2003 NISSAN X-TRAIL check engine

CYLINDER BLOCK
EM-193
[YD22DDTi]
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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-194
[YD22DDTi]
CYLINDER BLOCK
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90°to 95°[target: 90°].
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
lCheck crankshaft end side clearance. Refer toEM-200,
"CRANKSHAFT SIDE CLEARANCE".
9. Check the outer diameter of connecting rod bolts. Refer toEM-
207, "CONNECTING ROD BOLT DEFORMATION".
10. Install pistons to connecting rod.
a. Using long nose pliers, install snap rings to grooves on piston rear side.
lFit snap rings correctly into grooves.
b. Install pistons to connecting rods.
lUsing industrial dryer, heat pistons up to approx. 60 to 70°C(140to158°F) until piston pin can be
pressed down by finger touch. Then insert piston pins into piston and connecting rod from front side of
piston toward rear.
lAssemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being
positioned as shown in the figure.
c. Install snap rings to front side of pistons.
lRefertoabovestepaforprecautiononsnapringinstallation.
lAfter installation, check connecting rods for smooth move-
ment.
11. Use piston ring expander to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
lInstall top ring and second ring with stamped surfaces facing
upward.
lInstall rings so that three closed gap position 120°apart one
another.
lClosed gaps do not need to face in a specific directions, as long as each are positioned 120°apart.
JEM200G
JEM226G
JEM227G
Identification stamp:
To p r i n g : A E
Second ring : AE2
JEM228G

CYLINDER BLOCK
EM-195
[YD22DDTi]
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EM
12. Install connecting rod bearings to connecting rods and caps.
lWhile installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces,
but clean them completely.
lAlign stoppers on connecting rod bearings with connecting
rod stopper notches to install connecting rod bearings.
13. Install piston and connecting rod assembly to crankshaft.
lMove crankshaft pin to be assembled to BDC.
lAlign cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
lUsing piston ring compressor, install piston and connecting
rod assembly with front mark on piston crown facing toward
the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.
14. Install connecting rod caps and mounting nuts.
lAlign cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
lMake sure that the front mark on connecting rod cap faces
towards the front of the engine.
15. Tighten connecting rod nuts according to the following proce-
dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N·m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120°to 125°[target: 120°]. (angular tightening)
lAlways use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
lAfter tightening nuts, check that crankshaft rotates smoothly.
JEM229G
JEM230G
JEM227G
JEM231G

EM-196
[YD22DDTi]
CYLINDER BLOCK
lCheck connecting rod side clearance. Refer toEM-200,
"CONNECTING ROD SIDE CLEARANCE".
16. Force fit rear oil seal into rear oil seal retainer.
lUsing a drift [105 mm (4.13 in) dia.], force fit so that the
dimension is as specified in the figure.
lAvoid inclined fitting. Force fit perpendicularly.
17. Install rear oil seal and retainer assembly.
lApply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
18. Press fit pilot bushing into flywheel.
lUsing drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
19. Install fuel supplypump bracket.
lAlign the bracket with the dowel pins on the block to install.
lThe two bolts used for dowel pins have a longer shanks than
the other two.
20. Install parts to the engine in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of
assembly.
22. Install flywheel.
lHolding ring gear with ring stopper (SST), tighten securing
bolts with TORX bit (size: Q6T55 E9, Commercial Service
Tool).
lTighten bolts uniformly in a crisscross manner.
JEM232G
JEM233G
JEM234G
SBIA0200E

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTION
A
EX
EXHAUST SYSTEM
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2
Removal and Installation .......................................... 2
QR20DE ................................................................ 2
YD22DDTI ............................................................. 3RREMOVAL ........................................................... 3
INSTALLATION ..................................................... 3
Inspection After Installation ...................................... 4
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5
Tightening Torque ..................................................... 5

EX-2
EXHAUST SYSTEM
EXHAUST SYSTEM
PFP:20100
Checking Exhaust SystemEBS00AZ6
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
Removal and InstallationEBS003DN
CAUTION:
lBe sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
lPerform the operation with the exhaust system fully cooled down because the system will be hot
just after the engine stops.
lBe careful not to cut your hand on the insulator edge.
QR20DE
SMA211A
KBIA0291E
1 Main muffler 2 Mounting rubber 3 Spring
4 Gasket 5 Three way catalyst 6 Exhaust front tube
7 Seal bearing 8 Mounting rubber bracket 9 Mounting bracket
10 Exhaust center tube

EX-4
EXHAUST SYSTEM
Front exhaust side (QR20DE):
lInsert the seal bearing in the direction shown in the figure.
CAUTION:
Tighten the mounting bolt without causing interference with
the flange.
Main muffler side (QR20DE and YD22DDTi):
1. Insert the seal bearing in the direction shown in the figure.
2. Tighten the mounting bolt with the big end of the spring facing
the flange.
CAUTION:
Tighten the mounting bolt without causing interference with
the flange.
Inspection After InstallationEBS003DO
lWith the engine running, check exhaust tube joints for gas leakage and unusual noise.
KBIA0299E
SBIA0147E

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