2003 NISSAN X-TRAIL engine coolant

EM-184
[YD22DDTi]
ENGINE ASSEMBLY
ENGINE ASSEMBLY
PFP:10001
Removal and InstallationEBS00BOH
WAR NIN G:
lSituate vehicle on a flat and solid surface.
lPlace chocks at front and back of rear wheels.
lFor engines not equipped with engine slingers, attach proper slingers and bolts described in
PA R T S C ATA L O G.
CAUTION:
lAlways be careful to work safely, avoid forceful or uninstructed operations.
lDo not start working until exhaust system and coolant are cool enough.
lIf items or work required are not covered by the engine main body section, refer to the applicable
sections.
lAlways use the support point specified for lifting.
lUse either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
lFor supporting points for lifting and jacking point at rear axle, refer toGI-37, "Garage Jack and
Safety Stand".
REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle down ward.
Separate suspension member, and then separate engine and transaxle.
Preparation
SBIA0190E
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. RH engine mounting insulator
4. RH engine mounting bracket 5. Front engine mounting bracket 6. Front engine mounting insulator
7. Center member 8. LH engine mounting insulator 9. LH engine mounting bracket

ENGINE ASSEMBLY
EM-185
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
1. Remove engine hood.
2. Drain coolant from radiator drain plug.
3. Remove the following parts.
lLH/RH under cover
lLH/RH front wheel
lBattery
lAuxiliary drive belt; Refer toE M - 111 , "Removal and Installation".
lAir duct and air cleaner case assembly; Refer toEM-112, "Removal and Installation".
lAlternator
lRadiator and radiator fan assembly; Refer toCO-33, "Removal and Installation".
lCharge air cooler
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
6. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
7. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
8. Remove clutch operating cylinder from transaxle, and move it aside.
9. Disconnect shift cable from transaxle.
Engine room RH
10. Remove engine coolant reservoir tank.
11. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
12. Remove exhaust front tube.
13. Remove propeller shaft.
14. Remove steering shaft from steering gear.
15. Disconnect power steering fluid cooler piping at a point between body and engine.
16. Remove ABS sensor from brake caliper.
17. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
18. Remove LH/RH suspension from steering knuckle under strut.
Removal
19. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
20. Liftwithhoistandsecuretheengineinposition.Slinger bolts:
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
SBIA0191E

EM-186
[YD22DDTi]
ENGINE ASSEMBLY
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:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
21. Remove RH engine mounting insulator.
22. Pull LH engine mounting through-bolt out.
23. Remove mounting bolts at front end of center member.
24. Remove front suspension member mounting bolts and nuts.
25. 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.
26. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
27. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
28. Remove starter motor.
29. 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.
lBefore starting engine, bleed air from fuel piping. Refer toFL-16, "Air Bleeding".
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.
KBIA0256E
KBIA0257E
KBIA0270E

EM-190
[YD22DDTi]
CYLINDER BLOCK
e. Hoist engine and install it to the engine stand.
NOTE:
It is possible to set engine sub-attachment and engine attach-
ment to engine stand at first, then install engine later.
lCommercial engine stand can be used.
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
5. Drain engine oil and coolant from inside engine.
6. Remove the following parts and related parts. (Only major parts are listed.)
lIntake manifold collector and intake manifold (Refer toEM-115, "Removal and Installation".)
lExhaust manifold (Refer toEM-119, "Removal and Installation".)
lRocker cover (Refer toEM-147, "Removal and Installation").
lInjection tube and fuel injector (Refer toEM-135, "Removal and Installation".)
lOil pan and oil strainer (Refer toEM-125, "Removal and Installation".)
lWater pump (Refer toCO-40, "Removal and Installation".)
lThermostat and water piping (Refer toCO-42, "Removal and Installation".)
lVacuum pump and vacuum pipe (Refer toEM-131, "Removal and Installation".)
lSecondary timing chain (Refer toEM-158, "Removal and Installation")
lPrimary timing chain (Refer toEM-163, "Removal and Installation".)
lElectronic control fuel supply pump (Refer toEM-138, "Removal and Installation".)
lCamshaft (Refer toEM-149, "Removal and Installation".)
lCylinder head (Refer toEM-174, "Removal and Installation".)
lOil cooler (Refer toLU-25, "Removal and Installation".)
lAccessory, accessory bracket and mount brackets
7. Remove fuel supply pump bracket.
8. Remove rear oil seal retainer.
JEM193G
PBIC0085E

