engine NISSAN X-TRAIL 2003 Service Owners Manual

EM-136
[YD22DDTi]
INTAKE MANIFOLD

INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00LRF
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
2. Remove air duct. Refer to EM-133, "
Removal and Installation" .
3. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
4. Remove air inlet pipes. Refer to EM-141, "
Removal and Installation" .
5. Remove exhaust manifold insulator. Refer to EM-141, "
EXHAUST MANIFOLD AND TURBOCHARGER" .
1. Fuel gallery 2. Water hose 3. Air relief plug
4. Copper washer 5. Gasket 6. EGR passage
7. EGR volume control valve 8. Bracket 9. Washer
10. Water pipe 11. O-ring 12. EGR cooler
13. Exhaust manifold 14. Intake manifold 15. Cylinder head
16. Heater hose 17. Spill hose
PBIC2020E

INTAKE MANIFOLD
EM-137
[YD22DDTi]
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6. Disconnect EGR volume control valve water hoses and wiring harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
9. Remove injection tube center. Refer to EM-157, "
Removal and Installation" .
CAUTION:
Be careful not to spill fuel in the engine component.
10. Remove water pipe.
11. Remove fuel hoses and fuel gallery.

To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
12. Loosen bolts and nuts in reverse order of that shown in the fig-
ure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
13. Remove EGR volume control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion

Check distortion on the mounting surface with a straightedge
and feeler gauge.

If it exceeds the limit, replace intake manifold.
INSTALLATION
Following instructions below, install in the reverse order of removal.
1. Install EGR volume control valve.

Handle with care avoiding any shocks.

Do not disassemble.
2. Install intake manifold.

Tighten fixing bolts and nuts in numerical order as shown in the figure.

When stud bolts come off, install with the following torque.
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)

EM-138
[YD22DDTi]
INTAKE MANIFOLD

3. Install water hose.

Install water hose by referring to identification marks avoiding
twisting.

When 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.

When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
4. Install remaining parts in the reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.Dimension A : 25 - 30 mm (0.984 - 1.181 in)
PBIC2021E

CATALYST
EM-139
[YD22DDTi]
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
3. Remove radiator upper and lower hoses. Refer to CO-34, "
RADIATOR" .
4. Remove cooling fan. Refer to CO-36, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-34, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-44, "
THERMOSTAT AND WATER PIPING" .
7. Remove catalyst insulators.
8. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
1. Catalyst insulator 2. Gasket 3. Catalyst
4. Locking pin 5. Gusset 6. Gasket cap
7. Catalyst rear diffuser
PBIC2312E
Catalyst locking pin : Flange bolt (black)

EXHAUST MANIFOLD AND TURBOCHARGER
EM-141
[YD22DDTi]
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO-31, "Changing Engine Coolant" .
2. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
3. Remove air duct. Refer to EM-133, "
Removal and Installation" .
4. Remove air inlet pipe.
5. Remove engine undercover.
6. Remove radiator upper and lower hoses. Refer to CO-34, "
RADIATOR" .
7. Remove cooling fan. Refer to CO-36, "
DISASSEMBLY AND ASSEMBLY" .
8. Remove radiator mounting bracket and radiator. Refer to CO-34, "
Removal and Installation" .
9. Remove water inlet pipe. Refer to CO-44, "
THERMOSTAT AND WATER PIPING" .
10. Remove catalyst. Refer to EM-139, "
Removal and Installation" .
11. Remove exhaust manifold insulator.
12. Remove turbocharger insulator.
13. Remove oil feed tube and oil return tube.
1. EGR volume control valve 2. Gasket 3. EGR cooler
4. Air inlet pipe 5.Exhaust manifold and turbocharger
assembly6. Oil feed tube and oil return tube
7. Oil return hose 8. Copper washer 9. Eye-bolt
10. Turbocharger insulator 11. Exhaust manifold insulator 12. Air inlet pipe
PBIC2022E

EM-142
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER

14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
15. Rotate exhaust manifold and turbocharger assembly so that the rear side (EGR cooler mounting side)
faces upward. And then pull out the assembly from between the engine and the A/C piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling out the assembly.
INSTALLATION

When a stud bolt is pulled out, tighten it to the following torque:

Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to EM-141, "
Removal and Instal-
lation" .
2. Tighten the nuts in order specified in the figure.
3. Re-tighten the nuts 1 to 4.
4. Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
JEM266G
: 12.7 - 16.7 N·m (1.3 - 1.7 kg-m, 9 - 12 ft-lb)
JEM266G

EXHAUST MANIFOLD AND TURBOCHARGER
EM-145
[YD22DDTi]
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TURBINE WHEEL

Make sure that there is no engine oil adhesion.

