fuel NISSAN X-TRAIL 2003 Service User Guide

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
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ENGINE MECHANICAL
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PRECAUTIONS .......................................................... 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET .......................... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting — Engine Noise ................... 11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Changing Air Cleaner Filter .................................... 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
INTAKE MANIFOLD ................................................. 17
Removal and Installation (QR20DE) ...................... 17REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
INSPECTION AFTER INSTALLATION ................ 19
Removal and Installation (QR25DE) ...................... 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
OIL PAN AND OIL STRAINER ................................. 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 27
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 28
IGNITION COIL ......................................................... 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
SPARK PLUG ........................................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSPECTION AFTER REMOVAL ....................... 30
INSTALLATION ................................................... 31
FUEL INJECTOR AND FUEL TUBE ........................ 32
Removal and Installation (QR20DE) ...................... 32
REMOVAL ........................................................... 32
INSTALLATION ................................................... 34
INSPECTION AFTER INSTALLATION ................ 36
Removal and Installation (QR25DE) ...................... 37
REMOVAL ........................................................... 37
INSTALLATION ................................................... 39
INSPECTION AFTER INSTALLATION ................ 41

EM-2 ROCKER COVER ..................................................... 42
Removal and Installation ........................................ 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
TIMING CHAIN .......................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSPECTION AFTER REMOVAL ........................ 48
INSTALLATION .................................................... 49
CAMSHAFT ............................................................... 53
Removal and Installation ........................................ 53
REMOVAL ........................................................... 53
INSPECTION AFTER REMOVAL ........................ 55
INSTALLATION .................................................... 58
Valve Clearance ...................................................... 61
INSPECTION ....................................................... 61
ADJUSTMENT .................................................... 62
OIL SEAL .................................................................. 64
Removal and Installation of Valve Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 64
Removal and Installation of Front Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 65
Removal and Installation of Rear Oil Seal .............. 65
REMOVAL ........................................................... 65
INSTALLATION .................................................... 65
CYLINDER HEAD ..................................................... 67
On-Vehicle Service ................................................. 67
CHECKING COMPRESSION PRESSURE ......... 67
Removal and Installation ........................................ 68
REMOVAL ........................................................... 68
INSPECTION AFTER REMOVAL ........................ 69
INSTALLATION .................................................... 69
Disassembly and Assembly .................................... 71
DISASSEMBLY ................................................... 71
ASSEMBLY ......................................................... 72
Inspection After Disassembly ................................. 73
VALVE DIMENSIONS .......................................... 73
VALVE GUIDE CLEARANCE .............................. 73
VALVE GUIDE REPLACEMENT ......................... 74
VALVE SEAT CONTACT ..................................... 75
VALVE SEAT REPLACEMENT ........................... 75
VALVE SPRING SQUARENESS ......................... 77
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 77
ENGINE ASSEMBLY ................................................ 78
Removal and Installation ........................................ 78
REMOVAL ........................................................... 78
INSTALLATION .................................................... 81
INSPECTION AFTER INSTALLATION ................ 81
CYLINDER BLOCK ................................................... 82
Disassembly and Assembly .................................... 82
DISASSEMBLY ................................................... 83
ASSEMBLY ......................................................... 87
How to Select Piston and Bearing .......................... 92
DESCRIPTION .................................................... 92
HOW TO SELECT PISTON ................................. 92
HOW TO SELECT CONNECTING ROD BEAR-ING ....................................................................... 93
HOW TO SELECT MAIN BEARING .................... 95
Inspection After Disassembly .................................. 99
CRANKSHAFT END PLAY .................................. 99
CONNECTING ROD SIDE CLEARANCE ........... 99
PISTON TO PISTON PIN OIL CLEARANCE ....... 99
PISTON RING SIDE CLEARANCE ...................100
PISTON RING END GAP ..................................100
CONNECTING ROD BEND AND TORSION .....101
CONNECTING ROD BIG END DIAMETER ......101
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................101
CYLINDER BLOCK DISTORTION ....................102
MAIN BEARING HOUSING INNER DIAMETER .103
PISTON TO CYLINDER BORE CLEARANCE ..103
CRANKSHAFT MAIN JOURNAL DIAMETER ...104
CRANKSHAFT PIN JOURNAL DIAMETER ......105
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ...............................................................105
CRANKSHAFT RUNOUT ..................................105
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................105
MAIN BEARING OIL CLEARANCE ...................106
MAIN BEARING CRUSH HEIGHT ....................107
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................107
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ...........................................107
CONNECTING ROD BOLT OUTER DIAMETER .107
FLYWHEEL DEFLECTION (M/T MODELS) ......108
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ...........................................................108
SERVICE DATA AND SPECIFICATIONS (SDS) ....109
Standard and Limit ................................................109
GENERAL SPECIFICATIONS ...........................109
DRIVE BELT ......................................................109
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................109
SPARK PLUG ....................................................109
CYLINDER HEAD ..............................................109
VALVE ................................................................110
CAMSHAFT AND CAMSHAFT BEARING .........113
CYLINDER BLOCK ............................................114
PISTON, PISTON RING AND PISTON PIN ......115
CONNECTING ROD ..........................................116
CRANKSHAFT ...................................................116
MAIN BEARING .................................................118
CONNECTING ROD BEARING .........................119
Tightening Torque .................................................119
YD22DDTi
PRECAUTIONS .......................................................122
Precautions for Draining Engine Coolant ..............122
Precautions for Disconnecting Fuel Piping ...........122
Precautions for Removal and Disassembly ..........122
Precautions for Inspection, Repair and Replace-
ment ......................................................................122
Precautions for Assembly and Installation ............122

