torque NISSAN X-TRAIL 2005 Service User Guide

INTAKE MANIFOLD
EM-19
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b. Loosen mounting bolts in reverse order as shown in the figure,
and remove electric throttle control actuator and gasket.
CAUTION:

Handle carefully to avoid any shock to electric throttle
control actuator.

Do not disassemble.
5. Disconnect harness, power steering piping, vacuum hose and PCV hose from intake manifold, and move
them aside.
6. Remove intake manifold support and gasket.
7. Disconnect sub-harness from fuel injector. Refer to EM-34, "
Removal and Installation (QR20DE)" .
8. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold (with fuel tube and fuel
injector assembly) and gasket.
CAUTION:

Do not disassemble intake manifold.

Cover engine openings to avoid entry of foreign materi-
als.
NOTE:
Disregard No. 6 when loosening.
9. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-34, "
Removal and Installa-
tion (QR20DE)" .
10. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Check if gasket is not dropped from the installation groove of intake manifold.

Tighten in numerical order as shown in the figure.
NOTE:
No. 6 means double tightening of bolt No. 1.
EMJ1612D
PBIC2173E
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
PBIC2173E

INTAKE MANIFOLD
EM-23
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INSPECTION AFTER REMOVAL
Surface Distortion

Using straightedge and feeler gauge, check the surface distor-
tion of both the intake manifold collector mating surface and the
intake manifold mating surfaces.

If it exceeds the limit, replace intake manifold and/or intake man-
ifold collector.
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Tighten in numerical order as shown in the figure.
NOTE:
No. 6 means double tightening of bolt No. 1.
Intake Manifold Collector
Tighten in numerical order as shown in the figure.
NOTE:
No. 8 means double tightening of bolt No. 1.
Electric Throttle Control Actuator

Tighten mounting bolts equally and diagonally in several steps
and in numerical order as shown in the figure.

Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is discon-
nected. Refer to EC-47, "
Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-560, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).

Perform the “Idle Air Volume Learning” and “Throttle Valve
Closed Position Learning” when electric throttle control actuator
is replaced. Refer to EC-47, "
Idle Air Volume Learning" (WITH
EURO-OBD) or EC-560, "
Idle Air Volume Learning" (WITHOUT
EURO-OBD). Limit : 0.1 mm (0.004 in)
KBIA0235E
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
SBIA0231E
SBIA0230E
EMJ1612D

EM-26
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EXHAUST MANIFOLD AND THREE WAY CATALYST

5. Loosen nuts in reverse order as shown in the figure to remove
exhaust manifold and three way catalyst assembly.
NOTE:
Disregard No. 6 and 7 when loosening.
6. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
7. Remove exhaust manifold cover (lower) and three way catalyst cover from exhaust manifold and three
way catalyst assembly.
INSPECTION AFTER REMOVAL
Surface Distortion

Using straightedge and feeler gauge, check the surface distor-
tion of exhaust manifold and three way catalyst assembly mating
surface.

If it exceeds the limit, replace exhaust manifold and three way
catalyst assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold

If stud bolts were removed, install them and tighten to the specified torque below.

Tighten nuts in numerical order as shown in the figure.
NOTE:
No. 6 and 7 mean double tightening of bolts No. 1 and 3.
Heated Oxygen Sensor
CAUTION:

Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen
sensor thread cleaner and apply anti-seize lubricant (commercial service tool).

Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the “MI” coming on.
KBIA0045E
Limit : 0.3 mm (0.012 in)
KBIA0046E
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
KBIA0045E

TIMING CHAIN
EM-53
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b. Apply a continuous bead of liquid gasket with a tube presser
(special service tool: WS39930000) to front cover as shown in
the figure.
Use Genuine Liquid Gasket or equivalent.
NOTE:
Application instruction differs depending on the position.
c. Make sure that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:

Do not let A/C and power steering pipings interfere with upper part of front cover.

Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Tighten mounting bolts in numerical order as shown in the fig-
ure.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
8. Install chain guide between camshaft sprockets.
9. Install intake valve timing control cover with the following procedure:
a. Install intake valve timing control solenoid valves to intake valve timing control cover if removed.
b. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
c. Install O-ring to front cover.Detail of A : Cross over the start of the applica-
tion and the end.
Detail of B : Apply liquid gasket outside of bolt
holes. (For all bolt holes other than
B, apply to the inside.)
Detail of C : Between here only, apply 4.5 - 5.5
mm (0.177 - 0.217 in) dia.
SBIA0267E
KBIA0083E

CAMSHAFT
EM-59
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4. If out of the standard, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer.
2. If out of the standard, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer.
CAMSHAFT BRACKET INNER DIAMETER

Tighten camshaft bracket bolts with specified torque. Refer to EM-61, "INSTALLATION" for the tightening
procedure.

