2003 NISSAN X-TRAIL wheel

GI-40
TOW TRUCK TOWING

TOWING THE VEHICLE WITH REAR WHEELS RAISED (WITH FRONT WHEELS ON GROUND)
OR FRONT WHEELS RAISED
Never tow the vehicle with rear wheels raised (with front wheels on
ground) or front wheels raised as this may cause serious and expen-
sive damage to the transaxle. If it is necessary to tow it with rear
wheels raised or front wheels raised, always use a towing dolly
under the front wheels.
If the speed or distance must necessarily be greater, remove the
front and rear propeller shafts beforehand to prevent damage to the
transaxle.
Vehicle Recovery (Freeing a Stuck Vehicle) EAS000FM

Use the towing hook only, not other parts of the vehicle. Other-
wise, the vehicle body will be damaged.

Use the towing hook only to free a vehicle stuck in sand, snow,
mud, etc. Never tow the vehicle for a long distance using only
the towing hook.

The towing hook is under tremendous force when used to free a
stuck vehicle. Always pull the cable straight out from the front or
rear of the vehicle. Never pull on the hook at an angle.

Stand clear of a stuck vehicle.
WARNING:

Do not spin the tires at high speed. This could cause them
to explode and result in serious injury. Parts of the vehicle
could also overheat and be damaged.
PAIA0013E
PAIA0145E

IDENTIFICATION INFORMATION
GI-45
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AUTOMATIC TRANSAXLE NUMBER
MANUAL TRANSAXLE NUMBER
Dimensions EAS000GF
Unit: mm (in)
Wheels & Tires EAS000GG
PAIA0008E
PAIA0009E
PAIA0010E
Overall length 4,455
Overall width 1,765
Overall height1,675 (Standard)
1,750 (With Rear spoiler or Roof rail with Driving light)
Front tread 1,530
Rear tread 1,530
Wheelbase 2,625
Conventional Spare
Road wheel/offset mm (in)15 × 6JJ Steel/40 (1.57)
16 × 6.5JJ Steel/Aluminum/40 (1.57)Conventional
Tire size215/70 R15
215/65 R16Conventional

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

EM-3
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Parts Requiring Angle Tightening ......................... 122
Precautions For Liquid Gasket ............................. 123
REMOVAL OF LIQUID GASKET ...................... 123
LIQUID GASKET APPLICATION PROCEDURE . 123
PREPARATION ....................................................... 124
Special Service Tools ........................................... 124
Commercial Service Tools .................................... 127
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 129
NVH Troubleshooting — Engine Noise ................ 129
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 130
DRIVE BELTS ......................................................... 131
Checking Drive Belts ............................................ 131
Tension Adjustment .............................................. 131
A/C COMPRESSOR BELT ............................... 132
ALTERNATOR AND WATER PUMP BELT ....... 132
Removal and Installation ...................................... 132
REMOVAL ......................................................... 132
INSTALLATION ................................................. 132
AIR CLEANER AND AIR DUCT ............................. 133
Removal and Installation ...................................... 133
REMOVAL ......................................................... 133
INSTALLATION ................................................. 133
CHANGING AIR CLEANER FILTER ................. 134
CHARGE AIR COOLER ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSPECTION AFTER REMOVAL ..................... 135
INSTALLATION ................................................. 135
INTAKE MANIFOLD ............................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSPECTION AFTER REMOVAL ..................... 137
INSTALLATION ................................................. 137
INSPECTION AFTER INSTALLATION ............. 138
CATALYST .............................................................. 139
Removal and Installation ...................................... 139
REMOVAL ......................................................... 139
INSTALLATION ................................................. 140
EXHAUST MANIFOLD AND TURBOCHARGER .. 141
Removal and Installation ...................................... 141
REMOVAL ......................................................... 141
INSTALLATION ................................................. 142
INSPECTION AFTER INSTALLATION ............. 142
Disassembly and Assembly ................................. 143
DISASSEMBLY ................................................. 143
ASSEMBLY ....................................................... 143
INSPECTION AFTER DISASSEMBLY ............. 143
Turbocharger ........................................................ 144
ROTOR SHAFT CLEARANCE ......................... 144
ROTOR SHAFT END PLAY .............................. 144
TURBINE WHEEL ............................................. 145
COMPRESSOR WHEEL .................................. 145
TURBOCHARGER BOOST CONTROL ACTU-
ATOR ................................................................ 145
TROUBLE DIAGNOSIS OF TURBOCHARGER . 146OIL PAN AND OIL STRAINER ...............................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSPECTION AFTER REMOVAL .....................149
INSTALLATION .................................................149
INSPECTION AFTER INSTALLATION ..............151
GLOW PLUG ..........................................................152
Removal and Installation ......................................152
REMOVAL .........................................................152
INSTALLATION .................................................152
VACUUM PUMP ......................................................153
Removal and Installation ......................................153
INSPECTION BEFORE REMOVAL ..................153
REMOVAL .........................................................153
INSTALLATION .................................................154
INSPECTION AFTER INSTALLATION ..............155
Disassembly and Assembly ..................................155
DISASSEMBLY .................................................155
ASSEMBLY .......................................................156
INJECTION TUBE AND FUEL INJECTOR ............157
Removal and Installation ......................................157
REMOVAL .........................................................157
INSTALLATION .................................................159
INSPECTION AFTER INSTALLATION ..............160
FUEL PUMP ............................................................161
Removal and Installation ......................................161
REMOVAL .........................................................161
INSPECTION AFTER REMOVAL .....................165
INSTALLATION .................................................165
ROCKER COVER ...................................................168
Removal and Installation ......................................168
REMOVAL .........................................................168
INSTALLATION .................................................169
INSPECTION AFTER INSTALLATION ..............169
CAMSHAFT ............................................................170
Removal and Installation ......................................170
REMOVAL .........................................................170
INSPECTION AFTER REMOVAL .....................171
INSTALLATION .................................................174
Valve Clearance ...................................................175
INSPECTION ....................................................175
ADJUSTMENTS ................................................177
SECONDARY TIMING CHAIN ................................180
Removal and Installation ......................................180
REMOVAL .........................................................180
INSPECTION AFTER REMOVAL .....................182
INSTALLATION .................................................182
PRIMARY TIMING CHAIN ......................................185
Removal and Installation ......................................185
REMOVAL .........................................................187
INSPECTION AFTER REMOVAL .....................190
INSTALLATION .................................................190
CYLINDER HEAD ...................................................196
On-Vehicle Service ...............................................196
CHECKING COMPRESSION PRESSURE .......196
Removal and Installation ......................................197
REMOVAL .........................................................197
INSPECTION AFTER REMOVAL .....................198

