engine NISSAN X-TRAIL 2003 Service Manual PDF

CYLINDER HEAD
EM-67
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CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00KNP
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure by “Without CONSULT-II”. Refer to EC-48, "
FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-510, "
FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).

Leave fuel pump fuse disconnecting to avoid fuel injection during measurement.
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-29, "
IGNITION COIL" and EM-30,
"SPARK PLUG" .
4. Connect engine tachometer (not required in use of CONSULT-II).
5. Install compression tester with adapter onto spark plug hole.

Use compression gauge whose picking up end inserted to
spark plug hole is smaller than 20 mm (0.79 in) in diameter.
Otherwise, it may be caught by cylinder head during removal.
6. 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 cyl-
inder.
Compression pressure:
Unit: kPa (bar, kg/cm2 , psi) /rpm
CAUTION:
Always use a fully changed battery to obtain specified engine speed.

If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.

If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.

If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
–If the added engine oil improves the compression, piston rings may be worn out or damaged. Check
piston rings and replace if necessary.
KBIA0130E
SBIA0533E
Engine type Standard Minimum Differential limit between cylinders
QR20DE 1,190 (11.9, 12.1, 173) / 250 990 (9.9, 10.1, 144) / 250
100 (1.0, 1.0, 14) / 250
QR25DE 1,250 (12.5, 12.8, 181) / 250 1,060 (10.6, 10.8, 154) / 250

EM-68
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CYLINDER HEAD

–If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.

If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gas-
kets.
7. After inspection is completed, install removed parts.
8. Start engine, and confirm that engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-73, "
TROUBLE DIAGNOSIS" (WITH
EURO-OBD) or EC-520, "
TROUBLE DIAGNOSIS" (WITHOUT EURO-OBD).
Removal and InstallationEBS00KNQ
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. Drain engine coolant and engine oil. Refer to CO-9, "
Changing Engine Coolant" and LU-8, "Changing
Engine Oil" .
3. Remove the following components and related parts.

Exhaust manifold and three way catalyst assembly; Refer to EM-23, "EXHAUST MANIFOLD AND
THREE WAY CATALYST" .

Intake manifold and fuel tube assembly (QR20DE); Refer to EM-17, "Removal and Installation
(QR20DE)" .

Intake manifold collector, intake manifold and fuel tube assembly (QR25DE); Refer to EM-20, "Removal
and Installation (QR25DE)" .

Water control valve and housing (water outlet); Refer to CO-22, "THERMOSTAT AND WATER CON-
TROL VALVE" .
NOTE:
Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to EM-44, "
TIMING CHAIN" .
5. Remove camshafts. Refer to EM-53, "
CAMSHAFT" .
6. Securely support bottom of cylinder block with a jack or equivalent tool, and release the hoist that was
supporting it.
1. Cylinder head assembly 2. Cylinder head gasket 3. Cylinder head bolt
PBIC2185E

CYLINDER HEAD
EM-69
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7. Remove cylinder head loosening bolts in reverse order as
shown in the figure.

Using the following tool, loosen cylinder head bolts.
NOTE:
There are two types of cylinder head bolt because of parallel
manufacture.
8. Remove cylinder head gasket.
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter

Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.

If reduction of outer diameter appears in a position other than
“d2”, use it as “d2” point.
NOTE:
When replacing any cylinder head bolts, it is possible to use them
with mixing flange bolt and bolt with washer.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-102, "
CYLIN-
DER BLOCK DISTORTION" .
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.

