coolant capacity NISSAN X-TRAIL 2003 Service Repair Manual

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
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L
M
SECTION
A
CO

ENGINE COOLING SYSTEM
QR
PRECAUTIONS .......................................................... 3
Precautions for Liquid Gasket .................................. 3
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
System Chart ........................................................... 8
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ............... 13
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
RADIATOR (ALUMINUM TYPE) .............................. 14
Disassembly and Assembly ................................... 14
PREPARATION ................................................... 14
DISASSEMBLY ................................................... 14
ASSEMBLY ......................................................... 15
INSPECTION ...................................................... 17
COOLING FAN ......................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 18
DISASSEMBLY AND ASSEMBLY ...................... 18WATER PUMP .......................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 21
INSPECTION AFTER INSTALLATION ................ 21
THERMOSTAT AND WATER CONTROL VALVE .... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 23
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 24
Standard and Limit .................................................. 24
CAPACITY ........................................................... 24
THERMOSTAT .................................................... 24
WATER CONTROL VALVE ................................. 24
RADIATOR .......................................................... 24
Tightening Torque ................................................... 24
YD22DDTi
PRECAUTIONS ........................................................ 25
Precautions For Liquid Gasket ............................... 25
LIQUID GASKET APPLICATION PROCEDURE ... 25
PREPARATION ......................................................... 26
Special Service Tools ............................................. 26
Commercial Service Tools ...................................... 26
OVERHEATING CAUSE ANALYSIS ........................ 27
Troubleshooting Chart ............................................ 27
COOLING SYSTEM .................................................. 29
Cooling Circuit ........................................................ 29
System Chart .......................................................... 30
ENGINE COOLANT .................................................. 31
Inspection ............................................................... 31
LEVEL CHECK .................................................... 31

CO-2 CHECKING RADIATOR SYSTEM FOR LEAKS ... 31
Changing Engine Coolant ....................................... 31
DRAINING ENGINE COOLANT .......................... 31
REFILLING ENGINE COOLANT ......................... 32
FLUSHING COOLING SYSTEM ......................... 33
RADIATOR ................................................................ 34
Removal and Installation ........................................ 34
REMOVAL ........................................................... 34
INSTALLATION .................................................... 34
INSPECTION AFTER INSTALLATION ................ 34
Checking Radiator Cap .......................................... 35
Checking Radiator .................................................. 35
COOLING FAN .......................................................... 36
Removal and Installation ........................................ 36
REMOVAL ........................................................... 36
INSTALLATION .................................................... 36
DISASSEMBLY AND ASSEMBLY ....................... 36
RADIATOR (ALUMINUM TYPE) ............................... 38
Disassembly and Assembly .................................... 38
PREPARATION ................................................... 38
DISASSEMBLY ................................................... 38
ASSEMBLY ......................................................... 39
INSPECTION ....................................................... 41WATER PUMP ........................................................... 42
Removal and Installation ......................................... 42
REMOVAL ............................................................ 42
INSPECTION AFTER REMOVAL ........................ 43
INSTALLATION .................................................... 43
INSPECTION AFTER INSTALLATION ................ 43
THERMOSTAT AND WATER PIPING ....................... 44
Removal and Installation ......................................... 44
REMOVAL ............................................................ 44
INSPECTION AFTER REMOVAL ........................ 45
INSTALLATION .................................................... 45
INSPECTION AFTER INSTALLATION ................ 45
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 46
Standard and Limit .................................................. 46
CAPACITY ........................................................... 46
THERMOSTAT ..................................................... 46
RADIATOR ........................................................... 46
Tightening Torque ................................................... 46

CO-10
[QR]
ENGINE COOLANT

4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-10, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-82, "CYLINDER
BLOCK" .
2. Fill radiator and reservoir tank to specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.

Use Genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".
3. Warm up engine to normal operating temperature with radiator cap installed.
4. Run engine at 3,000 rpm for 10 seconds and return to idle speed.