Measure the inner diameter of camshaft bracket with an inside
micrometer.
CAMSHAFT JOURNAL OIL CLEARANCE

(Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)

If out of the standard, replace either or both camshaft and cylinder head.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-61, "INSTALLATION" for tightening procedure. Standard:
Intake
QR20DE : 45.015 - 45.205 mm (1.7722 - 1.7797 in)
QR25DE : 45.665 - 45.855 mm (1.7978 - 1.8053 in)
Exhaust
QR20DE : 42.825 - 43.015 mm (1.6860 - 1.6935 in)
QR25DE : 43.975 - 44.165 mm (1.7313 - 1.7388 in)
PBIC0039E
Standard:
No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 23.435 - 23.455 mm (0.9226 - 0.9234 in)
PBIC0040E
Standard:
No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC0041E
Standard: 0.045 - 0.086 mm (0.0018 - 0.0034 in)

EM-86
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ENGINE ASSEMBLY

2. Release fuel pressure. Refer to EC-49, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-562,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Drain engine coolant from radiator. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
4. Remove the following parts.

LH and RH undercovers

Front road wheels and tyres

Battery; Refer to SC-4, "BATTERY" .

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

Air duct and air cleaner case assembly; Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

Alternator; Refer to SC-13, "CHARGING SYSTEM" .

Radiator and radiator cooling fan assembly; Refer to CO-12, "RADIATOR" .
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. 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-34, "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-12,
"OPERATING CYLINDER" .
5. Disconnect shift and select cable from transaxle (M/T models). Refer to MT-16, "
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-11, "
STEERING COLUMN" .
4. Disconnect power steering fluid piping at a point between vehicle and engine. Refer to PS-37, "
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-27, "
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-19, "
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-46, "
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-94
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CYLINDER BLOCK

CAUTION:

Be careful not damage or deform signal plate mounted on
crankshaft.

When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.

Do not remove signal plate unless it is necessary to do
so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T30).
18. Pull rear oil seal out from rear end of crankshaft.
NOTE:
When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull it out from
between crankshaft and cylinder block.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
19. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Identify installation positions, and store them without mixing them up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure.

Apply liquid gasket to the thread of water drain plug “A”.
Use Genuine Liquid Gasket or equivalent.
NOTE:
Do not apply liquid gasket to the thread of plug “B”.

Tighten each plug as specified below.
3. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder
block.
SBIA0275E
PBIC2770E
Part Washer Tightening torque
A No 9.8 N·m (1.0 kg-m, 87 in-lb)
B Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)

CYLINDER BLOCK
EM-109
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CONNECTING ROD BEND AND TORSION

Check with a connecting rod aligner.

If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END DIAMETER

Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-94, "
ASSEMBLY" for the tightening procedure.

Measure the inner diameter of connecting rod big end with an
inside micrometer.

If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer.Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
To r s i o n :
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
PBIC2077E
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)
PBIC1641E
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E

CYLINDER BLOCK
EM-111
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Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge and feeler
gauge.

If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER

Install lower cylinder block without main bearings installed, and
tighten lower cylinder block mounting bolts to the specified
torque. Refer to EM-94, "
ASSEMBLY" for the tightening proce-
dure.

Measure the inner diameter of main bearing housing with a bore
gauge.

If out of the standard, replace cylinder block and lower cylinder
block assembly.
NOTE:
Cylinder block cannot be replaced as a single, because it is
machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction
of engine)
NOTE:
When determining cylinder bore grade, measure the cylinder
bore at “B” position.

If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or re-bore the cylinder inner wall.

Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the
piston to cylinder bore satisfies the standard.
CAUTION:
When using oversize piston, use it for all cylinders with oversize piston rings.Limit: 0.1 mm (0.004 in)
PBIC0121E
Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 in)
PBIC2012E
Standard inner diameter:
89.010 - 89.030 mm (3.5043 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.01 mm (0.0004 in)
Oversize (OS): 0.2 mm (0.008 in)
SBIA0284E

EM-112
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CYLINDER BLOCK

Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer.
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)

If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-100, "HOW TO SELECT PIS-
TON" .
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
2. Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores
may be distorted in final assembly. Refer to EM-94, "
ASSEMBLY" for the tightening procedure.
3. Cut cylinder bores.
NOTE:

When any cylinder needs boring, all other cylinders must also be bored.

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft main journals with a
micrometer.

If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-114, "
MAIN BEARING
OIL CLEARANCE" . Measure point
: Distance from the top 42.0 mm (1.654 in)
Standard
: 88.990 - 89.010 mm (3.5035 - 3.5043 in)
PBIC0125E
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
Re-bored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.
PBIC0270E