water pump NISSAN X-TRAIL 2003 Service Repair Manual

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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

EM-12
[QR]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00L7Q
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-61
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-56EM-55
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-99
EM-101
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-104EM-100
EM-100
EM-101
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-101EM-105
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-106EM-105
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-48
EM-44
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-20,
"WATER
PUMP"

DRIVE BELTS
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00KN7
WARNING:
Be sure to perform this step when the engine is stopped.

Make sure that the indicator (single line notch on fixed side) of drive belt auto-tensioner is within the pos-
sible use range (between three line notches on moving side).
NOTE:

Check the drive belt auto-tensioner indicator (single line notch on fixed side) when engine is cold.

When new drive belt is installed, the indicator (single line notch on fixed side) should be within the
range “A” in the figure.

Visually check entire belt for wear, damage or cracks.

If the indicator (single line notch on fixed side) is out of the possible use range or belt is damaged, replace
drive belt.
Tension AdjustmentEBS00KN8
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationEBS00KN9
REMOVAL
1. Remove splash guard on RH undercover.
2. With box wrench, and while securely holding the hexagonal part
in center of drive belt auto-tensioner pulley, move the wrench
handle in the direction of arrow (loosening direction of ten-
sioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
3. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of the retaining boss to fix
drive belt auto-tensioner pulley.
4. Loosen drive belt from water pump pulley in sequence, and
remove it.
PBIC1234E
PBIC2169E

EM-14
[QR]
DRIVE BELTS

INSTALLATION
1. With box wrench, and while securely holding the hexagonal part in center of drive belt auto-tensioner pul-
ley, move the wrench handle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off.
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole of
retaining boss to fix drive belt auto-tensioner pulley.
3. Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally.
CAUTION:
Confirm belt is completely set to pulleys.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator is within the range of possible use. Refer to EM-13, "
Checking
Drive Belts" .
Removal and Installation of Drive Belt Auto-TensionerEBS00KNA
REMOVAL
1. Remove splash guard on RH undercover.
2. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
3. Remove drive belt auto-tensioner.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
When installing drive belt auto-tensioner, be careful not to damage water pump pulley.
1. Drive belt auto-tensioner 2. Water pump pulley
PBIC2170E

EM-130
[YD22DDTi]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom.EBS00LR9
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-175
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-172EM-171
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearanceEM-226
EM-228
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-230EM-227
EM-227
EM-228
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance (Big
end)EM-228EM-232
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-233EM-232
Front of
engine
Timin g
chain
caseTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-180
EM-185
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-131
Creaking A B A B A BDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-42,
"WATER
PUMP"

DRIVE BELTS
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LRA

Before inspecting engine, make sure engine has cooled down;
wait approximately 30 minutes after engine has been stopped.

Visually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.

When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:

When checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.

Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00LRB

Adjust belts with the parts shown below.
CAUTION:

When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.

If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.

When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.

Make sure the belts are fully fitted into the pulley grooves during installation.

Handle with care to avoid smearing the belts with engine oil or engine coolant.

Do not twist or bend the belts with strong force.
PBIC1251E
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
A/C compressor belt Adjusting bolt on idler pulley
Alternator and water pump belt Adjusting bolt on alternator

EM-132
[YD22DDTi]
DRIVE BELTS

A/C COMPRESSOR BELT
1. Remove RH engine undercover.
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust. Refer to EM-131, "
Checking
Drive Belts" .
4. Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1. Loosen adjusting lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust. Refer to EM-131, "
Tension Adjustment" .
4. Tighten nut (C) and bolt (D) in this order.
Removal and InstallationEBS00LRC
REMOVAL
1. Loosen each belt. Refer to EM-131, "Tension Adjustment" .
2. Remove A/C compressor belt. Refer to EM-132, "
A/C COMPRESSOR BELT" .
3. Remove alternator and water pump belt. Refer to EM-132, "
ALTERNATOR AND WATER PUMP BELT" .
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt tension. Refer to EM-131, "
Tension Adjustment" .
3. Tighten nuts and bolts provided for adjustment to the specified torque.
4. Make sure again that each belt tension is as specified.Nut A:
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
PBIC1252E
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)

