heater NISSAN X-TRAIL 2003 Service Repair Manual

GI-46
TERMINOLOGY

TERMINOLOGYPFP:00011
SAE J1930 Terminology List EAS000GH
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve

ENGINE ASSEMBLY
EM-79
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Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Release fuel pressure. Refer to EC-48, "
FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Disconnect both battery terminals. Refer to SC-3, "
BATTERY" .
4. Drain engine coolant from radiator. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
5. Remove the following parts.

LH and RH undercovers

Front road wheels and tyres

Battery; Refer to SC-3, "BATTERY" .

Drive belt; Refer to EM-13, "DRIVE BELTS" .

Air duct and air cleaner case assembly; Refer to EM-15, "AIR CLEANER AND AIR DUCT" .

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

Radiator and radiator cooling fan assembly; Refer to CO-12, "RADIATOR" .
6. Disconnect engine room harness from the engine side and set it aside for easier work.
7. Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine Room LH
1. Disconnect fuel feed hose, and plug it to prevent fuel from draining. Refer to EM-32, "FUEL INJECTOR
AND FUEL TUBE"
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
3. Disconnect control cable from transaxle (A/T models). Refer to AT- 4 0 4 , "
ON-VEHICLE SERVICE" .
4. Disconnect clutch operating cylinder from transaxle, and move it aside (M/T models). Refer to CL-10,
"OPERATING CYLINDER" .
5. Disconnect shift and select cable from transaxle (M/T models). Refer to MT-14, "
CONTROL LINKAGE" .
Engine Room RH
1. Remove engine coolant reservoir tank. Refer to CO-12, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on vehicle side with a
rope to avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM" .
2. Remove propeller shaft. Refer to PR-3, "
REAR PROPELLER SHAFT" .
3. Remove steering lower joint from steering gear. Refer to PS-10, "
STEERING COLUMN" .
4. Disconnect power steering fluid piping at a point between vehicle and engine. Refer to PS-34, "
HYDRAU-
LIC LINE" .
5. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter
(A/T models). Refer to EM-25, "
OIL PAN AND OIL STRAINER" and AT- 4 1 3 , "REMOVAL AND INSTALLA-
TION" .
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-17, "
TRAN-
SAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 , "REMOVAL AND INSTALLATION" (A/T models).
7. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-45, "
WHEEL SEN-
SORS" (ABS) or BRC-116, "WHEEL SENSORS" (ESP/TCS/ABS).
8. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on
vehicle side with a rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
9. Remove lower ends of left and right strut from steering knuckle. Refer to FSU-5, "
FRONT SUSPENSION
ASSEMBLY" .
Removal
1. Install engine slingers into front left of cylinder head and rear right of cylinder head.

EM-136
[YD22DDTi]
INTAKE MANIFOLD

INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00LRF
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
2. Remove air duct. Refer to EM-133, "
Removal and Installation" .
3. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
4. Remove air inlet pipes. Refer to EM-141, "
Removal and Installation" .
5. Remove exhaust manifold insulator. Refer to EM-141, "
EXHAUST MANIFOLD AND TURBOCHARGER" .
1. Fuel gallery 2. Water hose 3. Air relief plug
4. Copper washer 5. Gasket 6. EGR passage
7. EGR volume control valve 8. Bracket 9. Washer
10. Water pipe 11. O-ring 12. EGR cooler
13. Exhaust manifold 14. Intake manifold 15. Cylinder head
16. Heater hose 17. Spill hose
PBIC2020E

INTAKE MANIFOLD
EM-137
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6. Disconnect EGR volume control valve water hoses and wiring harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
9. Remove injection tube center. Refer to EM-157, "
Removal and Installation" .
CAUTION:
Be careful not to spill fuel in the engine component.
10. Remove water pipe.
11. Remove fuel hoses and fuel gallery.

To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
12. Loosen bolts and nuts in reverse order of that shown in the fig-
ure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
13. Remove EGR volume control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion

Check distortion on the mounting surface with a straightedge
and feeler gauge.

If it exceeds the limit, replace intake manifold.
INSTALLATION
Following instructions below, install in the reverse order of removal.
1. Install EGR volume control valve.

Handle with care avoiding any shocks.

Do not disassemble.
2. Install intake manifold.

Tighten fixing bolts and nuts in numerical order as shown in the figure.

When stud bolts come off, install with the following torque.
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)

EM-154
[YD22DDTi]
VACUUM PUMP

10. Remove exhaust manifold cover. Refer to EM-141, "Removal and Installation" .
11. Disconnect heater hose. Refer to EM-136, "
INTAKE MANIFOLD" .
12. Remove EGR cooler. Refer to EM-136, "
INTAKE MANIFOLD" .
13. Disconnect vacuum hose from vacuum pump side.
14. Remove camshaft position sensor.
15. Remove cylinder head rear cover plate.
16. Loosen and remove the mounting bolts in rear camshaft sprocket. Refer to EM-155, "
Disassembly and
Assembly" .

Loosen rear camshaft sprocket mounting bolt by fixing the hexagonal portion of camshaft.
17. Remove vacuum pump and cylinder head rear cover assembly.

Remove and install vacuum pump, sprocket, drive chain and chain guide as an assembly.

Loosen mounting bolts in reverse order shown in figure.

Do not remove any bolts not shown in figure. (Especially
never remove M6 bolts on vacuum pump.)

U s e t h e 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
other suitable tool to remove.
INSTALLATION
1. Install vacuum pump and cylinder head rear cover assembly
onto cylinder head. Refer to EM-156, "
ASSEMBLY" .

Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) to area shown in the fig-
ure.
Use Genuine Liquid Gasket or equivalent.

Attaching should be done within 5 minutes after coating.
2. Tighten mounting bolts in order shown in the figure.
3. Install rear camshaft sprocket mounting bolts by fixing the hex-
agonal portion of camshaft.
4. Tighten rear camshaft sprocket mounting bolts.
SBIA0167E
PBIC1141E
SBIA0167E

ENGINE ASSEMBLY
EM-209
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REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate suspension member, and then separate engine and transaxle.
Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Drain engine coolant from radiator drain plug. Refer to CO-31, "
DRAINING ENGINE COOLANT" .
3. Remove the following parts.

LH/RH engine undercover

LH/RH front wheels

Battery; Refer to SC-3, "BATTERY" .

Drive belts; Refer to EM-132, "Removal and Installation" .

Air duct and air cleaner case assembly; Refer to EM-133, "Removal and Installation" .

Alternator; Refer to SC-16, "Removal and Installation" .

Radiator and cooling fan assembly; Refer to CO-34, "Removal and Installation" and CO-36, "COOL-
ING FAN" .

Charge air cooler; Refer to EM-135, "CHARGE AIR COOLER" .
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer to EM-136,
"INTAKE MANIFOLD" .
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to EM-136,
"INTAKE MANIFOLD" .
3. Remove clutch operating cylinder from transaxle, and move it aside. Refer to MT-17, "
TRANSAXLE
ASSEMBLY" and CL-10, "OPERATING CYLINDER" .
4. Disconnect shift cable from transaxle. Refer to MT-14, "
CONTROL LINKAGE" .
Engine room RH
1. Remove engine coolant reservoir tank. Refer to CO-34, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
2. Remove propeller shaft. Refer to PR-4, "
Removal and Installation" .
3. Remove steering shaft from steering gear. Refer to PS-10, "
STEERING COLUMN" .
4. Disconnect power steering fluid cooler piping at a point between body and engine. Refer to PS-34,
"HYDRAULIC LINE" .
5. Remove ABS sensor from brake caliper. Refer to BRC-45, "
WHEEL SENSORS" (ABS), BRC-116,
"WHEEL SENSORS" (ESP/TCS/ABS).
6. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
7. Remove left and right suspensions from steering knuckle under strut. Refer to FSU-5, "
FRONT SUSPEN-
SION ASSEMBLY" .

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-22
[QR]
THERMOSTAT AND WATER CONTROL VALVE

THERMOSTAT AND WATER CONTROL VALVEPFP:21200
Removal and InstallationEBS00KOO
REMOVAL
1. Drain engine coolant. Refer to CO-9, "Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belt.
2. Disconnect radiator hose (lower) at water inlet side. Refer to CO-12, "
RADIATOR" .
3. Remove water inlet and thermostat.
4. Remove water control valve with the following procedure:
a. Disconnect radiator hose (upper) at water control valve housing (water outlet) side.
b. Disconnect harness connector from engine coolant temperature sensor.
c. Remove heater pipe and heater hose.
d. Remove water control valve housing (water outlet) and water control valve.
1. Thermostat 2. O-ring 3. Water inlet
4. Water control valve 5. O-ring 6. Gasket
7. Water control valve housing (water outlet) 8. Washer 9. Engine coolant temperature sensor
10. Heater hose 11. O-ring 12. Heater pipe
13. Heater hose
PBIC2254E

THERMOSTAT AND WATER CONTROL VALVE
CO-23
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INSPECTION AFTER REMOVAL

Place a string so that it is caught in the valves of thermostat and
water control valve. Immerse fully in a container filled with water.
Heat while stirring. (The example in the figure shows thermo-
stat.)

The valve opening temperature is the temperature at which the
valve opens and falls from the thread.

Continue heating. Check the full open valve lift amount.
NOTE:
The full open valve lift amount standard temperature for water
control valve is the reference value.

After checking the full open valve lift amount, lower the water
temperature and check the valve closing temperature.
Standard:

If out of the standard, replace either or both thermostat and water control valve.
INSTALLATION
Note the following, and install in the reverse order of removal.
Thermostat and Water Control Valve

Install thermostat with making rubber ring groove fit to thermo-
stat flange with the whole circumference. (The example in the
figure shows thermostat.)
NOTE:
Same procedure is applied for installation of water control valve.

Install thermostat with jiggle valve facing upwards. (The position
deviation may be within the range of 20 degrees as shown in the
figure.)

Install water control valve with the arrow facing up and the frame
center part facing upwards. (The position deviation may be
within the range of 20 degrees as shown in the figure.)
Heater Pipe Installation
Apply a neutral detergent to O-ring, then quickly insert the insertion part of heater pipe into cylinder block.
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant using a radiator cap tester adapter (special service tool: EG17650301)
and a radiator cap tester (commercial service tool). Refer to CO-9, "
LEAK CHECK" .

Start and warm up engine. Visually check if there is no leaks of engine coolant and A/T fluid (A/T models).
SLC252B
Items Thermostat Water control valve
Valve opening temperature 80.5 - 83.5°C (177 - 182°F) 93.5 - 96.5°C (200 - 206°F)
Full open valve liftMore than 8 mm/ 95°C
(0.315 in/ 203°F)More than 8 mm/ 108°C
(0.315 in/ 226°F)
Valve closing temperature More than 77°C (171°F) More than 90°C (194°F)
PBIC0157E
PBIC0158E

ENGINE COOLANT
CO-33
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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 with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water from the system. Refer to CO-31, "
DRAINING ENGINE COOLANT" .
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.