manual taller nissan QR25 (EM)

ENGINE MECHANICAL

B ENGINE

SECTION

EM

ENGINE MECHANICAL

A

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CONTENTS PRECAUTIONS .......................................................... ..... 3 Precautions for Drain Engine Coolant and Engine Oil ............................................................................ . ..... 3 Precautions for Disconnecting Fuel Piping ............. . ..... 3 Precautions for Removal and Disassembly ............ . ..... 3 Precautions for Inspection, Repair and Replacement ........................................................................ . ..... 3 Precautions for Assembly Assembly and Installation .............. . ..... 3 Precautions for Angle Tightening ............................ . ..... 3 Precautions for Liquid Gasket ................................. . ..... 4 REMOVAL REMOVAL OF LIQUID GASKET ......................... . ..... 4 LIQUID GASKET APPLICATION APPLICATION PROCEDURE.... ...... 4 PREPARA PREPARATION TION ........................................................... ..... 5 Special Service Tools Tools ............................................... ..... 5 Commercial Service Tools Tools ................................... ............................... ......... ..... 6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ ..... 9 NVH Troubleshooting — Engine Engine Noise ................... . ..... 9 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... . .. 10 DRIVE BELTS BELTS ............................................................11 ....11 Checking Drive Belt .................................................11 ....11 Tension Adjustment .................................................11 ....11 Removal and Installation .........................................11 ....11 REMOVAL ............................................................11 ....11 INSTALLATION ................................................... . .. 12 Removal and Installation of Drive Belt Auto-TenAuto-Tensioner ..................................................................... ... 12 REMOVAL ........................................................... . .. 12 INSTALLATION ................................................... . .. 13 AIR CLEANER AND AIR DUCT ............................... . .. 14 Removal and Installation ........................................ . .. 14 REMOVAL ........................................................... . .. 14 INSPECTION AFTER REMOV REMOVAL AL ....................... . .. 15 INSTALLATION ................................................... . .. 15 Changing Air Cleaner Filter .................................... . .. 15 REMOVAL ........................................................... . .. 15 INSTALLATION ................................................... . .. 15

Revision: 2005 March

INTAKE INTAKE MANIFOLD ................................................. . .. 16 Removal and Installation ........................................ . .. 16 REMOVAL ........................................................... . .. 16 INSPECTION AFTER REMOVAL REMOVAL ....................... . .. 18 INSTALLATION ................................................... . .. 18 INSPECTION AFTER INSTALLATION INSTALLATION ................ . .. 19 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... . .. 20 Removal and Installation ........................................ . .. 20 REMOVAL ........................................................... . .. 20 INSPECTION AFTER REMOVAL REMOVAL ....................... . .. 21 INSTALLATION ................................................... . .. 21 OIL PAN PAN AND OIL STRAINER STRAINER ................................. . .. 22 Removal and Installation ........................................ . .. 22 REMOVAL ........................................................... . .. 22 INSPECTION AFTER REMOVAL REMOVAL ....................... . .. 24 INSTALLATION ................................................... . .. 24 INSPECTION AFTER INSTALLATION INSTALLATION ................ . .. 26 IGNITION COIL ......................................................... . .. 27 Removal and Installation ........................................ . .. 27 REMOVAL ........................................................... . .. 27 INSTALLATION ................................................... . .. 27 SPARK SPARK PLUG (PLATINUM-TIPPED TYPE) ............. . .. 28 Removal and Installation ........................................ . .. 28 REMOVAL ........................................................... . .. 28 INSPECTION AFTER REMOVAL REMOVAL ....................... . .. 28 INSTALLATION ................................................... . .. 29 FUEL INJECTOR AND FUEL TUBE TUBE ........................ . .. 30 Removal and Installation ........................................ . .. 30 REMOVAL ........................................................... . .. 30 INSTALLATION ................................................... . .. 32 INSPECTION AFTER INSTALLATION INSTALLATION ................ . .. 34 ROCKER COVER ..................................................... . .. 35 Removal and Installation ........................................ . .. 35 REMOVAL ........................................................... . .. 35 INSTALLATION ................................................... . .. 36 CAMSHAFT .............................................................. . .. 37 Removal and Installation ........................................ . .. 37 REMOVAL ........................................................... . .. 37 INSPECTION AFTER REMOVAL REMOVAL ....................... . .. 40

