alternator belt NISSAN X-TRAIL 2003 Electronic Repair Manual

REFRIGERANT LINES
ATC-127
C
D
E
F
G
H
I
K
L
MA
B
AT C
With Diesel Engine
1. Using recycling and recovery equipment (for HFC-134a), discharge the refrigerant.
2. Remove the engine under cover.
3. Remove the compressor-alternator belt.
Refer to,EM-13, "
Removal and Installation"QR engine;E M - 111 , "Removal and Installation"YD engine.
4. Remove the mounting nuts (bolts) from the high-pressure flexi-
ble hose and low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Disconnect the compressor connector.
RHA667H
RJIA0073E
RJIA0579E

WATER PUMP
CO-19
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
CO
WATER P UM PPFP:21020
Removal and InstallationEBS009SJ
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Water Pump Removal
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
2. Remove the following parts.
lEngine under cover
lAlternator, water pump and air compressor belt
Refer to drive beltEM-13, "
Removal and Installation".
3. Remove water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
Water Pump Housing Removal
1. Perform step 1 and 2 of “Water Pump Removal”.
2. Remove alternator.
3. Remove oil level gauge.
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
4. Remove bolts mounting water pipe.
5. Remove water pump housing.
Water Pipe Removal
1. Remove water pump housing.
KBIA0154E
1 Water pump 2 Gasket 3 Water pump housing
4 Water pipe

EM-3
C
D
E
F
G
H
I
J
K
L
M
EMA ALTERNATOR AND WATER PUMP BELT ....... . 111
Removal and Installation ...................................... . 111
REMOVAL ......................................................... . 111
INSTALLATION ................................................. . 111
AIR CLEANER AND AIR DUCT .............................. 112
Removal and Installation ....................................... 112
REMOVAL .......................................................... 112
INSTALLATION .................................................. 112
CHANGING AIR CLEANER ELEMENT ............. 112
CHARGE AIR COOLER .......................................... 114
Removal and Installation ....................................... 114
REMOVAL .......................................................... 114
INSPECTION AFTER REMOVAL ...................... 114
INSTALLATION .................................................. 114
INTAKE MANIFOLD ................................................ 115
Removal and Installation ....................................... 115
REMOVAL .......................................................... 115
INSPECTION AFTER REMOVAL ...................... 116
INSTALLATION .................................................. 116
INSPECTION AFTER INSTALLATION .............. 117
CATALYST ............................................................... 118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
EXHAUST MANIFOLD AND TURBOCHARGER ... 119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION ................................................. 120
INSPECTION AFTER INSTALLATION ............. 120
Disassembly and Assembly ................................. 121
REMOVAL ......................................................... 121
INSPECTION AFTER REMOVAL ..................... 121
Turbocharger ........................................................ 122
ROTOR SHAFT CLEARANCE ......................... 122
ROTOR SHAFT END PLAY .............................. 122
TURBINE WHEEL ............................................. 123
COMPRESSOR WHEEL .................................. 123
WASTEGATE VALVE ACTUATOR ................... 123
TROUBLE DIAGNOSIS OF TURBOCHARGER. 123
OIL PAN AND OIL STRAINER ............................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSPECTION AFTER REMOVAL ..................... 127
INSTALLATION ................................................. 127
INSPECTION AFTER INSTALLATION ............. 129
GLOW PLUG .......................................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130
VACUUM PUMP ..................................................... 131
Removal and Installation ...................................... 131
INSPECTION BEFORE REMOVAL .................. 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
INSPECTION AFTER INSTALLATION ............. 132
Disassembly and Assembly ................................. 133
DISASSEMBLY ................................................. 133
ASSEMBLY ....................................................... 133INJECTION TUBE AND FUEL INJECTOR ............135
Removal and Installation ......................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
INSPECTION AFTER INSTALLATION ..............137
FUEL SUPPLY PUMP .............................................138
Removal and Installation ......................................138
REMOVAL .........................................................138
INSPECTION AFTER REMOVAL .....................143
INSTALLATION .................................................143
ROCKER COVER ...................................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSTALLATION .................................................148
INSPECTION AFTER INSTALLATION ..............148
CAMSHAFT ............................................................149
Removal and Installation ......................................149
REMOVAL .........................................................149
INSPECTION AFTER REMOVAL .....................150
INSTALLATION .................................................153
Valve Clearance ...................................................154
INSPECTION ....................................................154
ADJUSTMENTS ................................................155
SECONDARY TIMING CHAIN ................................158
Removal and Installation ......................................158
REMOVAL .........................................................158
INSPECTION AFTER REMOVAL .....................160
INSTALLATION .................................................161
PRIMARY TIMING CHAIN ......................................163
Removal and Installation ......................................163
REMOVAL .........................................................165
INSPECTION AFTER REMOVAL .....................168
INSTALLATION .................................................168
CYLINDER HEAD ...................................................173
On-Vehicle Service ...............................................173
CHECKING COMPRESSION PRESSURE .......173
Removal and Installation ......................................174
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
Disassembly and Assembly ..................................178
DISASSEMBLY .................................................178
ASEMBLY ..........................................................179
INSPECTION AFTER DISASSEMBLY ..............179
ENGINE ASSEMBLY ..............................................184
Removal and Installation ......................................184
REMOVAL .........................................................184
INSTALLATION .................................................186
INSPECTION AFTER INSTALLATION ..............186
CYLINDER BLOCK ................................................188
Disassembly and Assembly ..................................188
DISASSEMBLY .................................................189
ASSEMBLY .......................................................193
How to Select Piston and Bearing ........................197
DESCRIPTION ..................................................197
HOW TO SELECT PISTON ..............................197
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................198