CYLINDER HEAD
EM-197
[YD22DDTi]
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10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuel pump fuse [ENG CONT (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no DTC is indicated for items of self-diagnosis.
Removal and InstallationEBS00LRW
REMOVAL
1. Drain engine coolant. Refer to CO-31, "Changing Engine Coolant" .
2. Remove the following:

Charge air cooler (Refer to EM-135, "Removal and Installation" .)

Rocker cover (Refer to EM-168, "Removal and Installation" .)

Air cleaner and air duct (Refer to EM-133, "Removal and Installation" .)

Vacuum pump (Refer to EM-153, "Removal and Installation" .)

Spill tube and fuel injector (Refer to EM-157, "Removal and Installation" .)

Intake manifold (Refer to EM-136, "Removal and Installation" .)

Exhaust manifold and Turbocharger (Refer to EM-141, "Removal and Installation" .)

Secondary timing chain (Refer to EM-180, "Removal and Installation" .)

Camshaft (Refer to EM-170, "Removal and Installation" .)
3. Remove cylinder head assembly.
1. Glow plug 2. Cylinder head assembly 3. Cylinder head bolt
4. Copper washer 5. Engine coolant temperature sensor 6. Gasket
7. Water outlet 8. Dowel pin 9. Gasket
10. Glow harness 11. Glow plate 12. Cap
PBIC2437E

EM-214
[YD22DDTi]
CYLINDER BLOCK

e. Hoist engine and install it to the engine stand (special service
tool).
NOTE:
It is possible to set engine sub-attachment and engine stand
shaft to the engine stand at first, then install engine later.

Widely use engine stand can be used.
NOTE:
The figure shows an example of general-purpose engine
stand that can hold mating surface of transmission with drive
plate and rear plate removed.
5. Drain engine oil and engine coolant from inside engine. Refer to LU-21, "
Changing Engine Oil" .
6. Drain engine coolant by removing drain plug from inside of
engine.
7. Remove the following parts and related parts. (Only major parts are listed.)

Intake manifold (Refer to EM-136, "Removal and Installation" .)

Exhaust manifold and turbocharger (Refer to EM-141, "Removal and Installation" .)

Rocker cover (Refer to EM-168, "Removal and Installation" .)

Fuel injector (Refer to EM-157, "Removal and Installation" .)

Oil pan and oil strainer (Refer to EM-147, "Removal and Installation" .)

Water pump (Refer to CO-42, "WATER PUMP" .)

Thermostat and water piping (Refer to CO-44, "THERMOSTAT AND WATER PIPING" .)
JEM193G
PBIC0085E
PBIC2439E

EM-236
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00ODZ
GENERAL SPECIFICATIONS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
DRIVE BELTS
Belt Deflection:
Unit: mm (in)
*: When engine is cold.Cylinder arrangementIn-line 4
Displacement
Unit: cm
3 (cu in)2,184 (133.27)
Bore and stroke Unit: mm (in) 86 x 94 (3.39 x 3.70)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio16.7
Compression pressure
Unit: kPa (bar, kg/cm
2 , psi)/200 rpmStandard 2,991 (29.9, 30.5, 434)
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Valve timing
Unit: degree
abc de f
224 212 2 30 -2 46
EM120
Item Limit
Surface distortionIntake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied*
New Adjusted Limit for re-adjusting
A/C compressor belt4 - 5
(0.16 - 0.20)6 - 7
(0.24 - 0.28)8.5 (0.335)
Alternator and water pump belt9.0 - 10.5
(0.354 - 0.413)11.0 - 12.5
(0.433 - 0.492)16.5 (0.650)