Repeat two or three times.
CAUTION:
Watch water temperature gauge so as not to overheat the engine.
5. Stop engine and cool down to less than approximately 50°C (122°F).

Cool down using a fan to reduce the time.

If necessary, refill radiator up to filler neck with engine coolant.
6. Refill reservoir tank to “MAX” level line with engine coolant.
7. Repeat steps 2 through 5 two or more times with radiator cap installed until engine coolant level no longer
drops.
8. Check cooling system for leaks with engine running.
9. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between “COOL” and “WARM”.

Sound may be noticeable at heater unit.
10. Repeat step 9 three times.
11. If sound is heard, bleed air from cooling system by repeating steps 2 through 5 until engine coolant level
no longer drops.

Clean excess engine coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator and reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.Engine coolant capacity
(with reservoir tank at “MAX” level)
: Approx. 7.1 (6-1/4 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.6 (1/2 lmp qt)
SMA412B

CO-24
[QR]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00KOP
CAPACITY
Unit: (lmp qt)
THERMOSTAT
WATER CONTROL VALVE
RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Tightening TorqueEBS00KOQ
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
Engine coolant capacity (With reservoir tank at “MAX” level) Approx. 7.1 (6-1/4)
Reservoir tank0.6 (1/2)
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Valve liftMore than 8 mm/ 95°C (0.315 in/ 203°F)
Valve closing temperature More than 77°C (171°F)
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Valve lift More than 8 mm/ 108°C (0.315 in/ 226°F)
Valve closing temperature More than 90°C (194°F)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11- 14)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Radiator mounting bracket 4.2 (0.43, 37)*
Radiator cooling fan assembly 4.2 (0.43, 37)*
Cooling fan3.43 (0.35, 30)*
Fan motor4.41 (0.45, 39)*
Water pump24.5 (2.5, 18)
Water pump housing28.0 (2.9, 21)
Water pipe28.0 (2.9, 21)
Water inlet28.0 (2.9, 21)
Water control valve housing (water outlet) 28.0 (2.9, 21)
Hater pipe28.0 (2.9, 21)
Engine coolant temperature sensor 24.5 (2.5, 18)

CO-32
[YD22DDTi]
ENGINE COOLANT

3. Remove air relief plug.
4. Open cylinder block drain plug. Refer to EM-212, "
CYLINDER BLOCK" .
5. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
6. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer to CO-33, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-212, "CYLIN-
DER BLOCK" .
2. Fill radiator and reservoir tank to the specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.

Use Genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".

When engine coolant overflows air relief hole, install air relief
plug with new copper washer.
3. Warm up engine to normal operating temperature without radiator cap installed.

If engine coolant overflows radiator filler hole, install radiator cap.
4. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed.

Repeat two or three times.
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
5. Stop engine and cool down to less than approximately 50°C(122°F).

Cool down using a fan to reduce the time.

If necessary, refill radiator up to filler neck with engine coolant.
6. Refill reservoir tank to MAX level line with engine coolant.
SBIA0130E
Engine coolant capacity
(with reservoir tank at “MAX” level)
: Approx. 9.5 (8-3/8 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.6 (1/2 lmp qt)
Air relief plug:
: 6.9 - 7.8 N·m (0.7 - 0.8 kg-m, 61 - 69 in-lb)
SMA412B

CO-46
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00CU0
CAPACITY
Unit: (lmp qt)
THERMOSTAT
RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Tightening TorqueEBS00BKE
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
Engine coolant capacity (With reservoir tank at MAX level) Approx 9.5 (8-3/8)
Reservoir tank0.6 (1/2)
Valve opening temperature 80 - 84°C (176 - 183°F)
Full open lift amount More than 10 mm/ 95°C (0.39 in/203°F)
Valve closing temperature More than 77°C (171°F)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Air relief plug6.9 - 7.8 (0.7 - 0.8, 61 - 69)*
Radiator mounting bracket
Cooling fan assembly
Cooling fan (left and right)
Cooling fan motors4.2 (0.42, 37)*
4.2 (0.42, 37)*
3.43 (0.35, 30)*
4.41 (0.45, 39)*
Water pump
Water pump pulley
Water inlet
Thermostat housing
Water inlet pipe
Heater return pipe26.5 (2.7, 20)
8.5 (0.86, 75)*
25 (2.6, 18)
25 (2.6, 18)
25 (2.6, 18)
25 (2.6, 18)

