2003 NISSAN X-TRAIL check engine

CYLINDER BLOCK
EM-71
[QR20DE]
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9. Restart tightening of lower cylinder block bolts with the following
procedure.
NOTE:
Step “a ”and “b” have been completed before installation of rear
oil seal (step 7).
a. Step “a” has been completed before installation of rear oil seal.
b. Step “b” has been completed before installation of rear oil seal.
c. Tighten M10 bolts to 60 to 65°(target: 60°) in order from 1to 10.
d. Tighten M8 ( in) bolts to 19.6 to 24.5 N·m (2.0 to 2.5 kg-m, 15 to
18 ft-lb) in order from 11 to 22.
CAUTION:
In step “c”, use an angle wrench (special service tool) or
protractor to check tightening angle. Do not make judgment
by visual inspection.
lAfter installing mounting bolts, make sure that crankshaft
can be rotated smoothly by hand.
lWipe off completely any protruding liquid gasket on front side
of engine.
lCheck crankshaft side clearance. Refer toEM-80, "CRANK-
SHAFT SIDE CLEARANCE".
10. Install the piston to the connecting rod.
a. Usingasnapringpliers,installthesnapringtothegroovesof
the piston rear side.
lInsert it fully into groove to install.
b. Install the piston to the connecting rod.
lUsing an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 C°(140 to 158°F)]. From the front to the rear, insert the piston
pin into the piston and the connecting rod.
lAssemble so that the front mark on the piston crown and the
oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown in the figure.
c. Install the snap rings to the front of the piston.
lAfter installing, check that the connecting rod moves
smoothly.
11. Using a piston ring expander, install the piston rings.
CAUTION:
Be careful not to damage the piston.
lPosition each ring with the gap as shown in the figure refer-
ring to the piston front mark.
lInstall the top ring and the second ring with the stamped sur-
face facing upward.
KBIA0063E
KBIA0065E
PBIC0099E
Stamped mark : 1E (top ring)
: 2A (second ring)
PBIC0100E

EM-72
[QR20DE]
CYLINDER BLOCK
12. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
lWhen installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
lWhen installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
lCheck the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft.
lPosition the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
lApply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
lMatch the cylinder position with the cylinder No. on the con-
necting rod to install.
lUsing a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.
14. Install the connecting rod cap.
lMatch the stamped cylinder number marks on the connecting
rodwiththoseonthecaptoinstall.
15. Tighten the connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of the connecting rod
bolts.
b. Tighten bolts to 18.6 to 20.6 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
c. Put mating (with paint) on each bolt and connecting rod cap, all
in the same direction (when using a protractor).
d. Then tighten all bolts 90 to 95 degrees clockwise (target: 90
degrees) (Angle tightening).
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.
lAfter tightening the bolt, make sure that the crankshaft rotates smoothly.
lCheck the connecting rod side clearance. Refer toEM-81, "CONNECTING ROD SIDE CLEARANCE".
PBIC0266E
PBIC0267E
KBIA0067E
KBIA0068E

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.

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
EM-109
[YD22DDTi]
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Use the Chart Below to Help You Find the Cause of the Symptom.EBS00BO6
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
headTick in g o r
clickingCA—AB—Tappet
noiseValve clearanceEM-154
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-151EM-150
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 clearance (Small
end)EM-201
EM-203
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-204EM-201
EM-202
EM-202
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance (Small
end)
Connecting rod bear-
ing oil clearance (Big
end)EM-203EM-206
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-206EM-206
Front of
engine
Timin g
chain
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-158
EM-163
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-110
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-40,
"WATER
PUMP"

EM-110
[YD22DDTi]
DRIVE BELTS
DRIVE BELTS
PFP:02117
Checking Drive BeltsEBS00BNX
lBefore inspecting the engine, make sure the engine has cooled
down; wait approximately 30 minutes after the engine has been
stopped.
lVisually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.
lWhen measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
lWhen checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing the crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
lTighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00BNY
lAdjust belts with the parts shown below.
CAUTION:
lWhen a new belt is installed as a replacement, adjust it to the value specified under “New” value
because of insufficient adaptability with pulley grooves.
lIf the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
lWhen checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
lMake sure the belts are fully fitted into the pulley grooves during installation.
lHandle with care to avoid smearing the belts with oil or cooling water etc.
lDo not twist or bend the belts with strong force.
JEM249G
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
Air conditioner compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator water pump belt Adjusting bolt on alternator

EM-116
[YD22DDTi]
INTAKE MANIFOLD
8. Remove EGR tube.
9. Remove vacuum hose.
10. Remove injection tube. Refer toEM-135, "
Removal and Installa-
tion".
11. Remove water pipe.
12. Remove fuel hose.
lTo prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
13. Loosen bolts and nuts in the reverse order of that shown in the
figure.
CAUTION:
Do not disassemble or adjust swirl control valve.
14. Remove electronic EGR control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
lConnect vacuum handy pump to actuator, and apply vacuum to close swirl control valve.
lCheck distortion on the mounting surface with a straightedge
and feeler gauge.
Swirl Control Valve
lConnect vacuum handy pump to actuator, confirm that rod
moves smoothly in accordance with the amount of vacuum
applied and vacuum is maintained.
INSTALLATION
Following instructions below, install in reverse order of removal.
1. Install EGR vacuum control valve.
lHandle with care avoiding any shocks.
SBIA0152E
SBIA0153E
Limit : 0.1 mm (0.004 in)
SBIA0154E
Vacuum reference value (Approx.)
At start of rod movement
: – 8.0 Kpa (– 80 mbar, – 60 mmHg, – 2.36 inHg)
At end of rod movementApprox.
: –26.7Kpa(–267bar,–200mmHg,–7.87inHg)
SBIA0155E

INTAKE MANIFOLD
EM-117
[YD22DDTi]
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lDo not disassemble or adjust.
2. Install intake manifold.
lTighten fixing bolts and nuts in numerical order as shown in the figure.
lWhen stud bolts come off, install with the following torque..
3. Install water hose.
lInstall water hose by referring to identification marks avoiding
twisting.
lWhen an insert stopper is not provided with the pipe, insert
the hose up to dimension A. When the pipe is shorter than
dimension A, insert hose fully until it reaches the end.
lWhen an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
lWhen marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
4. Install remaining parts in reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer toFL-16,
"Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Dimension A : 25 - 30 mm (0.984 - 1.181 in)
SBIA0156E

EM-120
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
14. Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
15. Rotate the exhaust manifold and turbocharger assembly so that
the rear side (EGR tube mounting side) faces upward. And then
pull out the assembly from between the engine and the air con-
ditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling
out the assembly.
INSTALLATION
lWhen a stud bolt is pulled out, tighten it to the following torque:
lTighten the exhaust manifold mounting nuts in the following procedure:
1. Tighten the nuts in the order specified in the figure.
2. Re-tighten the nuts 1 to 4.
3. Install the gasket so that the alignment protrusion faces the No.
4port.
4. Install in reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
JEM266G
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
JEM266G