EM-1

2005 X-Trail

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INSTALLA INSTALLATION TION ....................................................42 . ..42 INSPECTION INSPECTI ON AFTER INSTALLATION INSTALLATION ............. ....... ......... ... 45 Valve Valve Clearance ...................................................... ... 46 INSPECTION .......................................................46 . ..46 ADJUSTMENT ....................................................47 . ..47 TIMING CHAIN ..........................................................49 . ..49 Removal and Installation Installation ........................................49 . ..49 REMOVAL ...........................................................49 . ..49 INSPECTION AFTER REMOVAL ........................53 . ..53 INSTALLA INSTALLATION TION ....................................................54 . ..54 INSPECTION INSPECTI ON AFTER INSTALLATION INSTALLATION ............. ....... ......... ... 58 OIL SEAL ..................................................................59 . ..59 Removal and Installation of Valve Valve Oil Seal .............59 . ..59 REMOVAL ...........................................................59 . ..59 INSTALLA INSTALLATION TION ....................................................59 . ..59 Removal and Installation of Front Oil Seal .............60 . ..60 REMOVAL ...........................................................60 . ..60 INSTALLA INSTALLATION TION ....................................................60 . ..60 Removal and Installation of Rear Oil Seal ..............61 . ..61 REMOVAL ...........................................................61 . ..61 INSTALLA INSTALLATION TION ....................................................61 . ..61 CYLINDER HEAD .....................................................62 . ..62 On-Vehicle Service ................................................. ... 62 CHECKING COMPRESSION PRESSURE PRESSURE ...... .. .......62 . ..62 Removal and Installation Installation ........................................63 . ..63 REMOVAL ...........................................................63 . ..63 INSPECTION AFTER REMOVAL ........................64 . ..64 INSTALLA INSTALLATION TION ....................................................65 . ..65 INSPECTION INSPECTI ON AFTER INSTALLATION INSTALLATION ............. ....... ......... ... 65 Disassembly and Assembly ....................................67 . ..67 DISASSEMBLY ...................................................67 . ..67 ASSEMBLY .........................................................68 . ..68 Inspection After Disassembly .................................69 . ..69 VALVE ALVE DIMENSIONS .......................................... ... 69 VALVE ALVE GUIDE CLEARANCE .............................. ... 70 VALVE ALVE GUIDE REPLACEMENT .........................70 . ..70 VALVE ALVE SEAT CONTACT CONTACT .....................................72 . ..72 VALVE VALVE SEAT REPLACEMENT REPLACEM ENT ............. ....... ............. ........... .......72 . ..72 VALVE ALVE SPRING SQUARENESS .........................73 . ..73 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE PRESSURE LOAD ...............................73 . ..73 ENGINE ASSEMBLY ................................................74 . ..74 Removal and Installation Installation (2WD Models) ................74 . ..74 REMOVAL ...........................................................75 . ..75 INSTALLA INSTALLATION TION ....................................................76 . ..76 INSPECTION INSPECTI ON AFTER INSTALLATION INSTALLATION ............. ....... ......... ... 77 Removal and Installation (AWD Models) ................78 . ..78 REMOVAL ...........................................................78 . ..78 INSTALLA INSTALLATION TION ....................................................81 . ..81 INSPECTION INSPECTI ON AFTER INSTALLATION INSTALLATION ............. ....... ......... ... 81 CYLINDER BLOCK ...................................................82 . ..82 Disassembly and Assembly ....................................82 . ..82 DISASSEMBLY ...................................................83 . ..83


