acc NISSAN X-TRAIL 2003 Service Owner's Guide

EM-196
[YD22DDTi]
CYLINDER HEAD

CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00LRV
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-905,
"Basic Inspection" (WITH EURO-ODB) or EC-1231, "Basic Inspection" (WITHOUT EURO-ODB).

Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove charge air cooler. Refer to EM-135, "
Removal and Installation"
5. To prevent fuel from being injected during inspection, remove
fuel pump fuse [ENG CONT 2 (20A)] from fuse box on the left
side of engine room.

Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
pump fuse.
6. Remove glow plugs from all the cylinders. Refer to EM-152,
"Removal and Installation" .
CAUTION:

Before removal, clean the surrounding area to prevent
entry of any foreign materials into engine.

Carefully remove glow plugs to prevent any damage or
breakage.

Handle with care to avoid applying any shock to glow plugs.
7. Install compression gauge adapter (special service tool) to
installation holes of glow plugs and connect compression gauge
for diesel engine.
8. Connect battery negative terminal.
9. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.

Always use a fully-charged battery to obtain specified engine
speed.
Compression pressure
Unit: kPa (bar, kg/cm2 , psi)/rpm

When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.

If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.

If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.

If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
PBIC0680E
: 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
SEM112G
Standard Minimum Difference limit between cylinders
2,991 (29.9, 30.5, 434)/200 2,452 (24.5, 25.0, 356)/200 490 (4.9, 5.0, 71)/200

EM-200
[YD22DDTi]
CYLINDER HEAD

*: Measured with head bolts tightened
2. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
3. Install cylinder head assembly.

Tighten bolts in numerical order as shown in the figure
according to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten all bolts.
c. Tighten 180 degrees to 185 degrees [target: 180 degrees]
(angle tightening).
d. Loosen completely in reverse order of that shown in the figure.
e. Tighten all bolts.
f. Tighten 90 degrees to 95 degrees [target: 90 degrees] (angle
tightening).
g. Tighten another 90 degrees to 95 degrees [target: 90 degrees]
(angular tightening).
CAUTION:

When the angle wrench (special service tool) is not used, paint an alignment mark on the head
of cylinder head bolt and cylinder head surface before tightening. Check the angle with a pro-
tractor.
Piston protrusion mm (in) Gasket thickness* mm (in)Identification
Number of cut-outs
Less than 0.255 (0.0100) 0.900 (0.0354) 0
Less than 0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
Less than 0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
Less than 0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
Less than 0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
More than 0.355 (0.0140) 1.025 (0.0404) 5
PBIC1256E
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
JEM149G
: 0 N·m (0 kg-m, 0 ft-lb)
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
JEM166G

ENGINE ASSEMBLY
EM-211
[YD22DDTi]
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8. Remove power steering oil pump with piping connected from engine. Move it aside on suspension mem-
ber. Refer to PS-34, "
HYDRAULIC LINE" .
9. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
10. Remove starter motor. Refer to SC-21, "
STARTING SYSTEM" .
11. Separate engine and transaxle. Refer to MT-17, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.

Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-208, "
ENGINE ASSEMBLY" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION

Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than
required quantity, fill to the specified level.

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working
engine oil, fuel and exhaust gas.

Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.

After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level
Fuel — Leakage —
Exhaust gas — Leakage —

CYLINDER BLOCK
EM-215
[YD22DDTi]
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Vacuum pump (Refer to EM-153, "Removal and Installation" .)

Secondary timing chain (Refer to EM-180, "Removal and Installation" .)

Primary timing chain (Refer to EM-185, "Removal and Installation" .)

Fuel pump (Refer to EM-161, "Removal and Installation" .)

Camshaft (Refer to EM-170, "Removal and Installation" .)

Cylinder head (Refer to EM-197, "Removal and Installation" .)

Oil cooler (Refer to LU-28, "OIL COOLER" .)

Accessory, accessory bracket and mount brackets
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.

Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.

Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
11. Remove piston and connecting rod assembly.

Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-226, "
CONNECT-
ING ROD SIDE CLEARANCE" .
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION:
When removing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.
12. Remove connecting rod bearings from connecting rods and
caps.

Keep them by cylinder to avoid confusion.
13. Remove piston rings from pistons using the piston ring expander
(commercial service tool).
CAUTION:

When removing, prevent pistons from being damaged.

Do not expand piston rings excessively. This may dam-
age piston rings.
JEM195G
FEM086
JEM196G

EM-218
[YD22DDTi]
CYLINDER BLOCK

8. With the TORX socket (size: E14, commercial service tool),
tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees to 95 degrees [target: 90 degrees].
(angle tightening)
CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angular tightening. Avoid tightening
based on visual checks alone.

After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.

