2003 NISSAN X-TRAIL Electronic Repair Manual

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Page 1969 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual HEADLINING
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HEADLININGPFP:73910
Removal and InstallationEIS000ND
REMOVAL
1. Remove front pillar and center pillar garnishes. Refer toEI-26, "Removal and Installation".
2

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NISSAN X-TRAIL 2003 Electronic Repair Manual EI-30
HEADLINING
3. Remove rear pillar finisher. Refer toEI-26, "Removal and Installation".
4. Remove assistance grip.
NOTE:
When removing the assistants grip cover from a car with a sun-
roof, use a

Page 1971 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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ENGINE MECHANICAL
QR20DE
PRECAUTIONS .......................................................... 5
Precautions for Drain Cool

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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ENGINE MECHANICAL
QR20DE
PRECAUTIONS .......................................................... 5
Precautions for Drain 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 Angular Tightening ......................... 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET SEALING .......... 6
LIQUID GASKET APPLICATION PROCEDURE..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 8
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 ................................................... 13
Removal and Installation of Auxiliary Drive Belt
Auto- tensioner ....................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
CHANGING AIR CLEANER ELEMENT .............. 16INTAKE MANIFOLD ................................................. 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
OIL PAN AND OIL STRAINER ................................. 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 25
INSTALLATION ................................................... 25
INSPECTION AFTER INSTALLATION ................ 26
IGNITION COIL ......................................................... 27
Removal and Installation ........................................ 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 27
SPARK PLUG ........................................................... 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 28
INSPECTION AFTER REMOVAL ....................... 28
INSTALLATION ................................................... 28
FUEL INJECTOR AND FUEL TUBE ........................ 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 30
INSPECTION AFTER INSTALLATION ................ 30
ROCKER COVER ..................................................... 31
Removal and Installation ........................................ 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
CAMSHAFT .............................................................. 33
Removal and Installation ........................................ 33
REMOVAL ........................................................... 33
INSTALLATION ................................................... 35

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NISSAN X-TRAIL 2003 Electronic Repair Manual EM-2
INSPECTION AFTER REMOVAL ........................ 38
Valve Clearance ...................................................... 40
INSPECTION ....................................................... 4

EM-2
INSPECTION AFTER REMOVAL ........................ 38
Valve Clearance ...................................................... 40
INSPECTION ....................................................... 40
ADJUSTMENT .................................................... 41
TIMING CHAIN .......................................................... 43
Removal and Installation ........................................ 43
REMOVAL ........................................................... 44
INSPECTION AFTER REMOVAL ........................ 47
INSTALLATION .................................................... 48
CYLINDER HEAD ..................................................... 52
On-Vehicle Service ................................................. 52
CHECKING COMPRESSION PRESSURE ......... 52
Removal and Installation ........................................ 53
REMOVAL ........................................................... 53
INSPECTION AFTER REMOVAL ........................ 54
INSTALLATION .................................................... 54
Disassembly and Assembly .................................... 55
DISASSEMBLY ................................................... 55
ASSEMBLY ......................................................... 56
Inspection After Disassembly ................................. 56
CYLINDER HEAD DISTORTION ........................ 56
VALVE DIMENSIONS .......................................... 57
VALVE GUIDE CLEARANCE .............................. 57
VALVE GUIDE REPLACEMENT ......................... 57
VALVE SEAT CONTACT ..................................... 58
VALVE SEAT REPLACEMENT ........................... 58
VALVE SPRING SQUARENESS ......................... 60
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 60
ENGINE ASSEMBLY ................................................ 61
Removal and Installation ........................................ 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 63
INSPECTION AFTER INSTALLATION ................ 63
CYLINDER BLOCK ................................................... 64
Disassembly and Assembly .................................... 64
DISASSEMBLY ................................................... 65
ASSEMBLY ......................................................... 69
How to Select Piston and Bearing .......................... 73
DESCRIPTION .................................................... 73
HOW TO SELECT PISTON ................................. 74
HOW TO SELECT CONNCTING ROD BEARING... 74
HOW TO SELECT MAIN BEARING .................... 77
Inspection After Disassembly ................................. 80
CRANKSHAFT SIDE CLEARANCE .................... 80
CONNECTING ROD SIDE CLEARANCE ........... 81
PISTON AND PISTON PIN CLEARANCE .......... 81
PISTON RING SIDE CLEARANCE ..................... 82
PISTON RING END GAP .................................... 82
CONNECTING ROD BEND AND TORSION ....... 82
CONNECTING ROD BEARING (BIG END) ........ 83
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) ........................................... 83
CYLINDER BLOCK DISTORTION ...................... 84
INNER DIAMETER OF MAIN BEARING HOUS-
ING ...................................................................... 85
PISTON TO CYLINDER BORE CLEARANCE .... 85
OUTER DIAMETER OF CRANKSHAFT JOUR-NAL ......................................................................86
OUTER DIAMETER OF CRANKSHAFT PIN ......86
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT .................................................................87
CRANKSHAFT RUNOUT ....................................87
OIL CLEARANCE OF CONNECTING ROD
BEARING .............................................................87
OIL CLEARANCE OF MAIN BEARING ...............88
CRUSH HEIGH OF MAIN BEARING ...................88
OUTER DIAMETER OF LOWER CYLINDER
BLOCK MOUNTING BOLT ..................................88
OUTER DIAMETER OF CONNECTING ROD
BOLT ....................................................................89
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) .............................................................89
SERVICE DATA AND SPECIFICATIONS (SDS) ......90
Standard and Limit ..................................................90
GENERAL SPECIFICATIONS .............................90
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ...................................................................90
DRIVE BELTS ......................................................90
CYLINDER HEAD ................................................91
VALVE ..................................................................91
CAMSHAFT AND CAMSHAFT BEARING ...........94
CYLINDER BLOCK ..............................................94
PISTON, PISTON RING AND PISTON PIN ........95
CONNECTING ROD ............................................96
CRANKSHAFT .....................................................97
MAIN BEARING ...................................................98
CONNECTING ROD BEARING ...........................99
Tightening Torque ................................................. 100
YD22DDTi
PRECAUTIONS ....................................................... 102
Precautions for Drain Coolant ............................... 102
Precautions for Disconnecting Fuel Piping ........... 102
Precautions for Removal and Disassembly .......... 102
Precautions for Inspection, Repair and Replace-
ment ...................................................................... 102
Precautions for Assembly and Installation ............ 102
Parts Requiring Angular Tightening ...................... 102
Precautions for Liquid Gasket ............................... 103
REMOVAL OF LIQUID GASKET SEALING ...... 103
LIQUID GASKET APPLICATION PROCEDURE. 103
PREPARATION ....................................................... 104
Special Service Tools ............................................ 104
Commercial Service Tools .................................... 106
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 108
NVH Troubleshooting —Engine Noise .................. 108
Use the Chart Below to Help You Find the Cause
of the Symptom. .................................................... 109
DRIVE BELTS ..........................................................110
Checking Drive Belts .............................................110
Tension Adjustment ...............................................110
AIR CONDITIONER COMPRESSOR BELT ...... 111

