secure NISSAN X-TRAIL 2003 Electronic Workshop Manual

EM-62
[QR20DE]
ENGINE ASSEMBLY
1. Release fuel pressure. Refer toEC-34, "FUEL PRESSURE RELEASE"(WITH EURO-OBD),EC-399,
"FUEL PRESSURE RELEASE"(WITHOUT EURO-OBD).
2. Remove engine hood.
3. Drain coolant from radiator drain plug.
4. Remove the following parts.
lLH/RH under cover
lLH/RH Front wheel
lBattery
lAuxiliary drive belt; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt Auto- tensioner".
lAir duct and air cleaner case assembly; Refer toEM-15, "Removal and Installation".
lAlternator
lRadiator and radiator fan assembly; Refer toCO-12, "RADIATOR".
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
7. Disconnect fuel hose, and plug it to prevent fuel from draining. Refer toEM-17, "
INTAKE MANIFOLD"
8. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
9. Disconnect select cable from transaxle (A/T models).
10. Remove clutch operating cylinder from transaxle, and move it aside (M/T models).
11. Disconnect shift cable from transaxle (M/T models).
Engine room RH
12. Remove engine coolant reservoir tank.
13. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
14. Remove exhaust front tube.
15. Remove propeller shaft.
16. Remove steering shaft from steering gear.
17. Disconnect power steering fluid cooler piping at a point between body and engine.
18. Remove ABS sensor from brake caliper.
19. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
20. Remove LH/RH suspension from steering knuckle under strut.
Removal
21. Install engine slingers into front left of cylinder head and rear right of cylinder head.
lUse alternator bracket mounting bolt holes for the frontside.
22. Lift with hoist and secure the engine in position.Slinger bolts:
Front: 51.0 - 64.7 N·m (5.2 - 6.6 kg-m, 38 - 47 ft-lb)
Rear: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
KBIA0255E

ENGINE ASSEMBLY
EM-63
[QR20DE]
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lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
lPut a piece of wood or something similar as the support-
ing surface, secure a completely stable condition.
23. Remove RH engine mounting insulator.
24. Pull LH engine mounting through-bolt out.
25. Remove mounting bolts at front end of center member.
26. Remove front suspension member mounting bolts and nuts.
27. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
28. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
29. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
30. Remove starter motor.
31. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
lBleed air from passages in pipes and tubes of applicable lines.
KBIA0256E
KBIA0257E
KBIA0270E

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

EM-136
[YD22DDTi]
INJECTION TUBE AND FUEL INJECTOR
5. Remove nozzle oil seal.
lUsing a slotted screwdriver, pry flange to remove oil seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.
6. Remove rocker cover. Refer toEM-147, "
Removal and Installa-
tion".
7. Remove spill tube mounting bolts and nut.
lLoosen bolts and nut to the reverse order of the shown in the
figure and remove then.
8. Following steps below, remove fuel injector.
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION:
lHandle fuel injector carefully without giving any impact.
lDo not disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a
slotted screwdriver and pull it out.
INSTALLATION
1. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Secure it with support.
SBIA0176E
SBIA0205E
SBIA0204E

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

CAMSHAFT
EM-153
[YD22DDTi]
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INSTALLATION
1. Install the valve lifter and adjusting shim.
lMake sure that these are installed in the same position as before the removal process.
2. Install the camshaft.
lIdentify camshafts by the paint position and screw hole at the
rear end.
lInstall so that knock pins are positioned in the directions
showninthefigure.
3. Install camshaft brackets.
lInstall correctly, identifying brackets by the journal No. and
front mark on top surface.
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N·m (0.2 kg-m, 17 in-lb).
lMake sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N·m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N·m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
lCamshaft sprockets are commonly used for RH and LH.
lAlign camshaft sprocket and dowel pin on camshaft, and
install.
lHolding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
toEM-154, "
Va l v e C le a r a n c e".
7. Hereafter, install in the reverse order of removal.Camshaft RH : Paint is at position A without screw hole.
Camshaft LH : Paint is at position B with screw hole.
JEM173G
SEM516G
JEM175G
JEM160G

