engine NISSAN X-TRAIL 2003 Electronic Repair Manual

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

EM-190
[YD22DDTi]
CYLINDER BLOCK
e. Hoist engine and install it to the engine stand.
NOTE:
It is possible to set engine sub-attachment and engine attach-
ment to engine stand at first, then install engine later.
lCommercial engine stand can be used.
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
5. Drain engine oil and coolant from inside engine.
6. Remove the following parts and related parts. (Only major parts are listed.)
lIntake manifold collector and intake manifold (Refer toEM-115, "Removal and Installation".)
lExhaust manifold (Refer toEM-119, "Removal and Installation".)
lRocker cover (Refer toEM-147, "Removal and Installation").
lInjection tube and fuel injector (Refer toEM-135, "Removal and Installation".)
lOil pan and oil strainer (Refer toEM-125, "Removal and Installation".)
lWater pump (Refer toCO-40, "Removal and Installation".)
lThermostat and water piping (Refer toCO-42, "Removal and Installation".)
lVacuum pump and vacuum pipe (Refer toEM-131, "Removal and Installation".)
lSecondary timing chain (Refer toEM-158, "Removal and Installation")
lPrimary timing chain (Refer toEM-163, "Removal and Installation".)
lElectronic control fuel supply pump (Refer toEM-138, "Removal and Installation".)
lCamshaft (Refer toEM-149, "Removal and Installation".)
lCylinder head (Refer toEM-174, "Removal and Installation".)
lOil cooler (Refer toLU-25, "Removal and Installation".)
lAccessory, accessory bracket and mount brackets
7. Remove fuel supply pump bracket.
8. Remove rear oil seal retainer.
JEM193G
PBIC0085E

CYLINDER BLOCK
EM-193
[YD22DDTi]
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ASSEMBLY
1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase and cylinder bore to remove foreign matter.
2. Install oil jet relief valve.
3. Install oil jet.
lAlign knock pin on back of oil jet with hole on block when
installing oil jet.
4. Install main bearings and thrust bearings.
a. Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
lInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
c. Being careful with the direction, install main bearings.
lInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
lWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them
completely.
lAlign stopper notches on bearings to install them.
lCheck that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
5. Install crankshaft to cylinder block.
lMake sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
lIdentify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
lMain bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
7. Check the main bearing cap bolts for deformation.
Refer toEM-207, "
MAIN BEARING CAP BOLT DEFORMA-
TION".
PBIC0389E
JEM224G
JEM213G
JEM225G

EM-194
[YD22DDTi]
CYLINDER BLOCK
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90°to 95°[target: 90°].
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
lCheck crankshaft end side clearance. Refer toEM-200,
"CRANKSHAFT SIDE CLEARANCE".
9. Check the outer diameter of connecting rod bolts. Refer toEM-
207, "CONNECTING ROD BOLT DEFORMATION".
10. Install pistons to connecting rod.
a. Using long nose pliers, install snap rings to grooves on piston rear side.
lFit snap rings correctly into grooves.
b. Install pistons to connecting rods.
lUsing industrial dryer, heat pistons up to approx. 60 to 70°C(140to158°F) until piston pin can be
pressed down by finger touch. Then insert piston pins into piston and connecting rod from front side of
piston toward rear.
lAssemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being
positioned as shown in the figure.
c. Install snap rings to front side of pistons.
lRefertoabovestepaforprecautiononsnapringinstallation.
lAfter installation, check connecting rods for smooth move-
ment.
11. Use piston ring expander to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
lInstall top ring and second ring with stamped surfaces facing
upward.
lInstall rings so that three closed gap position 120°apart one
another.
lClosed gaps do not need to face in a specific directions, as long as each are positioned 120°apart.
JEM200G
JEM226G
JEM227G
Identification stamp:
To p r i n g : A E
Second ring : AE2
JEM228G

CYLINDER BLOCK
EM-195
[YD22DDTi]
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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

EM-210
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00BPO
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
Unit: mm (in)
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3(cu in)2,184 (133.27)
Bore and stroke Unit: mm (in) 86 x 94 (3.39 x 3.70)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.0
Compression pressure
Unit:kPa(bar,kg/cm
2,psi)/200rpmStandard 2,893 (28.9, 29.5, 419)
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
224 212 2 30 -2 46
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied*
New Adjusted Limit for re-adjusting
Air conditioner compressor
belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator & water pump
belt9.0 - 10.5
(0.354 - 0.413)11 . 0 - 1 2 . 5
(0.433 - 0.492)16.5 (0.650)

EM-220
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
M8 bolt 16.0- 19.0 (1.6 - 1.9, 12 - 14)
Injection tube Nozzle side 21.6 - 24.5 (2.2 - 2.5, 16 - 18)
Pump side 26.5 - 29.4 (2.7 - 3.0, 20 - 21)
Nozzle support25.1 - 28.0 (2.6 - 2.8, 19 - 20)
Spill tube Nozzle side 14.7 - 16.7 (1.5 - 1.7, 11 - 12)
Cylinder head side 16.7 - 20.6 (1.7 - 2.1, 13 - 15)
Common rail51.0 - 64.0 (5.2 - 6.5., 38 - 47)
Fuel supply pump46.0 - 56.0 (4.57 - 5.7, 37 - 41)
Fuel supply pump sprocket 37.0 - 41.0 (3.8 - 4.2, 28 - 30)
Fuel supply pump rear bracket 27.0 - 37.0 (2.8 - 3.8, 20 - 27)
Front chain case
6.9 - 8.8 ( 0.7 - 0.9, 61 - 78)*
2
Chain tensioner
8.5 - 10.7 (0.86 - 1.1, 75 - 95)*2
Tensior guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Slack guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Camshaft sprocket138- 147 (14.0 - 15.0, 102 - 108)
Fuel supply pump sprocket 38.0 -41.0 (3.8 - 4.2, 28 - 30)
Oil pump12 - 13 (1.3 - 1.4, 9 - 10)
Power steering pump51.0 - 56.0 (5.2 - 5.8, 38 - 41)
Rear chain case12.0 - 13.0 (1.2 - 1.4, 19 - 10)
Engine coolant temperature sensor 12.0- 15.0 (1.2 - 1.6, 9- 11)
*1 Cylinder head 1) 29 - 38 (2.9 - 3.9, 21 - 28)
2) 180°to185°
3) 0 (0, 0)
4) 35 to 44 (3.5 - 4.5, 26 - 32)
5) 90°to 95°(angle tightening)
6) 90°to 95°(angle tightening)
Water outlet21 - 28 (2.1 - 2.9, 16 - 20)
Glow plug18.0 - 2.0 (1.8 - 2.2, 13 - 15)
*1 Flywheel103 - 112 (10.5 - 115, 76 - 83)
Oil pressure switch13.0 - 17.0 (1.25 - 1.75, 9 - 12)
Oil jet6.1 - 10.7(0.62 - 1.1, 54 - 95)
Oil jet relief valve40 - 58 (4.0 - 6.0, 29 - 43)
Rear oil seal retainer12.0 - 13.0 (1.2 - 1.4, 9 - 10)

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