2003 NISSAN X-TRAIL dimensions

PRECAUTIONS
EM-123
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Precautions For Liquid GasketEBS00ODW
REMOVAL OF LIQUID GASKET

After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (special service tool) and remove
the old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.

In areas where the seal cutter (special service tool) is difficult to
use, use a plastic hammer to lightly tap (1) the seal cutter where
the liquid gasket is applied. Use a plastic hammer to slide the
seal cutter (2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.

Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket tube to the tube presser (special service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.

If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If the liquid gasket protrudes, wipe it off immediately.

Do not retighten after the installation.

After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F

PREPARATION
EM-127
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Commercial Service ToolsEBS00LR7
KV11106050
Hexagonal wrenchRemoving and installing fuel pump sprocket
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
KV11106060
Sprocket holderHolding fuel pump sprocket Tool number
Tool nameDescription
SBIA0224E
SBIA0225E
Tool nameDescription
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
Manual lift table caddy Removing and installing engine
Valve guide reamer Reaming valve guide with (1) or hole for
oversize valve guide with (2)
Intake and Exhaust:
d
1 = 6.0 mm (0.236 in) dia.
d
2 = 10.2 mm (0.402 in) dia.
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
NT048
NT030
ZZA1210D
NT016
NT015

EM-150
[YD22DDTi]
OIL PAN AND OIL STRAINER


Tighten bolts in numerical order to the specified torque.

Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.

The shank length under the bolt neck above is the length of
the threaded part (pilot portion not included).
3. Tighten transaxle joint bolts.
4. Install rear plate cover.
5. Install center member. Refer to EM-208, "
ENGINE ASSEMBLY" .
6. Install crankshaft position sensor.
7. Install oil pan lower with the following procedure.
a. Use a scraper to remove old liquid gasket from mating surfaces.
CAUTION:

Also remove old liquid gasket from mating surface of oil
pan upper.

Remove old liquid gasket from bolt hole and thread.
b. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
Use Genuine Liquid Gasket or equivalent.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.

Attaching should be done within 5 minutes after coating.M6 x 30 mm (1.18 in) : Bolt No. 15, 16
M8 x 25 mm (0.98 in) : Bolt No. 3, 4, 9, 10
M8 x 60 mm (2.36 in) : Bolt No. 1, 2, 5, 6, 7, 8,
11, 12, 13, 14
SBIA0162E
PBIC2277E
SBIA0163E
SBIA0164E

CYLINDER HEAD
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5. Install valves.

Install the valves with bigger outer diameter to intake valve
side.

Note that valve layout here is different from that of conven-
tional engine.
6. Install valve spring.
7. Install valve spring retainers.
8. Using the valve spring compressor (special service tool), com-
press valve springs.
Then install valve collets using magnet hand.

After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
9. Install valve lifters and adjusting shims to the same positions as before.
INSPECTION AFTER DISASSEMBLY
Valve Dimension

Check dimensions of each valve. For dimensions, refer to EM-
237, "Valve Dimensions" .

If dimensions are out of the standard, replace valve.
Valve Guide Clearance
Valve Stem Diameter

Measure diameter of valve stem with micrometer.
Valve Guide Inner Diameter

Measure inner diameter of valve guide with inside micrometer.
SBIA0196E
PBIC2388E
SEM188A
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.945 - 5.960 mm (0.2341 - 0.2346 in)
SEM938C

EM-206
[YD22DDTi]
CYLINDER HEAD

2. Ream cylinder head recess diameter for service valve seat.

Be sure to ream in circles concentric to the valve guide center.

This will enable valve seat to fit correctly.
3. Heat cylinder head to approximately 110 to 130°C (230 to
266°F) in oil bath.
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
CAUTION:

Do not touch the cooled valve seats directly by hand.

Cylinder head contains heat, when working, wear protec-
tive equipment to avoid getting burned.
5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.
Grind to obtain the dimensions indicated in the figure. Refer to
EM-240, "
Va l v e S e a t" . Oversize [0.5 mm (0.020 in)]:
Intake : 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust : 29.500 - 29.516 mm (1.1614 - 1.1620 in)
SEM795A
SEM008A
SEM934C
PBIC2028E

CYLINDER HEAD
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6. Using compound, perform valve fitting.
7. Check again to make sure that contacting status is satisfactory.
For details, Refer to EM-205, "
Valve Seat Contact" .
8. Use the depth gauge to measure the distance between the
mounting surface of cylinder head spring seat and the valve
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new
one.
Valve Spring Square

Position the try square to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of
spring and the try square.

If it exceeds the limit, replace valve spring.
Valve Spring Dimensions and Valve Spring Pressure Load

Using valve spring tester, check the following.

If out of the standard, replace the valve spring.Valve seat resurface limit “L”:
Intake : 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust : 36.53 - 37.01 mm (1.4382 - 1.4571 in)
JEM253G
Limit : 1.9 mm (0.075 in)
PBIC0080E
Standard:
Free height : 43.7 mm (1.720 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during
valve open: 24.82 mm (0.9772 in)
Load with valve
open: 320 - 360 N
(32.65 - 36.73 kg, 71.9 - 80.9 lb)
SEM113

CYLINDER BLOCK
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2. install main bearing caps and tighten bolts to the specified torque. Refer to EM-217, "ASSEMBLY" . This
will prevent distortion of cylinder bores.
3. Cut cylinder bore.
NOTE:

When any cylinder needs boring, all other cylinders must also be bored.

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:

Measurement should be done after cylinder bore cools down.
CRANKSHAFT JOURNAL OUTER DIAMETER

Use micrometer to measure journal outer diameter.

If out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer to EM-233, "
MAIN BEAR-
ING OIL CLEARANCE" .
CRANKSHAFT PIN OUTER DIAMETER

Use micrometer to measure crankshaft pin outer diameter.

If out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer to EM-232,
"CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT OUT-OF-ROUND AND TAPER

Using micrometer, measure each journal and pin at four points
shown in the figure.

Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.

Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.

If the measured value exceeds the limit, correct or replace crankshaft.A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
FEM114
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
PBIC0127E
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E

CYLINDER BLOCK
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FLYWHEEL DEFLECTION

Measure the deflection of flywheel contact surface to clutch with
a dial indicator.

Measure the deflection at 210 mm (8.27 in) dia.

If measured value is out of the standard, replace flywheel.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL
CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction

Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.

If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.

Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side.

If measured value is out of the standard, replace flywheel.Standard : 0.45 mm (0.0177 in) or less.
PBIC2646E
Standard : 1.3 mm (0.051 in) or less
Standard: 26.2 mm (1.031 in) or less.
PBIC1263E