engine NISSAN X-TRAIL 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-71
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9. Restart tightening of lower cylinder block bolts with the following
procedure.
NOTE:
Step “a ”and “b” have been completed before installation of rear
oil seal (step 7).
a. Step “a” has been completed before installation of rear oil seal.
b. Step “b” has been completed before installation of rear oil seal.
c. Tighten M10 bolts to 60 to 65°(target: 60°) in order from 1to 10.
d. Tighten M8 ( in) bolts to 19.6 to 24.5 N·m (2.0 to 2.5 kg-m, 15 to
18 ft-lb) in order from 11 to 22.
CAUTION:
In step “c”, use an angle wrench (special service tool) or
protractor to check tightening angle. Do not make judgment
by visual inspection.
lAfter installing mounting bolts, make sure that crankshaft
can be rotated smoothly by hand.
lWipe off completely any protruding liquid gasket on front side
of engine.
lCheck crankshaft side clearance. Refer toEM-80, "CRANK-
SHAFT SIDE CLEARANCE".
10. Install the piston to the connecting rod.
a. Usingasnapringpliers,installthesnapringtothegroovesof
the piston rear side.
lInsert it fully into groove to install.
b. Install the piston to the connecting rod.
lUsing an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 C°(140 to 158°F)]. From the front to the rear, insert the piston
pin into the piston and the connecting rod.
lAssemble so that the front mark on the piston crown and the
oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown in the figure.
c. Install the snap rings to the front of the piston.
lAfter installing, check that the connecting rod moves
smoothly.
11. Using a piston ring expander, install the piston rings.
CAUTION:
Be careful not to damage the piston.
lPosition each ring with the gap as shown in the figure refer-
ring to the piston front mark.
lInstall the top ring and the second ring with the stamped sur-
face facing upward.
KBIA0063E
KBIA0065E
PBIC0099E
Stamped mark : 1E (top ring)
: 2A (second ring)
PBIC0100E

EM-72
[QR20DE]
CYLINDER BLOCK
12. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
lWhen installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
lWhen installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
lCheck the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft.
lPosition the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
lApply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
lMatch the cylinder position with the cylinder No. on the con-
necting rod to install.
lUsing a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.
14. Install the connecting rod cap.
lMatch the stamped cylinder number marks on the connecting
rodwiththoseonthecaptoinstall.
15. Tighten the connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of the connecting rod
bolts.
b. Tighten bolts to 18.6 to 20.6 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
c. Put mating (with paint) on each bolt and connecting rod cap, all
in the same direction (when using a protractor).
d. Then tighten all bolts 90 to 95 degrees clockwise (target: 90
degrees) (Angle tightening).
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.
lAfter tightening the bolt, make sure that the crankshaft rotates smoothly.
lCheck the connecting rod side clearance. Refer toEM-81, "CONNECTING ROD SIDE CLEARANCE".
PBIC0266E
PBIC0267E
KBIA0067E
KBIA0068E

CYLINDER BLOCK
EM-85
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INNER DIAMETER OF MAIN BEARING HOUSING
lInstall the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
lUsing a bore gauge, measure the inner diameter of the main
bearing housing.
lIf out of the standard, replace the cylinder block and lower cylin-
der block assembly.
NOTE:
These components cannot be replaced as a single unit because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
lUsing a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C)(Y is in longitudinal direction of engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at B
position.
lIf the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or rebore the inner wall.
lAn oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance
of the piston cylinder satisfies the standard.
OuterDiameterofPiston
lMeasure piston skirt diameter.Standard : 58.944 - 58.967 mm (2.3206 - 2.3215 in)
PBIC0269E
KBIA0151E
Standard inner diameter:
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)
Over size (OS) : 0.2 mm (0.008 in)
Standard : 88.980 - 89.010 mm (3.5031 - 3.5043 in)
PBIC0125E

EM-102
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Drain CoolantEBS00BNO
lDrain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00BNP
lBefore starting work, make sure no fire or spark producing items are in the work area.
lRelease fuel pressure before disassembly.
lAfter disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00BNQ
lWhen instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
lExercise maximum care to avoid damage to mating or sliding surfaces.
lCover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
lMark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
lWhen loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00BNR
lBefore repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS00BNS
lUse torque wrench to tighten bolts or nuts.
lWhen tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
lReplace with new gasket, packing, oil seal or O-ring.
lThoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
lAvoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
lRelease air within route after draining coolant.
lAfter repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular TighteningEBS00BNT
lUse an angle wrench for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
lDo not use a torque value for final tightening.
lThe torque value for these parts are for a preliminary step.
lEnsure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS
EM-103
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Precautions for Liquid GasketEBS00BNU
REMOVAL OF LIQUID GASKET SEALING
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing 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 areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
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 text of 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
SEM159F

EM-104
[YD22DDTi]
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEBS00BNV
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV11105900
Engine sub-attachmentUsed with KV10106500
KV10115600
Valve oil seal driftInstalling valve oil seal
UsesideA.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV11103000
Injection pump drive gear pullerRemoving crankshaft pulley
NT042
NT028
NT799
NT603
NT605
NT676

EM-108
[YD22DDTi]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting —Engine NoiseEBS00BO5
SBIA0148E

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
EM-109
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Use the Chart Below to Help You Find the Cause of the Symptom.EBS00BO6
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTick in g o r
clickingCA—AB—Tappet
noiseValve clearanceEM-154
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-151EM-150
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearance (Small
end)EM-201
EM-203
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-204EM-201
EM-202
EM-202
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance (Small
end)
Connecting rod bear-
ing oil clearance (Big
end)EM-203EM-206
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-206EM-206
Front of
engine
Timin g
chain
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-158
EM-163
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-110
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-40,
"WATER
PUMP"

EM-110
[YD22DDTi]
DRIVE BELTS
DRIVE BELTS
PFP:02117
Checking Drive BeltsEBS00BNX
lBefore inspecting the engine, make sure the engine has cooled
down; wait approximately 30 minutes after the engine has been
stopped.
lVisually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.
lWhen measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
lWhen checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing the crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
lTighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00BNY
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the value specified under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with oil or cooling water etc.
lDo not twist or bend the belts with strong force.
JEM249G
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
Air conditioner compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator

INTAKE MANIFOLD
EM-115
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INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00BO9
REMOVAL
WA RN ING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
2. Remove air duct. Refer toEM-112, "
Removal and Installation".
3. Remove charge air cooler and bracket. Refer toEM-114, "
Removal and Installation".
4. Remove air inlet pipes. Refer toEM-119, "
Removal and Installation"
5. Remove exhaust manifold cover.
6. Disconnect electronic EGR control valve water hoses and harness.
7. Disconnect heater hose.
SBIA0151E
1. Vacuum & fuel gallery 2. Water hose 3. Electronic EGR volume control valve
4. Gasket 5. EGR passage 6. EGR support
7. Water pipe 8. EGR tube 9. Intake manifold