NISSAN X-TRAIL 2005 Service Repair Manual

PRIMARY TIMING CHAIN
EM-207
[YD22DDTi]
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a. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
b. Install oil pump drive spacer to crankshaft.

Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
d. Install oil pump housing.

When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.

When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
14. Check gaps on upper oil pan mounting surface.

Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:

If the measured value is out of the standard, install again.
15. Install crankshaft pulley as follows:
a. Install crankshaft pulley, taking care not to damage front oil seal.
CAUTION:
Do not tap pulley on the side surface where belt is installed (outer circumference).A : Leave the start and end areas of the bead slightly
protruding from the surface.
B : Apply liquid gasket along upper end surface of oil
pump housing.
JEM144G
JEM145G
JEM133G
Oil pump housing and rear chain case:
Standard : – 0.09 to 0.09 mm (– 0.0035 to 0.0035 in)
Rear chain case and cylinder block:
Standard : – 0.19 to 0.07 mm (– 0.0075 to 0.0028 in)
JEM146G

EM-208
[YD22DDTi]
PRIMARY TIMING CHAIN

b. Hold crankshaft pulley with the pulley holder (special service
tool).
c. Apply engine oil onto threaded parts of crankshaft pulley bolt
and seating area.
d. Tighten crankshaft pulley fixing bolt.
e. Put an alignment mark on crankshaft pulley that aligns with one
of the punched marks on the bolt.
f. Then turn all bolts 60 degrees clockwise (turn by one notch).
16. Install secondary timing chain and the associated parts. Refer to EM-195, "
INSTALLATION" .
17. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for inter-
ference among parts.
18. Install in the reverse order of removal.: 24.5 N·m (2.5 kg-m, 18 ft-lb)
JEM131G
JEM147G

CYLINDER HEAD
EM-209
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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-1012,
"Basic Inspection" (WITH EURO-ODB) or EC-1382, "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 battery cable from the negative terminal.
4. Remove charge air cooler. Refer to EM-144, "
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-162,
"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 the battery cable to the 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
: 20 N·m (2.0 kg-m, 15 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-210
[YD22DDTi]
CYLINDER HEAD

10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the 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 the battery cable to the 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-32, "Changing Engine Coolant" .
2. Remove the following:

Charge air cooler (Refer to EM-144, "Removal and Installation" .)

Rocker cover (Refer to EM-178, "Removal and Installation" .)

Air cleaner and air duct (Refer to EM-142, "Removal and Installation" .)

Vacuum pump (Refer to EM-163, "Removal and Installation" .)

Spill tube and fuel injector (Refer to EM-167, "Removal and Installation" .)

Intake manifold (Refer to EM-146, "Removal and Installation" .)

Exhaust manifold and turbocharger (Refer to EM-151, "Removal and Installation" .)

Secondary timing chain (Refer to EM-193, "Removal and Installation" .)

Camshaft (Refer to EM-180, "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. Cylinder gasket
10. Glow harness 11. Glow plate 12. Cap
PBIC2437E

CYLINDER HEAD
EM-211
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Remove cylinder head bolts in reverse order as shown in the
figure with the cylinder head bolt wrench (commercial service
tool).

Lift up cylinder head assembly to avoid interference with
dowel pins located between the cylinder block and cylinder
head, and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder
head, or, place wood blocks beneath both ends of cylin-
der head to keep the cylinder bottom from any contact.

For glow plug removal, the following shall be noted.
CAUTION:

To avoid breakage, do not remove glow plug unless necessary.

Perform continuity test with glow plug installed.

Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]

Do not use air impact wrench.
4. Remove cylinder head gasket.
INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation

Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.

If the necking point can be identified, set it as measuring point
“d1”.

Calculate the difference between “d1” and “d2”.

If it exceeds the limit, replace cylinder head bolt.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-249, "
CYLIN-
DER BLOCK TOP SURFACE DISTORTION" .
1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions.

If it exceeds the limit, replace cylinder head.
JEM149G
Limit : 0.15 mm (0.0059 in)
JEM171G
Limit : 0.1mm (0.004 in)
SEM496G

EM-212
[YD22DDTi]
CYLINDER HEAD

Cylinder head- to- block Difference Check

After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head.

