check engine NISSAN X-TRAIL 2003 Service User Guide

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Parts Requiring Angle Tightening ......................... 122
Precautions For Liquid Gasket ............................. 123
REMOVAL OF LIQUID GASKET ...................... 123
LIQUID GASKET APPLICATION PROCEDURE . 123
PREPARATION ....................................................... 124
Special Service Tools ........................................... 124
Commercial Service Tools .................................... 127
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 129
NVH Troubleshooting — Engine Noise ................ 129
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 130
DRIVE BELTS ......................................................... 131
Checking Drive Belts ............................................ 131
Tension Adjustment .............................................. 131
A/C COMPRESSOR BELT ............................... 132
ALTERNATOR AND WATER PUMP BELT ....... 132
Removal and Installation ...................................... 132
REMOVAL ......................................................... 132
INSTALLATION ................................................. 132
AIR CLEANER AND AIR DUCT ............................. 133
Removal and Installation ...................................... 133
REMOVAL ......................................................... 133
INSTALLATION ................................................. 133
CHANGING AIR CLEANER FILTER ................. 134
CHARGE AIR COOLER ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSPECTION AFTER REMOVAL ..................... 135
INSTALLATION ................................................. 135
INTAKE MANIFOLD ............................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSPECTION AFTER REMOVAL ..................... 137
INSTALLATION ................................................. 137
INSPECTION AFTER INSTALLATION ............. 138
CATALYST .............................................................. 139
Removal and Installation ...................................... 139
REMOVAL ......................................................... 139
INSTALLATION ................................................. 140
EXHAUST MANIFOLD AND TURBOCHARGER .. 141
Removal and Installation ...................................... 141
REMOVAL ......................................................... 141
INSTALLATION ................................................. 142
INSPECTION AFTER INSTALLATION ............. 142
Disassembly and Assembly ................................. 143
DISASSEMBLY ................................................. 143
ASSEMBLY ....................................................... 143
INSPECTION AFTER DISASSEMBLY ............. 143
Turbocharger ........................................................ 144
ROTOR SHAFT CLEARANCE ......................... 144
ROTOR SHAFT END PLAY .............................. 144
TURBINE WHEEL ............................................. 145
COMPRESSOR WHEEL .................................. 145
TURBOCHARGER BOOST CONTROL ACTU-
ATOR ................................................................ 145
TROUBLE DIAGNOSIS OF TURBOCHARGER . 146OIL PAN AND OIL STRAINER ...............................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSPECTION AFTER REMOVAL .....................149
INSTALLATION .................................................149
INSPECTION AFTER INSTALLATION ..............151
GLOW PLUG ..........................................................152
Removal and Installation ......................................152
REMOVAL .........................................................152
INSTALLATION .................................................152
VACUUM PUMP ......................................................153
Removal and Installation ......................................153
INSPECTION BEFORE REMOVAL ..................153
REMOVAL .........................................................153
INSTALLATION .................................................154
INSPECTION AFTER INSTALLATION ..............155
Disassembly and Assembly ..................................155
DISASSEMBLY .................................................155
ASSEMBLY .......................................................156
INJECTION TUBE AND FUEL INJECTOR ............157
Removal and Installation ......................................157
REMOVAL .........................................................157
INSTALLATION .................................................159
INSPECTION AFTER INSTALLATION ..............160
FUEL PUMP ............................................................161
Removal and Installation ......................................161
REMOVAL .........................................................161
INSPECTION AFTER REMOVAL .....................165
INSTALLATION .................................................165
ROCKER COVER ...................................................168
Removal and Installation ......................................168
REMOVAL .........................................................168
INSTALLATION .................................................169
INSPECTION AFTER INSTALLATION ..............169
CAMSHAFT ............................................................170
Removal and Installation ......................................170
REMOVAL .........................................................170
INSPECTION AFTER REMOVAL .....................171
INSTALLATION .................................................174
Valve Clearance ...................................................175
INSPECTION ....................................................175
ADJUSTMENTS ................................................177
SECONDARY TIMING CHAIN ................................180
Removal and Installation ......................................180
REMOVAL .........................................................180
INSPECTION AFTER REMOVAL .....................182
INSTALLATION .................................................182
PRIMARY TIMING CHAIN ......................................185
Removal and Installation ......................................185
REMOVAL .........................................................187
INSPECTION AFTER REMOVAL .....................190
INSTALLATION .................................................190
CYLINDER HEAD ...................................................196
On-Vehicle Service ...............................................196
CHECKING COMPRESSION PRESSURE .......196
Removal and Installation ......................................197
REMOVAL .........................................................197
INSPECTION AFTER REMOVAL .....................198

