dimensions NISSAN X-TRAIL 2003 Service Repair Manual

GI-2 ENGINE SERIAL NUMBER ................................ 44
AUTOMATIC TRANSAXLE NUMBER ................. 45
MANUAL TRANSAXLE NUMBER ....................... 45Dimensions ............................................................. 45
Wheels & Tires ........................................................ 45
TERMINOLOGY ........................................................ 46
SAE J1930 Terminology List ................................... 46

IDENTIFICATION INFORMATION
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AUTOMATIC TRANSAXLE NUMBER
MANUAL TRANSAXLE NUMBER
Dimensions EAS000GF
Unit: mm (in)
Wheels & Tires EAS000GG
PAIA0008E
PAIA0009E
PAIA0010E
Overall length 4,455
Overall width 1,765
Overall height1,675 (Standard)
1,750 (With Rear spoiler or Roof rail with Driving light)
Front tread 1,530
Rear tread 1,530
Wheelbase 2,625
Conventional Spare
Road wheel/offset mm (in)15 × 6JJ Steel/40 (1.57)
16 × 6.5JJ Steel/Aluminum/40 (1.57)Conventional
Tire size215/70 R15
215/65 R16Conventional

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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PRECAUTIONS

Precautions for Liquid GasketEBS00MRW
REMOVAL OF LIQUID GASKET

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

In areas where seal cutter (special service tool) is difficult to use,
use a plastic hammer to lightly tap (1) seal cutter where the liq-
uid gasket is applied. Use a plastic hammer to slide seal cutter
(2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
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 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. Occasionally, it should be applied outside the
holes. Make sure to read the text of service 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 mounting bolts or nut after the installation.

Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

PREPARATION
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Commercial Service ToolsEBS00L7O
Tool nameDescription
Spark plug wrench Removing and installing spark plug
Pulley holderCrankshaft pulley removing and installing
Valve seat cutter set Finishing valve seat dimensions
TORX socketRemoving and installing flywheel
Size: T55
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT047
ZZA1010D
S-NT048
PBIC1113E
S-NT030
S-NT015
S-NT016

EM-48
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TIMING CHAIN

a. Lift lever up, and release ratchet claw for return proof.
b. Push tensioner sleeve in, and hold it.
c. Matching the hole on lever with the one on body, insert a stopper
pin to secure tensioner sleeve.
NOTE:
Use approximately 1 mm (0.04 in) dia. hard metal pin as a stop-
per pin.
d. Remove balancer unit timing chain tensioner.
21. Remove balancer unit timing chain and crankshaft sprocket.
22. Loosen mounting bolts in reverse order as shown in the figure,
and remove balancer unit.
CAUTION:
Do not disassemble balancer unit.
NOTE:
Use TORX socket (size E14).
INSPECTION AFTER REMOVAL
Timing Chain
Check timing chain for cracks and any excessive wear at the roller
links of timing chain. Replace timing chain if necessary.
Balancer Unit Mounting Bolt Outer Diameter

Measure the outer diameters (“d1” , “d2” ) at two positions as
shown in the figure.

If reduction appears in “A” range, regard it as “d2 ”.

If it exceeds the limit (large difference in dimensions), replace it
with a new one.
KBIA0121E
KBIA0122E
PBIC0282E
Limit (“d1 ” - “d2 ”) : 0.15 mm (0.0059 in)
PBIC1137E

CYLINDER HEAD
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Compress valve spring with a valve spring compressor,
attachment and adapter (special service tool). Install valve
collet with a magnet hand.
CAUTION:
When working, be careful not to damage valve lifter
holes.

Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
8. Install valve lifter.
9. Install spark plug tube if removed.

Press-fit it into cylinder head with the following procedure:
a. Remove old liquid gasket from cylinder head side installation
hole.
b. Apply liquid gasket all round on spark plug tube within approxi-
mately 12 mm (0.47 in) width from edge of spark plug tube on
the press-fit side.
Use Genuine Liquid Gasket or equivalent.
c. Using a drift, press-fit spark plug tube so that height is as same
as “H” shown in figure.
CAUTION:

When press-fitting, be careful not to deform spark plug tube.

