2003 NISSAN X-TRAIL height adjustment

EM-2 ROCKER COVER ..................................................... 42
Removal and Installation ........................................ 42
REMOVAL ........................................................... 42
INSTALLATION .................................................... 43
TIMING CHAIN .......................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSPECTION AFTER REMOVAL ........................ 48
INSTALLATION .................................................... 49
CAMSHAFT ............................................................... 53
Removal and Installation ........................................ 53
REMOVAL ........................................................... 53
INSPECTION AFTER REMOVAL ........................ 55
INSTALLATION .................................................... 58
Valve Clearance ...................................................... 61
INSPECTION ....................................................... 61
ADJUSTMENT .................................................... 62
OIL SEAL .................................................................. 64
Removal and Installation of Valve Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 64
Removal and Installation of Front Oil Seal ............. 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 65
Removal and Installation of Rear Oil Seal .............. 65
REMOVAL ........................................................... 65
INSTALLATION .................................................... 65
CYLINDER HEAD ..................................................... 67
On-Vehicle Service ................................................. 67
CHECKING COMPRESSION PRESSURE ......... 67
Removal and Installation ........................................ 68
REMOVAL ........................................................... 68
INSPECTION AFTER REMOVAL ........................ 69
INSTALLATION .................................................... 69
Disassembly and Assembly .................................... 71
DISASSEMBLY ................................................... 71
ASSEMBLY ......................................................... 72
Inspection After Disassembly ................................. 73
VALVE DIMENSIONS .......................................... 73
VALVE GUIDE CLEARANCE .............................. 73
VALVE GUIDE REPLACEMENT ......................... 74
VALVE SEAT CONTACT ..................................... 75
VALVE SEAT REPLACEMENT ........................... 75
VALVE SPRING SQUARENESS ......................... 77
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 77
ENGINE ASSEMBLY ................................................ 78
Removal and Installation ........................................ 78
REMOVAL ........................................................... 78
INSTALLATION .................................................... 81
INSPECTION AFTER INSTALLATION ................ 81
CYLINDER BLOCK ................................................... 82
Disassembly and Assembly .................................... 82
DISASSEMBLY ................................................... 83
ASSEMBLY ......................................................... 87
How to Select Piston and Bearing .......................... 92
DESCRIPTION .................................................... 92
HOW TO SELECT PISTON ................................. 92
HOW TO SELECT CONNECTING ROD BEAR-ING ....................................................................... 93
HOW TO SELECT MAIN BEARING .................... 95
Inspection After Disassembly .................................. 99
CRANKSHAFT END PLAY .................................. 99
CONNECTING ROD SIDE CLEARANCE ........... 99
PISTON TO PISTON PIN OIL CLEARANCE ....... 99
PISTON RING SIDE CLEARANCE ...................100
PISTON RING END GAP ..................................100
CONNECTING ROD BEND AND TORSION .....101
CONNECTING ROD BIG END DIAMETER ......101
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................101
CYLINDER BLOCK DISTORTION ....................102
MAIN BEARING HOUSING INNER DIAMETER .103
PISTON TO CYLINDER BORE CLEARANCE ..103
CRANKSHAFT MAIN JOURNAL DIAMETER ...104
CRANKSHAFT PIN JOURNAL DIAMETER ......105
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ...............................................................105
CRANKSHAFT RUNOUT ..................................105
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................105
MAIN BEARING OIL CLEARANCE ...................106
MAIN BEARING CRUSH HEIGHT ....................107
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................107
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ...........................................107
CONNECTING ROD BOLT OUTER DIAMETER .107
FLYWHEEL DEFLECTION (M/T MODELS) ......108
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ...........................................................108
SERVICE DATA AND SPECIFICATIONS (SDS) ....109
Standard and Limit ................................................109
GENERAL SPECIFICATIONS ...........................109
DRIVE BELT ......................................................109
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................109
SPARK PLUG ....................................................109
CYLINDER HEAD ..............................................109
VALVE ................................................................110
CAMSHAFT AND CAMSHAFT BEARING .........113
CYLINDER BLOCK ............................................114
PISTON, PISTON RING AND PISTON PIN ......115
CONNECTING ROD ..........................................116
CRANKSHAFT ...................................................116
MAIN BEARING .................................................118
CONNECTING ROD BEARING .........................119
Tightening Torque .................................................119
YD22DDTi
PRECAUTIONS .......................................................122
Precautions for Draining Engine Coolant ..............122
Precautions for Disconnecting Fuel Piping ...........122
Precautions for Removal and Disassembly ..........122
Precautions for Inspection, Repair and Replace-
ment ......................................................................122
Precautions for Assembly and Installation ............122

CLUTCH MASTER CYLINDER
CL-9
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CL


Drain clutch fluid from reservoir tank and remove hose.

Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Using a flare nut torque wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. First remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehi-
cle.
INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
2. Install master cylinder assembly and tighten mounting nut to the specified torque. Refer to CL-8,
"Removal and Installation" .
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Refer to CL-11,
"Removal and Installation" .
4. Attach clevis of clevis pin to clutch pedal.
5. Attach snap pin to clevis pin.
6. Install hose to nipple.
7. After completing this procedure, inspect and adjust pedal height and then bleed clutch tube. Refer to CL-
5, "On-Vehicle Inspection and Adjustment" , CL-7, "Air Bleeding Procedure"
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin, nipple and seal from cylinder body using a
pin punch.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove seat.
4. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to reduce possibility of the pis-
ton popping out.
5. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole

Damaged or deformed nipple or reservoir tank

Settling of spring

Cracked or deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of cylinder body, sliding surface of piston assembly, and piston
cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install seat.
4. Install clevis to push rod and tighten lock nut to the specified torque. Refer to CL-8, "
Removal and Installa-
tion" .
5. Install seal and nipple to cylinder body. Install spring pin, using a pin punch.
PCIB0274E

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-15
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.

Measure clutch disc spline and input shaft spline backlash at the
circumference of the disc. If outside the specification, replace.

Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench.

Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:

Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.

Broken thrust ring will make a clinking sound when cover is shaken up and down.

If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).Runout limit/diameter of the area to be measured:
1.0 mm (0.039 in) or less/230 mm(9.06 in) dia.
Maximum allowable spline backlash:
1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head):
0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
Tool number : ST 20050240
PCIB0276E
Allowable flywheel runout:
Vehicles with QR engine models:
Refer to EM-108, "
FLYWHEEL DEFLECTION (M/T
MODELS)" .
Vehicles with YD engine models:
Refer toEM-235, "
FLYWHEEL DEFLECTION" .AEM100

BR-6
BRAKE PEDAL

BRAKE PEDALPFP:46501
On-Vehicle Inspection and AdjustmentEFS000C1
Adjust clearance between dash panel and brake pedal upper surface
to the following dimensions.
1. Loosen stop lamp switch by rotating it counter-clockwise by 45°.
2. Loosen input rod lock nut (A), then rotate input rod, set pedal to
the specified height, and tighten lock nut (A).
CAUTION:
Confirm threaded end of input rod remains inside the cle-
vis.
3. Pull pedal by hand and hold it. Press stop lamp switch until its
threaded end contacts the stopper rubber.
4. While holding it against the stopper rubber, turn the switch clock-
wise by 45° and secure it.
CAUTION:
Be sure stopper rubber to stop lamp switch screw threaded
end gap (C) is within the specifications.
5. Check pedal free play.
CAUTION:
Be sure stop lamps go off when pedal is released.
6. Start engine and check brake pedal depressed height.
SFIA0348E
H1Brake pedal heightM/T model 156 - 166 mm (6.14 - 6.54 in)
A/T model 164 - 174 mm (6.46 - 6.85 in)
H
2
Pedal height when depressed
[With engine running and at a depression force of 490 N (50 kg,110.6
lb)]M/T model 80 mm (3.15 in) or more
A/T model 85 mm (3.35 in) or more
C Clearance between stopper rubber and threaded end of stop lamp switch 0.74 - 1.96 mm (0.0291 - 0.0772 in)
A Pedal play3 - 11 mm (0.12 - 0.43 in)
: 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)
SFIA0160E

