seats NISSAN X-TRAIL 2003 Service Repair Manual

EM-76
[QR]
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 BLOCK
EM-91
[QR]
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a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
c. Then turn all bolts 90 degrees clockwise (Angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench (special service tool) or protractor. Avoid judge-
ment by visual inspection without the tool.

After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.

Check the connecting rod side clearance. Refer to EM-99, "CONNECTING ROD SIDE CLEARANCE" .
13. Install flywheel (M/T models) or drive plate (A/T models).

Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times.

Install drive plate, reinforcement plate and pilot converter as
shown in figure (A/T models).

Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot con-
verter into the end of crankshaft until it stops (A/T models).
14. Install knock sensor.

Install knock sensor with connector facing lower left by 45
degrees as shown in the figure.
CAUTION:

Do not tighten mounting bolts while holding the connec-
tor.

If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.

Make sure that knock sensor does not interfere with other
parts.
15. Install crankshaft position sensor (POS).
16. Assemble in the reverse order of disassembly after this step. : 19.6 N·m (2.0 kg-m, 14 ft-lb)
KBIA0068E
KBIA0075E
KBIA0069E

EM-196
[YD22DDTi]
CYLINDER HEAD

CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00LRV
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-905,
"Basic Inspection" (WITH EURO-ODB) or EC-1231, "Basic Inspection" (WITHOUT EURO-ODB).

Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove charge air cooler. Refer to EM-135, "
Removal and Installation"
5. To prevent fuel from being injected during inspection, remove
fuel pump fuse [ENG CONT 2 (20A)] from fuse box on the left
side of engine room.

Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
pump fuse.
6. Remove glow plugs from all the cylinders. Refer to EM-152,
"Removal and Installation" .
CAUTION:

Before removal, clean the surrounding area to prevent
entry of any foreign materials into engine.

Carefully remove glow plugs to prevent any damage or
breakage.

Handle with care to avoid applying any shock to glow plugs.
7. Install compression gauge adapter (special service tool) to
installation holes of glow plugs and connect compression gauge
for diesel engine.
8. Connect battery negative terminal.
9. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.

Always use a fully-charged battery to obtain specified engine
speed.
Compression pressure
Unit: kPa (bar, kg/cm2 , psi)/rpm

When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.

If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.

If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.

If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
PBIC0680E
: 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
SEM112G
Standard Minimum Difference limit between cylinders
2,991 (29.9, 30.5, 434)/200 2,452 (24.5, 25.0, 356)/200 490 (4.9, 5.0, 71)/200

EM-202
[YD22DDTi]
CYLINDER HEAD

2. Remove valve collet.

Using the valve spring compressor (special service tool),
compress valve spring. Using magnet hand, remove valve
collets.
3. Remove valve spring retainers and valve springs.
4. Remove valves as pressing valve stems toward combustion chamber.

Before removing valve, check the valve guide clearance. Refer to EM-203, "Valve Guide Clearance" .
NOTE:
Refer to the figure for intake and exhaust valve positions.
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.
5. Remove valve oil seals using the valve oil seal puller (special
service tool).
6. Remove valve spring seats.
7. Before removing valve seats, perform valve seat contact check.
Refer to EM-205, "
Valve Seat Contact" .
8. Before removing valve guides, perform valve guide clearance
check. Refer to EM-203, "
Valve Guide Clearance" .
ASSEMBLY
1. Install valve guides. Refer to EM-204, "Valve Guide Replacement" .
2. Install valve seats. Refer to EM-205, "
Valve Seat Replacement" .
3. Using the valve oil seal drift (special service tool), install valve oil
seals referring to the dimension shown in the figure.
4. Install valve spring seats.
PBIC2388E
SBIA0196E
JEM153G
JEM165G

EM-206
[YD22DDTi]
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 approximately 110 to 130°C (230 to
266°F) in oil bath.
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
CAUTION:

Do not touch the cooled valve seats directly by hand.