If it exceeds the limit, replace cylinder head.
INSTALLATION
1. Install cylinder head gasket.Bolt with washer
:Hexagonal wrench [size 10 mm (0.39 in)]
Flange bolt
:TORX socket (size E20)
KBIA0058E
Limit (“d1” – “d2”): 0.23 mm (0.0091 in)
SBIA0269E
Limit: 0.1 mm (0.004 in)
PBIC0075E

EM-70
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CYLINDER HEAD

2. Tighten cylinder head bolts in numerical order as shown in figure
with the following procedure, and install cylinder head.
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Refer to EM-69, "
Cylinder Head
Bolts Outer Diameter" .
a. Apply new engine oil to threads and seating surface of mounting
bolts.
b. Tighten all bolts.
c. Turn all bolts 60 degrees clockwise (angle tightening).
d. Completely loosen.
CAUTION:
In this step, loosen bolts in reverse order of that indicated in the figure.
e. Tighten all bolts.
f. Turn all bolts 75 degrees clockwise (angle tightening).
g. Turn all bolts 75 degrees clockwise again (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench (special service tool) or protractor. Avoid judgment
by visual inspection without the tool.
3. Install in the reverse order of removal after this step. : 5.0 N·m (0.51 kg-m, 4 ft-lb)
: 0 N·m (0 kg-m, 0 ft-lb)
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
KBIA0058E
KBIA0059E

EM-78
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ENGINE ASSEMBLY

ENGINE ASSEMBLYPFP:10001
Removal and InstallationEBS00KNT
WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:

Always be careful to work safely, avoid forceful or uninstructed operations.

Do not start working until exhaust system and engine coolant are cool enough.

If items or work required are not covered by the engine section, refer to the applicable sections.

Always use the support point specified for lifting.

Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.

For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate front suspension member, and then separate engine and transaxle.
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. RH engine mounting insulator
4. RH engine mounting bracket 5. Front engine mounting bracket 6. Front engine mounting insulator
7. Center member 8. LH engine mounting insulator 9. LH engine mounting bracket
10. Stopper 11. Grommet
PBIC2392E

ENGINE ASSEMBLY
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Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Release fuel pressure. Refer to EC-48, "
FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Disconnect both battery terminals. Refer to SC-3, "
BATTERY" .
4. Drain engine coolant from radiator. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
5. Remove the following parts.

LH and RH undercovers

Front road wheels and tyres

Battery; Refer to SC-3, "BATTERY" .

Drive belt; Refer to EM-13, "DRIVE BELTS" .

Air duct and air cleaner case assembly; Refer to EM-15, "AIR CLEANER AND AIR DUCT" .

Alternator; Refer to SC-12, "CHARGING SYSTEM" .

Radiator and radiator cooling fan assembly; Refer to CO-12, "RADIATOR" .
6. Disconnect engine room harness from the engine side and set it aside for easier work.
7. Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine Room LH
1. Disconnect fuel feed hose, and plug it to prevent fuel from draining. Refer to EM-32, "FUEL INJECTOR
AND FUEL TUBE"
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
3. Disconnect control cable from transaxle (A/T models). Refer to AT- 4 0 4 , "
ON-VEHICLE SERVICE" .
4. Disconnect clutch operating cylinder from transaxle, and move it aside (M/T models). Refer to CL-10,
"OPERATING CYLINDER" .
5. Disconnect shift and select cable from transaxle (M/T models). Refer to MT-14, "
CONTROL LINKAGE" .
Engine Room RH
1. Remove engine coolant reservoir tank. Refer to CO-12, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on vehicle side with a
rope to avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM" .
2. Remove propeller shaft. Refer to PR-3, "
REAR PROPELLER SHAFT" .
3. Remove steering lower joint from steering gear. Refer to PS-10, "
STEERING COLUMN" .
4. Disconnect power steering fluid piping at a point between vehicle and engine. Refer to PS-34, "
HYDRAU-
LIC LINE" .
5. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter
(A/T models). Refer to EM-25, "
OIL PAN AND OIL STRAINER" and AT- 4 1 3 , "REMOVAL AND INSTALLA-
TION" .
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-17, "
TRAN-
SAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 , "REMOVAL AND INSTALLATION" (A/T models).
7. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-45, "
WHEEL SEN-
SORS" (ABS) or BRC-116, "WHEEL SENSORS" (ESP/TCS/ABS).
8. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on
vehicle side with a rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
9. Remove lower ends of left and right strut from steering knuckle. Refer to FSU-5, "
FRONT SUSPENSION
ASSEMBLY" .
Removal
1. Install engine slingers into front left of cylinder head and rear right of cylinder head.

