NISSAN X-TRAIL 2003 Service Repair Manual

CYLINDER BLOCK
EM-219
[YD22DDTi]
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Install top ring and second ring with punched mark surfaces
facing upward.

Install rings so that three closed gap position 120 degrees
apart one another.

Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
12. Install connecting rod bearing to connecting rod and cap.

While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.

Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
13. Install piston and connecting rod assembly to crankshaft.

Move crankshaft pin to be assembled to BDC.

Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.

Using the piston ring compressor (special service tool) or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet.
14. Install connecting rod caps and mounting nuts.

Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.

Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
15. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
c. Loosen completely.Punched mark:
Top ring : RTop
Second ring : R2nd
JEM228G
JEM229G
PBIC1619E
MBIA0024E
: 29 - 30 N·m (2.9 - 3.1 kg-m, 21 - 22 ft-lb)
: 0 N·m (0 kg-m, 0 in-lb)

EM-220
[YD22DDTi]
CYLINDER BLOCK

d. Tighten bolts.
e. Tighten 120 degrees to 125 degrees [target: 120 degrees].
(angle tightening)

Always use either the angle wrench (special service tool)
or protractor during angular tightening. Avoid tightening
based on visual checks alone.

After tightening nuts, make sure that crankshaft rotates
smoothly.

Check connecting rod side clearance. Refer to EM-226,
"CONNECTING ROD SIDE CLEARANCE" .
16. Press fit rear oil seal into rear oil seal retainer.

Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.

Avoid inclined fitting. Force fit perpendicularly.
17. Install rear oil seal retainer to cylinder block.

Apply new engine oil to the oil and dust seal lips.

Apply liquid gasket to rear oil seal retainer using the tube
presser (special service tool: WS39930000) as shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
18. Press fit pilot bush into flywheel.

Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bush until it stops.: 19 - 20 N·m (1.9 - 2.1 kg-m, 14 - 15 ft-lb)
JEM231G
JEM232G
JEM233G
JEM234G

CYLINDER BLOCK
EM-221
[YD22DDTi]
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19. Install fuel pump bracket.

Align the bracket with the dowel pins on cylinder block to
install.

The two bolts used for dowel pins have a longer shanks than
the other two.
20. Install parts to engine in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of assembly.
22. Install flywheel.

When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin-
hole.

There is a mating mark on the clutch cover side, Refer it dur-
ing installation.

Holding ring gear with the ring stopper (special service tool),
tighten securing bolts with TORX bit (size: T55, Commercial
Service Tool).

Tighten bolts uniformly in a crisscross manner.
PBIC2329E
PBIC2538E
PBIC2495E
PBIC2406E

EM-222
[YD22DDTi]
CYLINDER BLOCK

How to Select Piston and BearingEBS00ODY
DESCRIPTION

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 Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.

The part No. of piston is specified together with piston pin as
an assembly.
When Re-using an Old Cylinder Block
1. Measure cylinder bore inner diameter. Refer to EM-230, "Cylinder Bore Inner Diameter" .
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
3. Select piston of the same grade.
Selection points Selection parts Selection items Selection methods
Between cylinder block to
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 to connect-
ing 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 to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
JEM208G
MBIA0025E

CYLINDER BLOCK
EM-223
[YD22DDTi]
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Piston Selection Table
Unit: mm (in)
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
When Using New Crankshaft and Connecting Rod
1. Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
When Re-using the Removed Crankshaft and Connecting Rod
1. Measure the inner diameter of the big end of connecting rod and make sure it is within the specified
range. Refer to EM-228, "
CONNECTING ROD BIG END INNER DIAMETER" .
2. Measure the outer diameter of the crankshaft pin. Refer to EM-231, "
CRANKSHAFT PIN OUTER DIAME-
TER" .
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
Selection Table of connecting Rod Bearing
Unit: mm (in)
Unit: mm (in)
Under Size Bearing Usage

If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under
size bearings.