CYLINDER BLOCK
EM-193
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
ASSEMBLY
1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase and cylinder bore to remove foreign matter.
2. Install oil jet relief valve.
3. Install oil jet.
lAlign knock pin on back of oil jet with hole on block when
installing oil jet.
4. Install main bearings and thrust bearings.
a. Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
lInstall thrust bearings with oil groove facing to crankshaft arm
(outside).
c. Being careful with the direction, install main bearings.
lInstall main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
lWhile installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them
completely.
lAlign stopper notches on bearings to install them.
lCheck that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
5. Install crankshaft to cylinder block.
lMake sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
lIdentify 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.
lMain bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
7. Check the main bearing cap bolts for deformation.
Refer toEM-207, "
MAIN BEARING CAP BOLT DEFORMA-
TION".
PBIC0389E
JEM224G
JEM213G
JEM225G

EM-220
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
M8 bolt 16.0- 19.0 (1.6 - 1.9, 12 - 14)
Injection tube Nozzle side 21.6 - 24.5 (2.2 - 2.5, 16 - 18)
Pump side 26.5 - 29.4 (2.7 - 3.0, 20 - 21)
Nozzle support25.1 - 28.0 (2.6 - 2.8, 19 - 20)
Spill tube Nozzle side 14.7 - 16.7 (1.5 - 1.7, 11 - 12)
Cylinder head side 16.7 - 20.6 (1.7 - 2.1, 13 - 15)
Common rail51.0 - 64.0 (5.2 - 6.5., 38 - 47)
Fuel supply pump46.0 - 56.0 (4.57 - 5.7, 37 - 41)
Fuel supply pump sprocket 37.0 - 41.0 (3.8 - 4.2, 28 - 30)
Fuel supply pump rear bracket 27.0 - 37.0 (2.8 - 3.8, 20 - 27)
Front chain case
6.9 - 8.8 ( 0.7 - 0.9, 61 - 78)*
2
Chain tensioner
8.5 - 10.7 (0.86 - 1.1, 75 - 95)*2
Tensior guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Slack guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Camshaft sprocket138- 147 (14.0 - 15.0, 102 - 108)
Fuel supply pump sprocket 38.0 -41.0 (3.8 - 4.2, 28 - 30)
Oil pump12 - 13 (1.3 - 1.4, 9 - 10)
Power steering pump51.0 - 56.0 (5.2 - 5.8, 38 - 41)
Rear chain case12.0 - 13.0 (1.2 - 1.4, 19 - 10)
Engine coolant temperature sensor 12.0- 15.0 (1.2 - 1.6, 9- 11)
*1 Cylinder head 1) 29 - 38 (2.9 - 3.9, 21 - 28)
2) 180°to185°
3) 0 (0, 0)
4) 35 to 44 (3.5 - 4.5, 26 - 32)
5) 90°to 95°(angle tightening)
6) 90°to 95°(angle tightening)
Water outlet21 - 28 (2.1 - 2.9, 16 - 20)
Glow plug18.0 - 2.0 (1.8 - 2.2, 13 - 15)
*1 Flywheel103 - 112 (10.5 - 115, 76 - 83)
Oil pressure switch13.0 - 17.0 (1.25 - 1.75, 9 - 12)
Oil jet6.1 - 10.7(0.62 - 1.1, 54 - 95)
Oil jet relief valve40 - 58 (4.0 - 6.0, 29 - 43)
Rear oil seal retainer12.0 - 13.0 (1.2 - 1.4, 9 - 10)

FAX-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
CautionEDS0005P
Observe the following precautions when disassembling and servicing drive shaft.
lThe wheel joint cannot be disassembled. Do not attempt to disassemble it.
lPerform work in a location which is as dust-free and dirt-free as possible.
lBefore disassembling and servicing, clean the outside of parts.
lThe disassembly and service location must be clean. Care must be taken to prevent parts from becoming
dirty and to prevent the entry of foreign objects.
lDisassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
lPaper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
lDisassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.
Precautions for Brake SystemEDS0 00 I0
lWhen installing rubber parts, final tightening must be carried out
under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
lUse flare nut wrench when removing or installing brake tubes.
lAfter installing removed suspension parts, check wheel align-
ment and adjust if necessary.
lAlways torque brake lines when installing.
SBR686C

FL-16
[YD22DDTi]
FUEL FILTER
Air Bleeding
EBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel path as follows:
1. Move priming pump up and down to bleed air from fuel path.
2. When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
3. Crank the engine until it starts. Do not crank the engine for more
than 30 seconds.
4. If the engine does not starts, stop cranking and repeat step 1
above.
5. If the engine does not operate smoothly after it has started, race
it two or three times.
6. If air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel injection pump. After that, operate priming pump
and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine mount
insulator.
Draining WaterEBS00BLC
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:
lCoolant in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volum.
lDrained coolant is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mount insulator.
3. After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged and
fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer toFL-16, "
Air Bleeding".
5. Start engine.
SBIA0137E
SBIA0138E