lock NISSAN X-TRAIL 2003 Service Manual PDF

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)

CATALYST
EM-139
[YD22DDTi]
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
3. Remove radiator upper and lower hoses. Refer to CO-34, "
RADIATOR" .
4. Remove cooling fan. Refer to CO-36, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-34, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-44, "
THERMOSTAT AND WATER PIPING" .
7. Remove catalyst insulators.
8. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
1. Catalyst insulator 2. Gasket 3. Catalyst
4. Locking pin 5. Gusset 6. Gasket cap
7. Catalyst rear diffuser
PBIC2312E
Catalyst locking pin : Flange bolt (black)

OIL PAN AND OIL STRAINER
EM-149
[YD22DDTi]
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13. Loosen bolts in reverse order of illustration to remove oil pan
upper.
14. Remove oil pan upper.

Insert the Seal cutter (special service tool) between oil pan
upper and cylinder block. Slide the Seal cutter by tapping on
the side of the Seal cutter with a hammer. Remove oil pan
upper.

Be careful not to damage aluminum mating surface.

Do not insert screwdriver, or oil pan flange will be
deformed.
15. Remove oil strainer.
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install oil strainer.
2. Install oil pan upper with the following procedure.
a. Use the scraper to remove old liquid gasket from mating sur-
faces.

Also remove old liquid gasket from mating surface of cyl-
inder block, rear chain case and oil pan lower.

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

At the 8 bolt holes marked , liquid gasket should be
applied outside holes.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the silicon bead is different around the
front.)

Attaching should be done within 5 minutes after coating.
c. Install oil pan upper.
SBIA0162E
SEM365EA
JEM117G
PBIC2314E

CAMSHAFT
EM-171
[YD22DDTi]
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Loosen the camshaft sprocket mounting bolt by fixing the hex-
agonal portion of camshaft.
10. Remove camshaft.

Place distinguishing marks on the right and left sides with paint.

Loosen and remove the camshaft sprocket bolts in reverse
order shown in the figure.
11. Remove adjusting shim and valve lifter.

Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
INSPECTION AFTER REMOVAL
Visual Check of Camshaft

Check the camshaft for one sided wear or scratches.

Replace the camshaft if there are abnormalities.
Camshaft Runout

Prepare V-block on a flat surface and secure camshaft journals
No. 2 and No. 5.

Set the dial gauge vertically on journal No. 3.

Rotate camshaft in one direction by hand, then read needle
movement on dial gauge. (Total indicator reading)

If it exceeds the limit, replace camshaft.
JEM159G
JEM160G
Limit : 0.02 mm (0.0008 in)
JEM161G

EM-176
[YD22DDTi]
CAMSHAFT


Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
1. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
2. Remove air duct. Refer to EM-133, "
Removal and Installation" .
3. Remove rocker cover. Refer to EM-168, "
Removal and Installation" .
4. Remove fuel injector. Refer to EM-157, "
Removal and Installation" .
5. Set the No. 1 piston to TDC on its compression stroke.

Turn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
6. Put an alignment mark with paint, etc. on crankshaft pulley and
on oil pump housing as an angle indicator.
7. While referring to the figure, measure the valve clearance
marked in the table below.
NOTE:

The injection order is 1-3-4-2.
SBIA0178E
PBIC2533E
JEM177G
Measuring pointNo. 1No. 2No. 3No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCXXX X
SBIA0180E

CAMSHAFT
EM-177
[YD22DDTi]
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Measure the valve clearance using the feeler gauge when
engine is cool (at normal temperature).
8. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
9. While referring to the figure, measure the valve clearance
marked in the table below.
10. If the valve clearance is outside the specification, adjust as fol-
lows.
ADJUSTMENTS

Remove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
3. Grip camshaft with the camshaft pliers (special service tool),
then using camshaft as a support point, push adjusting shim
downward to compress valve spring.
CAUTION:
Do not damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.Valve clearance (Cold):
Standard:
Intake : 0.24 - 0.32 mm (0.0094 - 0.0126 in)
Exhaust : 0.26 - 0.34 mm (0.0102 - 0.0134 in)
SBIA0181E
Measuring pointNo. 1No. 2No. 3No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDCXX XX
SBIA0182E
SBIA0183E
PBIC2321E

SECONDARY TIMING CHAIN
EM-181
[YD22DDTi]
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Loosen fixing bolts in reverse order of that shown in the figure
and remove them.

Remove No. 6, 10 and 11 bolts with the rubber washer as
space is limited for pulling them out.
CAUTION:

While front chain case is removed, cover openings to
prevent entry of foreign material into engine.

Do not remove two mass dampers on the back of
cover.
5. Set the No. 1 piston to TDC on its compression stroke.

Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.

No position indicator is provided on crankshaft pulley.

When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not
be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.
6. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
JEM121G
SBIA0189E
SEM515G
JEM124G

PRIMARY TIMING CHAIN
EM-191
[YD22DDTi]
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a. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) on locations shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
c. Install rear chain case.

When installing, align the dowel pin with the pin hole.
PBIC1255E
JEM141G

EM-194
[YD22DDTi]
PRIMARY TIMING CHAIN

a. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing.
b. Install oil pump drive spacer to crankshaft.

Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
d. Install oil pump housing.

When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.

When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
14. Check gaps on upper oil pan mounting surface.

Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:

If the measured value is out of the standard, install again.
15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
JEM144G
JEM145G
JEM133G
Oil pump housing and rear chain case:
Standard : – 0.09 to 0.09 mm (– 0.0035 to 0.0035 in)
Rear chain case and cylinder block:
Standard : – 0.19 to 0.07 mm (– 0.0075 to 0.0028 in)
JEM146G

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