engine NISSAN X-TRAIL 2003 Service Manual Online

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-109
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00KNX
GENERAL SPECIFICATIONS
DRIVE BELT
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
SPARK PLUG
Unit: mm (in)
CYLINDER HEAD
Unit: mm (in) Engine typeQR20DE QR25DE
Cylinder arrangementIn-line 4
Displacement
cm
3 (cu in)1,998 (121.92) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 80.3 (3.504 x 3.161) 89.0 x 100.0 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Compression ratio 9.0 9.5
Compression pressure
kPa (bar, kg/cm
2 , psi) / 250 rpmStandard 1,190 (11.9, 12.1, 173) 1,250 (12.5, 12.8, 181)
Minimum 990 (9.9, 10.1, 144) 1,060 (10.6, 10.8, 154)
Differential limit between cylinders 100 (1.0, 1.0, 14)
Tension of drive belt Auto adjustment by auto-tensioner
Items Limit
Surface distortionIntake manifold collector (QR25DE) 0.1 (0.004)
Intake manifold (QR25DE) 0.1 (0.004)
Exhaust manifold and three way catalyst assembly 0.3 (0.012)
MakeNGK
Standard typeLFR5A-11
Hot typeLFR4A-11
Cold typeLFR6A-11
Spark plug gap Standard 1.0 - 1.1 (0.039 - 0.043)
ItemsLimit
Head surface distortion 0.1 (0.004)
PBIC0283E

EM-110
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SERVICE DATA AND SPECIFICATIONS (SDS)

VA LV E
Valve Timing
Unit: degree
( ): Valve timing control “ON”
Valve Dimensions
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*: Approximately 20°C (68°F) Va l v e t i m i n g
Engine type a b c d e f
QR20DE 212 236 -4 (26) 60 (30)
329
QR25DE 224 244 0 (30) 64 (27) 41
PBIC0187E
Valve head diameter “D”Intake 35.5 - 35.8 (1.398 - 1.409)
Exhaust 30.5 - 30.8 (1.201 - 1.213)
Valve length “L”Intake 97.16 (3.8252)
Exhaust 98.82 (3.8905)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Valve seat angle “α”Intake
45°15′ - 45°45′
Exhaust
Valve margin “T”Intake 1.1 (0.043)
Exhaust 1.3 (0.051)
SEM188A
Items Hot Cold* (reference data)
Intake 0.32 - 0.40 (0.013 - 0.016) 0.24 - 0.32 (0.009 - 0.013)
Exhaust 0.33 - 0.41 (0.013 - 0.016) 0.26 - 0.34 (0.010 - 0.013)

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.

PRECAUTIONS
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Precautions For Liquid GasketEBS00ODW
REMOVAL OF LIQUID GASKET

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

In areas where the seal cutter (special service tool) is difficult to
use, use a plastic hammer to lightly tap (1) the seal cutter where
the liquid gasket is applied. Use a plastic hammer to slide the
seal cutter (2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
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 the 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. If specified, it should be applied outside the holes.
Make sure to read the instruction in this 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 after the installation.

After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

EM-124
[YD22DDTi]
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsEBS00LR6
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV11105900
Engine sub-attachmentUsed with KV10106500
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV11103000
Pulley pullerRemoving crankshaft pulley
ED19600610
Compression gauge adapterChecking compression pressure
NT042
NT028
NT799
NT603
S-NT605
NT676
ZZA1188D

PREPARATION
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Commercial Service ToolsEBS00LR7
KV11106050
Hexagonal wrenchRemoving and installing fuel pump sprocket
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
KV11106060
Sprocket holderHolding fuel pump sprocket Tool number
Tool nameDescription
SBIA0224E
SBIA0225E
Tool nameDescription
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
Manual lift table caddy Removing and installing engine
Valve guide reamer Reaming valve guide with (1) or hole for
oversize valve guide with (2)
Intake and Exhaust:
d
1 = 6.0 mm (0.236 in) dia.
d
2 = 10.2 mm (0.402 in) dia.
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
NT048
NT030
ZZA1210D
NT016
NT015

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting — Engine NoiseEBS00LR8
PBIC2311E

EM-130
[YD22DDTi]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00LR9
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-175
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-172EM-171
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearanceEM-226
EM-228
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-230EM-227
EM-227
EM-228
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance (Big
end)EM-228EM-232
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-233EM-232
Front of
engine
Timin g
chain
caseTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-180
EM-185
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-131
Creaking A B A B A BDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-42,
"WATER
PUMP"

DRIVE BELTS
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LRA

Before inspecting engine, make sure engine has cooled down;
wait approximately 30 minutes after engine has been stopped.

Visually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.

When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:

When checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.

Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00LRB

Adjust belts with the parts shown below.
CAUTION:

When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.

If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.

When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.

Make sure the belts are fully fitted into the pulley grooves during installation.

Handle with care to avoid smearing the belts with engine oil or engine coolant.

Do not twist or bend the belts with strong force.
PBIC1251E
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
A/C compressor belt Adjusting bolt on idler pulley
Alternator and water pump belt Adjusting bolt on alternator

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)