BL-1
BODY, LOCK & SECURITY SYSTEM
I BODY
CONTENTS
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SECTION
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BODY, LOCK & SECURITY SYSTEM
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Work ................................................ 4
Wiring Diagnosis and Trouble Diagnosis ................. 4
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 6
Work Flow ................................................................ 6
CUSTOMER INTERVIEW ..................................... 6
DUPLICATE THE NOISE AND TEST DRIVE ....... 7
CHECK RELATED SERVICE BULLETINS ........... 7
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 7
REPAIR THE CAUSE ........................................... 7
CONFIRM THE REPAIR ....................................... 8
Generic Squeak and Rattle Troubleshooting ........... 8
INSTRUMENT PANEL .......................................... 8
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 9
SUNROOF/HEADLINING ..................................... 9
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
HOOD ....................................................................... 12
Fitting Adjustment .................................................. 12
LONGITUDINAL AND LATERAL CLEARANCE
ADJUSTMENT .................................................... 12
FRONT END HEIGHT ADJUSTMENT ............... 12
SURFACE HEIGHT ADJUSTMENT ................... 14
Removal and Installation of Hood Assembly .......... 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Removal and Installation of Hood Lock Control ..... 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
Hood Lock Control Inspection ................................ 17
DOOR ....................................................................... 18Fitting Adjustment ................................................... 18
FRONT DOOR .................................................... 18
REAR DOOR ....................................................... 18
STRIKER ADJUSTMENT .................................... 18
Removal and Installation of Front Door .................. 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 19
Removal and Installation of Rear Door ................... 19
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
Door Weatherstrip .................................................. 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
POWER DOOR LOCK SYSTEM .............................. 22
System Description ................................................. 22
OPERATION ........................................................ 22
Component Parts and Harness Connector Location ... 22
Schematic ............................................................... 23
Wiring Diagram — D/LOCK — ............................... 24
Terminal and Reference Value for Time Control Unit ... 28
Symptom Chart ....................................................... 29
Power Supply and Ground Circuit Check ............... 29
Door Lock/Unlock Switch Check ............................ 30
Door Key Cylinder Switch Check ............................ 32
Front Door Lock Actuator (Driver Side) Check ....... 34
Front Door Lock Actuator (Passenger Side) Check ... 35
Rear Door Lock Actuator LH Check ....................... 36
Rear Door Lock Actuator RH Check ....................... 37
Back Door Lock Actuator Check ............................. 38
Door Switch Check ................................................. 39
Door Unlock Sensor Check .................................... 40
Key Switch Check ................................................... 41
POWER DOOR LOCK — SUPER LOCK — ............ 42
System Description ................................................. 42
OUTLINE ............................................................. 42
OPERATION ........................................................ 42
Schematic ............................................................... 44
Wiring Diagram — S/LOCK — ............................... 45
Terminal and Reference Value for Time Control Unit ... 51
Trouble Diagnoses ................................................. 53

BL-12
HOOD

HOODPFP:65100
Fitting AdjustmentEIS009QH
LONGITUDINAL AND LATERAL CLEARANCE ADJUSTMENT
1. Remove hood lock assembly, loosen the hood hinge nuts and close the hood.
2. Adjust the lateral and longitudinal clearance, and open the hood to tighten the hood hinge mounting bolts
to the specified torque.
3. Install the hood lock temporarily, and align the hood striker and lock so that the centers of striker and lock
become vertical viewed from the front, by moving the hood lock laterally.
4. Tighten hood lock mounting bolts to the specified torque.
FRONT END HEIGHT ADJUSTMENT
1. Remove the hood lock and adjust the height by rotating the bumper rubber until the hood becomes 1 to1.5
mm (0.04 to 0.059 in) lower than the fender.
PIIB1215E

BL-14
HOOD

SURFACE HEIGHT ADJUSTMENT
1. Remove hood lock, and adjust the surface height difference of hood, fender and headlamp according to
the fitting standard dimension, by rotating RH and LH bumper rubbers.
2. Install hood lock temporarily, and move hood lock laterally until the centers of striker and lock become ver-
tical when viewed from the front.
3. Make sure that the hood lock secondary latch is properly
engaged with the secondary striker with hood's own weight.
4. Make sure that the hood lock primary latch is securely engaged
with the hood striker with hood's own weight by dropping hood
from approx. 200 mm(7.87 in) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or
more.
5. Move hood lockup and down until striker smoothly engages the
lock when the hood is closed.
6. When pulling the hood opener lever gently, make sure that front
end of the hood rises by approximately 20 mm (0.79 in) and that hood striker and hood lock primary latch
is disengaged. Also make sure that hood opener returns to the original position.
7. After adjustment, tighten lock bolts to the specified torque.
PIIB1082E

HOOD
BL-17
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4. Connect cable securely to the lock.
5. After connection, confirm proper adjustment and operation for
both hood lock and hood opener.
Hood Lock Control InspectionEIS009QK
CAUTION:
If the hood lock cable is bent or deformed, replace it.
1. Make sure that the hood lock secondary latch is securely
engaged with the secondary striker with hood's own weight.
2. Make sure that the hood lock primary latch is securely engaged
with the hood striker with hood's own weight by dropping it from
approx 200 mm (7.87 in) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or
more.
3. When pulling hood opener lever gently, make sure that front end of the hood rises by approximately 20
mm (0.79 in) and that hood striker and hood lock primary latch are disengaged. Also make sure that hood
opener returns to the original position.
4. Confirm hood lock is properly lubricated. If necessary, apply
“body grease” at the point shown in the figure.
PIIA3552E
PIIB1082E
PIIA3550E