ASSEMBLY ..........................................................86 ...86 How to Select Piston and Bearing ..........................91 ...91 DESCRIPTION ....................................................91 ...91 HOW TO SELECT PISTON .................................92 ...92 HOW TO SELECT CONNECTING ROD BEARING .......................................................................93 ...93 HOW TO SELECT SELECT MAIN BEARING ....................95 ...95 Inspection After Disassembly ..................................99 ...99 CRANKSHAFT END PLAY PLAY ..................................99 ...99 CONNECTING ROD ROD SIDE CLEARANCE ...........99 ...99 PISTON TO PISTON PIN OIL CLEARANCE .......99 .......99 PISTON RING SIDE CLEARANCE CLEARANCE ...................100 .100 PISTON RING END END GAP ..................................100 .100 CONNECTING CONNECTI NG ROD BEND AND TORSION .... . ....101 .1 01 CONNECTING ROD BIG END DIAMETER ......101 .101 CONNECTING ROD BUSHING OIL CLEARANCE .................................................................101 .101 CYLINDER BLOCK DISTORTION ....................102 .102 MAIN BEARING HOUSING INNER DIAMETER.103 DIAMETER.103 PISTON TO CYLINDER BORE CLEARANCE CLEARANCE ..103 103 CRANKSHAFT MAIN JOURNAL DIAMETER ...104 .104 CRANKSHAFT PIN JOURNAL DIAMETER ......105 .105 OUT-OF-ROUND AND TAPER OF CRANKSHAFT ...............................................................105 .105 CRANKSHAFT RUNOUT ..................................105 .105 CONNECTING ROD BEARING OIL CLEARANCE .................................................................105 .105 MAIN BEARING OIL CLEARANCE CLEARANCE ...................106 .106 MAIN BEARING CRUSH HEIGHT HEIGHT ....................107 .107 CONNECTING ROD BEARING CRUSH HEIGHT .............................................................107 .107 LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER ...........................................107 .107 CONNECTING ROD BOLT OUTER DIAMETER.107 DIAMETER.107 FLYWHEEL FLYWHEEL DEFLECTION (M/T MODELS) ......108 .108 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) ...........................................................108 .108 SERVICE DATA DATA AND SPECIFICATIONS (SDS) ....109 ....109 Standard and Limit ................................................109 .109 GENERAL SPECIFICATIONS SPECIFICATIONS ...........................109 .109 DRIVE BELT ......................................................109 .109 INTAKE INTAKE MANIFOLD AND EXHAUST MANIFOLD .................................................................109 .109 SPARK PLUG ....................................................109 .109 CYLINDER HEAD ..............................................109 .109 VALVE ALVE ................................................................110 .110 CAMSHAFT AND CAMSHAFT BEARING .........114 .114 CYLINDER BLOCK ............................................114 .114 PISTON, PISTON RING AND PISTON PISTON PIN ......116 .116 CONNECTING ROD ..........................................117 .117 CRANKSHAFT ...................................................117 .117 MAIN BEARING .................................................119 .119 CONNECTING ROD BEARING .........................120 .120

EM-2

2005 X-Trail

PRECAUTIONS PRECAUTIONS Precautions for Drain Engine Coolant and Engine Oil

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A ABS00CIL

Drain engine coolant and engine oil when the engine is cooled.

Precautions for Disconnecting Fuel Piping q q q

Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly q

q q q q

ABS00CIM

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ABS00CIN

When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with a tape or the th e equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precautions for Inspection, Repair and Replacement

ABS00CIO

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary. necessary.

Precautions for Assembly and Installation q q

q q

q

q q

q

q

– – – –

– q q q

ABS00CIQ

Use the angle wrench [SST: [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts. Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle tightening) Balancer unit Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.