EM-14
[QR20DE]
DRIVE BELTS
2. Insert a rod approximately 6 mm (0.24in) in diameter through the rear of engine into holding boss to fix
tensioner pulley.
3. Hook auxiliary drive belt onto all pulleys except for water pump. Hook belt onto water pump pulley at the
end.
CAUTION:
Confirm belts are completely set to pulleys.
4. Release tensioner, and apply tensions to belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tensions of belt at indicator is within the allowable use range. Refer toEM-13, "
Checking Drive
Belts".
Removal and Installation of Auxiliary Drive Belt Auto- tensionerEBS009QR
REMOVAL
1. Remove front RH engine side cover.
2. Remove auxiliary drive belt.
lKeep tensioner pulley fixed with a tool such as a short-length screwdriver.
3. Remove alternator and then auxiliary drive belt auto-tensioner.
lRemove and install auxiliary drive belt auto-tensioner by fixing tension pulley.
INSTALLATION
lInstall in the reverse order of removal.
CAUTION:
Install auxiliary drive belt auto-tensioner carefully not to damage the water pump pulley.
KBIA0092E

EM-44
[QR20DE]
TIMING CHAIN
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove the parts listed below.
lEngine hood
lUndercover
lPCV hose
lIgnition coil; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lEngine coolant reservoir tank
lAuxiliary drive belt; Refer toEM-13, "Removal and Installation".
lAlternator
lAuxiliary drive belt auto-tensioner; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt
Auto- tensioner".
lExhaust front tube; Refer toEX-2, "EXHAUST SYSTEM".
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Move power steering pump with piping connected, and secure it to vehicle side temporarily.
5. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
lTo avoid power steering fluid leakage, temporarily fix reservoir tank vertically.
6. Suspend engine with a hoist, and support the engine posture.
For installation of engine slingers, refer toEM-61, "
ENGINE ASSEMBLY"
7. Remove RH engine mount insulator.
8. Remove center member and rear engine mounting bracket.
9. Drain engine oil.
10. Remove oil pan upper and lower, and oil strainer. Refer toEM-24, "
Removal and Installation".
11. Remove Intake valve timing control cover.
a. Loosen bolts in reverse order shown in the figure.
b. Remove the cover using Tool (Seal cutter).
12. Pull chain guide between camshaft sprockets out through front
cover.
13. Set No.1 cylinder at TDC on its compression stroke with the fol-
lowing procedure.
a. Rotate crankshaft pulley clockwise and align mating marks to
timid indicator on front cover.
KBIA0085E
KBIA0190E

CYLINDER HEAD
EM-53
[QR20DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
lIf some cylinders have low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
–If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
–If the compression pressure remains at low level despite the addition of engine oil, the valves may be mal-
functioning. Check the valves for damage. Replace the valve or valve seat accordingly.
lIf two adjacent cylinders have respectively low compression pressure and their compression remains low
even after the addition of engine oil, the gaskets are leaking. In such a case, replace the cylinder head
gaskets.
8. Install spark plug, ignition coil and harness connectors.
Removal and InstallationEBS009R4
REMOVAL
1. Release fuel pressure. Refer toEC-34, "FUEL PRESSURE RELEASE"(WITH EURO-OBD),EC-399,
"FUEL PRESSURE RELEASE"(WITHOUT EURO-OBD).
2. Drain engine coolant and engine oil.
3. Remove the following components and related parts.
lEngine hood and engine under cover.
lAir cleaner case and air duct assembly; Refer toEM-15, "Removal and Installation".
lIgnition coils; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lEngine Coolant reservoir tank
lAuxiliary drive belt; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt Auto- tensioner".
lAlternator
lAuxiliary drive belt auto -tensioner; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt Auto-
tensioner".
lExhaust front tube; Refer toEX-2, "EXHAUST SYSTEM".
lExhaust manifold; Refer toEM-22, "Removal and Installation".
lIntake manifold collector, intake manifold and fuel tube assembly; Refer toEM-17, "Removal and Installa-
tion".
lWater control valve and housing; Refer toCO-21, "THERMOSTAT AND WATER CONTROL VALVE".
4. Remove front cover and timing chain. Refer toEM-43, "
Removal and Installation".
KBIA0250E
1 Cylinder head assembly 2 Cylinder head gasket 3 Cylinder head bolt

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

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

DRIVE BELTS
EM-111
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
AIR CONDITIONER COMPRESSOR BELT
1. Remove RH splash cover (with undercover attached).
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust.
lRefer toEM-110, "Checking Drive Belts".
4. Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1. Loosen adjusting lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust.
lRefer toEM-110, "Tension Adjustment".
4. Tighten nut (C) and bolt (D) in this order.
Removal and InstallationEBS00BNZ
REMOVAL
1. Loosen each belt. Refer toEM-110, "Tension Adjustment".
2. Remove air conditioner compressor belt.
3. Remove alternator and water pump belt.
INSTALLATION
1. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer toEM-110, "
Tension Adjustment".
3. Tighten nuts and bolts provided for adjustment to the specified torque.
4. Check again that each belt tension is as specified.Nut A:
: 31 - 39 N-m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
JEM251G
Nut C:
: 19 - 24 N-m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N-m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)

ENGINE ASSEMBLY
EM-185
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
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