NISSAN X-TRAIL 2003 Service Repair Manual

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i. Tighten M10 bolts in numerical order from No. 1 to 10.
ii. Turn M10 bolts 60 degrees clockwise (angle tightening) in order
from No. 1 to 10 in the figure.
CAUTION:
Check and confirm the tightening angle by using an angle
wrench (special service tool) or protractor. Avoid judgment
by visual inspection without the tool.

After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.

Wipe off completely any protruding liquid gasket on front side of engine.

Check crankshaft end play. Refer to EM-99, "CRANKSHAFT END PLAY" .
7. Install piston to connecting rod with the following procedure:
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.

Insert it fully into groove to install.
b. Assemble piston to connecting rod.

Using 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 piston pin
into piston and connecting rod.

Assemble so that the front mark on the piston head and the oil
holes and the cylinder number on connecting rod are posi-
tioned as shown in the figure.
c. Install new snap ring to the groove of the piston front side.

Insert it fully into groove to install.

After installing, make sure that connecting rod moves
smoothly.
8. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
Be careful not to damage piston. : 39.2 N·m (4.0 kg-m, 29 ft-lb)
KBIA0063E
KBIA0065E
PBIC2194E

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Position each ring with the gap as shown in the figure refer-
ring to the piston front mark.

Install second ring with the stamped surface facing upward.
NOTE:
If there is no stamped mark on piston ring, no specific orienta-
tion is required for installation.
9. Install connecting rod bearings to connecting rod and connecting rod cap.

When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply new engine oil to the back surface, but thoroughly clean it.

When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of connecting rod and connecting rod
cap to install.

Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
10. Install piston and connecting rod assembly to crankshaft.

Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.

Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.

Match the cylinder position with the cylinder number on connecting rod to install.

Using a piston ring compressor (special service tool) or suit-
able tool, install piston with the front mark on the piston head
facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
11. Install connecting rod cap.

Match the stamped cylinder number marks on connecting rod
with those on connecting rod cap to install.
12. Tighten connecting rod bolt with the following procedure:Stamped mark:
To p r i n g : —
Second ring : 2F
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PBIC0266E
PBIC1619E
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a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
c. Then turn all bolts 90 degrees clockwise (Angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench (special service tool) or protractor. Avoid judge-
ment by visual inspection without the tool.

After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.

Check the connecting rod side clearance. Refer to EM-99, "CONNECTING ROD SIDE CLEARANCE" .
13. Install flywheel (M/T models) or drive plate (A/T models).

Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times.

Install drive plate, reinforcement plate and pilot converter as
shown in figure (A/T models).

Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot con-
verter into the end of crankshaft until it stops (A/T models).
14. Install knock sensor.

Install knock sensor with connector facing lower left by 45
degrees as shown in the figure.
CAUTION:

Do not tighten mounting bolts while holding the connec-
tor.

If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.

Make sure that knock sensor does not interfere with other
parts.
15. Install crankshaft position sensor (POS).
16. Assemble in the reverse order of disassembly after this step. : 19.6 N·m (2.0 kg-m, 14 ft-lb)
KBIA0068E
KBIA0075E
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How to Select Piston and Bearing EBS00KNV
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The
information at the shipment from the plant is described as a reference.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block is Used

Check the cylinder bore grade on rear left side of cylinder block,
and select piston of the same grade.

If there is a corrected stamp mark on the cylinder block, use it as
a correct reference.
When Cylinder Block is Reused
1. Measure the cylinder bore inner diameter. Refer to EM-103, "Cylinder Bore Inner Diameter" .
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
3. Select piston of the same grade.
Piston Selection Table
Unit: mm (in)
NOTE:

There is no piston grade “1”.

Piston is available together with piston pin as an assembly.
Selection points Selection parts Selection items Selection methods
Between cylinder block and
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft and con-
necting rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block and pis-
tonPiston and piston pin assembly
(piston is available together
with piston pin as an assembly.)Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
Between piston and connecting
rod
*———
SBIA0283E
Grade number (Mark) 2 (or no mark) 3
Cylinder bore Inner diameter 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter 88.990 - 89.000 (3.5035 - 3.5039) 89.000 - 89.010 (3.5039 - 3.5043)

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The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected. (Only grade “0” is available.)
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
1. Apply connecting rod big end diameter grade stamped on con-
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
2. Apply crankshaft pin journal diameter grade stamped on crank-
shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
When Crankshaft and Connecting Rod are Reused
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-101, "
CONNECTING ROD BIG END DIAMETER" and EM-105, "CRANKSHAFT
PIN JOURNAL DIAMETER" .
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
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PBIC2198E

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Connecting Rod Bearing Selection Table
Connecting Rod Bearing Grade Table
Unit: mm (in)
Undersize Bearings Usage Guide

When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.

When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the stan-
dard.
PBIC2199E
Grade number 0 1 2 3
Thickness1.495 - 1.499
(0.0589 - 0.0590)1.499 - 1.503
(0.0590 - 0.0592)1.503 - 1.507
(0.0592 - 0.0593)1.507 - 1.511
(0.0593 - 0.0595)
Identification color Black Brown Green Yellow

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CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
Bearing undersize table
Unit: mm (in)
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block.

If there is a corrected stamp mark on cylinder block, use it as
a correct reference.
2. Apply main journal diameter grade stamped on crankshaft front
side to column in the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-103, "
MAIN BEARING HOUSING INNER DIAMETER" and EM-
104, "CRANKSHAFT MAIN JOURNAL DIAMETER" .
PBIC2200E
Size Thickness
US 0.25 (0.0098) 1.624 - 1.632 (0.0639 - 0.0643)
SBIA0283E
PBIC2198E

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2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
Main Bearing Selection Table (No. 1, 3 and 5 journals)
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Main Bearing Selection Table (No. 2 and 4 journals)
PBIC2202E

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Main Bearing Grade Table (All Journals)
Unit: mm (in)
Use Undersize Bearing Usage Guide

When the specified main bearing oil clearance is not obtained with standard size main bearings, use
undersize (US) bearing.

When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
Bearing undersize table
Unit: mm (in) Grade number Thickness Identification color Remarks
0 1.973 - 1.976 (0.0777 - 0.0778) Black
Grade and color are the same
for upper and lower bearings. 1 1.976 - 1.979 (0.0778 - 0.0779) Brown
2 1.979 - 1.982 (0.0779- 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow
4 1.985 - 1.988 (0.0781 - 0.0783) Blue
5 1.988 - 1.991 (0.0783 - 0.0784) Pink
6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White
01UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
Grade and color are different
for upper and lower bearings. LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
23UPR 1.979 - 1.982 (0.0779- 0.0780) Green
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
34UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
PBIC2200E
Size Thickness
US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832)