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NISSAN X-TRAIL 2003 Electronic Repair Manual EM-3
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EMA ALTERNATOR AND WATER PUMP BELT ....... . 111
Removal and Installation ...................................... . 111
REMOVAL ..............................................

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EMA ALTERNATOR AND WATER PUMP BELT ....... . 111
Removal and Installation ...................................... . 111
REMOVAL ......................................................... . 111
INSTALLATION ................................................. . 111
AIR CLEANER AND AIR DUCT .............................. 112
Removal and Installation ....................................... 112
REMOVAL .......................................................... 112
INSTALLATION .................................................. 112
CHANGING AIR CLEANER ELEMENT ............. 112
CHARGE AIR COOLER .......................................... 114
Removal and Installation ....................................... 114
REMOVAL .......................................................... 114
INSPECTION AFTER REMOVAL ...................... 114
INSTALLATION .................................................. 114
INTAKE MANIFOLD ................................................ 115
Removal and Installation ....................................... 115
REMOVAL .......................................................... 115
INSPECTION AFTER REMOVAL ...................... 116
INSTALLATION .................................................. 116
INSPECTION AFTER INSTALLATION .............. 117
CATALYST ............................................................... 118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
EXHAUST MANIFOLD AND TURBOCHARGER ... 119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION ................................................. 120
INSPECTION AFTER INSTALLATION ............. 120
Disassembly and Assembly ................................. 121
REMOVAL ......................................................... 121
INSPECTION AFTER REMOVAL ..................... 121
Turbocharger ........................................................ 122
ROTOR SHAFT CLEARANCE ......................... 122
ROTOR SHAFT END PLAY .............................. 122
TURBINE WHEEL ............................................. 123
COMPRESSOR WHEEL .................................. 123
WASTEGATE VALVE ACTUATOR ................... 123
TROUBLE DIAGNOSIS OF TURBOCHARGER. 123
OIL PAN AND OIL STRAINER ............................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSPECTION AFTER REMOVAL ..................... 127
INSTALLATION ................................................. 127
INSPECTION AFTER INSTALLATION ............. 129
GLOW PLUG .......................................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130
VACUUM PUMP ..................................................... 131
Removal and Installation ...................................... 131
INSPECTION BEFORE REMOVAL .................. 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
INSPECTION AFTER INSTALLATION ............. 132
Disassembly and Assembly ................................. 133
DISASSEMBLY ................................................. 133
ASSEMBLY ....................................................... 133INJECTION TUBE AND FUEL INJECTOR ............135
Removal and Installation ......................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
INSPECTION AFTER INSTALLATION ..............137
FUEL SUPPLY PUMP .............................................138
Removal and Installation ......................................138
REMOVAL .........................................................138
INSPECTION AFTER REMOVAL .....................143
INSTALLATION .................................................143
ROCKER COVER ...................................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSTALLATION .................................................148
INSPECTION AFTER INSTALLATION ..............148
CAMSHAFT ............................................................149
Removal and Installation ......................................149
REMOVAL .........................................................149
INSPECTION AFTER REMOVAL .....................150
INSTALLATION .................................................153
Valve Clearance ...................................................154
INSPECTION ....................................................154
ADJUSTMENTS ................................................155
SECONDARY TIMING CHAIN ................................158
Removal and Installation ......................................158
REMOVAL .........................................................158
INSPECTION AFTER REMOVAL .....................160
INSTALLATION .................................................161
PRIMARY TIMING CHAIN ......................................163
Removal and Installation ......................................163
REMOVAL .........................................................165
INSPECTION AFTER REMOVAL .....................168
INSTALLATION .................................................168
CYLINDER HEAD ...................................................173
On-Vehicle Service ...............................................173
CHECKING COMPRESSION PRESSURE .......173
Removal and Installation ......................................174
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
Disassembly and Assembly ..................................178
DISASSEMBLY .................................................178
ASEMBLY ..........................................................179
INSPECTION AFTER DISASSEMBLY ..............179
ENGINE ASSEMBLY ..............................................184
Removal and Installation ......................................184
REMOVAL .........................................................184
INSTALLATION .................................................186
INSPECTION AFTER INSTALLATION ..............186
CYLINDER BLOCK ................................................188
Disassembly and Assembly ..................................188
DISASSEMBLY .................................................189
ASSEMBLY .......................................................193
How to Select Piston and Bearing ........................197
DESCRIPTION ..................................................197
HOW TO SELECT PISTON ..............................197
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................198

