check engine NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-195
[YD22DDTi]
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EM
12. Install connecting rod bearings to connecting rods and caps.
lWhile installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces,
but clean them completely.
lAlign stoppers on connecting rod bearings with connecting
rod stopper notches to install connecting rod bearings.
13. Install piston and connecting rod assembly to crankshaft.
lMove crankshaft pin to be assembled to BDC.
lAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
lUsing piston ring compressor, install piston and connecting
rod assembly with front mark on piston crown facing toward
the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.
14. Install connecting rod caps and mounting nuts.
lAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
lMake sure that the front mark on connecting rod cap faces
towards the front of the engine.
15. Tighten connecting rod nuts according to the following proce-
dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N·m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120°to 125°[target: 120°]. (angular tightening)
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening nuts, check that crankshaft rotates smoothly.
JEM229G
JEM230G
JEM227G
JEM231G

EM-196
[YD22DDTi]
CYLINDER BLOCK
lCheck connecting rod side clearance. Refer toEM-200,
"CONNECTING ROD SIDE CLEARANCE".
16. Force fit rear oil seal into rear oil seal retainer.
lUsing a drift [105 mm (4.13 in) dia.], force fit so that the
dimension is as specified in the figure.
lAvoid inclined fitting. Force fit perpendicularly.
17. Install rear oil seal and retainer assembly.
lApply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
18. Press fit pilot bushing into flywheel.
lUsing drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
19. Install fuel supplypump bracket.
lAlign the bracket with the dowel pins on the block to install.
lThe two bolts used for dowel pins have a longer shanks than
the other two.
20. Install parts to the engine in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of
assembly.
22. Install flywheel.
lHolding ring gear with ring stopper (SST), tighten securing
bolts with TORX bit (size: Q6T55 E9, Commercial Service
Tool).
lTighten bolts uniformly in a crisscross manner.
JEM232G
JEM233G
JEM234G
SBIA0200E

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTION
A
EX
EXHAUST SYSTEM
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2
Removal and Installation .......................................... 2
QR20DE ................................................................ 2
YD22DDTI ............................................................. 3RREMOVAL ........................................................... 3
INSTALLATION ..................................................... 3
Inspection After Installation ...................................... 4
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5
Tightening Torque ..................................................... 5

EX-2
EXHAUST SYSTEM
EXHAUST SYSTEM
PFP:20100
Checking Exhaust SystemEBS00AZ6
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
Removal and InstallationEBS003DN
CAUTION:
lBe sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
lPerform the operation with the exhaust system fully cooled down because the system will be hot
just after the engine stops.
lBe careful not to cut your hand on the insulator edge.
QR20DE
SMA211A
KBIA0291E
1 Main muffler 2 Mounting rubber 3 Spring
4 Gasket 5 Three way catalyst 6 Exhaust front tube
7 Seal bearing 8 Mounting rubber bracket 9 Mounting bracket
10 Exhaust center tube

EX-4
EXHAUST SYSTEM
Front exhaust side (QR20DE):
lInsert the seal bearing in the direction shown in the figure.
CAUTION:
Tighten the mounting bolt without causing interference with
the flange.
Main muffler side (QR20DE and YD22DDTi):
1. Insert the seal bearing in the direction shown in the figure.
2. Tighten the mounting bolt with the big end of the spring facing
the flange.
CAUTION:
Tighten the mounting bolt without causing interference with
the flange.
Inspection After InstallationEBS003DO
lWith the engine running, check exhaust tube joints for gas leakage and unusual noise.
KBIA0299E
SBIA0147E

FAX-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
CautionEDS0005P
Observe the following precautions when disassembling and servicing drive shaft.
lThe wheel joint cannot be disassembled. Do not attempt to disassemble it.
lPerform work in a location which is as dust-free and dirt-free as possible.
lBefore disassembling and servicing, clean the outside of parts.
lThe disassembly and service location must be clean. Care must be taken to prevent parts from becoming
dirty and to prevent the entry of foreign objects.
lDisassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
lPaper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
lDisassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.
Precautions for Brake SystemEDS0 00 I0
lWhen installing rubber parts, final tightening must be carried out
under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
lUse flare nut wrench when removing or installing brake tubes.
lAfter installing removed suspension parts, check wheel align-
ment and adjust if necessary.
lAlways torque brake lines when installing.
SBR686C