EM-3

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ABS00CIP

Use torque wrench to tighten bolts or nuts to specification. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route when refilling after draining engine coolant. Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make sure there are no leaks at fuel line connections. After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

Precautions for Angle Tightening

EM

2005 X-Trail

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PRECAUTIONS Precautions for Liquid Gasket

ABS00CIR

REMOVAL REMOVAL OF LIQUID GASKET q

q

q

After removing the mounting nuts and bolts, separate the mating surface using a seal cutter [SST] and remove the old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces. s urfaces. Tap seal cutter to insert it, and then slide it by tapping on the side as shown in the figure. In areas where the seal cutter [SST] is difficult to use, use u se plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason a tool such as screwdriver is used, be careful not to damage the mating surfaces.

PBIC0002E

LIQUID GASKET APPLICATION APPLICATION PROCEDURE 1.

2.

Using Using a scraper scraper,, remove remove the the old liquid liquid gasket gasket adhering adhering to the liquid gasket application surface and the mating surface. q Remove the liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts and bolt holes. Wipe the liquid liquid gasket gasket applicati application on surfac surface e and the mating mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

PBIC0003E

3.

4.

Attach Attach liquid liquid gasket gasket tube tube to to the tube presse presserr [SST [SST: WS39930000 WS39930000 ( — )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . Apply the liquid liquid gasket without without breaks breaks to the the specifi specified ed location location with the specified dimensions. q If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. EMA0622D

As for the bolt holes, normally apply the liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual. q Within 5 minutes of liquid gasket application, install the mating component. q If the liquid gasket protrudes, wipe it off immediately. immediately. q Do not retighten mounting nuts or bolts after the installation. q Wait 30 minutes or more after installation before refilling engine oil and engine coolant. CAUTION: If there are instructions in this manual, observe them. q


EM-4

SEM159F

2005 X-Trail

PREPARATION PREPARATION Special Service Tools

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The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

EM

Description

KV10111100 (J37228) Seal cutter

Removing oil pan and front c over, etc.

C

D S-NT046

KV10116200 (J26336-A) Valve spring compressor 1. KV10115900 (J26336-20) Attachment 2. KV10109220 ( — ) Adapter

Disassembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but Part (2) is not so.

E

F

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PBIC1650E

KV10112100 (BT8653-A) Angle wrench

Tightening bolts for connecting rod bearing cap, cylinder head, etc. in angle

H

I NT014

KV10117100 (J-3647-A) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensors For 22 mm (0.87 in) width hexagon nut

J

K NT379

KV10107902 (J38959) Valve oil seal puller

L

Replacing valve oil seal

M

NT011

KV10115600 (J-38958) Valve oil seal drift

Installing valve oil seal

NT024


EM-5

2005 X-Trail

PREPARATION Tool number (Kent-Moore No.) Tool name na me

Description

EM03470000 (J-8037) Piston ring compressor

Installing piston assembly into cylinder bore

NT044

ST16610001 (J-23907) Pilot bushing puller

Removing pilot converter (A/T models)

NT045

WS39930000 ( — ) Tube presser

Pressing the tube of liquid gasket

NT052

— (J-45488) Quick connector release

Removing fuel tube quick connectors in engine room

PBIC0198E

Commercial Service Tools

ABS00CIT

(Kent-Moore No.) Tool name na me

Description

Power tool

Loosening nuts and bolts

PBIC0190E

( — ) Spark plug wrench

Removing and installing spark plug

S-NT047


EM-6

2005 X-Trail

PREPARATION (Kent-Moore No.) Tool name

Description

( — ) Pulley holder

A

Removing and installing crankshaft pulley

EM

C ZZA1010D

( — ) Pulley puller

Removing crankshaft pulley

D

E NT676

( — ) 1. Compression tester 2. Adapter

Checking compression pressure

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ZZA0008D

(J24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with the a ngle wrench [SST: KV10112100 KV10112100 (BT8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) NT583

( — ) Valve seat cutter set

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Finishing valve seat dimensions

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TORX socket

Removing and installing flywheel Size: T55

M

PBIC1113E

( — ) Piston ring expander

Removing and installing piston ring

S-NT030


EM-7

2005 X-Trail

PREPARATION (Kent-Moore No.) Tool name na me

Description

( — ) 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.