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Grade (punched) 1 2 3
Cylinder bore
inner diameter86.000 - 86.010(3.3858 - 3.3862) 86.010 - 86.020(3.3862 - 3.3866) 86.020 - 86.030(3.3866 - 3.3870)
Piston outer
diameter85.928 - 85.942(3.3830 - 3.3835) 85.938 - 85.952(3.3834 - 3.3839) 85.948 - 85.962(3.3838 - 3.3843)
JEM215G
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin outer diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.492 - 1.496 (0.0587 - 0.0589) STD 0 Black
51.961 - 51.968 (2.0457 - 2.0460) 1 1.496 - 1.500 (0.0589 - 0.0591) STD 1 Brown
51.954 - 51.961 (2.0454 - 2.0457) 2 1.500 - 1.504 (0.0591 - 0.0592) STD 2 Green

EM-224
[YD22DDTi]
CYLINDER BLOCK

Connecting Rod Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
HOW TO SELECT MAIN BEARING
When Using New Cylinder Block and Crankshaft
1. Identify the crank journal grade (No. 0, 1, or 2) on LH surface at
the rear of the cylinder block, and locate the applicable grade on
the “Grade” row in the “Main Bearing Grade Table”.
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of
crankshaft, and locate the applicable grade under the “Grade”
column in the “Main Bearing Grade Table”.
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-229, "MAIN BEARING
HOUSING INNER DIAMETER" .
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-231, "
CRANKSHAFT JOURNAL OUTER
DIAMETER" .
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G
JEM208G
JEM215G

CYLINDER BLOCK
EM-225
[YD22DDTi]
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Main Bearing Grade Table
Unit: mm (in)
Under Size Bearing Usage

If bearing clearance is out of the specifications for main bearings in standard size, use under size bear-
ings.

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to the specification.
Main Bearing Under Size List
Unit: mm (in)
CAUTION:
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)
Inner diameter of Cylinder block main bearing housing66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft journal
outer diameterGrade
(punched)012
62.967 - 62.975
(2.4790 - 2.4793)0

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
62.959 - 62.967
(2.4787 - 2.6790)1

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Ye l l o w
62.951 - 62.959
(2.4784 - 2.4787)2

Bearing grade No.

Bearing thickness

Oil clearance

Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Ye l l o wSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
Size Thickness
US 0.25(0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in)
JEM216G

EM-226
[YD22DDTi]
CYLINDER BLOCK

Inspection After DisassemblyEBS00ODP
CRANKSHAFT END PLAY

Using dial gauge, measure crankshaft travel amount by moving
the crankshaft forward or backward.

If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
CONNECTING ROD SIDE CLEARANCE

Using feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.

If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
PISTON TO PISTON PIN CLEARANCE
Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.
Piston Pin Outer Diameter
Using micrometer, measure piston pin outer diameter.
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)

If out of the standard, replace piston/piston pin assembly.Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
JEM202G
Standard : 0.20 - 0.35 (0.0079 - 0.0138 in)
Limit : 0.40 mm (0.0157 in)
JEM203G
Standard : 28.003 - 28.009 mm (1.1025 - 1.1027 in)
PBIC0116E
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)

CYLINDER BLOCK
EM-227
[YD22DDTi]
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NOTE:
Piston is available together with piston pin as assembly.
PISTON RING SIDE CLEARANCE

Using feeler gauge, measure the side clearance between piston
ring and piston ring groove.
Unit: mm (in)

Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.

If side clearance exceeds the limit, replace piston ring.

Check clearance again. If side clearance still exceeds the limit,
replace piston.
PISTON RING END GAP

Make sure that cylinder bore diameter is within the specifica-
tions. Refer to EM-230, "
PISTON TO CYLINDER BORE
CLEARANCE" .

Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure piston ring end gap with feeler gauge.
Unit: mm (in)

If out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder
and use oversized piston and piston ring. Refer to EM-230, "
PISTON TO CYLINDER BORE CLEAR-
ANCE" .
Item Standard Limit
Top ring 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
FEM100
Item Standard Limit
Top ring 0.20 - 0.30 (0.0079 - 0.0118)
1.0 (0.039) 2nd ring 0.31 - 0.51 (0.0122 - 0.0201)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)
FEM101

EM-228
[YD22DDTi]
CYLINDER BLOCK

CONNECTING ROD BEND AND TORSION

Use connecting rod aligner to check bend and torsion.

If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END INNER DIAMETER

Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Refer to EM-
217, "ASSEMBLY" .

Using inside micrometer, measure connecting rod big end inner
diameter.

If out of the standard, replace connecting rod.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Use inside micrometer to measure bushing inner diameter.Bend limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
Torsion limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
PBIC2077E
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
PBIC1641E
Standard : 28.026 - 28.038 mm (1.1034 - 1.1039 in)
PBIC0120E