If out of the standard, check fitting of dowel pins and cylinder
head.
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.

Cylinder head gasket to be installed is selected by its thickness through the following procedure.
–When replacing gasket alone
 Install a gasket with same thickness as that of the one removed.
 Identify the thickness of gasket by the number of cut-outs on
the rear right side.
*: Measured with head bolts tightened
 Gasket thickness can be identified at the location shown in
the figure by the numbers of cut-outs before removal.
–When the following parts have been repaired/replaced:

With cylinder block upper surface and/or crankshaft pin journal ground

With cylinder block, pistons, connecting rods, and/or crankshaft replaced
a. Set piston at a point close to TDC.Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)
JEM172G
Gasket thickness* mm (in) Number of grade Number of cut-outs
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1
0.950 (0.0374) 3 2
0.975 (0.0384) 4 3
1.000 (0.0394) 5 4
1.025 (0.0404) 6 5
MBIA0020E
PBIC0682E

CYLINDER HEAD
EM-213
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b. Set the dial indicator at the location as shown in the figure. Turn-
ing crankshaft gradually, set the indicator scale to “0” where the
piston protrusion is maximized.
c. Move the dial indicator stand so that the tip of dial indicator can
contact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
*: Measured with head bolts tightened
2. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
3. Install cylinder head assembly.
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten all bolts in numerical order as shown.
PBIC2645E
Piston protrusion mm (in) Gasket thickness* mm (in)Identification
Number of cut-outs
Less than 0.255 (0.0100) 0.900 (0.0354) 0
Less than 0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
Less than 0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
Less than 0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
Less than 0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
More than 0.355 (0.0140) 1.025 (0.0404) 5
A : Apply bead so that it does not protrude into oil pas-
sage.
B : Minimize the overlapping area of the bead, with
start and end areas of bead as shown in the figure.
* : Comes at an external location but cannot be viewed
externally after engine is assembled.
PBIC1256E
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM149G

EM-214
[YD22DDTi]
CYLINDER HEAD

c. Tighten 180 degrees in numerical order as shown (angle tight-
ening).
d. Loosen completely in reverse order of that shown in the figure.
e. Tighten all bolts in numerical order as shown.
f. Tighten 90 degrees in numerical order as shown (angle tighten-
ing).
g. Tighten another 90 degrees in numerical order as shown (angle
tightening).
CAUTION:

When the angle wrench (special service tool) is not used, paint an alignment mark on the head
of cylinder head bolt and cylinder head surface before tightening. Check the angle with a pro-
tractor.
4. Install glow plug.
CAUTION:

To avoid damage, glow plugs should be removed only when required.

Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.

Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.
5. Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.

Bleed air from lines and hoses of applicable lines, such as in cooling system.

After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
: 0 N·m (0 kg-m, 0 ft-lb)
:39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM166G
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

CYLINDER HEAD
EM-215
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Disassembly and AssemblyEBS00LRX
DISASSEMBLY
1. Remove adjusting shims and valve lifters.

Check the installation positions, and keep them to avoid being confused.
2. Remove valve collet.

Using the valve spring compressor, attachment and adapter
(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-217, "Valve Guide Clearance" .
1. Adjusting shim 2. Valve lifter 3. Valve collet
4. Valve spring retainer 5. Valve spring 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (Exhaust) 12. Valve (Intake)
PBIC2328E
PBIC2388E

EM-216
[YD22DDTi]
CYLINDER HEAD

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. When removing valve seats must be replaced. Refer to EM-219, "
Valve Seat Replacement" .
8. When removing valve guides must be replaced. Refer to EM-218, "
Valve Guide Replacement" .
ASSEMBLY
1. Install valve guides if removed. Refer to EM-218, "Valve Guide Replacement" .
2. Install valve seats if removed. Refer to EM-219, "
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.
5. Install valves.

Install larger diameter to intake valve side.

Note that valve layout here is different from that of conven-
tional engine.
6. Install valve spring.
SBIA0196E
JEM153G
JEM165G
SBIA0196E