure d2 within the range A.
lIf the value difference (d1 – d2) exceeds the limit (a dimension
difference is large), replace it with a new one.
KBIA0121E
KBIA0122E
PBIC0282E
Limit : 0.15 mm ( 0. 0059in) or more.
KBIA0126E

TIMING CHAIN
EM-51
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9. Install Intake valve timing control cover with the following procedure.
a. Install Intake valve timing control solenoid valves to Intake valve timing control cover.
b. Install Oil rings to the intake camshaft sprocket insertion points on Intake valve timing control backside
cover.
c. Install O-ring to front cover.
d. Apply liquid gasket to the positions in the figure.
e. Tighten mounting bolts in the numerical order shown in the fig-
ure.
10. Insert crankshaft pulley by aligning with crankshaft key.
lTap its center with a plastic hammer to insert.
lDo not tap belt hook.
11. Tighten crankshaft pulley mounting bolts.
lSecure crankshaft pulley with a pulley holder, and tighten the bolts.
lPerform angle tightening with the following procedure.
a. Apply new engine oil to threads and seat surfaces of mounting bolts.
b. Tighten to 37.3 to 47.1 N·m (3.8 to 4.8 kg-m, 28 to 34 ft-lb).
c. put a paint mark on front cover, mating with any one of six easy
to recognize stamp marks on bolt flange.
d. Turn another 60°to 66°[Target: 60°].
lCheck vertical mounting angle with movement of one stamp
mark.
12. Install remaining parts in reverse order of removal.
KBIA0084E
KBIA0085E
PBIC0258E

EM-54
[QR20DE]
CYLINDER HEAD
5. Remove camshaft. Refer toEM-33, "Removal and Installation".
6. Securely support bottom of cylinder block with a jack or equivalent tool, and remove the hoist that was
supporting it.
7. Remove cylinder head loosening bolts in reverse order shown in
the figure.
INSPECTION AFTER REMOVAL
OuterDiameterofCylinderHeadBolts
lCylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new one.
lIf reduction of outer diameter appears in a position other than
d2, use it as d2 point.
INSTALLATION
1. Install cylinder head gasket.
2. Follow the steps below to tighten fixing bolts in the order shown
in figure to install cylinder head.
CAUTION:
lIf cylinder head bolts are re-used, check their outer diam-
eters before installation. Refer toEM-54, "
Outer Diameter
of Cylinder Head Bolts".
lIn step “c”, loosen bolts in the reverse order of that indi-
catedinfigure.
a. Apply new engine oil to threads and seating surface of mounting
bolts.
b. Tighten all bolts to 98.1 N·m (10 kg-m, 72 ft-lb).
c. Completely loosen to 0 N·m (0 kg-m, 0 ft-lb).
d. Tighten all bolts to 34.3 to 44.1 N·m (3.5 to 4.4 kg-m, 26 to 32 ft-lb).
e. Turn all bolts 75°to 80°(target: 75°) degrees clockwise.
f. Turn all bolts 75°to 80°(target: 75°) degrees clockwise again.
CAUTION:
Check and confirm the tightening angle by using angle
wrench or protractor. Avoid judgment by visual inspection
without the tool.
KBIA0058E
Limit (d1 - d2) : More than 0.23 mm (0.0091 in)
KBIA0189E
KBIA0058E
KBIA0059E