MA-2 INSPECTION AFTER INSTALLATION ................ 32
Changing Air Cleaner Filter .................................... 32
VISCOUS PAPER TYPE ..................................... 32
Changing Engine Oil ............................................... 33
Changing Oil Filter (TYPE A) .................................. 33
REMOVAL ........................................................... 33
INSTALLATION .................................................... 34
INSPECTION AFTER INSTALLATION ................ 34
Changing Oil Filter (TYPE B) .................................. 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 36
INSPECTION AFTER INSTALLATION ................ 36
Draining Water ........................................................ 36
CHASSIS AND BODY MAINTENANCE ................... 37
Checking Exhaust System ...................................... 37
Checking Clutch Fluid Level and Leaks ................. 37
Checking Clutch System ........................................ 37
Checking M/T Oil .................................................... 37
Changing M/T Oil .................................................... 38
Checking A/T Fluid ................................................. 38
Changing A/T Fluid ................................................. 39
Checking Transfer Oil ............................................. 39
Changing Transfer Oil ............................................. 39
Checking Propeller Shaft ........................................ 40
Checking Differential Gear Oil ................................ 40
Changing Differential Gear Oil ................................ 40
Balancing Wheels ................................................... 41
Rotation .................................................................. 41
Checking Brake Fluid Level and Leaks .................. 41
Checking Brake Lines and Cables ......................... 41Changing Brake Fluid ............................................. 42
Checking Disc Brake ............................................... 43
ROTOR ................................................................ 43
CALIPER .............................................................. 43
PAD ...................................................................... 43
Checking Steering Gear and Linkage ..................... 43
STEERING GEAR ............................................... 43
STEERING LINKAGE .......................................... 43
Checking Power Steering Fluid and Lines .............. 44
Axle and Suspension Parts ..................................... 44
Drive Shaft .............................................................. 45
Lubricating Locks, Hinges and Hood Latches ......... 45
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 45
Checking Body Corrosion ....................................... 45
HEMMED PANELS .............................................. 45
PANEL JOINT ...................................................... 45
PANEL EDGE ...................................................... 45
PARTS CONTACT ............................................... 45
PROTECTORS .................................................... 46
ANTI-CORROSION MATERIALS ........................ 46
DRAIN HOLES ..................................................... 46
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 47
Standard and Limit .................................................. 47
BELT DEFLECTION AND TENSION ................... 47
RADIATOR ........................................................... 47
ENGINE COOLANT CAPACITY .......................... 47
ENGINE OIL CAPACITY (APPROXIMATE) ........ 47
SPARK PLUG ...................................................... 47

RECOMMENDED FLUIDS AND LUBRICANTSMA-17
C
DE
F
G H
I
J
K
M A
B
MA

RECOMMENDED FLUIDS AND LUBRICANTSPFP:00000
Fluids and LubricantsELS000C8
*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Genuine Nissan Anti-freeze Coolant (L250) or equivalent in its quality, in order to avoid possible aluminum corrosion w ithin the
engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRON
TM III/MER-
CONTM Automatic Transmission Fluid.
*5: Never mix different types of fluids (DOT 3 and DOT 4). Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refill With oil filter
change
QR20DE,
QR25DE
3.9 3-3/8 qt

Gasoline engine
API SG, SH, SJ or SL *1
ILSAC grade GF-I, GF-II or GF-III *1
ACEA A2

