Chain NISSAN X-TRAIL 2003 Service Repair Manual

PRECAUTIONS
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PRECAUTIONSPFP:00001
DescriptionEAS000FN
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EAS000P8
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for NATS (NISSAN ANTI-THEFT SYSTEM)EAS000FP
NATS will immobilize the engine if someone tries to start it without the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.

When NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.

When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-
II operation manual, NATS.
Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly con-
fidential to maintain the integrity of the anti-theft function.

When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to
receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS.

When failing to start the engine first time using the key of NATS, start as follows.
1. Leave the ignition key in "ON" position for approximately 5 seconds.
2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds.
3. Repeat step 1 and 2 again.
4. Restart the engine while keeping the key separate from any others on key-chain.

TOW TRUCK TOWING
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TOW TRUCK TOWINGPFP:00000
Tow Truck TowingEAS000FL
CAUTION:

All applicable local laws regarding the towing operation must be obeyed.

It is necessary to use proper towing equipment to avoid possible damage to the vehicle during
towing operation. Towing is in accordance with Towing Procedure Manual at dealer.

Always attach safety chains before towing.

When towing, make sure that the transmission, steering system and power train are in good order.
If any unit is damaged, dollies must be used.

Never tow an automatic transmission model from the rear (that is backward) with four wheels on
the ground. This may cause serious and expensive damage to the transmission.
NISSAN recommends that towing dollies be used when towing your
vehicle beplaced on a flat bed truck as illustrated.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND
Observe the following restricted towing speeds and distances.
CAUTION:
Never tow an automatic transaxle model from the rear (i.e., backward) with four wheels on the ground
as this may cause serious and expensive damage to the transaxle.
PAIA0012E
Speed :Below 50 km/h (30 MPH)
Distance :Less than 65 km(40 miles)

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

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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

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-12
[QR]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00L7Q
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-61
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-56EM-55
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-99
EM-101
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-104EM-100
EM-100
EM-101
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-101EM-105
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-106EM-105
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-48
EM-44
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-20,
"WATER
PUMP"

EM-44
[QR]
TIMING CHAIN

TIMING CHAINPFP:13028
Removal and InstallationEBS00KNL
REMOVAL
1. Remove the following parts.
1. O-ring 2. Camshaft sprocket (INT) 3. Camshaft sprocket (EXH)
4. Chain tensioner 5. Spring 6. Chain tensioner plunger
7. Timing chain slack guide 8. Timing chain 9. Front cover
10. Chain guide 11.Intake valve timing control solenoid
valve12. Intake valve timing control cover
13. RH engine mounting bracket 14. Crankshaft pulley bolt 15. Crankshaft pulley
16. Front oil seal 17. Balancer unit timing chain tensioner 18. Oil pump drive spacer
19. Crankshaft sprocket 20. Timing chain tension guide 21. Balancer unit timing chain
22. Balancer unit 23. Oil ring
PBIC2181E

TIMING CHAIN
EM-45
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Hood assembly; Refer to BL-12, "HOOD" .

RH and LH undercovers

PCV hose; Refer to EM-17, "INTAKE MANIFOLD" .

Ignition coil; Refer to EM-29, "IGNITION COIL" .

Rocker cover; Refer to EM-42, "ROCKER COVER" .

Engine coolant reservoir tank; Refer to CO-12, "RADIATOR" .

Drive belt; Refer to EM-13, "REMOVAL" .

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

Drive belt auto-tensioner; Refer to EM-14, "REMOVAL" .

Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" .
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Remove power steering oil pump with piping connected, and secure it to vehicle side temporarily. Refer to
PS-34, "
HYDRAULIC LINE" .
5. Remove power steering reservoir tank from bracket to move power steering piping. Refer to PS-34,
"HYDRAULIC LINE" .
CAUTION:
To avoid power steering fluid leakage, temporarily fix power steering reservoir tank vertically.
6. Install engine slingers into front left of cylinder head and rear
right of cylinder head.

Use alternator bracket mounting bolt holes for the front side.
7. Lift with hoist, and support the engine posture.
8. Remove RH engine mounting insulator and bracket. Refer to EM-78, "
ENGINE ASSEMBLY" .
9. Remove center member and rear engine mounting bracket. Refer to EM-78, "
ENGINE ASSEMBLY" .
10. Drain engine oil. Refer to LU-8, "
Changing Engine Oil" .
11. Remove oil pan (upper and lower), and oil strainer. Refer to EM-25, "
OIL PAN AND OIL STRAINER" .
12. Remove intake valve timing control cover.

Loosen bolts in reverse order as shown in the figure.

U s e a s e a l c u t t e r ( s p e c i a l s e r v i c e t o o l : K V 1 0 1111 0 0 ) o r e q u i v -
alent tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage mounting surface.
13. Pull chain guide between camshaft sprockets out through front cover.
14. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: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
KBIA0085E

EM-46
[QR]
TIMING CHAIN

a. Rotate crankshaft pulley clockwise and align TDC mark to timing
indicator on front cover.
b. At the same time, make sure that the mating marks on camshaft
sprockets are located as shown in the figure.

If not, rotate crankshaft pulley one more turn to align mating
marks to the positions in the figure.
15. Remove crankshaft pulley with the following procedure:
a. Fix crankshaft pulley with a pulley holder (commercial service
tool), loosen crankshaft pulley bolt, and locate bolt seating sur-
face at 10 mm (0.39 in) from its original position.
b. Attach a pulley puller (special service tool) in the M 6 thread hole
on crankshaft pulley, and remove crankshaft pulley.
16. Remove front cover with the following procedure:
KBIA0190E
PBIC2351E
PBIC2434E
PBIC2413E

TIMING CHAIN
EM-47
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a. Loosen mounting bolts in reverse order as shown in the figure,
and remove them.
b . U s e a s e a l c u t t e r ( s p e c i a l s e r v i c e t o o l : K V 1 0 1111 0 0 ) o r e q u i v a -
lent tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage mounting surface.
17. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.
CAUTION:
Be careful not to damage front cover.
18. Remove timing chain and camshaft sprockets with the following procedure:
a. Push in chain tensioner plunger. Insert a stopper pin into hole on
chain tensioner body to secure chain tensioner plunger and
remove chain tensioner.
NOTE:
Use approx. 0.5 mm (0.02 in) dia. hard metal pin as a stopper
pin.
b. Secure hexagonal part of camshaft with a wrench. Loosen cam-
shaft sprocket mounting bolts and remove timing chain and
camshaft sprockets.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
19. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.
20. Remove balancer unit timing chain tensioner with the following procedure:
KBIA0083E
KBIA0048E
KBIA0049E