troubleshooting NISSAN X-TRAIL 2005 Service Repair Manual

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION EM
A
EM

ENGINE MECHANICAL
QR
PRECAUTIONS .......................................................... 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET .......................... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting — Engine Noise ................... 11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 17
Changing Air Cleaner Filter .................................... 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INTAKE MANIFOLD ................................................. 18
Removal and Installation (QR20DE) ...................... 18
REMOVAL ........................................................... 18INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
Removal and Installation (QR25DE) ...................... 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 24
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 26
INSTALLATION ................................................... 26
OIL PAN AND OIL STRAINER ................................. 27
Removal and Installation ........................................ 27
REMOVAL ........................................................... 27
INSPECTION AFTER REMOVAL ....................... 29
INSTALLATION ................................................... 29
INSPECTION AFTER INSTALLATION ................ 30
IGNITION COIL ......................................................... 31
Removal and Installation ........................................ 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
SPARK PLUG ........................................................... 32
Removal and Installation ........................................ 32
REMOVAL ........................................................... 32
INSPECTION AFTER REMOVAL (EXCEPT
RUSSIA) .............................................................. 32
INSPECTION AFTER REMOVAL (FOR RUS-
SIA) ..................................................................... 33
INSTALLATION ................................................... 33
FUEL INJECTOR AND FUEL TUBE ........................ 34
Removal and Installation (QR20DE) ...................... 34
REMOVAL ........................................................... 34
INSTALLATION ................................................... 36
INSPECTION AFTER INSTALLATION ................ 38
Removal and Installation (QR25DE) ...................... 39
REMOVAL ........................................................... 39
INSTALLATION ................................................... 41
INSPECTION AFTER INSTALLATION ................ 43

EM-3
C
D
E
F
G
H
I
J
K
L
M
EMA

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

PRECAUTIONS
EM-5
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM

[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.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-11
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM

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"

EM-130
[YD22DDTi]
PRECAUTIONS

[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Draining Engine CoolantEBS00LQZ
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00LR0

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

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00LR1

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 ReplacementEBS00LR2
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00LR3

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 liquid gasket, packing, oil seal or O-ring.

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

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine 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, engine oil sliding surfaces well.

Release air within route when refilling after draining coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00LR4

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

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-138
[YD22DDTi]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting — Engine NoiseEBS00LR8
PBIC2311E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-139
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

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
Top of
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-185
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-182EM-181
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-246
EM-248
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-250EM-247
EM-247
EM-248
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance (Big
end)EM-248EM-252
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-253EM-252
Front of
engine
Timing
chain
caseTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-193
EM-198
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-140
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-43,
"WATER
PUMP"

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION CO
A
CO

ENGINE COOLING SYSTEM
QR
PRECAUTIONS .......................................................... 3
Precautions for Liquid Gasket .................................. 3
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
System Chart ........................................................... 8
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ............... 13
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
RADIATOR (ALUMINUM TYPE) .............................. 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18
COOLING FAN ......................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19INSTALLATION ................................................... 19
Disassembly and Assembly .................................... 20
DISASSEMBLY ................................................... 20
INSPECTION AFTER DISASSEMBLY ................ 20
ASSEMBLY ......................................................... 20
WATER PUMP .......................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
THERMOSTAT AND WATER CONTROL VALVE .... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 24
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 25
Standard and Limit .................................................. 25
CAPACITY ........................................................... 25
RADIATOR .......................................................... 25
THERMOSTAT .................................................... 25
WATER CONTROL VALVE ................................. 25
Tightening Torque ................................................... 25
YD22DDTi
PRECAUTIONS ........................................................ 26
Precautions For Liquid Gasket ............................... 26
LIQUID GASKET APPLICATION PROCEDURE ... 26
PREPARATION ......................................................... 27
Special Service Tools ............................................. 27
Commercial Service Tools ...................................... 27
OVERHEATING CAUSE ANALYSIS ........................ 28
Troubleshooting Chart ............................................ 28
COOLING SYSTEM .................................................. 30
Cooling Circuit ........................................................ 30
System Chart .......................................................... 31
ENGINE COOLANT .................................................. 32
Inspection ............................................................... 32

OVERHEATING CAUSE ANALYSIS
CO-5
[QR]
C
D
E
F
G
H
I
J
K
L
MA
CO

OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartEBS00KOD
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat and water con-
trol valve stuck closed—
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant viscosity —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration