air filter NISSAN X-TRAIL 2003 Service Repair Manual

PRECAUTIONS
GI-7
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HOSE CLAMPING

If old rubber hose is re-used, install hose clamp in its original
position (at the indentation where the old clamp was). If there is
a trace of tube bulging left on the old rubber hose, align rubber
hose at that position.

Discard old clamps; replace with new ones.

After installing plate clamps, apply force to them in the direction
of the arrow, tightening rubber hose equally all around.
Precautions for Engine OilsEAS000FW
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS

Avoid prolonged and repeated contact with oils, particularly used engine oils.

Wear protective clothing, including impervious gloves where practicable.

Do not put oily rags in pockets.

Avoid contaminating clothes, particularly underpants, with oil.

Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.

First aid treatment should be obtained immediately for open cuts and wounds.

Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepa-
rations containing lanolin replace the natural skin oils which have been removed.

Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

If skin disorders develop, obtain medical advice without delay.

Where practical, degrease components prior to handling.

Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS
Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-
posal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal
facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources.
The regulations concerning pollution vary between regions.
Precautions for Air Conditioning EAS000FX
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.
SMA021D
SMA022D

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
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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-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

AIR CLEANER AND AIR DUCT
EM-15
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AIR CLEANER AND AIR DUCTPFP:16500
Removal and InstallationEBS00KNB
REMOVAL
1. Remove mass air flow sensor harness clamp.
2. Disconnect harness connector from mass air flow sensor.
3. Remove air duct (inlet), air ducts and air cleaner case/mass air flow sensor assembly disconnecting their
joints.

Add marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case upper.
CAUTION:
Handle mass air flow sensor with following cares.

Do not shock it.

Do not disassemble it.

Do not touch its sensor.
5. Remove resonator in fender lifting left fender protector.
1. Air cleaner filter 2. Clip 3. Air cleaner case upper
4. Clamp 5. Air duct 6. PCV hose
7. Clamp 8. Bracket 9. Mass air flow sensor
10. O-ring 11. Air duct 12. Air duct (inlet)
13. Clip 14. Collar 15. Grommet
16. Resonator 17. Bracket (A/T models) 18. Mounting rubber
19. Collar 20. Grommet 21. Air cleaner case lower
PBIC2171E

EM-16
[QR]
AIR CLEANER AND AIR DUCT

INSTALLATION
Note the following, and install in the reverse order of removal.

Align marks. Attach each joint. Screw clamps firmly.
Changing Air Cleaner FilterEBS0123Q
REMOVAL
1. Unfasten clips and lift up air cleaner case upper.
2. Remove air cleaner filter.
INSTALLATION
Install in the reverse order of removal.

AIR CLEANER AND AIR DUCT
EM-133
[YD22DDTi]
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AIR CLEANER AND AIR DUCTPFP:16500
Removal and InstallationEBS00LRD
REMOVAL
1. Remove mass air flow sensor harness clamp.
2. Disconnect harness connector from mass air flow sensor.
3. Remove air duct, air cleaner case (upper)/ mass air flow sensor.

Add marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
Handle mass air flow sensor with following cares.

Do not shock it.

Do not disassemble it.

Do not touch its sensor.
5. Remove air cleaner case (lower) and air duct side.
INSTALLATION
Note the following, and install in the reverse order of removal.

Align marks. Attach each joint. Screw clamps firmly.
1. Air cleaner case (upper) 2. Clamp 3. Air duct
4. Mass air flow sensor 5. Grommet 6. Air duct side
7. Mounting rubber 8. Air cleaner case (lower) 9. Air cleaner filter
PBIC1235E

EM-134
[YD22DDTi]
AIR CLEANER AND AIR DUCT

CHANGING AIR CLEANER FILTER
Removal
1. Unfasten clips and lift up air cleaner case (upper).
2. Remove air cleaner filter.
Installation
Install in the reverse order of removal.