EM-80
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ENGINE ASSEMBLY


Use alternator bracket mounting bolt holes for the front side.
2. Lift with hoist and secure engine in position.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove mounting bolts at front end of center member.
7. Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "
FRONT SUSPENSION ASSEMBLY" .
8. Remove engine, transaxle and transfer assembly with front suspension member and center member from
vehicle downward by carefully operating supporting tools.
CAUTION:

During the operation, make sure that no part interferes with vehicle side.

Before and during this lifting, always check if any harnesses are left connected.

During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.

If necessary, support vehicle by setting a jack or equivalent tool at the rear.Slinger bolts:
Front
: 57.9 N·m (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0271E
KBIA0256E
PBIC2188E
KBIA0270E

ENGINE ASSEMBLY
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9. Remove power steering oil pump with piping connected from engine. Move it aside on front suspension
member. Refer to PS-34, "
HYDRAULIC LINE" .
10. Remove front engine mounting and rear engine mounting through-bolts to remove front suspension mem-
ber and center member.
11. Remove starter motor. Refer to SC-21, "
STARTING SYSTEM" .
12. Separate engine and transaxle. Refer to MT-17, "
TRANSAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 ,
"REMOVAL AND INSTALLATION" (A/T models).
INSTALLATION
Note the following, and 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-78, "
Removal and Installation" .

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.

Use procedure below to make sure there is no fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, make sure there
are no fuel leaks at connection points.
–Start engine. With engine speed increased, check again if there are no fuel leaks at connection points.

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid,
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
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DISASSEMBLY
1. Remove engine, transaxle and transfer assembly from vehicle, and separate transaxle and transfer
assembly from engine. Refer to EM-78, "
ENGINE ASSEMBLY" .
2. Mount engine on an engine stand with the following procedure:
a. Remove oil cooler with oil cooler bracket on right side of cylinder block. Refer to LU-11, "
OIL COOLER" .
b. Install engine sub-attachment (special service tool) to right side
of cylinder block.

Do not use bolt hole at the upper right looking from bolt inser-
tion side as shown in the figure.

Machine a bolt hole at the lower right of the engine sub-
attachment looking from bolt insertion side as shown in the
figure.
c. Lift engine, and mount it onto the engine stand (special service
tool).
PBIC2190E
SBIA0272E
KBIA0140E

EM-84
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CYLINDER BLOCK


A widely use engine stand can be used.
NOTE:
This example is an engine stand for holding at transaxle
mounting side with flywheel (M/T models) or drive plate (A/T
models) removed.
3. Drain engine oil. Refer to LU-8, "
Changing Engine Oil" .
4. Drain engine coolant by removing water drain plug from inside of
engine.
5. Remove cylinder head. Refer to EM-67, "
CYLINDER HEAD" .
6. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS).
CAUTION:

Avoid impacts such as a dropping.

Do not disassemble.

Keep it away from metal particles.

Do not place sensor in a location where it is exposed to
magnetism.
8. Remove clutch cover and clutch disc (M/T models). Refer to CL-14, "
CLUTCH DISC, CLUTCH COVER
AND FLYWHEEL" .
9. Remove flywheel (M/T models) or drive plate (A/T models).

Secure crankshaft with a stopper plate, and remove mounting
bolts.

Using the following TORX socket, loosen mounting bolts.
CAUTION:
Be careful not to damage contact surface for clutch disc of
flywheel (M/T models).
PBIC0085E
PBIC2443E
PBIC2191E
Flywheel (M/T models)
: size T55 (commercial service tool)
Drive plate (A/T models)
: size E20
PBIC2352E