Make sure that there is no carbon accumulation.

Make sure that blades of turbine wheel are not bent or broken.

Make sure that turbine wheel does not interfere with turbine
housing.
COMPRESSOR WHEEL

Make sure that there is no engine oil adhesion inside the air
inlet.

Make sure that compressor wheel does not interfere with com-
pressor housing.

Make sure that compressor wheel is not bent or broken.
TURBOCHARGER BOOST CONTROL ACTUATOR

Connect the handy vacuum pump to the actuator, and make
sure that the rod strokes smoothly in compliance with the follow-
ing pressure.

Pressure to be applied at actuator part to move rod end as fol-
lows:
PBIC0729E
PBIC0730E
Standard (Pressure/rod stroke amount):
:–52.0 to –54.6 kPa (–520 to –546 mbar, –390 to –410
mmHg, –15.4 to –16.1 inHg)/0.2 mm (0.0079 in)
: –32.0 to –40.0 kPa (–320 to –400 mbar, –240 to –300
mmHg, –9.45 to –11.8 inHg)/5.0 mm (0.197 in)
PBIC0941E

EM-146
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER

TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:

Make sure that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil
amount is more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbo-
charger is misjudged malfunction.)

Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.

Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.

If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
A: Large possibility
B: Medium possibility
C: Small possibilityInspection item Inspection resultSymptom
(when each inspection item meets each inspection result)
Engine oil
leakageSmoke NoiseInsufficient power/accel-
eration malfunction
Turbine wheelEngine oil leaks C A C C
Carbon is accumulated C A B B
Friction with housing C B A B
Blades are bent or broken — — A A
Compressor wheelInside the air inlet is seriously con-
taminated by engine oil.BB— —
Friction with housing C B A B
Blades are bent or broken — — A A
After checking both turbine and
compressor, inspect rotor shaft
end play.There is resistance when the rotor
shaft is rotated by your fingertips.—CC B
The rotor shaft sometimes does not
rotate by your fingertips.——— A
There is too much play in the bear-
ing.CCB C
Oil return portCarbon or sludge is accumulated in
the waste oil hole.CAC C

OIL PAN AND OIL STRAINER
EM-147
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OIL PAN AND OIL STRAINERP F P : 1111 0
Removal and InstallationEBS00LRK
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove engine undercover.
2. Drain engine oil. Refer to LU-21, "
Changing Engine Oil" .
3. Remove oil pan lower bolts, Loosen bolts in reverse order of that
shown in the figure.
4. Remove oil pan lower.
1. Rear plate cover 2. Oil pan upper 3. Gasket
4. Oil strainer 5. Oil pan drain plug 6. Drain plug washer
7. Oil pan lower 8. Crankshaft position sensor
PBIC2313E
SBIA0161E

EM-148
[YD22DDTi]
OIL PAN AND OIL STRAINER

a. Insert the Seal cutter (special service tool) between oil pan
upper and oil pan lower.
CAUTION:

Be careful not to damage aluminum mating surface.

Do not insert screwdriver, or oil pan flange will be
deformed.
b. Slide the Seal cutter by tapping on the side of the Seal cutter
with a hammer.
c. Remove oil pan lower.
5. Remove A/C compressor belt. Refer to EM-131, "
Tension Adjustment" .
6. Remove A/C compressor and bracket. Refer to ATC-144, "
Removal and Installation of Compressor" .
7. Remove front exhaust tube and its support. Refer to EX-2, "
EXHAUST SYSTEM" .
8. Remove crankshaft position sensor from transaxle.
CAUTION:

Avoid impacts such as a dropping.

Do not disassemble.

Keep it away from metal particles.

Do not place sensor close to magnetic materials.
9. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger. Refer to EM-208, "
Removal and
Installation" .
10. Remove center member. Refer to EM-208, "
ENGINE ASSEM-
BLY" .
11. Remove rear plate cover and transaxle joint bolts.
12. Remove catalyst and catalyst rear diffuser. Refer to EM-139,
"Removal and Installation" .
SEM544G
SEM545G
PBIC2277E
JEM553G