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AIR CLEANER AND AIR DUCT
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AIR CLEANER AND AIR DUCTPFP:16500
Removal and InstallationEBS00LRD
REMOVAL
1. Remove mass air flow sensor harness clamp.
2. Disconnect harness connector from mass air flow sensor.
3. Remove air duct, air cleaner case (upper)/ mass air flow sensor.
Add marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
Handle mass air flow sensor with following cares.
Do not shock it.
Do not disassemble it.
Do not touch its sensor.
5. Remove air cleaner case (lower) and air duct side.
INSTALLATION
Note the following, and install in the reverse order of removal.
Align marks. Attach each joint. Screw clamps firmly.
1. Air cleaner case (upper) 2. Clamp 3. Air duct
4. Mass air flow sensor 5. Grommet 6. Air duct side
7. Mounting rubber 8. Air cleaner case (lower) 9. Air cleaner filter
PBIC1235E
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EM-134
[YD22DDTi]
AIR CLEANER AND AIR DUCT
CHANGING AIR CLEANER FILTER
Removal
1. Unfasten clips and lift up air cleaner case (upper).
2. Remove air cleaner filter.
Installation
Install in the reverse order of removal.
Page 187 of 4179
![NISSAN X-TRAIL 2003 Service Repair Manual CHARGE AIR COOLER
EM-135
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CHARGE AIR COOLERPFP:14461
Removal and InstallationEBS00LRE
REMOVAL
1. Remove charge air cooler cover.
2. Disconnect harness connector f NISSAN X-TRAIL 2003 Service Repair Manual CHARGE AIR COOLER
EM-135
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CHARGE AIR COOLERPFP:14461
Removal and InstallationEBS00LRE
REMOVAL
1. Remove charge air cooler cover.
2. Disconnect harness connector f](/manual-img/5/57404/w960_57404-186.png)
CHARGE AIR COOLER
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CHARGE AIR COOLERPFP:14461
Removal and InstallationEBS00LRE
REMOVAL
1. Remove charge air cooler cover.
2. Disconnect harness connector from turbocharger boost sensor.
3. Remove air inlet tube and air inlet hose.
Add marks as necessary for easier installation.
4. Remove charge air cooler.
5. Remove air inlet tube from charge air cooler.
6. Remove turbocharger boost sensor if necessary.
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
Be careful not to deform core fins.
For cleaning procedure of charge air cooler core, refer to CO-35, "Checking Radiator".
INSTALLATION
Note the following, and install in the reverse order of removal.
Pay attention to identification mark color and direction when installing air inlet hose.
Align marks. Attach each joint. Screw clamps firmly.
1. Charge air cooler cover 2. Charge air cooler 3. Gasket
4. Air inlet tube 5. Clamp 6. Air inlet hose
7. Bottom bracket 8. Turbocharger boost sensor
PBIC2019E
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EM-136
[YD22DDTi]
INTAKE MANIFOLD
INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00LRF
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
2. Remove air duct. Refer to EM-133, "
Removal and Installation" .
3. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
4. Remove air inlet pipes. Refer to EM-141, "
Removal and Installation" .
5. Remove exhaust manifold insulator. Refer to EM-141, "
EXHAUST MANIFOLD AND TURBOCHARGER" .
1. Fuel gallery 2. Water hose 3. Air relief plug
4. Copper washer 5. Gasket 6. EGR passage
7. EGR volume control valve 8. Bracket 9. Washer
10. Water pipe 11. O-ring 12. EGR cooler
13. Exhaust manifold 14. Intake manifold 15. Cylinder head
16. Heater hose 17. Spill hose
PBIC2020E
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![NISSAN X-TRAIL 2003 Service Repair Manual INTAKE MANIFOLD
EM-137
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6. Disconnect EGR volume control valve water hoses and wiring harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
9. Remove injectio NISSAN X-TRAIL 2003 Service Repair Manual INTAKE MANIFOLD
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6. Disconnect EGR volume control valve water hoses and wiring harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
9. Remove injectio](/manual-img/5/57404/w960_57404-188.png)
INTAKE MANIFOLD
EM-137
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6. Disconnect EGR volume control valve water hoses and wiring harness.
7. Disconnect heater hose.
8. Remove EGR Cooler.
9. Remove injection tube center. Refer to EM-157, "
Removal and Installation" .
CAUTION:
Be careful not to spill fuel in the engine component.
10. Remove water pipe.
11. Remove fuel hoses and fuel gallery.
To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
12. Loosen bolts and nuts in reverse order of that shown in the fig-
ure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
13. Remove EGR volume control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
Check distortion on the mounting surface with a straightedge
and feeler gauge.
If it exceeds the limit, replace intake manifold.
INSTALLATION
Following instructions below, install in the reverse order of removal.
1. Install EGR volume control valve.
Handle with care avoiding any shocks.
Do not disassemble.
2. Install intake manifold.
Tighten fixing bolts and nuts in numerical order as shown in the figure.
When stud bolts come off, install with the following torque.
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Page 190 of 4179
EM-138
[YD22DDTi]
INTAKE MANIFOLD
3. Install water hose.
Install water hose by referring to identification marks avoiding
twisting.
When 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.
When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
4. Install remaining parts in the reverse order of removal.
5. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.Dimension A : 25 - 30 mm (0.984 - 1.181 in)
PBIC2021E
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CATALYST
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-31, "
Changing Engine Coolant" .
3. Remove radiator upper and lower hoses. Refer to CO-34, "
RADIATOR" .
4. Remove cooling fan. Refer to CO-36, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-34, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-44, "
THERMOSTAT AND WATER PIPING" .
7. Remove catalyst insulators.
8. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
1. Catalyst insulator 2. Gasket 3. Catalyst
4. Locking pin 5. Gusset 6. Gasket cap
7. Catalyst rear diffuser
PBIC2312E
Catalyst locking pin : Flange bolt (black)
Page 192 of 4179
EM-140
[YD22DDTi]
CATALYST
INSTALLATION
Install in the reverse order of removal.
Pushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.