EM-4 INSTALLATION ..................................................199
Disassembly and Assembly ..................................201
DISASSEMBLY .................................................201
ASSEMBLY .......................................................202
INSPECTION AFTER DISASSEMBLY ..............203
ENGINE ASSEMBLY ..............................................208
Removal and Installation ......................................208
REMOVAL .........................................................209
INSTALLATION ..................................................211
INSPECTION AFTER INSTALLATION ..............211
CYLINDER BLOCK .................................................212
Disassembly and Assembly ..................................212
DISASSEMBLY .................................................213
ASSEMBLY .......................................................217
How to Select Piston and Bearing ........................222
DESCRIPTION ..................................................222
HOW TO SELECT PISTON ...............................222
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................223
HOW TO SELECT MAIN BEARING ..................224
Inspection After Disassembly ...............................226
CRANKSHAFT END PLAY ................................226
CONNECTING ROD SIDE CLEARANCE .........226
PISTON TO PISTON PIN CLEARANCE ...........226
PISTON RING SIDE CLEARANCE ...................227
PISTON RING END GAP ..................................227
CONNECTING ROD BEND AND TORSION .....228
CONNECTING ROD BIG END INNER DIAME-
TER ...................................................................228
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................228
CYLINDER BLOCK TOP SURFACE DISTOR-TION ..................................................................229
MAIN BEARING HOUSING INNER DIAMETER .229
PISTON TO CYLINDER BORE CLEARANCE ..230
CRANKSHAFT JOURNAL OUTER DIAMETER .231
CRANKSHAFT PIN OUTER DIAMETER ..........231
CRANKSHAFT OUT-OF-ROUND AND TAPER .231
CRANKSHAFT RUNOUT ..................................232
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................232
MAIN BEARING OIL CLEARANCE ...................233
CRUSH HEIGHT OF MAIN BEARING ..............233
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................233
MAIN BEARING CAP BOLT DEFORMATION ...234
CONNECTING ROD BOLT DEFORMATION ....234
OIL JET ..............................................................234
OIL JET RELIEF VALVE ....................................234
FLYWHEEL DEFLECTION ................................235
MOVEMENT AMOUNT OF FLYWHEEL ...........235
SERVICE DATA AND SPECIFICATIONS (SDS) ....236
Standard and Limit ................................................236
GENERAL SPECIFICATIONS ...........................236
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................236
DRIVE BELTS ....................................................236
CYLINDER HEAD ..............................................237
VALVE ................................................................237
CAMSHAFT .......................................................241
CYLINDER BLOCK ............................................241
PISTON, PISTON RING AND PISTON PIN ......242
CONNECTING ROD ..........................................243
CRANKSHAFT ...................................................243
AVAILABLE MAIN BEARING .............................244
AVAILABLE CONNECTING ROD BEARING .....244
MISCELLANEOUS COMPONENTS ..................244
Tightening Torque .................................................245

PREPARATION
EM-9
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Commercial Service ToolsEBS00L7O
Tool nameDescription
Spark plug wrench Removing and installing spark plug
Pulley holderCrankshaft pulley removing and installing
Valve seat cutter set Finishing valve seat dimensions
TORX socketRemoving and installing flywheel
Size: T55
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT047
ZZA1010D
S-NT048
PBIC1113E
S-NT030
S-NT015
S-NT016

OIL SEAL
EM-65
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Drive belt; Refer to EM-13, "DRIVE BELTS" .

Crankshaft pulley; Refer to EM-44, "TIMING CHAIN" .
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.

Press-fit front oil seal until it is flush with front end surface of
front cover with a suitable tool.
CAUTION:

Be careful not to damage front cover and crankshaft.

Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
3. Install in the reverse order of removal after this step.
Removal and Installation of Rear Oil SealEBS00KNO
REMOVAL
1. Remove transaxle assembly. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 ,
"REMOVAL AND INSTALLATION" (A/T models).
2. Remove drive plate (A/T models) or flywheel (M/T models). Refer to EM-82, "
CYLINDER BLOCK" .
3. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
SEM829E
SEM715A
SBIA0266E

EM-78
[QR]
ENGINE ASSEMBLY

ENGINE ASSEMBLYPFP:10001
Removal and InstallationEBS00KNT
WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:

Always be careful to work safely, avoid forceful or uninstructed operations.

Do not start working until exhaust system and engine coolant are cool enough.

If items or work required are not covered by the engine section, refer to the applicable sections.

Always use the support point specified for lifting.

Use 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.

For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate front suspension member, and then separate engine and transaxle.
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
10. Stopper 11. Grommet
PBIC2392E