After press-fitting, wipe off any protruding liquid gasket on top surface of cylinder head.
10. Install spark plug with spark plug wrench (commercial service tool).
Inspection After DisassemblyEBS00KNS
VALVE DIMENSIONS

Check dimensions of each valve. For dimensions, refer to EM-
11 0 , "Valve Dimensions" .

If dimensions are out of the standard, replace valve.
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of valve stem with a micrometer.
PBIC1791E
Standard press-fit height “H”:
41.2 - 42.2 mm (1.622 - 1.661 in)
SBIA0252E
SEM188A
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
SEM938C

CYLINDER HEAD
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4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as shown
in the figure.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
6. Apply reamer finish to valve guide with a valve guide reamer
(commercial service tool).
VALVE SEAT CONTACT

After confirming that the dimensions of valve guides and valves
are within specifications, perform this procedure.

Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.

Check if the contact area band is continuous all around the cir-
cumference.

If not, grind to adjust valve fitting and check again. If the contact-
ing surface still has NG conditions even after the re-check,
replace valve seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-113, "
Va l v e S e a t" .
SEM008A
Projection “H”:
Intake : 10.1 - 10.3 mm (0.398 - 0.406 in)
Exhaust : 10.0 - 10.4 mm (0.394 - 0.409 in)
PBIC2187E
Standard
Intake and exhaust:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
SBIA0322E

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CYLINDER HEAD

2. Ream cylinder head recess diameter for service valve seat.

Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:

Avoid directly to touching cold valve seats.

Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions.
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.

Grind to obtain the dimensions indicated in the figure.
*1 : Diameter made by intersection point of conic angles 60 degrees and 89.5 degrees
*2 : Diameter made by intersection point of conic angles 89.5 degrees and 120 degrees
*3 : 120 degrees cutter diameter
6. Using compound, grind to adjust valve fitting. Oversize [0.5 mm (0.020 in)]
Intake : 37.000 - 37.016 mm (1.4567 - 1.4573 in)
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
SEM795A
SEM008A
SEM934C
Standard
D1 dia.
: 33.5 mm (1.319 in)
*1
D2 dia.
: 35.1 - 35.3 mm (1.382 - 1.390 in)*2
D3 dia.
: 39.0 - 39.2 mm (1.535 - 1.543 in)*3
D4 dia.
: 28.0 mm (1.102 in)*1
D5 dia.
: 29.9 - 30.1 mm (1.177 - 1.185 in)*2
D6 dia.
: 33.5 - 33.7mm (1.319 - 1.327 in)*3SBIA0226E

CYLINDER HEAD
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7. Check again for normal contact. Refer to EM-75, "VALVE SEAT CONTACT" .
VALVE SPRING SQUARENESS

Set try square along the side of valve spring and rotate the
spring. Measure the maximum clearance between the top face
of spring and try square.

If it exceeds the limit, replace valve spring.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

Check valve spring pressure with valve spring seat installed at
specified spring height.
CAUTION:
Do not remove valve spring seat from valve spring.
Standard:

If the installation load or load with valve open is out of the standard, replace valve spring.Limit : 1.9 mm (0.075 in)
PBIC0080E
SEM113
Items INTAKE EXHAUST
Free height 44.84 - 45.34 mm (1.7654 - 1.7850 in) 45.28 - 45.78 mm (1.7827 - 1.8024 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb) 151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)
Height during valve open 24.94 mm (0.9819 in) 26.39 mm (1.0390 in)
Load with valve open 358 - 408 N (36.5 - 41.6 kg, 80 - 92 lb) 325 - 371 N (33.1 - 37.8 kg, 73 - 83 lb)
Identification color Blue Yellow