torque NISSAN X-TRAIL 2003 Service Owner's Manual

EM-108
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CYLINDER BLOCK

FLYWHEEL DEFLECTION (M/T MODELS)

Measure the deflection of flywheel contact surface to clutch with
a dial gauge.

Measure the deflection at 210 mm (8.27 in) dia.

If measured value is out of the standard, replace flywheel.
CAUTION:
When measuring, keep magnetic fields (such as dial gauge
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction

Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.

If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.

Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side.

If measured value is out of the standard, replace flywheel.Standard : 0.45 mm (0.0177 in) or less.
SBIA0287E
Standard : 1.3 mm (0.051 in) or less
Standard: 28.3 mm (1.114 in) or less.
PBIC1263E

SERVICE DATA AND SPECIFICATIONS (SDS)
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CONNECTING ROD BEARING
Undersize
Unit: mm (in)
Bearing Oil Clearance
Unit: mm (in)
Tightening TorqueEBS00KNY
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*2
Grade number Thickness mm (in) Identification color
0 1.495 - 1.499 (0.0589 - 0.0590) Black
1 1.499 - 1.503 (0.0590 - 0.0592) Brown
2 1.503 - 1.507 (0.0592 - 0.0593) Green
3 1.507 - 1.511(0.0593 - 0.0595) Yellow
Item Thickness Crank pin journal diameter
US 0.25 (0.0098) 1.624 - 1.632 (0.0639 - 0.0643) Grind so that bearing clearance is the specified value.
Connecting rod bearing oil clearanceStandard 0.028 - 0.045 (0.0011 - 0.0018)
Limit 0.10 (0.0039)
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Auto-tensioner 21.6 (2.2, 16)
Mass air flow sensor
3.8 (0.39, 34) *
2
Resonator
3.8 (0.39, 34)*2
Air cleaner case lower
3.8 (0.39, 34)*2
*1 Intake manifold19.6 (2.0, 14)
Intake manifold collector (QR25DE) 19.6 (2.0, 14)
Intake manifold support (QR20DE) 19.6 (2.0, 14)
Intake manifold support (QR25DE) M6 bolt
8.83 (0.90, 78) *
2
M10 bolt 46.6 (4.8, 34)
Intake manifold rear support (QR25DE) 19.6 (2.0, 14)
Electric throttle control actuator
8.43 (0.86, 75) *
2
EVAP canister purge volume control solenoid valve
5.1 (0.52, 45) *2
*1 Exhaust manifold and three way catalyst assembly 41.7 (4.3, 31)
Exhaust manifold covers (upper and lower)
5.8 (0.59, 51) *
2
Three way catalyst cover
5.8 (0.59, 51) *2
Heated oxygen sensor 1 45 (4.6, 33)
Heated oxygen sensor 2 45 (4.6, 33)
*1 Oil pan upper M6 bolt
8.8 (0.90, 78) *
2
M8 bolt 21.6 (2.2, 16)
Oil pan upper to transaxle joint bolts 42.7 (4.4, 31)
*1 Oil pan lower
6.9 (0.70, 61) *
2
Oil pan drain plug34.3 (3.5, 25)
Rear plate cover
6.9 (0.70, 61) *
2
Oil level gauge guide 21.6 (2.2, 16)

EM-122
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PRECAUTIONS

[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Draining Engine CoolantEBS00LQZ
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00LR0

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

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00LR1

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 ReplacementEBS00LR2
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00LR3

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 liquid gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine 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, engine oil sliding surfaces well.

Release air within route when refilling after draining coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00LR4

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

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-132
[YD22DDTi]
DRIVE BELTS

A/C COMPRESSOR BELT
1. Remove RH engine undercover.
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust. Refer to EM-131, "
Checking
Drive Belts" .
4. Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1. Loosen adjusting lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust. Refer to EM-131, "
Tension Adjustment" .
4. Tighten nut (C) and bolt (D) in this order.
Removal and InstallationEBS00LRC
REMOVAL
1. Loosen each belt. Refer to EM-131, "Tension Adjustment" .
2. Remove A/C compressor belt. Refer to EM-132, "
A/C COMPRESSOR BELT" .
3. Remove alternator and water pump belt. Refer to EM-132, "
ALTERNATOR AND WATER PUMP BELT" .
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt tension. Refer to EM-131, "
Tension Adjustment" .
3. Tighten nuts and bolts provided for adjustment to the specified torque.
4. Make sure again that each belt tension is as specified.Nut A:
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
PBIC1252E
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)

INTAKE MANIFOLD
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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-140
[YD22DDTi]
CATALYST

INSTALLATION
Install in the reverse order of removal.

Pushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.

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
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Disassembly and AssemblyEBS00LRI
DISASSEMBLY

After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
ASSEMBLY

When a stud bolt is pulled out, tighten it to the following torque:
INSPECTION AFTER DISASSEMBLY
Surface Distortion

Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.

If it exceeds the limit, replace exhaust manifold.
1. Exhaust manifold 2. Gasket 3. Oil feed tube and oil return tube
4. Turbocharger 5. Copper washer
PBIC2435E
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
Limit : 0.3 mm (0.012 in)
JEM267G

EM-150
[YD22DDTi]
OIL PAN AND OIL STRAINER


Tighten bolts in numerical order to the specified torque.

Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.

The shank length under the bolt neck above is the length of
the threaded part (pilot portion not included).
3. Tighten transaxle joint bolts.
4. Install rear plate cover.
5. Install center member. Refer to EM-208, "
ENGINE ASSEMBLY" .
6. Install crankshaft position sensor.
7. Install oil pan lower with the following procedure.
a. Use a scraper to remove old liquid gasket from mating surfaces.
CAUTION:

Also remove old liquid gasket from mating surface of oil
pan upper.

Remove old liquid gasket from bolt hole and thread.
b. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
Use Genuine Liquid Gasket or equivalent.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.

Attaching should be done within 5 minutes after coating.M6 x 30 mm (1.18 in) : Bolt No. 15, 16
M8 x 25 mm (0.98 in) : Bolt No. 3, 4, 9, 10
M8 x 60 mm (2.36 in) : Bolt No. 1, 2, 5, 6, 7, 8,
11, 12, 13, 14
SBIA0162E
PBIC2277E
SBIA0163E
SBIA0164E

OIL PAN AND OIL STRAINER
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c. Install oil pan lower.

Tighten bolts in numerical order to the specified torque.
8. Install oil pan drain plug.

Refer to figure in EM-147, "Removal and Installation" .
9. Install in the reverse order of removal.
NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-20, "ENGINE OIL" .
2. Check for leakage of engine oil when engine is warmed.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-20, "
ENGINE OIL" .
SEM159F
SBIA0161E