engine NISSAN X-TRAIL 2005 Service Owner's Manual

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YD22DDTi
PRECAUTIONS ...................................................... 130
Precautions for Draining Engine Coolant ............. 130
Precautions for Disconnecting Fuel Piping .......... 130
Precautions for Removal and Disassembly ......... 130
Precautions for Inspection, Repair and Replace-
ment ..................................................................... 130
Precautions for Assembly and Installation ........... 130
Parts Requiring Angle Tightening ......................... 130
Precautions For Liquid Gasket ............................. 131
REMOVAL OF LIQUID GASKET ...................... 131
LIQUID GASKET APPLICATION PROCEDURE . 131
PREPARATION ....................................................... 132
Special Service Tools ........................................... 132
Commercial Service Tools .................................... 136
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 138
NVH Troubleshooting — Engine Noise ................ 138
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 139
DRIVE BELTS ......................................................... 140
Checking Drive Belts ............................................ 140
Tension Adjustment .............................................. 140
A/C COMPRESSOR BELT ............................... 141
ALTERNATOR AND WATER PUMP BELT ....... 141
Removal and Installation ...................................... 141
REMOVAL ......................................................... 141
INSTALLATION ................................................. 141
AIR CLEANER AND AIR DUCT ............................. 142
Removal and Installation ...................................... 142
REMOVAL ......................................................... 142
INSTALLATION ................................................. 142
CHANGING AIR CLEANER FILTER ................. 143
CHARGE AIR COOLER ......................................... 144
Removal and Installation ...................................... 144
REMOVAL ......................................................... 144
INSPECTION AFTER REMOVAL ..................... 144
INSTALLATION ................................................. 144
INTAKE MANIFOLD ............................................... 146
Removal and Installation ...................................... 146
REMOVAL ......................................................... 146
INSPECTION AFTER REMOVAL ..................... 147
INSTALLATION ................................................. 147
INSPECTION AFTER INSTALLATION ............. 148
CATALYST .............................................................. 149
Removal and Installation ...................................... 149
REMOVAL ......................................................... 149
INSTALLATION ................................................. 150
EXHAUST MANIFOLD AND TURBOCHARGER .. 151
Removal and Installation ...................................... 151
REMOVAL ......................................................... 151
INSTALLATION ................................................. 152
INSPECTION AFTER INSTALLATION ............. 152
Disassembly and Assembly ................................. 153
DISASSEMBLY ................................................. 153
ASSEMBLY ....................................................... 153INSPECTION AFTER DISASSEMBLY ..............154
Turbocharger ........................................................154
ROTOR SHAFT CLEARANCE ..........................154
ROTOR SHAFT END PLAY ..............................155
TURBINE WHEEL .............................................155
COMPRESSOR WHEEL ...................................155
TURBOCHARGER BOOST CONTROL ACTU-
ATOR .................................................................155
TROUBLE DIAGNOSIS OF TURBOCHARGER .156
OIL PAN AND OIL STRAINER ...............................157
Removal and Installation ......................................157
REMOVAL .........................................................157
INSPECTION AFTER REMOVAL .....................159
INSTALLATION .................................................159
INSPECTION AFTER INSTALLATION ..............161
GLOW PLUG ..........................................................162
Removal and Installation ......................................162
REMOVAL .........................................................162
INSTALLATION .................................................162
VACUUM PUMP ......................................................163
Removal and Installation ......................................163
INSPECTION BEFORE REMOVAL ..................163
REMOVAL .........................................................163
INSTALLATION .................................................164
INSPECTION AFTER INSTALLATION ..............165
Disassembly and Assembly ..................................165
DISASSEMBLY .................................................165
ASSEMBLY .......................................................166
INJECTION TUBE AND FUEL INJECTOR ............167
Removal and Installation ......................................167
REMOVAL .........................................................167
INSTALLATION .................................................169
INSPECTION AFTER INSTALLATION ..............170
FUEL PUMP ............................................................171
Removal and Installation ......................................171
REMOVAL .........................................................171
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
ROCKER COVER ...................................................178
Removal and Installation ......................................178
REMOVAL .........................................................178
INSTALLATION .................................................179
INSPECTION AFTER INSTALLATION ..............179
CAMSHAFT ............................................................180
Removal and Installation ......................................180
REMOVAL .........................................................180
INSPECTION AFTER REMOVAL .....................181
INSTALLATION .................................................184
Valve Clearance ...................................................185
INSPECTION ....................................................185
ADJUSTMENTS ................................................187
OIL SEAL ................................................................190
Removal and Installation of Valve Oil Seal ...........190
REMOVAL .........................................................190
INSTALLATION .................................................190
Removal and Installation of Front Oil Seal ...........191
REMOVAL .........................................................191

