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![NISSAN X-TRAIL 2005 Service Repair Manual INTAKE MANIFOLD
EM-147
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5. Remove exhaust manifold insulator. Refer to EM-151, "EXHAUST MANIFOLD AND TURBOCHARGER" .
6. Disconnect harness connector from EGR volu NISSAN X-TRAIL 2005 Service Repair Manual INTAKE MANIFOLD
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5. Remove exhaust manifold insulator. Refer to EM-151, "EXHAUST MANIFOLD AND TURBOCHARGER" .
6. Disconnect harness connector from EGR volu](/manual-img/5/57403/w960_57403-200.png)
INTAKE MANIFOLD
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5. Remove exhaust manifold insulator. Refer to EM-151, "EXHAUST MANIFOLD AND TURBOCHARGER" .
6. Disconnect harness connector from EGR volume control valve and water hoses.
7. Disconnect heater hose.
8. Remove EGR cooler.
9. Remove injection tube center. Refer to EM-167, "
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.
CAUTION:
Handle with care avoiding any shocks.
Do not disassemble.
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.
PBIC0676E
Limit : 0.1 mm (0.004 in)
PBIC0677E
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EM-148
[YD22DDTi]
INTAKE MANIFOLD
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.
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 to the length below.
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. : 10.5 N·m (1.1 kg-m, 8 ft-lb)
PBIC0676E
: 25 - 30 mm (0.984 - 1.181 in)
PBIC2021E
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![NISSAN X-TRAIL 2005 Service Repair Manual CATALYST
EM-149
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-32, "
Changing Engin NISSAN X-TRAIL 2005 Service Repair Manual CATALYST
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-32, "
Changing Engin](/manual-img/5/57403/w960_57403-202.png)
CATALYST
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CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-32, "
Changing Engine Coolant" .
3. Remove radiator hose (upper and lower). Refer to CO-35, "
RADIATOR" .
4. Remove cooling fan assembly. Refer to CO-37, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-35, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-45, "
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 8. Turbocharger insulator
PBIC2670E
Catalyst locking pin : Flange bolt (black)
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EM-150
[YD22DDTi]
CATALYST
INSTALLATION
Note the following, and 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.
Assemble catalyst insulator with making clearance from catalyst.
Page 205 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EXHAUST MANIFOLD AND TURBOCHARGER
EM-151
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO NISSAN X-TRAIL 2005 Service Repair Manual EXHAUST MANIFOLD AND TURBOCHARGER
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO](/manual-img/5/57403/w960_57403-204.png)
EXHAUST MANIFOLD AND TURBOCHARGER
EM-151
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EXHAUST MANIFOLD AND TURBOCHARGERPFP:14004
Removal and InstallationEBS00LRH
REMOVAL
1. Drain engine coolant. Refer to CO-32, "Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
2. Remove charge air cooler. Refer to EM-144, "
Removal and Installation" .
3. Remove air duct. Refer to EM-142, "
Removal and Installation" .
4. Remove air inlet pipe.
5. Remove engine undercover.
6. Remove radiator hose (upper and lower). Refer to CO-35, "
RADIATOR" .
7. Remove cooling fan assembly. Refer to CO-37, "
DISASSEMBLY AND ASSEMBLY" .
8. Remove radiator mounting bracket and radiator. Refer to CO-35, "
Removal and Installation" .
9. Remove water inlet pipe. Refer to CO-45, "
THERMOSTAT AND WATER PIPING" .
10. Remove catalyst. Refer to EM-149, "
Removal and Installation" .
11. Remove exhaust manifold insulator.
1. EGR volume control valve 2. Gasket 3. EGR cooler
4. Air inlet pipe 5.Exhaust manifold and turbocharger
assembly6. Oil feed tube
7. Oil return hose 8. Washer 9. Eye-bolt
10. Turbocharger insulator 11. Exhaust manifold insulator 12. Air inlet pipe
PBIC3614E
Page 206 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-152
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
12. Remove turbocharger insulator.
13. Remove oil feed tube.
14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
15. Rotate NISSAN X-TRAIL 2005 Service Repair Manual EM-152
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
12. Remove turbocharger insulator.
13. Remove oil feed tube.
14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
15. Rotate](/manual-img/5/57403/w960_57403-205.png)
EM-152
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
12. Remove turbocharger insulator.
13. Remove oil feed tube.
14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
15. Rotate exhaust manifold and turbocharger assembly so that the rear side (EGR cooler mounting side)
faces upward. And then pull out the assembly from between the engine and the A/C piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling out the assembly.
16. Remove exhaust manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
When a stud bolt is pulled out, tighten it to the following torque:
Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to EM-151, "
Removal and Instal-
lation" .
2. Tighten the nuts in order specified in the figure.
3. Re-tighten the nuts 1 to 4.
4. Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
JEM266G
: 14.7 N·m (1.5 kg-m, 11ft-lb)
JEM266G
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EXHAUST MANIFOLD AND TURBOCHARGER
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Disassembly and AssemblyEBS00LRI
DISASSEMBLY
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
ASSEMBLY
When a stud bolt is pulled out, tighten it to the following torque:
1. Exhaust manifold 2. Gasket 3. Oil feed tube
4. Turbocharger 5. Washer 6. Eye- bolt
PBIC3613E
Exhaust manifold side
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
Catalyst side
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
Air inlet side
: 11.3 N·m (1.2 kg-m, 8 ft-lb)
Page 208 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-154
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
INSPECTION AFTER DISASSEMBLY
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a fee NISSAN X-TRAIL 2005 Service Repair Manual EM-154
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
INSPECTION AFTER DISASSEMBLY
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a fee](/manual-img/5/57403/w960_57403-207.png)
EM-154
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
INSPECTION AFTER DISASSEMBLY
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
If it exceeds the limit, replace exhaust manifold.
TurbochargerEBS00LRJ
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
ROTOR SHAFT CLEARANCE
Make sure that the rotor shaft rotates smoothly without any
resistance when it is rotated by your fingertips.
Make sure that the rotor shaft is not loose when it is moved ver-
tically or horizontally.
Measure looseness with a dial indicator inserting its measuring
rod through oil drain hole of turbocharger.
Replace turbocharger if out of standard.Limit : 0.3 mm (0.012 in)
JEM267G
PBIC2532E
Suction side : Between turbocharger and air cleaner
Exhaust side : Between turbocharger and catalyst
Standard : 0.086 - 0.117 mm (0.0034 - 0.0046 in)
PBIC0727E