2003 NISSAN X-TRAIL engine coolant

ENGINE ASSEMBLY
EM-63
[QR20DE]
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lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
lPut a piece of wood or something similar as the support-
ing surface, secure a completely stable condition.
23. Remove RH engine mounting insulator.
24. Pull LH engine mounting through-bolt out.
25. Remove mounting bolts at front end of center member.
26. Remove front suspension member mounting bolts and nuts.
27. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
28. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
29. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
30. Remove starter motor.
31. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
lBleed air from passages in pipes and tubes of applicable lines.
KBIA0256E
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EM-66
[QR20DE]
CYLINDER BLOCK
lA commercial engine stand can be used.
NOTE:
lThis example is an engine stand for holding at transaxle
mounting side with the flywheel or drive plate removed.
3. Drain engine oil and coolant from inside of engine.
4. Remove the following components and associated parts.
lExhaust manifold and three way catalyst assembly; Refer to
EM-22, "
Removal and Installation".
lIntake manifold collector; Refer toEM-17, "Removal and
Installation".
lIntake manifold and fuel tube assembly; Refer toEM-17,
"Removal and Installation".
lIgnition coil; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lOil pan and oil strainer; Refer toEM-24, "Removal and Installation".
lFront cover, timing chain and balancer unit; Refer toEM-43, "Removal and Installation".
lCamshaft; Refer toEM-33, "Removal and Installation".
lCylinder head; Refer toEM-53, "Removal and Installation".
5. Remove knock sensor.
CAUTION:
Carefully handle the sensor avoiding shocks.
6. Remove crankshaft position sensor (POS).
CAUTION:
lAvoid impacts such as a dropping.
lDo not disassemble.
lKeep it away from metal particles.
lDo not place sensor close to magnetic materials.
7. Remove flywheel (M/T models) or drive plate (A/T models). Fix crankshaft with a stopper plate, and
remove mounting bolts.
Torx bit (size T55) : Flywheel (M/T models)
Torx socket (size E20): Drive plate (A/T models)
CAUTION:
lBe careful not to damage contact surface for the clutch
disc of the flywheel.
NOTE:
lThe flywheels, two block construction, allows movement in
response to transmission side pressure, or when twisted in its
rotational direction. Therefore, some amount of noise is nor-
mal.
PBIC0085E
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CYLINDER BLOCK
EM-69
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CAUTION:
Identify installation positions, and store them without mixing them up.
ASSEMBLY
1. Fully air-blow the coolant and oil passages in the cylinder block, the cylinder bore and the crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to the cylinder block.
lApply liquid gasket.
Use Genuine Liquid Gasket or equivalent.
lReplace the copper washers with new ones.
3. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the lower cylinder block.
b. Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block.
lInstall the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
c. Install the main bearings paying attention to the direction.
lThe main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
lOnly the main bearing (on the cylinder block) for No. 3 journal
has different specifications.
lBefore installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
lWhen installing, align the bearing stopper to the notch.
lEnsuretheoilholesoncylinderblockandthoseonthecorre-
sponding bearing are aligned.
4. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
lDowel pins of crankshaft and signal plate are provided as a
set for each.
5. Install the crankshaft to the cylinder block.
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EM-102
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Drain CoolantEBS00BNO
lDrain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00BNP
lBefore starting work, make sure no fire or spark producing items are in the work area.
lRelease fuel pressure before disassembly.
lAfter disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00BNQ
lWhen instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
lExercise maximum care to avoid damage to mating or sliding surfaces.
lCover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
lMark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
lWhen 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 ReplacementEBS00BNR
lBefore repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS00BNS
lUse torque wrench to tighten bolts or nuts.
lWhen 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.
lReplace with new gasket, packing, oil seal or O-ring.
lThoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
lAvoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
lRelease air within route after draining coolant.
lAfter repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular TighteningEBS00BNT
lUse an angle wrench 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 angular
tightening)
lDo not use a torque value for final tightening.
lThe torque value for these parts are for a preliminary step.
lEnsure thread and seat surfaces are clean and coated with engine oil.

PRECAUTIONS
EM-103
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Precautions for Liquid GasketEBS00BNU
REMOVAL OF LIQUID GASKET SEALING
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
lIn areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
gasket to the groove.
lAs for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the text of service manual.
lWithin five minutes of gasket application, install the mating com-
ponent.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten after the installation.
lAfter 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe
them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F

INTAKE MANIFOLD
EM-115
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INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00BO9
REMOVAL
WA RN ING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
2. Remove air duct. Refer toEM-112, "
Removal and Installation".
3. Remove charge air cooler and bracket. Refer toEM-114, "
Removal and Installation".
4. Remove air inlet pipes. Refer toEM-119, "
Removal and Installation"
5. Remove exhaust manifold cover.
6. Disconnect electronic EGR control valve water hoses and harness.
7. Disconnect heater hose.
SBIA0151E
1. Vacuum & fuel gallery 2. Water hose 3. Electronic EGR volume control valve
4. Gasket 5. EGR passage 6. EGR support
7. Water pipe 8. EGR tube 9. Intake manifold

EM-118
[YD22DDTi]
CATALYST
CATALYST
PFP:20905
Removal and InstallationEBS00BOA
REMOVAL
1. Remove engine under cover.
2. Drain engine coolant. Refer toCO-30, "
Changing Engine Coolant".
3. Remove radiator upper hose.
4. Remove radiator fan. Refer toCO-33, "
Removal and Installation".
5. Remove radiator mount bracket and radiator.
6. Remove water inlet pipe.
7. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
8. Remove catalyst.
CAUTION:
Do not disassemble.
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
INSTALLATION
Install in reverse order of removal.
lPushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
SBIA0157E
1. Insulator 2. Catalyst 3. Catalyst rear diffuser
4. Gasket
Catalyst locking pin : Flange bolt (black)
Insulator mounting bolt : Washer bolt (silver or yellow)

EXHAUST MANIFOLD AND TURBOCHARGER
EM-119
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00BOB
REMOVAL
1. Drain engine coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove charge air cooler. Refer toEM-114, "
Removal and Installation".
3. Remove air duct and air inlet pipe. Refer toEM-112, "
Removal and Installation".
4. Remove engine under cover.
5. Remove radiator upper hose.
6. Remove radiator fan. Refer toCO-34, "
Disassembly and Assembly Radiator Fan".
7. Remove radiator mount bracket and radiator. Refer toCO-33, "
Removal and Installation".
8. Remove water inlet pipe.
9. Disconnect exhaust front tube. Refer toEX-2, "
EXHAUST SYSTEM".
10. Remove catalyst. Refer toEM-118, "
Removal and Installation".
11. Remove exhaust manifold cover.
12. Remove insulator.
13. Each wiring and piping (disconnect/move)
SBIA0158E
1. Electronic EGR control valve 2. Gasket 3. EGR tube
4. Air inlet pipe 5.Exhaust manifold & turbocharger
assembly6. Oil return hose
7. Turbo insulator 8. Exhaust manifold insulator 9. Air inlet pipe