check engine NISSAN X-TRAIL 2003 Electronic Repair Manual

INTAKE MANIFOLD
EM-117
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lDo not disassemble or adjust.
2. Install intake manifold.
lTighten fixing bolts and nuts in numerical order as shown in the figure.
lWhen stud bolts come off, install with the following torque..
3. Install water hose.
lInstall water hose by referring to identification marks avoiding
twisting.
lWhen an insert stopper is not provided with the pipe, insert
the hose up to dimension A. When the pipe is shorter than
dimension A, insert hose fully until it reaches the end.
lWhen an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
lWhen marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
4. Install remaining parts in reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer toFL-16,
"Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Dimension A : 25 - 30 mm (0.984 - 1.181 in)
SBIA0156E

EM-120
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
14. Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
15. Rotate the exhaust manifold and turbocharger assembly so that
the rear side (EGR tube mounting side) faces upward. And then
pull out the assembly from between the engine and the air con-
ditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling
out the assembly.
INSTALLATION
lWhen a stud bolt is pulled out, tighten it to the following torque:
lTighten the exhaust manifold mounting nuts in the following procedure:
1. Tighten the nuts in the order specified in the figure.
2. Re-tighten the nuts 1 to 4.
3. Install the gasket so that the alignment protrusion faces the No.
4port.
4. Install in reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
JEM266G
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
JEM266G

EXHAUST MANIFOLD AND TURBOCHARGER
EM-123
[YD22DDTi]
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TURBINE WHEEL
lCheck that there is no oil adhesion.
lCheck that there is no carbon accumulation.
lCheck that blades of the turbine wheel are not bent or broken.
lCheck that the turbine wheel does not interfere with the turbine
housing.
COMPRESSOR WHEEL
lCheck that there is no oil adhesion inside the air inlet.
lCheck that the compressor wheel does not interfere with the
compressor housing.
lCheck that the wheel is not bent or broken.
WASTEGATE VALVE ACTUATOR
lConnect the handy pump to the actuator, and check that the rod
strokes smoothly in compliance with the following pressure.
lPressure to be applied at actuator part to move rod end as fol-
lows:
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
lCheck that the engine oil level is between MIN and MAX of the dipstick. (When the engine oil amount is
more than MAX, the oil flows into the inlet duct through the blow-by gas passage, and the turbocharger is
misjudged failure.)
lAsk the customer if he/she always runs the vehicle in idle engine speed to cool the oil down after driving.
lReplace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
lIf no malfunction is found after the unit inspections, judge that the turbocharger body has no failure. Check
the other parts again.
SEM272G
SEM273G
Standard (Pressure/rod stroke amount):
: 150.80 - 156.20 kPa (1,508 - 1,562 mbar, 1,131 - 1,172
mmHg, 44.0 - 46.2 inHg)/0.38 mm (0.0150 in)
: 176.50 - 185.90 kPa (1,765 - 1,859 mbar, 1,324 - 1,394
mmHg, 52.2 - 54.9 inHg)/4.0 mm (0.157 in)
SEM274G
Inspection item Inspection resultSymptom
(when each inspection item meets each inspection result)
Oil leakage Smoke NoiseInsufficient power/
acceleration failure

OIL PAN AND OIL STRAINER
EM-129
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7. Install in the reverse order of removal after this step.
lPour engine oil or start engine at least 30 minutes after
oil pan is installed.
INSPECTION AFTER INSTALLATION
Check for leakage of engine oil when engine is warmed.
SBIA0161E

VACUUM PUMP
EM-131
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VACUUM PUMPPFP:41920
Removal and InstallationEBS00BO4
INSPECTION BEFORE REMOVAL
1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
lDisconnect point where vacuum from vacuum pump can be measured directly and install 3-way con-
nector.
2. Start engine and measure generated vacuum at idle speed.
lIf out of standard, check for air suction in vacuum route, and measure again.
lIf still outside of standard, replace vacuum pump.
REMOVAL
1. Drain engine coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove air duct and air cleaner case. Refer toEM-112, "
Removal and Installation".
3. Remove charge air cooler and bracket. Refer toEM-114, "
Removal and Installation".
4. Disconnect harness connector from fuel injector.
5. Remove injection tube. Refer toEM-135, "
Removal and Installation".
6. Remove fuel injector oil seal.
7. Remove rocker cover. Refer toEM-147, "
Removal and Installation".
8. Remove spill tube. Refer toEM-135, "
Removal and Installation".
9. Remove nozzle support from NO.2 cylinder and fuel injector. Refer toEM-135, "
Removal and Installation"
.
10. Remove air inlet pipes. Refer toEM-119, "
Removal and Installation".
11. Remove exhaust manifold cover.
SBIA0166E
Standard : – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to –
29.92 inHg)

EM-132
[YD22DDTi]
VACUUM PUMP
12. Disconnect electronic EGR control valve water hose and harness.
13. Disconnect heater hose.
14. Remove EGR tube.
15. Disconnect vacuum hose from vacuum pump side.
16. Remove camshaft position sensor.
17. Remove cylinder head rear cover plate.
18. Loosen and remove the installation bolts in rear cam sprocket.
lLoosen rear cam sprocket installation bolts by fixing the hexagonal portion of the camshaft.
19. Remove vacuum pump and cylinder head rear cover assembly.
lRemove and install vacuum pump, sprocket, drive chain and
chain guide as an assembly.
lLoosen mounting bolts in reverse order shown in figure.
lDo not remove any bolts not shown in figure. (Especially
never remove M6 bolts on vacuum pump.)
lUse seal cutter (special service tool) or other suitable tool to
remove.
INSTALLATION
1. Install vacuum pump and cylinder head rear cover assembly
onto cylinder head. Refer toEM-133, "
ASSEMBLY".
lApply Genuine Liquid Gasket or equivalent (Refer toEM-103,
"Precautions for Liquid Gasket".) to area shown in the figure.
lAttaching should be done with in 5 minutes after coating.
2. Tighten mounting bolts in order shown in the figure.
3. Install rear cam sprocket mounting bolts by fixing the hexagonal
portion of the camshaft. .
4. Tighten rear cam sprocket mounting bolts.
5. Install cylinder head rear cover plate.
lApply Genuine Liquid Gasket or equivalent (Refer toEM-103,
"Precautions for Liquid Gasket".) to area shown in the figure.
lAttaching should be done with in 5 minutes after coating.
CAUTION:
Never start engine with vacuum circuit being open. If
engine is started and vehicle is running while vacuum
pump is open (with vacuum hose disconnected), blow-by
flow rate will increase and engine may be damaged.
6. Install in reverse order of removal after this step.
lWhen vacuum hose is connected, insert it securely by at least
15 mm (0.59 in).
INSPECTION AFTER INSTALLATION
Check generated vacuum satisfies the specification at idle speed. Refer toEM-131, "INSPECTION BEFORE
REMOVAL".
SBIA0167E
SBIA0167E
SBIA0169E

INJECTION TUBE AND FUEL INJECTOR
EM-137
[YD22DDTi]
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2. Connect spill tube.
lTighten fixing bolts and nut in the numerical order shown in
the figure.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to specified torque. It does not affect performance.
3. Carry out air tightness test for spill tube.
lConnect a vacuum handy pump to spill connector. Check that
vacuum is retained while applying following vacuum.
lIf outside of standard, reconnect spill tube. (Replace gasket in
this case.)
4. Install rocker cover. Refer toEM-147, "
Removal and Installation"
.
5. Install nozzle oil seal.
lInsert it straight until its flange fully contacts rocker cover.
CAUTION:
lCheck gutter spring in seal on fuel injector for missing.
6. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
7. Connect spill hose.
8. Install remaining parts in reverse order of removal.
9. Before starting engine, bleed air from fuel piping. Refer toFL-16, "
Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
SBIA0205E
Standard :-53 to-67 kPa (-533 to-667 mbar,-400
to-500 mmHg,-15.75 to-19.69 inHg)
JEF250Z
SBIA0203E

FUEL SUPPLY PUMP
EM-143
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21. Remove the fuel supply pump mounting bolts.
NOTE:
The seal washer of the mounting bolts cannot be reused.
CAUTION:
For removal, be careful not to drop the seal washer into the
engine.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Before the fuel supply pump is installed, check that the notch of
its flange and the 6 mm (0.24 in) dia. hole on the body are
aligned.
2. Insert the fuel supply pump to the mounting position from the
rear side of the engine.
SBIA0221E
SEM984C
SBIA0222E
SBIA0223E

EM-148
[YD22DDTi]
ROCKER COVER
6. Remove rocker cover.
lLoosen holding bolts in the reverse order of that shown in the
figure and remove.
INSTALLATION
1. Apply 3.0 mm (0.118 in) dia. of Genuine Liquid Gasket or equiv-
alent (Refer toEM-103, "
Precautions for Liquid Gasket".) on
locactions shown in the figure.
2. Tighten holding bolts in the numerical order shown in the figure.
lRe-tighten to the same torque in the same order as above.
3. Install nozzle oil seal.
lInsert it straight until flange fully contacts cylinder head.
4. Install remaining parts in reverse order removal.
5. Before starting engine, bleed air from fuel piping. ReferFL-16,
"Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
SBIA0175E
JEM248G
SBIA0175E

EM-150
[YD22DDTi]
CAMSHAFT
6. Remove injection tube and fuel injector. Refer toEM-135, "Removal and Installation".
7. Remove secondary timing chain. Refer toEM-158, "
Removal and Installation".
8. Set the No. 1 cylinder at TDC on its compression stroke.
9. Remove the camshaft stroke.
lLoosen the camshaft gear installation bolt by fixing the hexag-
onal portion of the camshaft.
10. Remove the camshaft.
lPlace distinguishing marks on the right and left sides with
paint.
lLoosen and remove the installation bolt in reverse order
shown in the figure.
11. Remove the adjusting shim and valve lifter.
lRemove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
INSPECTION AFTER REMOVAL
Visual Check of Camshaft
lCheck the camshaft for one sided wear or scratches.
lReplace the camshaft if there are abnormalities.
Camshaft Runout
lPrepare V-block on a flat surface and secure camshaft journals
No. 1 and No. 5.
lSet the dial gauge vertically on journal No. 3.
lRotate camshaft in one direction by hand, then read needle
movement on dial indicator. (Total indicator reading)
Height of Cam Nose
Measure by using a micrometer.
JEM159G
JEM160G
Limit : 0.04 mm (0.0016 in)
JEM161G
Standard:
Intake : 39.505 - 39.695 mm (1.5553 - 1.5628 in
Exhaust : 39.905 - 40.095 mm (1.5711 - 1.5785 in)
SEM549A