egr NISSAN X-TRAIL 2005 Service Owner's Manual

EM-164
[YD22DDTi]
VACUUM PUMP

10. Remove exhaust manifold cover. Refer to EM-151, "Removal and Installation" .
11. Disconnect heater hose. Refer to EM-146, "
INTAKE MANIFOLD" .
12. Remove EGR cooler. Refer to EM-146, "
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-165, "
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-166, "
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 hexagonal portion of camshaft.
4. Tighten rear camshaft sprocket mounting bolts.
SBIA0167E
PBIC1141E
SBIA0167E

CAMSHAFT
EM-187
[YD22DDTi]
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Measure the valve clearance using the feeler gauge when
engine is cool (at normal temperature).
Valve clearance:
Unit: mm (in)
*: Reference data approximately 80°C (176°F)
8. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
9. While referring to the figure, measure the valve clearance
marked in the table below.
10. If the valve clearance is outside the specification, adjust as follows.
ADJUSTMENTS

Remove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
SBIA0181E
Item Cold Hot* (Reference data)
Intake 0.24 -0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
Measuring pointNo. 1No. 2No. 3No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDCXX XX
SBIA0182E
SBIA0183E

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

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 BLOCK
EM-237
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7. Install main bearing caps.

Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.

Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-254, "
MAIN BEARING CAP BOLT
DEFORMATION" .
9. With the TORX socket (size: E14, commercial service tool),
tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees. (angle tightening)
CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angle tightening. Avoid tightening based
on visual checks alone.

After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.

Check crankshaft end play. Refer to EM-245, "CRANKSHAFT
END PLAY" .
10. Check the outer diameter of connecting rod bolts. Refer to EM-
254, "CONNECTING ROD BOLT DEFORMATION" .
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.

Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.

Using the industrial use dryer, heat pistons up to approx. 60 to
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
JEM225G
: 27 N·m (2.8 kg-m, 20 ft-lb)
JEM200G
JEM226G
PBIC0089E

EM-238
[YD22DDTi]
CYLINDER BLOCK


Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.

Refer to above step a for precaution on snap ring installation.

After installation, check connecting rods for smooth move-
ment.
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.

Install top ring and second ring with punched mark surfaces
facing upward.

Install rings so that three closed gap position 120 degrees
apart one another.

Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
13. Install connecting rod bearing to connecting rod and cap.

While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.

Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
14. Install piston and connecting rod assembly to crankshaft.

Move crankshaft pin to be assembled to BDC.

Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.

Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.

Using the piston ring compressor (special service tool) or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:

When removing piston and connecting rod assembly,
prevent the big end of connecting rod from interfering with oil jet.

Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference
of the connecting rod big end.
MBIA0024E
Punched mark:
Top ring : RTop
Second ring : R2nd
JEM228G
JEM229G
PBIC1619E

CYLINDER BLOCK
EM-239
[YD22DDTi]
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15. Install connecting rod caps and mounting nuts.

Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.

Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
16. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
c. Loosen completely.
d. Tighten bolts.
e. Tighten 120 degrees. (angle tightening)

Always use either the angle wrench (special service tool)
or protractor during angle tightening. Avoid tightening
based on visual checks alone.

After tightening nuts, make sure that crankshaft rotates
smoothly.

Check connecting rod side clearance. Refer to EM-246,
"CONNECTING ROD SIDE CLEARANCE" .
17. Press fit rear oil seal into rear oil seal retainer.

Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.

Avoid inclined fitting. Force fit perpendicularly.
MBIA0024E
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
: 0 N·m (0 kg-m, 0 in-lb)
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
JEM231G
JEM232G

EM-256
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS01FCM
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)

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-259
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CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in) Item Standard Limit
Cylinder head distortion Less than 0.03 (0.0012) 0.1 (0.004)
JEM204G
Valve head diameter “D”Intake 28.0 - 28.3 (1.102 - 1.114)
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Valve length “L”Intake 106.72 (4.2016)
Exhaust 106.36 (4.1874)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α”Intake
45 degrees 15′ - 45 degrees 45′
Exhaust
Valve margin “T”Intake 1.38 (0.0543)
Exhaust 1.48 (0.0583)
Valve margin “T” limitMore than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
SEM188

EM-266
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

Bearing Oil Clearance
Unit: mm (in)
Tightening TorqueEBS01FCN
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*2
Connecting rod bearing oil
clearanceStandard 0.031 - 0.061 (0.0012 - 0.0024)
Idler pulley Nut A 35 (3.6, 26)
Alternator Nut C 21.5 (2.2, 16)
Nut D 50.5 (5.2, 37)
Charge air cooler Bracket 22 (2.2, 16)
Charge air cooler cover
7.0 (0.71, 62)*
2
EGR volume control valve 70 (7.1, 52)
EGR cooler Exhaust manifold side 64.5 (6.6, 48)
EGR volume control
valve side70 (7.1, 52)
EGR volume control valve bracket 23.5 (2.4, 17)
Exhaust manifold insulator
7.4 (0.75, 65)*
2
*1 Exhaust manifold31 (3.2, 23)
Turbocharger48.5 (4.9, 36)
Catalyst48.5 (4.9, 36)
Catalyst rear diffuser33.5 (3.4, 25)
Catalyst insulator Catalyst side
7.4 (0.75, 65)*
2
Catalyst rear diffuser
side9.6 (0.97, 85)*
2
Oil pan lower
7 (0.7, 62)*2
Oil pan drain plug34 (3.5, 25)
Oil strainer17 (1.7, 13)
*1 Oil pan upper M6 bolt
7 (0.7, 62)*
2
M8 bolt 21.5 (2.2, 16)
M10 bolt 33.5 (3.4, 25)
Vacuum pump23.5 (2.4, 17)
Cylinder head rear cover M6 bolt
9.7 (0.98, 86) *
2
M8 bolt 17 (1.7, 13)
Injection tube Nozzle side 23.0 (2.3, 17)
Fuel rail side 23.0 (2.3, 17)
Injection tube center23.0 (2.3, 17)
Nozzle support26.2 (2.7, 19)
Spill tube Nozzle side 18.7 (1.9, 14)
Cylinder head side 18.7 (1.9, 14)
Fuel rail57.5 (5.9, 42)
Fuel pump31.4 (3.2, 23)
Fuel pump sprocket39 (4.0, 29)