S-NT015

( — ) Valve guide reamer

1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide Intake and Exhaust: d1 : 6.0 mm (0.236 in) dia. d2 : 10.2 mm (0.402 in) dia.

S-NT016

a: (J-43897-18) b: (J-43897-12) Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = 18 mm (0.71 in) dia. for zirconia heated oxygen sensor b = 12 mm (0.47 in) dia. for titania heated oxygen sensor AEM488

(

—

)

Anti-seize lubricant i.e.: (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

TM

AEM489

( — ) Manual lift table caddy

Removing and installing the engine

ZZA1210D


EM-8

2005 X-Trail

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting — Engine Noise

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PBIC2768E


EM-9

2005 X-Trail

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING Use the Chart Below to Help You Find the Cause of the Symptom.

ABS00CIV

1. Loca Locate te the the are area a where where noi noise se occu occurs rs.. 2. Co Conf nfir irm m the the type type of of nois noise. e. 3. Specif Specify y the the opera operatin ting g condi conditio tion n of eng engine. ine. 4. Ch Chec eck k spec specif ifie ied d nois noise e sour source ce.. If necessary, repair or replace these parts. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head

Type of noise

When starting

When idling

When racing

While driving

Ticking or clicking

C

A

—

A

B

—

Tappet noise

Valve clearance

EM-46

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal oil clearance Camshaft runout

EM-40 EM-40

—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-99 EM-101

A

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-103 EM-100 EM-100 EM-101

B

Connecting rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-101 EM-105

C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-106 EM-105

B

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-53 EM-49

C

Drive belt (Sticking or slipping)

Drive belt deflection

—

Slap or rap

Knock

Knock

Front of engine Front cover

Front of engine

Reference page

After warmup

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Source of noise

Before warmup

Tapping or or ticking

A

A

A

A

A

—

B

B

A

—

—

C

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—

B

B

B

A

B

B

B

B

B

B

Check item

Squeaking or fizzing

A

Creaking

A

B

A

B

A

B

Drive belt (Slipping)

Idler pulley bearing operation

Squall Creak

A

B

—

B

A

B

Water pump noise

Water pump operation

A: Clos Closel ely y rela relate ted d

B: Rela Relate ted d


B

—

B

—

EM-11

CO-20, "WATER PUMP"

C: Some Someti time mes s relat related ed —: Not Not rela relate ted d

EM-10

2005 X-Trail

DRIVE BELTS DRIVE BELTS BELTS Checking Drive Belt

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PBIC2622E

WARNING: Be sure to perform this step when the engine is stopped. Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use q range (between three line notches on moving side). NOTE: q Check the drive belt auto-tensioner indication when the engine is cold. q When new drive belt is installed, the indicator (notch on fixed side) should be within the range “a” in the figure. q Visually check entire drive belt for f or wear, damage or cracks. q If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment

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Belt tensioning is not necessary, necessary, as it is automatically adjusted by drive belt auto-tensioner.

Removal and Installation REMOVAL 1. 2.

3. 4.

Remove splash Remove splash gua guard rd on RH und underc ercove overr. Hold Hold the hexago hexagonal nal part part in cent center er of drive drive belt belt auto-t auto-tensi ensioner oner pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: q Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. q Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counterclockwise). If turned counterclockwise, the complete drive belt autotensioner must be replaced as a unit, including the pulley. Insert Insert a rod rod approxi approximatel mately y 6 mm (0.24 in) in diamet diameter er such such as as short-length screwdriver into the hole of the retaining boss to fix drive belt auto-tensioner pulley. Loosen drive drive belt belt from from water water pump pump pulley pulley in sequence sequence,, and remove remove it.


EM-11

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PBIC2169E

2005 X-Trail

DRIVE BELTS INSTALLATION 1.

2.

3.

4. 5. 6.