Check crankshaft end play. Refer to EM-226, "CRANKSHAFT
END PLAY" .
9. Check the outer diameter of connecting rod bolts. Refer to EM-
234, "CONNECTING ROD BOLT DEFORMATION" .
10. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.

Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.

Using the industrial use dryer, heat pistons up to approx. 60 to
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.

Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.

Refer to above step a for precaution on snap ring installation.

After installation, check connecting rods for smooth move-
ment.
11. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.: 25 - 30 N·m (2.5 - 3.1 kg-m, 18 - 22 ft-lb)
JEM200G
JEM226G
PBIC0089E
MBIA0024E

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-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

EM-232
[YD22DDTi]
CYLINDER BLOCK


If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-233, "
MAIN BEARING OIL CLEARANCE" and/or EM-
232, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT

Place V-block onto surface plate to support journals at both ends
of crankshaft.

Position dial gauge vertically onto No. 3 journal.

Rotate crankshaft to read needle movement on dial gauge.
(Total indicator reading)

If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement

Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer to EM-217,
"ASSEMBLY" . Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)

If clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin outer diameter to obtain specified bearing oil
clearance. Refer to EM-223, "
HOW TO SELECT CONNECTING
ROD BEARING" .
Method of Using Plastigage

Remove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.

Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.

Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Do not rotate crankshaft.

Remove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.031 - 0.061 mm (0.0012 - 0.0024 in)
PBIC1642E
EM142

EC-1
ENGINE CONTROL SYSTEM
B ENGINE
CONTENTS
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SECTION EC
A
EC

ENGINE CONTROL SYSTEM
QR (WITH EURO-OBD)
INDEX FOR DTC ...................................................... 19
Alphabetical Index .................................................. 19
DTC No. Index ....................................................... 21
PRECAUTIONS ........................................................ 24
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................ 24
On Board Diagnostic (OBD) System of Engine and
A/T .......................................................................... 24
Precaution .............................................................. 24
Wiring Diagrams and Trouble Diagnosis ................ 27
PREPARATION ......................................................... 28
Special Service Tools ............................................. 28
Commercial Service Tools ...................................... 29
ENGINE CONTROL SYSTEM .................................. 30
System Diagram ..................................................... 30
Vacuum Hose Drawing ........................................... 32
System Chart ......................................................... 34
Multiport Fuel Injection (MFI) System .................... 34
Electronic Ignition (EI) System ............................... 37
Air Conditioning Cut Control ................................... 37
Fuel Cut Control (at No Load and High Engine
Speed) .................................................................... 38
CAN Communication Unit ...................................... 38
BASIC SERVICE PROCEDURE .............................. 44
Idle Speed and Ignition Timing Check .................... 44
Accelerator Pedal Released Position Learning ...... 45
Throttle Valve Closed Position Learning ................ 46
Idle Air Volume Learning ........................................ 46
Fuel Pressure Check .............................................. 48
ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 51
Introduction ............................................................ 51
Two Trip Detection Logic ........................................ 51
Emission-related Diagnostic Information ................ 52
NATS (Nissan Anti-theft System) ........................... 64
Malfunction Indicator (MI) ....................................... 64
OBD System Operation Chart ................................ 67
TROUBLE DIAGNOSIS ............................................ 73
Trouble Diagnosis Introduction ............................... 73DTC Inspection Priority Chart ................................. 76
Fail-safe Chart ........................................................ 77
Basic Inspection ..................................................... 79
Symptom Matrix Chart ............................................ 84
Engine Control Component Parts Location ............ 88
Circuit Diagram ....................................................... 93
ECM Harness Connector Terminal Layout ............. 95
ECM Terminals and Reference Value ..................... 95
CONSULT-II Function ...........................................102
Generic Scan Tool (GST) Function .......................112
CONSULT-II Reference Value in Data Monitor Mode
.114
Major Sensor Reference Graph in Data Monitor
Mode .....................................................................116
TROUBLE DIAGNOSIS - SPECIFICATION VALUE .119
Description ............................................................119
Testing Condition ..................................................119
Inspection Procedure ............................................119
Diagnostic Procedure ...........................................120
TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-
DENT .......................................................................123
Description ............................................................123
Diagnostic Procedure ...........................................123
POWER SUPPLY AND GROUND CIRCUIT ...........124
Wiring Diagram .....................................................124
Diagnostic Procedure ...........................................125
Component Inspection ..........................................131
Ground Inspection ................................................131
DTC U1000, U1001 CAN COMMUNICATION LINE .132
Description ............................................................132
On Board Diagnosis Logic ....................................132
DTC Confirmation Procedure ...............................132
Wiring Diagram .....................................................133
Diagnostic Procedure ...........................................134
DTC P0011 IVT CONTROL .....................................135
Description ............................................................135
CONSULT-II Reference Value in Data Monitor Mode
.135
On Board Diagnosis Logic ....................................136

