engine NISSAN X-TRAIL 2003 Electronic Repair Manual

EM-116
[YD22DDTi]
INTAKE MANIFOLD
8. Remove EGR tube.
9. Remove vacuum hose.
10. Remove injection tube. Refer toEM-135, "
Removal and Installa-
tion".
11. Remove water pipe.
12. Remove fuel hose.
lTo prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
13. Loosen bolts and nuts in the reverse order of that shown in the
figure.
CAUTION:
Do not disassemble or adjust swirl control valve.
14. Remove electronic EGR control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
lConnect vacuum handy pump to actuator, and apply vacuum to close swirl control valve.
lCheck distortion on the mounting surface with a straightedge
and feeler gauge.
Swirl Control Valve
lConnect vacuum handy pump to actuator, confirm that rod
moves smoothly in accordance with the amount of vacuum
applied and vacuum is maintained.
INSTALLATION
Following instructions below, install in reverse order of removal.
1. Install EGR vacuum control valve.
lHandle with care avoiding any shocks.
SBIA0152E
SBIA0153E
Limit : 0.1 mm (0.004 in)
SBIA0154E
Vacuum reference value (Approx.)
At start of rod movement
: – 8.0 Kpa (– 80 mbar, – 60 mmHg, – 2.36 inHg)
At end of rod movementApprox.
: –26.7Kpa(–267bar,–200mmHg,–7.87inHg)
SBIA0155E

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-118
[YD22DDTi]
CATALYST
CATALYST
PFP:20905
Removal and InstallationEBS00BOA
REMOVAL
1. Remove engine under cover.
2. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
3. Remove radiator upper hose.
4. Remove radiator fan. Refer toCO-33, "
Removal and Installation".
5. Remove radiator mount bracket and radiator.
6. Remove water inlet pipe.
7. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
8. Remove catalyst.
CAUTION:
Do not disassemble.
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
INSTALLATION
Install in reverse order of removal.
lPushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
SBIA0157E
1. Insulator 2. Catalyst 3. Catalyst rear diffuser
4. Gasket
Catalyst locking pin : Flange bolt (black)
Insulator mounting bolt : Washer bolt (silver or yellow)

EXHAUST MANIFOLD AND TURBOCHARGER
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00BOB
REMOVAL
1. Drain engine coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove charge air cooler. Refer toEM-114, "
Removal and Installation".
3. Remove air duct and air inlet pipe. Refer toEM-112, "
Removal and Installation".
4. Remove engine under cover.
5. Remove radiator upper hose.
6. Remove radiator fan. Refer toCO-34, "
Disassembly and Assembly Radiator Fan".
7. Remove radiator mount bracket and radiator. Refer toCO-33, "
Removal and Installation".
8. Remove water inlet pipe.
9. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
10. Remove catalyst. Refer toEM-118, "
Removal and Installation".
11. Remove exhaust manifold cover.
12. Remove insulator.
13. Each wiring and piping (disconnect/move)
SBIA0158E
1. Electronic EGR control valve 2. Gasket 3. EGR tube
4. Air inlet pipe 5.Exhaust manifold & turbocharger
assembly6. Oil return hose
7. Turbo insulator 8. Exhaust manifold insulator 9. Air inlet pipe

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
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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
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OIL PAN AND OIL STRAINERP F P : 1111 0
Removal and InstallationEBS00BO1
REMOVAL
WA RN ING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove engine under cover at both side.
2. Drain engine oil. Refer toLU-19, "
Changing Engine Oil".
3. Remove lower oil pan bolts, Loosen bolts in the reverse order of
that shown in the figure.
SBIA0160E
1. Rear plate cover 2. Oil pan upper 3. Oil strainer
4. Drain plug 5. Oil pan lower
SBIA0161E

EM-126
[YD22DDTi]
OIL PAN AND OIL STRAINER
4. Remove lower oil pan.
a. Insert Tool between upper oil pan and lower oil pan.
lBe careful not to damage aluminum mating surface.
lDo not insert screwdriver, or oil pan flange will be
deformed.
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove lower oil pan.
5. Remove drive belts.
6. Remove A/C compressor and bracket.
7. Remove front exhaust tube and its support.
8. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger. Refer toEM-184, "
Removal and
Installation".
9. Remove center member.
10. Remove rear plate cover and four engine-to transaxle bolts.
11. Remove catalyst and rear diffuser. Refer toEM-118, "
Removal
and Installation".
12. Loosen bolts in reverse order of illustration to remove upper oil
pan.
SEM544G
SEM545G
JEM553G
SBIA0162E

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
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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)