Page 1974 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual EM-4
HOW TO SELECT MAIN BEARING ..................199
Inspection After Disassembly ...............................200
CRANKSHAFT SIDE CLEARANCE ..................200
CONNECTING ROD SIDE CLEARANCE ....

EM-4
HOW TO SELECT MAIN BEARING ..................199
Inspection After Disassembly ...............................200
CRANKSHAFT SIDE CLEARANCE ..................200
CONNECTING ROD SIDE CLEARANCE .........200
PISTON TO PISTON PIN CLEARANCE ...........201
PISTON RING SIDE CLEARANCE ...................201
PISTON RING END GAP ..................................202
CONNECTING ROD BEND AND TORSION .....202
CONNECTING ROD BIG END INNER DIAME-
TER ...................................................................202
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .........................................203
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................203
MAIN BEARING HOUSING INNER DIAMETER. 204
PISTON TO CYLINDER BORE CLEARANCE ..204
CRANKSHAFT JOURNAL OUTER DIAMETER. 205
CRANKSHAFT PIN OUTER DIAMETER ..........205
CRANKSHAFT OUT-OF-ROUND AND TAPER. 205
CRANKSHAFT RUNOUT ..................................206
CONNECTING ROD BEARING OIL CLEAR-ANCE ................................................................. 206
MAIN BEARING OIL CLEARANCE ................... 206
MAIN BEARING CRUSH HETIGH .................... 207
MAIN BEARING CAP BOLT DEFORMATION ... 207
CONNECTING ROD BOLT DEFORMATION .... 207
OIL JET .............................................................. 208
OIL JET RELIEF VALVE .................................... 208
MOVEMENT AMOUNT OF FLYWHEEL ........... 208
SERVICE DATA AND SPECIFICATIONS (SDS) .... 210
Standard and Limit ................................................ 210
GENERAL SPECIFICATIONS ........................... 210
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ................................................................. 210
DRIVE BELTS .................................................... 210
CYLINDER HEAD ..............................................211
VALVE ................................................................211
CAMSHAFT AND CAMSHAFT BEARING ......... 215
CYLINDER BLOCK ............................................ 215
PISTON, PISTON RING AND PISTON PIN ...... 216
CONNCTING ROD ............................................ 217
CRANKSHAFT ................................................... 217
AVAILABLE MAIN BEARING ............................. 218
AVAILABLE CONNECTING ROD BEARING ..... 218
MISCELLANEOUS COMPONENTS .................. 219
Tightening Torque ................................................. 219

Page 1975 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual PRECAUTIONS
EM-5
[QR20DE]
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[QR20DE]PRECAUTIONSPFP:00001
Precautions for Drain CoolantEBS009QD
lDrain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEB

PRECAUTIONS
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[QR20DE]PRECAUTIONSPFP:00001
Precautions for Drain CoolantEBS009QD
lDrain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS009QE
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 DisassemblyEBS009QF
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 ReplacementEBS009QG
lBefore repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS009QH
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 TighteningEBS009QI
lUse an angle wrench 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 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.

Page 1976 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual EM-6
[QR20DE]
PRECAUTIONS
Precautions for Liquid Gasket
EBS009QJ
REMOVAL OF LIQUID GASKET SEALING
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing using a s

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