FAX-12
FRONT DRIVE SHAFT
lDo not allow drive shaft, with transaxle inserted, to hang down without support for counter
shaft, wheel joints, and other parts.
lWhen the drive shafts listed below have been removed, check that a circular clip is attached to the end.
lRemove installation bolt from right-side drive shaft support bearing bracket. Then remove bracket from
engine.
lRemove installation bolt from right-side drive shaft and remove drive shaft from side shaft.
INSPECTION AFTER REMOVAL
lMove joint in up/down, left/right, and axial directions. Check for
motion that is not smooth and for significant looseness.
lCheck for cracking and damage of boots, and for grease leak-
age.
INSTALLATION
lInstall support bearing bracket onto engine and tighten installation bolts to specified torque.
lInstall drive shaft to side shaft and tighten installation bolts to specified torque.
1. In order to prevent damage to differential side oil seal, first fit a
protector onto oil seal before inserting drive shaft. Slide drive
shaft slide joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circular clip is securely fastened.
2. Insert drive shaft into steering knuckle. Install washers and tem-
porarily tighten lock nuts.
3. Install installation bolt for steering knuckle and strut.
4. Use lock plate to fix brake hose to strut.
5. Install tie rod to steering knuckle.
6. Install ABS wheel speed sensor.
7. Tighten lock nuts to specified torque.
8. Install cotter pin.
CAUTION:
Discard the old cotter pin; replace with a new one.
Engine typeDrive shaft with circular clip
Right Left
QR20DE —m
YD22ET —m
RAA0030D
Model type Protector SST No.
RH KV38107800
LH KV38105500
SDIA0593E
SDIA0603E

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION
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FL
FUEL SYSTEM
QR20DE
PREPARATION ........................................................... 2
Commercial Service Tool ......................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6
INSPECTION AFTER INSTALLATION ................. 7
Disassembly and Assembly ..................................... 7
DISASSEMBLY ..................................................... 7
ASSEMBLY ........................................................... 8
FUEL TANK ................................................................ 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 10
Inspection After Installation .....................................11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12
Standard and Limit ................................................. 12
Tightening Torque ................................................... 12
YD22DDTi
PREPARATION ......................................................... 13
Commercial Service Tool ........................................ 13
FUEL SYSTEM ......................................................... 14
Checking Fuel Lines ............................................... 14
General Precautions ............................................... 14
FUEL FILTER ............................................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Air Bleeding ............................................................ 16
Draining Water ........................................................ 16
FUEL LEVEL SENSOR UNIT ................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
FUEL TANK .............................................................. 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 22
Inspection After Installation .................................... 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23
Standard and Limit .................................................. 23
Tightening Torque ................................................... 23

FUEL SYSTEM
FL-3
[QR20DE]
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS00BKP
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
General PrecautionsEBS00BKQ
WA RN ING:
when replacing fuel line parts, be sure to observe the following.
lPut a “ CAUTION: FLAMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system, keep open flames and spark away from work area.
CAUTION:
lBefore removing fuel line parts, carry out the following procedures.
–a) Put drained fuel in an explosion-proof container and put the lid on securely, keep the container
in safe area.
–b) Release fuel pressure from fuel line, Refer toEC-34, "Fuel Pressure Check",EC-399, "Fuel
Pressure Check".
–c) Disconnect battery ground cable.
lAlways replace O-ring and clamps with new ones.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lDo not kink or twist tubes when they are being installed.
lAfter installing tubes, run engine and check for fuel leaks at connections.
SMA803A

FL-8
[QR20DE]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
2. Disconnect fuel pump harness connector.
3. Separate the fuel filter and fuel level sensor unit.
a. Fit a used O-ring into space between fuel level sensor unit and
fuel filter. Undo catches and separate fuel level sensor unit and
fuel filter.
lFor reference when reassembling, put a mating mark on outer
edges of fuel level sensor unit and fuel filter with some means
which cannot be erased by fuel.
b. Insert blade end screwdriver to the gap between the fuel filter
and fuel level sensor unit to separate them.
CAUTION:
Put cloth or similar one on the edge of screwdriver not to
damage the inserted portion.
4. Remove pressure regulator from fuel filter.
a. Open and remove the clip.
b. Pull the pressure regulator straight out during removal.
CAUTION:
lAvoid impacts such as falling during removal.
lDo not disassemble or adjust.
ASSEMBLY
Install in the reverse order of removal paying attention to the following.
lInstall the fuel filter and fuel pump with the tabs aligned, Make sure a click sound of secure engagement
is heard.
lSecurely connect the harness connector of the fuel pump.
lInstall the pressure regulator O-ring as follows.
CAUTION:
lWhen replacing, always use a new O-ring.
lHandle it with bare hands. (Do not use gloves.)
lVisually check the O-ring, mounting parts and mating parts for foreign materials and flaws.
lBefore installing, apply new engine oil.
lTo avid damage, do not apply an excessive force (pulling or starching).
lInstall the pressure regulator as follows.
1. Insert the clip to the groove of the regulator.
2. With the clip installed, insert the regulator straight by matching
the fuel filter protrusion and the clip notch.
3. Make sure that the fuel filter protrusion and clip notch are
securely engaged.
PBIC0243E
PBIC0244E
PBIC0245E