EM-156
[YD22DDTi]
CAMSHAFT
5. With the valve spring in a compressed state, remove the cam-
shaft pliers by securely setting the outer circumference of the
valve lifter with the end of the lifter stopper.
lHold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the cam-
shaft will be damaged.
6. Move the rounded hole of the adjusting shim to the front with a
very thin screwdriver or like that.
lWhen the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 to release the end of the lifter
stopper from touching the adjusting shim.
7. Remove the adjusting shim from the valve lifter by blowing air
through the rounded hole of the shim with an air gun.
CAUTION:
To prevent any remaining oil from being blown around,
thoroughly wipe the area clean and wear protective gog-
gles.
8. Remove the adjusting shim by using a magnetic hand.
9. Measure the thickness of the adjusting shim using a micrometer.
lMeasure near the center of the shim (the part that touches the
camshaft).
10. Select the new adjusting shim from the following methods.
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SBIA0187E
Calculation method of the adjusting shim thickness:
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0010 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
FEM032

ENGINE ASSEMBLY
EM-185
[YD22DDTi]
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1. Remove engine hood.
2. Drain coolant from radiator drain plug.
3. Remove the following parts.
lLH/RH under cover
lLH/RH front wheel
lBattery
lAuxiliary drive belt; Refer toE M - 111 , "Removal and Installation".
lAir duct and air cleaner case assembly; Refer toEM-112, "Removal and Installation".
lAlternator
lRadiator and radiator fan assembly; Refer toCO-33, "Removal and Installation".
lCharge air cooler
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
6. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
7. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
8. Remove clutch operating cylinder from transaxle, and move it aside.
9. Disconnect shift cable from transaxle.
Engine room RH
10. Remove engine coolant reservoir tank.
11. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
12. Remove exhaust front tube.
13. Remove propeller shaft.
14. Remove steering shaft from steering gear.
15. Disconnect power steering fluid cooler piping at a point between body and engine.
16. Remove ABS sensor from brake caliper.
17. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
18. Remove LH/RH suspension from steering knuckle under strut.
Removal
19. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
20. Liftwithhoistandsecuretheengineinposition.Slinger bolts:
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
SBIA0191E

EM-186
[YD22DDTi]
ENGINE ASSEMBLY
lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
21. Remove RH engine mounting insulator.
22. Pull LH engine mounting through-bolt out.
23. Remove mounting bolts at front end of center member.
24. Remove front suspension member mounting bolts and nuts.
25. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
26. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
27. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
28. Remove starter motor.
29. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lBefore starting engine, bleed air from fuel piping. Refer toFL-16, "Air Bleeding".
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
KBIA0256E
KBIA0257E
KBIA0270E

CYLINDER BLOCK
EM-189
[YD22DDTi]
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CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove engine assembly from the vehicle, then separate engine and transaxle. Refer toEM-184,
"ENGINE ASSEMBLY".
2. Remove clutch cover and disk. Refer toCL-15, "
CLUTCH DISC,
CLUTCH COVER AND FLYWHEEL".
3. If they need to be replaced, replace pilot bushing.
lUsing pilot bushing puller, remove the bushing from rear edge
of crankshaft.
4. Install engine to engine stand as follows.
a. Remove flywheel.
b. Secure ring gear with ring gear stopper, then loosen mounting
bolts with TORX bit (size: Q6T55 E9, Commercial Service Tools)
and remove them. As an alternative method hold the crankshaft
pulley with a pulley holder (SST) to remove the flywheel.
CAUTION:
Do not disassemble flywheel.
c. Install engine sub-attachment to the rear side of cylinder block.
lAlign knock pins on cylinder block with pin holes on attach-
ment to install.
NOTE:
Installation bolts are part of engine sub-attachment.
d. Install engine attachment.
NOTE:
Use commercially available M12 (0.47 in) mounting bolts and
nuts (4 sets) with strength grade of 9T (minimum).
1. Rear oil seal retainer 2. Oil pressure switch 3. Coppet washer
4. Oil jet relief valve 5. Cylinder block 6. Top ring
7. Second ring 8. Oil ring 9. Oil jet
10. Piston pin 11. Snap ring 12. Piston
13. Main bearing 14. Thrust bearing 15. Connecting rod
16. Key 17. Connecting rod bearing 18. Connecting rod cap
19. Connecting rod nut 20. Main bearing 21. Crankshaft
22. Main bearing cap 23. Pilot bush 24. Flywheel
25. Drain plug 26. Rear oil seal
SEM500G
SBIA0199E
JEM192G