PRIMARY TIMING CHAIN
EM-187
[YD22DDTi]
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REMOVAL
1. Remove engine coolant reservoir tank. Refer to CO-34, "RADIATOR" .
2. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
3. Remove air cleaner and air duct. Refer to EM-133, "
Removal and Installation" .
4. Remove rocker cover. Refer to EM-168, "
Removal and Installation" .
5. Remove RH engine mounting insulator and bracket. Refer to EM-208, "
Removal and Installation" .
6. Pull power steering reservoir tank out of brackets to move power steering piping. Refer to PS-34,
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets move it with power steering pip-
ing aside.
7. Remove oil pan (upper and lower). Refer to EM-147, "
Removal and Installation" .
8. Remove oil filter bracket. Refer to LU-26, "
OIL FILTER BRACKET" .
9. Remove fuel injector. Refer to EM-157, "
Removal and Installation" .
10. Remove secondary timing chain and associated parts. Refer to EM-180, "
Removal and Installation" .
11. When removing rear chain case, remove camshaft sprockets. Refer to EM-170, "
Removal and Installa-
tion" .
12. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (special service
tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
c. Using the pulley puller (special service tool), remove crankshaft
pulley.

Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
13. Remove oil pump housing.
10. O-ring 11. Chain guide 12. Tension guide
13. Spacer 14. Gasket 15. Front chain case
16. Rubber washer 17. Crankshaft pulley 18. Front oil seal
19. Power steering oil pump cover 20. Oil pump housing 21. Primary timing chain
22. Oil pump drive spacer 23. Crankshaft sprocket 24. Secondary timing chain
25. Rear chain case 26. Power steering oil pump 27. Key
JEM131G
JEM132G

ENGINE OIL
LU-7
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ENGINE OILPFP:KLA92
InspectionEBS00KO3
ENGINE OIL LEVEL
NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and make sure the engine oil level is within
the range shown in the figure.
3. If it is out of range, adjust it.
ENGINE OIL APPEARANCE

Check engine oil for white turbidity or heavy contamination.

If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.

Oil pan

Oil pan drain plug

Oil pressure switch

Oil filter

Oil cooler

Intake valve timing control cover and intake valve timing control solenoid valve

Front cover

Mating surface between cylinder block and lower cylinder block

Mating surface between cylinder block and cylinder head

Mating surface between cylinder head and rocker cover

Crankshaft oil seals (front and rear)
OIL PRESSURE CHECK
WARNING:

Be careful not to burn yourself, as engine oil may be hot.

Engine oil pressure check should be in “ Parking position” (A/T models) or “Neutral position” (M/T
models), and should apply parking brake securely.
1. Check engine oil level. Refer to LU-7, "
ENGINE OIL LEVEL" .
2. Remove RH undercover.
PBIC0249E

LU-20
[YD22DDTi]
ENGINE OIL

ENGINE OILPFP:KLA92
InspectionEBS00B03
ENGINE OIL LEVEL
NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and make sure the engine oil level is within
the range shown in the figure.
3. If it is out of range, adjust it.
ENGINE OIL APPEARANCE

Check engine oil for white turbidity or heavy contamination.

If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.

Oil pan

Oil pan drain plug

Oil pressure switch

Oil filter bracket

Oil cooler.

Oil pump housing

Va c u u m p u m p

Cylinder head rear cover assembly

Front and rear chain cases

Mating surface between cylinder block and cylinder head

Mating surface between cylinder head and rocker cover

Front and rear oil seals

Turbocharger

Oil tube connecting parts from turbocharger
ENGINE OIL PRESSURE CHECK
WARNING:

Be careful not to burn yourself, as the engine oil is hot.

Be sure to check oil pressure in “ Neutral position” and parking brake should be applied securely.
1. Check the engine oil level. Refer to LU-20, "
ENGINE OIL LEVEL" .
2. Remove RH engine undercover.
3. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
SBIA0122E