Cylinder head contains heat, when working, wear protec-
tive equipment to avoid getting burned.
5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.
Grind to obtain the dimensions indicated in the figure. Refer to
EM-240, "
Va l v e S e a t" . Oversize [0.5 mm (0.020 in)]:
Intake : 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust : 29.500 - 29.516 mm (1.1614 - 1.1620 in)
SEM795A
SEM008A
SEM934C
PBIC2028E

EC-240
[QR (WITH EURO-OBD)]
DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MIS-
FIRE

5. CHECK IGNITION SPARK
1. Disconnect ignition coil assembly from rocker cover.
2. Connect a known good spark plug to the ignition coil assembly.
3. Place end of spark plug against a suitable ground and crank engine.
4. Check for spark.
OK or NG
OK >> GO TO 6.
NG >> Check ignition coil, power transistor and their circuits.
Refer to EC-417, "
IGNITION SIGNAL" .
6. CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
OK or NG
OK >> GO TO 7.
NG >> Repair or replace spark plug(s) with standard type
one(s). For spark plug type, refer to MA-26, "
Checking
and Changing Spark Plugs" .
7. CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-67, "
CHECKING COMPRESSION PRESSURE" .
OK or NG
OK >> GO TO 8.
NG >> Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
8. CHECK FUEL PRESSURE
1. Install all removed parts.
2. Release fuel pressure to zero. Refer to EC-48, "
FUEL PRESSURE RELEASE" .
3. Install fuel pressure gauge and check fuel pressure. Refer to EC-48, "
FUEL PRESSURE CHECK" .
OK or NG
OK >> GO TO 9.
NG >> Follow the construction of FUEL PRESSURE CHECK.
SEF575Q
SEF156I
Standard:
1,190 kPa (11.9 bar, 12.1 kg/cm2 , 172 psi)/250 rpm
Minimum:
990 kPa (9.9 bar, 10.1 kg/cm
2 , 144 psi)/250 rpm
Difference between each
cylinder:98 kPa (0.98 bar, 1.0 kg/cm
2 , 14 psi)/250 rpm
At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm
2 , 51 psi)

TF-70
TRANSFER ASSEMBLY

2. Apply recommended thread locking sealant into the thread hole
for the drive gear.
a. Completely clean and degrease the drive gear back face, thread
holes, and drive gear mounting bolts.
b. Apply recommended thread locking sealant onto the first and
second threads under the thread hole chamfering of the drive
gear on 3 or more different points.
3. Install the drive gear to gear ring, and apply anti-corrosive oil
onto threads and seats on the mounting bolts, and then tighten
to the specified torque. Refer to TF-57, "
COMPONENTS" .
CAUTION:

Temporary installation before tightening the bolts through to the completion of the tightening
should be within 90 seconds.

If the thread locking sealant is applied aside, quickly wipe it off.
4. Apply gear oil to gear ring bearing inner race (transfer case
side). Using a drift, install gear ring bearing inner race.
5. Apply gear oil to gear ring bearing inner race (adapter case
side). Using a drift, install gear ring bearing inner race.
6. Install the drive gear assembly to the transfer case.
7. Install the adapter case.
8. Check backlash, preload torque, tooth contact, and companion
flange runout. Refer to TF-58, "
ASSEMBLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.
Adapter Case
1. Select the gear ring bearing adjusting shim (adapter case side). Refer to TF-67, "SELECTING ADJUST-
ING SHIMS" .
2. Install the oil gutter.
3. Using a drift, install the selected gear ring bearing adjusting
shim (adapter case side) and gear ring bearing outer race
(adapter case side).
SDIA0541E
Tool number A: ST30720000
B: ST27863000
C: KV40101630
SDIA1566E
Tool number A: ST30720000
B: KV38102510
SDIA1810E
Tool number A: ST30720000
B: KV40105230
SDIA1535E

TRANSFER ASSEMBLY
TF-71
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4. Using a drift, drive the adapter case oil seal until it becomes
flush with the case end.
CAUTION:

When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
5. Apply recommended sealant on drain plug and install it to the
adapter case. Refer to TF-57, "
COMPONENTS" .
6. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the adapter case.
CAUTION:
Do not reuse the O-ring.
7. Install the adapter case to the transfer case, and apply anti-cor-
rosive oil onto threads and seats on the mounting bolts. Tighten
to the specified torque.
8. Check backlash, preload torque, tooth contact, and companion
flange runout. Refer to TF-58, "
ASSEMBLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.Tool number : KV38101700
Bolt symbol
Bolt length “ ” mm (in)Tightening torque
N·m (kg-m, ft-lb)
A 35 (1.38)
15.2 (1.6, 11)
B 30 (1.18)
SDIA1568E
SDIA2318E

TRANSFER ASSEMBLY
TF-73
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9. Using a drift and press in the companion flange.
10. Apply anti-corrosion oil onto threads and seat of the pinion lock
nut and adjust the pinion lock nut tightening torque and pinion
bearing preload torque (P’
1 ), using a preload gauge.
CAUTION:

Do not reuse the pinion lock nut.

