Page 289 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-235
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
15. Remove main bearing cap bolts.
With a TORX socket (size: E NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-235
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
15. Remove main bearing cap bolts.
With a TORX socket (size: E](/manual-img/5/57403/w960_57403-288.png)
CYLINDER BLOCK
EM-235
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.
15. Remove main bearing cap bolts.
With a TORX socket (size: E14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in reverse
order of that shown in the figure and remove them.
Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-245, "
CRANKSHAFT END PLAY" .
16. Remove main bearing caps.
Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts. Store them so they do not get mixed up.
19. Remove oil jet.
20. Remove oil jet relief valve.
ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
EMM0072D
JEM200G
JEM201G
Page 290 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-236
[YD22DDTi]
CYLINDER BLOCK
2. Install drain plug to cylinder block.
Apply liquid gasket.
Use Genuine Liquid Gasket or equivalent.
3. Install oil jet relief valve.
4. Install oil jet.
Align k NISSAN X-TRAIL 2005 Service Repair Manual EM-236
[YD22DDTi]
CYLINDER BLOCK
2. Install drain plug to cylinder block.
Apply liquid gasket.
Use Genuine Liquid Gasket or equivalent.
3. Install oil jet relief valve.
4. Install oil jet.
Align k](/manual-img/5/57403/w960_57403-289.png)
EM-236
[YD22DDTi]
CYLINDER BLOCK
2. Install drain plug to cylinder block.
Apply liquid gasket.
Use Genuine Liquid Gasket or equivalent.
3. Install oil jet relief valve.
4. Install oil jet.
Align knock pin on back of oil jet with hole on block when
installing oil jet.
5. Install main bearings and thrust bearings as follows:
a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
Install thrust bearings with face oil groove facing to crankshaft
arm (outside).
c. Being careful with the direction, install main bearings.
Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
Align stopper notches on bearings to install them.
Make sure that the oil holes on the cylinder block body are
mated with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block.
Make sure crankshaft rotates smoothly by hand.: 9.8 N·m (1.0 kg-m, 87 in-lb)
PBIC2439E
PBIC0389E
JEM224G
JEM213G
Page 291 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-237
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
7. Install main bearing caps.
Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-237
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
7. Install main bearing caps.
Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing](/manual-img/5/57403/w960_57403-290.png)
CYLINDER BLOCK
EM-237
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
7. Install main bearing caps.
Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-254, "
MAIN BEARING CAP BOLT
DEFORMATION" .
9. With the TORX socket (size: E14, commercial service tool),
tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees. (angle tightening)
CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angle tightening. Avoid tightening based
on visual checks alone.
After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
Check crankshaft end play. Refer to EM-245, "CRANKSHAFT
END PLAY" .
10. Check the outer diameter of connecting rod bolts. Refer to EM-
254, "CONNECTING ROD BOLT DEFORMATION" .
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.
Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.
Using the industrial use dryer, heat pistons up to approx. 60 to
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
JEM225G
: 27 N·m (2.8 kg-m, 20 ft-lb)
JEM200G
JEM226G
PBIC0089E
Page 292 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-238
[YD22DDTi]
CYLINDER BLOCK
Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install s NISSAN X-TRAIL 2005 Service Repair Manual EM-238
[YD22DDTi]
CYLINDER BLOCK
Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install s](/manual-img/5/57403/w960_57403-291.png)
EM-238
[YD22DDTi]
CYLINDER BLOCK
Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.
Refer to above step a for precaution on snap ring installation.
After installation, check connecting rods for smooth move-
ment.
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
Install top ring and second ring with punched mark surfaces
facing upward.
Install rings so that three closed gap position 120 degrees
apart one another.
Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
13. Install connecting rod bearing to connecting rod and cap.
While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
14. Install piston and connecting rod assembly to crankshaft.
Move crankshaft pin to be assembled to BDC.
Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
Using the piston ring compressor (special service tool) or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
When removing piston and connecting rod assembly,
prevent the big end of connecting rod from interfering with oil jet.
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference
of the connecting rod big end.
MBIA0024E
Punched mark:
Top ring : RTop
Second ring : R2nd
JEM228G
JEM229G
PBIC1619E
Page 293 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-239
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
15. Install connecting rod caps and mounting nuts.
Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-239
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
15. Install connecting rod caps and mounting nuts.
Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod](/manual-img/5/57403/w960_57403-292.png)
CYLINDER BLOCK
EM-239
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
15. Install connecting rod caps and mounting nuts.
Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
16. Tighten connecting rod nuts according to the following procedure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
c. Loosen completely.
d. Tighten bolts.
e. Tighten 120 degrees. (angle tightening)
Always use either the angle wrench (special service tool)
or protractor during angle tightening. Avoid tightening
based on visual checks alone.