EM-4 INSTALLATION ..................................................191
Removal and Installation of Rear Oil Seal ............192
REMOVAL .........................................................192
INSTALLATION ..................................................192
SECONDARY TIMING CHAIN ................................193
Removal and Installation ......................................193
REMOVAL .........................................................193
INSPECTION AFTER REMOVAL ......................195
INSTALLATION ..................................................195
PRIMARY TIMING CHAIN ......................................198
Removal and Installation ......................................198
REMOVAL .........................................................200
INSPECTION AFTER REMOVAL ......................203
INSTALLATION ..................................................203
CYLINDER HEAD ...................................................209
On-Vehicle Service ...............................................209
CHECKING COMPRESSION PRESSURE .......209
Removal and Installation ......................................210
REMOVAL .........................................................210
INSPECTION AFTER REMOVAL ......................211
INSTALLATION ..................................................212
INSPECTION AFTER INSTALLATION ..............214
Disassembly and Assembly ..................................215
DISASSEMBLY .................................................215
ASSEMBLY .......................................................216
INSPECTION AFTER DISASSEMBLY ..............217
ENGINE ASSEMBLY ..............................................222
Removal and Installation (2WD Models) ..............222
REMOVAL .........................................................223
INSTALLATION ..................................................224
INSPECTION AFTER INSTALLATION ..............225
Removal and Installation (4WD Models) ..............226
REMOVAL .........................................................227
INSTALLATION ..................................................229
INSPECTION AFTER INSTALLATION ..............229
CYLINDER BLOCK .................................................230
Disassembly and Assembly ..................................230
DISASSEMBLY .................................................231
ASSEMBLY .......................................................235
How to Select Piston and Bearing ........................241
DESCRIPTION ..................................................241
HOW TO SELECT PISTON ...............................242
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................242HOW TO SELECT MAIN BEARING ..................244
Inspection After Disassembly ................................245
CRANKSHAFT END PLAY ................................245
CONNECTING ROD SIDE CLEARANCE .........246
PISTON TO PISTON PIN CLEARANCE ...........246
PISTON RING SIDE CLEARANCE ...................247
PISTON RING END GAP ..................................247
CONNECTING ROD BEND AND TORSION .....248
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................248
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................248
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................249
MAIN BEARING HOUSING INNER DIAMETER .249
PISTON TO CYLINDER BORE CLEARANCE ..250
CRANKSHAFT MAIN JOURNAL DIAMETER ...251
CRANKSHAFT PIN JOURNAL DIAMETER ......251
CRANKSHAFT OUT-OF-ROUND AND TAPER .251
CRANKSHAFT RUNOUT ..................................252
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................252
MAIN BEARING OIL CLEARANCE ...................253
CRUSH HEIGHT OF MAIN BEARING ..............253
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................253
MAIN BEARING CAP BOLT DEFORMATION ...254
CONNECTING ROD BOLT DEFORMATION ....254
OIL JET ..............................................................254
OIL JET RELIEF VALVE ....................................254
FLYWHEEL DEFLECTION ................................255
MOVEMENT AMOUNT OF FLYWHEEL ...........255
SERVICE DATA AND SPECIFICATIONS (SDS) ....256
Standard and Limit ................................................256
GENERAL SPECIFICATIONS ...........................256
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................256
DRIVE BELTS ....................................................256
CAMSHAFT .......................................................257
CYLINDER HEAD ..............................................259
VALVE ................................................................259
CYLINDER BLOCK ............................................262
PISTON, PISTON RING AND PISTON PIN ......263
CONNECTING ROD ..........................................264
CRANKSHAFT ...................................................264
AVAILABLE MAIN BEARING .............................265
AVAILABLE CONNECTING ROD BEARING .....265
Tightening Torque .................................................266

PRECAUTIONS
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ

Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Dowel pins are used for several parts alignment. When replacing and reassembling with dowel pins, make
sure that dowel pins are installed in the original portion.

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining coolant.

Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure there are no leaks at fuel line connections.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00KN5

Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
–Balancer unit

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

EM-6
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PRECAUTIONS

Precautions for Liquid GasketEBS00MRW
REMOVAL OF LIQUID GASKET

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter (special service tool) and remove the
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.

Tap seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.

In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.

Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser (special service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.

If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of service manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If the liquid gasket protrudes, wipe it off immediately.

Do not retighten mounting bolts or nut after the installation.

Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEBS00L7N
Tool number
Tool nameDescription
KV10111100
Seal cutterRemoving oil pan and timing chain case
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV10115300
Engine sub-attachment
KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
AdapterDisassembling and assembling valve
mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.
KV10112100
Angle wrenchTightening bolts for bearing cap, cylinder
head, etc.
KV10117100
Heated oxygen sensor wrenchLoosening or tightening heated oxygen
sensors with 22 mm (0.87 in) hexagon nut
S-NT046
NT042
NT028
ZZA1078D
PBIC1650E
S-NT014
NT379

EM-8
[QR]
PREPARATION

KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
ST16610001
Pilot bushing pullerRemoving pilot converter
WS39930000
Tube presserPressing the tube of liquid gasket
KV11103000
Pulley pullerRemoving crankshaft pulley
Quick connector release Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210) Tool number
Tool nameDescription
S-NT605
S-NT603
S-NT044
S-NT045
S-NT052
NT676
PBIC0198E

EM-10
[QR]
PREPARATION

Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new air fuel ratio sensor
and heated oxygen sensor (Use with anti-
seize lubricant shown below.)
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor and air fuel ratio sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
Anti-seize lubricant i.e.: (Permatex
TM
133AR or equivalent meeting MIL
specification MIL-A-907)Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads
Manual lift table caddy Removing and installing engine Tool nameDescription
AEM488
AEM489
ZZA1210D

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting — Engine NoiseEBS00L7P
PBIC2768E

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-64
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-59EM-58
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-107
EM-109
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-112EM-108
EM-108
EM-109
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-109EM-113
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-114EM-113
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-50
EM-46
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-21,
"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 (notch on fixed side) of drive belt auto-tensioner is within the possible use
range (between three line notches on moving side).
NOTE:

Check the drive belt auto-tensioner indication when the engine is cold.

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

Visually check entire drive belt for wear, damage or cracks.

If the indicator (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. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle 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.

Do not loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pul-
ley.
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.
PBIC2622E
PBIC2169E