PRECAUTIONS
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ

Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining coolant.

Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure there are no leaks at fuel line connections.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00KN5

Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
–Balancer unit

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

EM-12
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00L7Q
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-61
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-56EM-55
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-99
EM-101
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-104EM-100
EM-100
EM-101
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-101EM-105
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-106EM-105
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-48
EM-44
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-20,
"WATER
PUMP"

DRIVE BELTS
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00KN7
WARNING:
Be sure to perform this step when the engine is stopped.

Make sure that the indicator (single line notch on fixed side) of drive belt auto-tensioner is within the pos-
sible use range (between three line notches on moving side).
NOTE:

Check the drive belt auto-tensioner indicator (single line notch on fixed side) when engine is cold.

When new drive belt is installed, the indicator (single line notch on fixed side) should be within the
range “A” in the figure.

Visually check entire belt for wear, damage or cracks.

If the indicator (single line notch on fixed side) is out of the possible use range or belt is damaged, replace
drive belt.
Tension AdjustmentEBS00KN8
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationEBS00KN9
REMOVAL
1. Remove splash guard on RH undercover.
2. With box wrench, and while securely holding the hexagonal part
in center of drive belt auto-tensioner pulley, move the wrench
handle in the direction of arrow (loosening direction of ten-
sioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
3. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of the retaining boss to fix
drive belt auto-tensioner pulley.
4. Loosen drive belt from water pump pulley in sequence, and
remove it.
PBIC1234E
PBIC2169E

EM-18
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INTAKE MANIFOLD

b. Loosen mounting bolts in reverse order as shown in the figure,
and remove electric throttle control actuator and gasket.
CAUTION:

Handle carefully to avoid any shock to electric throttle
control actuator.

Do not disassemble.
5. Disconnect harness, power steering piping, vacuum hose and PCV hose from intake manifold, and move
them aside.
6. Remove intake manifold support and gasket.
7. Disconnect sub-harness from fuel injector. Refer to EM-32, "
Removal and Installation (QR20DE)" .
8. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold (with fuel tube and fuel
injector assembly) and gasket.
CAUTION:

Do not disassemble intake manifold.

Cover engine openings to avoid entry of foreign materi-
als.
NOTE:
Disregard No. 6 when loosening.
9. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-32, "
Removal and Installa-
tion (QR20DE)" .
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Check if gasket is not dropped from the installation groove of intake manifold.

Tighten in numerical order as shown in the figure.
NOTE:
No. 6 means double tightening of bolt No. 1.
EMJ1612D
PBIC2173E
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
PBIC2173E

INTAKE MANIFOLD
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Electric Throttle Control Actuator

Tighten mounting bolts equally and diagonally in several steps
and in numerical order as shown in the figure.

Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is discon-
nected. Refer to EC-46, "
Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-508, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).

Perform the “Idle Air Volume Learning” and “Throttle Valve
Closed Position Learning” when electric throttle control actuator
is replaced. Refer to EC-46, "
Idle Air Volume Learning" (WITH
EURO-OBD) or EC-508, "
Idle Air Volume Learning" (WITHOUT
EURO-OBD).
INSPECTION AFTER INSTALLATION
Make sure there are no fuel leaks at connections with the following procedure:
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then make sure
there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot.
EMJ1612D

INTAKE MANIFOLD
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a. Disconnect harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure,
and remove electric throttle control actuator and gasket.
CAUTION:

Handle carefully to avoid any shock to electric throttle
control actuator.