After tightening nuts, make sure that crankshaft rotates
smoothly.
Check connecting rod side clearance. Refer to EM-246,
"CONNECTING ROD SIDE CLEARANCE" .
17. Press fit rear oil seal into rear oil seal retainer.
Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
Avoid inclined fitting. Force fit perpendicularly.
MBIA0024E
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
: 0 N·m (0 kg-m, 0 in-lb)
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
JEM231G
JEM232G
Page 294 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-240
[YD22DDTi]
CYLINDER BLOCK
18. Install rear oil seal retainer to cylinder block.
Apply new engine oil to the oil and dust seal lips.
Apply liquid gasket to rear oil seal retainer using the t NISSAN X-TRAIL 2005 Service Repair Manual EM-240
[YD22DDTi]
CYLINDER BLOCK
18. Install rear oil seal retainer to cylinder block.
Apply new engine oil to the oil and dust seal lips.
Apply liquid gasket to rear oil seal retainer using the t](/manual-img/5/57403/w960_57403-293.png)
EM-240
[YD22DDTi]
CYLINDER BLOCK
18. Install rear oil seal retainer to cylinder block.
Apply new engine oil to the oil and dust seal lips.
Apply liquid gasket to rear oil seal retainer using the tube
presser (special service tool: WS39930000) as shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
19. Press fit pilot bush into crankshaft.
Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bush until it stops.
20. Install fuel pump bracket.
Align the bracket with the dowel pins on cylinder block to
install.
The two bolts used for dowel pins have a longer shanks than
the other two.
21. Install parts to engine in the reverse order of disassembly.
22. Remove engine from engine stand in the reverse order of assembly.
23. Install flywheel.
When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin
hole.
CAUTION:
If these are not aligned correctly, engine runs roughly
and “MI” turns on.
JEM233G
JEM234G
PBIC2329E
PBIC2538E
Page 295 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-241
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
There is a mating mark on the clutch cover side, Refer it dur-
ing installation.
Holding ring gear with the ring stopper (special service NISSAN X-TRAIL 2005 Service Repair Manual CYLINDER BLOCK
EM-241
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
There is a mating mark on the clutch cover side, Refer it dur-
ing installation.
Holding ring gear with the ring stopper (special service](/manual-img/5/57403/w960_57403-294.png)
CYLINDER BLOCK
EM-241
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM
There is a mating mark on the clutch cover side, Refer it dur-
ing installation.
Holding ring gear with the ring stopper (special service tool),
tighten securing bolts with TORX bit (size: T55, Commercial
Service Tool).
Tighten bolts uniformly in a crisscross manner.
Apply engine oil to bolt threads and seat surfaces.
How to Select Piston and BearingEBS00ODY
DESCRIPTION
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
PBIC2495E
PBIC2406E
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft main jour-
nal grade (outer diameter of
main journal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin journal
diameter determine connecting
rod bearing selection.
Between cylinder block to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston skirt diam-
eter)Piston grade = cylinder bore
grade (inner diameter of bore)
Page 296 of 4555
![NISSAN X-TRAIL 2005 Service Repair Manual EM-242
[YD22DDTi]
CYLINDER BLOCK
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston NISSAN X-TRAIL 2005 Service Repair Manual EM-242
[YD22DDTi]
CYLINDER BLOCK
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston](/manual-img/5/57403/w960_57403-295.png)
EM-242
[YD22DDTi]
CYLINDER BLOCK
HOW TO SELECT PISTON
When Using New Cylinder Block
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.
The part No. of piston is specified together with piston pin as
an assembly.
When Re-using Old Cylinder Block
1. Measure cylinder bore inner diameter. Refer to EM-250, "Cylinder Bore Inner Diameter" .
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
3. Select piston of the same grade.
Piston Selection Table
Unit: mm (in)
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
When Using New Crankshaft and Connecting Rod
1. Identify the pin journal diameter grade (No. 0, 1, or 2) on front
surface of crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
PBIC2589E
MBIA0025E
Grade (punched) 1 2 3
Cylinder bore
inner diameter86.000 - 86.010 (3.3858 - 3.3862) 86.010 - 86.020 (3.3862 - 3.3866) 86.020 - 86.030 (3.3866 - 3.3870)
Piston skirt diam-
eter85.928 - 85.942 (3.3830 - 3.3835) 85.938 - 85.952 (3.3834 - 3.3839) 85.948 - 85.962 (3.3838 - 3.3843)
PBIC2590E