EC-6 PREPARATION .......................................................490
Special Service Tools ...........................................490
Commercial Service Tools ....................................491
ENGINE CONTROL SYSTEM ................................492
System Diagram ...................................................492
Vacuum Hose Drawing .........................................494
System Chart ........................................................496
Multiport Fuel Injection (MFI) System ...................496
Electronic Ignition (EI) System .............................499
Air Conditioning Cut Control .................................499
Fuel Cut Control (at No Load and High Engine
Speed) ..................................................................500
CAN Communication Unit .....................................500
BASIC SERVICE PROCEDURE .............................506
Idle Speed and Ignition Timing Check ..................506
Accelerator Pedal Released Position Learning ....507
Throttle Valve Closed Position Learning ...............508
Idle Air Volume Learning ......................................508
Fuel Pressure Check ............................................510
ON BOARD DIAGNOSTIC (OBD) SYSTEM ..........513
Introduction ...........................................................513
Two Trip Detection Logic ......................................513
Emission-related Diagnostic Information ..............513
NATS (Nissan Anti-theft System) ..........................515
Malfunction Indicator (MI) .....................................516
TROUBLE DIAGNOSIS ..........................................520
Trouble Diagnosis Introduction .............................520
DTC Inspection Priority Chart ...............................523
Fail-safe Chart ......................................................524
Basic Inspection ...................................................526
Symptom Matrix Chart ..........................................532
Engine Control Component Parts Location ..........536
Circuit Diagram .....................................................541
ECM Harness Connector Terminal Layout ...........543
ECM Terminals and Reference Value ...................543
CONSULT-II Function ...........................................551
CONSULT-II Reference Value in Data Monitor Mode
.561
Major Sensor Reference Graph in Data Monitor
Mode .....................................................................563
TROUBLE DIAGNOSIS - SPECIFICATION VALUE .566
Description ............................................................566
Testing Condition ..................................................566
Inspection Procedure ............................................566
Diagnostic Procedure ...........................................567
TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-
DENT .......................................................................570
Description ............................................................570
Diagnostic Procedure ...........................................570
POWER SUPPLY AND GROUND CIRCUIT ...........571
Wiring Diagram .....................................................571
Diagnostic Procedure ...........................................572
Component Inspection ..........................................578
Ground Inspection ................................................578
DTC U1000, U1001 CAN COMMUNICATION LINE .579
Description ............................................................579
On Board Diagnosis Logic ....................................579
DTC Confirmation Procedure ...............................579Wiring Diagram .....................................................580
Diagnostic Procedure ............................................581
DTC P0011 IVT CONTROL .....................................582
Description ............................................................582
CONSULT-II Reference Value in Data Monitor Mode
.582
On Board Diagnosis Logic ....................................583
DTC Confirmation Procedure ................................583
Overall Function Check .........................................585
Wiring Diagram .....................................................586
Diagnostic Procedure ............................................587
Component Inspection ..........................................589
Removal and Installation .......................................589
DTC P0102, P0103 MAF SENSOR .........................590
Component Description ........................................590
CONSULT-II Reference Value in Data Monitor Mode
.590
On Board Diagnosis Logic ....................................590
DTC Confirmation Procedure ................................590
Wiring Diagram .....................................................592
Diagnostic Procedure ............................................593
Component Inspection ..........................................596
Removal and Installation .......................................596
DTC P0117, P0118 ECT SENSOR ..........................597
Component Description ........................................597
On Board Diagnosis Logic ....................................597
DTC Confirmation Procedure ................................598
Wiring Diagram .....................................................599
Diagnostic Procedure ............................................600
Component Inspection ..........................................602
Removal and Installation .......................................602
DTC P0122, P0123 TP SENSOR ............................603
Component Description ........................................603
CONSULT-II Reference Value in Data Monitor Mode
.603
On Board Diagnosis Logic ....................................603
DTC Confirmation Procedure ................................603
Wiring Diagram .....................................................605
Diagnostic Procedure ............................................607
Component Inspection ..........................................610
Removal and Installation .......................................610
DTC P0132 HO2S1 .................................................611
Component Description ........................................611
CONSULT-II Reference Value in Data Monitor Mode
.611
On Board Diagnosis Logic ....................................611
DTC Confirmation Procedure ................................612
Wiring Diagram .....................................................613
Diagnostic Procedure ............................................614
Component Inspection ..........................................616
Removal and Installation .......................................617
DTC P0134 HO2S1 .................................................618
Component Description ........................................618
CONSULT-II Reference Value in Data Monitor Mode
.618
On Board Diagnosis Logic ....................................618
Overall Function Check .........................................619
Wiring Diagram .....................................................620
Diagnostic Procedure ...........................................