Adjust the lower limit of the pinion lock nut tightening torque first.

While confirming the preload torque, tighten pinion lock nut by 5° to 10°. Because preload will
increase suddenly.

If specified preload torque is exceeded, replace the collapsible spacer and tighten again. Never
loosen the pinion lock nut for further preload torque adjustment.

After the adjustment, rotate the companion flange back and forth 2 to 3 times to check for
unusual noise, rotation malfunction, and other malfunctions.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion sleeve.
CAUTION:
Do not reuse the old O-ring.
12. Assemble the selected pinion sleeve shim.
13. Install the pinion sleeve assembly, and apply anti-corrosive oil onto threads and seats on the mounting
bolts. Tighten to the specified torque. Refer to TF-57, "
COMPONENTS" .
14. Check backlash, preload torque, tooth contact and companion flange runout. Refer to TF-58, "
ASSEMBLY
INSPECTION" .
The total preload torque is as follows:Tool number : ST33200000
Pinion lock nut tightening torque
: 128 - 294 N·m (13 - 29 kg-m, 95 - 216 ft-lb)
Pinion bearing preload torque (P’
1 )
: 0.40 - 0.78 N·m (0.04 - 0.08 kg-m, 4 - 6 in-lb)
Total preload torque
With all oil seals installed : P’
1 + 0.45 - 0.47 N·m (0.045 - 0.048 kg-m, 3.9 - 4.1 in-lb)
Without transfer case oil seal and adapter case oil seal
: P’
1 + 0.35 - 0.37 N·m (0.035 - 0.038 kg-m, 3.1 - 3.2 in-lb)
SDIA1811E

FSU-8
COIL SPRING AND SHOCK ABSORBER

COIL SPRING AND SHOCK ABSORBERPFP:54302
Removal and InstallationEES00074
REMOVAL
1. Remove tyre. Remove brake caliper and hung it aside.
CAUTION:
Avoid depressing brake pedal with brake caliper removed.
2. Remove electrical wires of wheel sensor from strut.
3. Remove brake hose lock plate.
4. Remove mounting bolts and nuts securing steering knuckle to strut.
5. Remove mounting nuts on upper mounting plate and remove upper mounting plate and strut from vehicle.
INSTALLATION

Refer to FSU-5, "Components" in “Front Suspension Assembly” for tightening torque. Tighten in the
reverse order of removal.

Be sure arrows on strut mount insulator and spring upper seat
are positioned as shown. Also be sure notch in strut spacer is
positioned as shown. Then install strut.

Assemble upper mounting plate with its notch facing toward the
outside.
Disassembly and AssemblyEES00075
DISASSEMBLY
1. Install strut attachment (SST) to strut and fix it in a vise.
CAUTION:
When installing strut attachment (SST), wrap a shop cloth
around strut to protect it from damage.
2. Slightly loosen piston rod lock nut.
WARNING:
Do not remove piston rod lock nut completely. If it is
removed completely, coil spring jumps out and may cause
serious damage or injury.
3. Compress coil spring using a spring compressor.
WARNING:
Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The
spring compressors must be tightened alternately so as not to tilt the spring.
4. After making sure coil spring is free between upper and lower seats after Step 3. Remove piston rod lock
nut.
5. Remove small parts on strut.

Remove strut spacer, strut mount insulator, strut mounting insulator bracket thrust bearing, spring upper
seat, and upper rubber seat. Then remove coil spring.
6. Remove bound bumper from spring upper seat.
7. Gradually release spring compressor (commercial service tool), and remove coil spring.
INSPECTION AFTER DISASSEMBLY
Strut

Check strut for deformation, cracks, and damage, and replace if necessary.

Check piston rod for damage, uneven wear, and distortion, and replace if necessary.

Check welded and sealed areas for oil leakage, and replace if necessary.
SEIA0123E
SEIA0124E