Diesel engine
API CF-4*1, *2
ACEA B1, B3, B4, B5*1, *2
YD22DDTi 5.2 4-5/8 qt
Without oil filter
change QR20DE,
QR25DE
3.5 3-1/8 qt
YD22DDTi 4.9 4-3/8 qt
Dry engine (engine overhaul) QR20DE,
QR25DE
4.5 4 qt
YD22DDTi 6.3 5-1/2 qt
Cooling system (with reservoir) QR20DE,
QR25DE
7.1 6-1/4 qt

Genuine Nissan Anti-freeze Coolant (L250) or
equivalent in its quality*3
YD22DDTi 9.5 8-3/8 qt
Reservoir tank QR20DE,
QR25DE
0.6 1/2 qt
YD22DDTi 0.6 1/2 qt
Manual transaxle gear oil
2.3 4pt

Genuine Nissan gear oil or API GL-4, Viscos-
ity SAE 75W-85
Transfer gear oil 0.31 1/2 pt

API GL-5*1, Viscosity SAE 80W-90
Differential gear oil 0.55 1 pt

API GL-5*1, Viscosity SAE 80W-90
Automatic transaxle fluid 8.5 7-1/2 qt Genuine Nissan ATF or equivalent*4
Power steering fluid — — DEXRON
TM III type ATF or equivalent
Brake and clutch fluid — —

DOT 3 or DOT 4 (US FMVSS No. 116)*5
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)

ENGINE MAINTENANCE (QR20DE·QR25DE)
MA-21
C
D
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F
G
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MA
B
MA

When drain all of engine coolant in the system, open water drain plug on cylinder block. Refer to
EM-82, "
CYLINDER BLOCK" .
3. Remove reservoir tank and drain engine coolant.
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-10, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-82, "CYLIN-
DER BLOCK" .
2. Fill radiator and reservoir tank to specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.

Use Genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".
3. Warm up engine to normal operating temperature with radiator cap installed.
4. Run engine at 3,000 rpm for 10 seconds and return to idle speed.

Repeat two or three times.
CAUTION:
Watch water temperature gauge so as not to overheat the engine.
5. Stop engine and cool down to less than approximately 50°C (122°F).

Cool down using a fan to reduce the time.

If necessary, refill radiator up to filler neck with engine coolant.
6. Refill reservoir tank to “MAX” level line with engine coolant.
7. Repeat steps 2 through 5 two or more times with radiator cap installed until engine coolant level no longer
drops.
8. Check cooling system for leaks with engine running.
9. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between “COOL” and “WARM”.

Sound may be noticeable at heater unit.
10. Repeat step 9 three times.
11. If sound is heard, bleed air from cooling system by repeating steps 2 through 5 until engine coolant level
no longer drops.

Clean excess engine coolant from engine.Engine coolant capacity
(with reservoir tank at “MAX” level)
: Approx. 7.1 (6-1/4 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.6 (1/2 lmp qt)
SMA412B

ENGINE MAINTENANCE (YD22DDTI)
MA-29
C
D
E
F
G
H
I
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MA
B
MA

3. Remove air relief plug.
4. Open cylinder block drain plug. Refer to EM-212, "
CYLINDER BLOCK" .
5. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
6. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer to CO-33, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-82, "CYLIN-
DER BLOCK" .
2. Fill radiator and reservoir tank to specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.

Use Genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".

When engine coolant overflows air relief hole, install air relief
plug with new copper washer.
3. Warm up engine to normal operating temperature without radiator cap installed.

If engine coolant overflows radiator filler hole, install radiator cap.
4. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed.

Repeat two or three times.
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
5. Stop engine and cool down to less than approximately 50°C(122°F).

Cool down using a fan to reduce the time.

If necessary, refill radiator up to filler neck with engine coolant.
6. Refill reservoir tank to MAX level line with engine coolant.
SBIA0130E
Engine coolant capacity
(with reservoir tank at “MAX” level)
: Approx. 9.5 (8-3/8 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.6 (1/2 lmp qt)
Air relief plug:
: 6.9 - 7.8 N·m (0.7 - 0.8 kg-m, 61 - 69 in-lb)
SMA412B