Do not disassemble.
5. Disconnect harness, vacuum hose and PCV hose from intake manifold collector, and move them aside.
6. Remove intake manifold rear support and intake manifold support.
7. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold collector and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
NOTE:
Disregard No. 8 when loosening.
8. Disconnect power steering piping from intake manifold, and move them aside.
9. Disconnect sub-harness from fuel injector. Refer to EM-37, "
Removal and Installation (QR25DE)" .
10. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold (with fuel tube and fuel
injector assembly) and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
NOTE:
Disregard No. 6 when loosening.
11. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-37, "
Removal and Installa-
tion (QR25DE)" .
INSPECTION AFTER REMOVAL
Surface Distortion

Using straightedge and feeler gauge, check the surface distor-
tion of both the intake manifold collector mating surface and the
intake manifold mating surfaces.

If it exceeds the limit, replace intake manifold and/or intake man-
ifold collector.
EMJ1612D
SBIA0230E
SBIA0231E
Limit : 0.1 mm (0.004 in)
KBIA0235E

EM-22
[QR]
INTAKE MANIFOLD

INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Tighten in numerical order as shown in the figure.
NOTE:
No. 6 means double tightening of bolt No. 1.
Intake Manifold Collector
Tighten in numerical order as shown in the figure.
NOTE:
No. 8 means double tightening of bolt No. 1.
Electric Throttle Control Actuator

Tighten mounting bolts equally and diagonally in several steps
and in numerical order as shown in the figure.

Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is discon-
nected. Refer to EC-46, "
Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-508, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).

Perform the “Idle Air Volume Learning” and “Throttle Valve
Closed Position Learning” when electric throttle control actuator
is replaced. Refer to EC-46, "
Idle Air Volume Learning" (WITH
EURO-OBD) or EC-508, "
Idle Air Volume Learning" (WITHOUT
EURO-OBD).
INSPECTION AFTER INSTALLATION
Make sure there are no fuel leaks at connections with the following procedure:
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then make sure
there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot. : 10.8 N·m (1.1 kg-m, 8 ft-lb)
SBIA0231E
SBIA0230E
EMJ1612D

EM-24
[QR]
EXHAUST MANIFOLD AND THREE WAY CATALYST

5. Loosen nuts in reverse order as shown in the figure to remove
exhaust manifold and three way catalyst assembly.
NOTE:
Disregard No. 6 and 7 when loosening.
6. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
7. Remove exhaust manifold cover (lower) and three way catalyst cover from exhaust manifold and three
way catalyst assembly. .
INSPECTION AFTER REMOVAL
Surface Distortion

Using straightedge and feeler gauge, check the surface distor-
tion of exhaust manifold and three way catalyst assembly mating
surface.

If it exceeds the limit, replace exhaust manifold and three way
catalyst assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Tighten nuts in numerical order as shown in the figure.
NOTE:
No. 6 and 7 mean double tightening of bolts No. 1 and 3.
Heated Oxygen Sensor
CAUTION:

Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen
sensor thread cleaner and apply anti-seize lubricant (commercial service tool).

Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the “MI” coming on.
KBIA0045E
Limit : 0.3 mm (0.012 in)
KBIA0046E
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
KBIA0045E

EM-28
[QR]
OIL PAN AND OIL STRAINER

2. Install oil strainer.
3. Install oil pan (lower) with the following procedure:
a. Use a scraper to remove old liquid gasket from mating surfaces.

Also remove old liquid gasket from mating surface of oil
pan (upper).
b. Apply a continuous bead of liquid gasket with a tube presser
(special service tool: WS39930000) as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
c. Tighten bolts in numerical order as shown in the figure.
4. Install oil pan drain plug.

Refer to the figure of components of former page for installation direction of washer. Refer to EM-25,
"Removal and Installation" .
5. Install in the reverse order of removal after this step.
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-7, "ENGINE OIL" .
2. Start engine, and make sure there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-7, "
ENGINE OIL" .
SEM958F
SBIA0254E
KBIA0096E