NISSAN X-TRAIL 2003 Service Workshop Manual

TERMINOLOGY
GI-49
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***: Not applicableTransmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
temWU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter sys-
temWU-TWC system ***
Wide open throttle position switch WOTP switch Full switchNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

GI-50
TERMINOLOGY

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
EM

ENGINE MECHANICAL
QR
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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EMA
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

EM-4 INSTALLATION ..................................................199
Disassembly and Assembly ..................................201
DISASSEMBLY .................................................201
ASSEMBLY .......................................................202
INSPECTION AFTER DISASSEMBLY ..............203
ENGINE ASSEMBLY ..............................................208
Removal and Installation ......................................208
REMOVAL .........................................................209
INSTALLATION ..................................................211
INSPECTION AFTER INSTALLATION ..............211
CYLINDER BLOCK .................................................212
Disassembly and Assembly ..................................212
DISASSEMBLY .................................................213
ASSEMBLY .......................................................217
How to Select Piston and Bearing ........................222
DESCRIPTION ..................................................222
HOW TO SELECT PISTON ...............................222
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................223
HOW TO SELECT MAIN BEARING ..................224
Inspection After Disassembly ...............................226
CRANKSHAFT END PLAY ................................226
CONNECTING ROD SIDE CLEARANCE .........226
PISTON TO PISTON PIN CLEARANCE ...........226
PISTON RING SIDE CLEARANCE ...................227
PISTON RING END GAP ..................................227
CONNECTING ROD BEND AND TORSION .....228
CONNECTING ROD BIG END INNER DIAME-
TER ...................................................................228
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................228
CYLINDER BLOCK TOP SURFACE DISTOR-TION ..................................................................229
MAIN BEARING HOUSING INNER DIAMETER .229
PISTON TO CYLINDER BORE CLEARANCE ..230
CRANKSHAFT JOURNAL OUTER DIAMETER .231
CRANKSHAFT PIN OUTER DIAMETER ..........231
CRANKSHAFT OUT-OF-ROUND AND TAPER .231
CRANKSHAFT RUNOUT ..................................232
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................232
MAIN BEARING OIL CLEARANCE ...................233
CRUSH HEIGHT OF MAIN BEARING ..............233
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................233
MAIN BEARING CAP BOLT DEFORMATION ...234
CONNECTING ROD BOLT DEFORMATION ....234
OIL JET ..............................................................234
OIL JET RELIEF VALVE ....................................234
FLYWHEEL DEFLECTION ................................235
MOVEMENT AMOUNT OF FLYWHEEL ...........235
SERVICE DATA AND SPECIFICATIONS (SDS) ....236
Standard and Limit ................................................236
GENERAL SPECIFICATIONS ...........................236
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................236
DRIVE BELTS ....................................................236
CYLINDER HEAD ..............................................237
VALVE ................................................................237
CAMSHAFT .......................................................241
CYLINDER BLOCK ............................................241
PISTON, PISTON RING AND PISTON PIN ......242
CONNECTING ROD ..........................................243
CRANKSHAFT ...................................................243
AVAILABLE MAIN BEARING .............................244
AVAILABLE CONNECTING ROD BEARING .....244
MISCELLANEOUS COMPONENTS ..................244
Tightening Torque .................................................245

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-6
[QR]
PRECAUTIONS

Precautions for Liquid GasketEBS00MRW
REMOVAL OF LIQUID GASKET

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter (special service tool) and remove the
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.

In areas where seal cutter (special service tool) is difficult to use,
use a plastic hammer to lightly tap (1) seal cutter where the liq-
uid gasket is applied. Use a plastic hammer to slide seal cutter
(2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.

Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser (special service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.

If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of service manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If the liquid gasket protrudes, wipe it off immediately.

Do not retighten mounting bolts or nut after the installation.

Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEBS00L7N
Tool number
Tool nameDescription
KV10111100
Seal cutterRemoving oil pan and timing chain case
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV10115300
Engine sub-attachment
KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
AdapterDisassembling and assembling valve
mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc.
KV10117100
Heated oxygen sensor wrenchLoosening or tightening heated oxygen
sensors with 22 mm (0.87 in) hexagon nut
S-NT046
NT042
NT028
ZZA1078D
PBIC1650E
S-NT014
NT379

EM-8
[QR]
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