EM-3
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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-8
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PREPARATION

KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
ST16610001
Pilot bushing pullerRemoving pilot convertor
WS39930000
Tube presserPressing the tube of liquid gasket
KV11103000
Pulley pullerRemoving crankshaft pulley
Quick connector release Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210) Tool number
Tool nameDescription
S-NT605
S-NT603
S-NT044
S-NT045
S-NT052
NT676
PBIC0198E

EM-10
[QR]
PREPARATION

Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new air fuel ratio sensor
and heated oxygen sensor (Use with anti-
seize lubricant shown below.)
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor and air fuel ratio sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
Anti-seize lubricant i.e.: (Permatex
TM
133AR or equivalent meeting MIL
specification MIL-A-907)Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads
Manual lift table caddy Removing and installing engine Tool nameDescription
AEM488
AEM489
ZZA1210D

INTAKE MANIFOLD
EM-17
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INTAKE MANIFOLDPFP:14003
Removal and Installation (QR20DE)EBS00KNC
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-32, "
Removal and
Installation (QR20DE)" .
4. Remove electric throttle control actuator with the following procedure:
a. Disconnect harness connector.
1. Vacuum hose 2. Intake manifold 3. PCV hose
4. Bracket 5. Gasket 6. Electric throttle control actuator
7. Gasket 8. Intake manifold support 9. Gasket
10. Vacuum hose 11.EVAP canister purge volume con-
trol solenoid valve12. Vacuum hose
13. Bracket 14. Bracket
PBIC2172E
PBIC2175E

EM-18
[QR]
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
EM-19
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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

EM-20
[QR]
INTAKE MANIFOLD

Removal and Installation (QR25DE)EBS011TH
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-37, "
Removal and
Installation (QR25DE)" .
4. Remove electric throttle control actuator with the following procedure:
1. Bracket 2. PCV hose 3. Intake manifold collector
4. Gasket 5. Electric throttle control actuator 6. Intake manifold rear support
7.EVAP canister purge volume control
solenoid valve8. Vacuum hose 9. Intake manifold
10. Vacuum reservoir tank 11. VIAS control solenoid valve 12. Vacuum hose
13. Bracket 14. Intake manifold support 15. Vacuum reservoir tank bracket
PBIC2174E
PBIC2175E