Hold the hexagon hexagonal al part part in center center of of drive drive belt belt auto-te auto-tensione nsionerr pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: q Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. q Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counterclockwise). If turned counterclockwise, the complete drive belt autotensioner must be replaced as a unit, including the pulley. Insert Insert a rod approximat approximately ely 6 mm (0.24 in) in diamete diameterr such such as short-length screwdriver into the hole of o f retaining boss to fix drive belt auto-tensioner pulley. pulley.

PBIC2627E

Hook drive drive belt belt onto all pulleys pulleys except except for water pump, pump, and then then onto water water pump pump pulley finall finally y. CAUTION: q Confirm drive belt is completely set to pulleys. q Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each pulley groove. Release Release drive drive belt belt auto-tens auto-tensioner ioner,, and apply apply tension tension to drive drive belt. belt. Turn Turn crankshaf crankshaftt pulley clockw clockwise ise several several times times to equalize equalize tension tension between between each each pulley pulley.. Confirm Confirm tension tension of drive drive belt at indicator indicator (notch (notch on fixed fixed side) is is within the the possible possible use range. range. Refer to EM-11, EM-1 1, "Checking Drive Belt" .

Removal and Installation of Drive Belt Auto-Tensioner

ABS00CIZ

PBIC2170E

1.

Drive belt auto-tensioner

2.

Water pump pulley

REMOVAL CAUTION: The complete drive belt auto-tensioner must be replaced as a unit, including the pulley. 1. Rem Remove ove splash splash guard guard on RH und underc ercove overr. 2. Re Remo move ve driv drive e bel belt. t. Re Refe ferr to to EM-1 EM-11, 1, "Removal and Installation" . 3. Releas Release e the fixed fixed drive drive belt belt auto-t auto-tens ension ioner er pulley pulley.. 4. Rem Remove ove drive drive belt belt autoauto-ten tensio sioner ner..


EM-12

2005 X-Trail

DRIVE BELTS CAUTION: Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including the pulley.

INSTALLATION

A

EM

Note the following, and install in the reverse order of removal. When installing drive belt auto-tensioner auto -tensioner,, be careful not to interfere with water pump pulley. q CAUTION: q If there is damage greater than peeled paint, replace drive belt auto-tensioner. auto-tensioner. q Do not swap the pulley between new and old drive belt auto-tensioner. auto-tensioner.

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EM-13

2005 X-Trail

AIR CLEANER AND AIR DUCT AIR CLEANER AND AIR DUCT Removal and Installation

PFP:16500 ABS00CJ0

PBIC2171E

1.

Air cleaner filter

2.

Clip

3.

Air cleaner case upper

4.

Clamp

5.

Air duct

6.

PC P CV hose

7.

Clamp

8.

Bracket

9.

Mass air flow sensor

10. OO-ring

11. Ai A ir duct

12. Ai Air duct (inlet)

13. Clip

14. Collar

15. Grommet

16. Resonator

17. Bracket (A/T models)

18. Mounting rubber

19. Collar

20. Grommet

21. Air cleaner case lower

REMOVAL 1. 2. 3. 4.

Remove mass Remove mass air air flow flow sens sensor or harn harness ess clamp. clamp. Disconnect Disconnect harness harness connecto connectorr from from mass air flow sensor. sensor. Disc Discon onne nect ct PC PCV V hose hose.. Remove Remove air duct (inlet) (inlet),, air ducts ducts and air cleaner cleaner case/mas case/mass s air flow sensor sensor assembl assembly y disconnecti disconnecting ng their joints. q Add mating marks as necessary for easier installation. 5. Remove Remove mass mass air flow flow sensor sensor from from air air cleaner cleaner case case upper, upper, as necessary necessary.. CAUTION: Handle mass air flow sensor with the following cares. q Do not shock it. q Do not disassemble it. q Do not touch its sensor. Revision: 2005 March

EM-14

2005 X-Trail

AIR CLEANER AND AIR DUCT 6.

Remove Remove resonator resonator in in fender fender lifting lifting left left fender fender protector protector,, as necessar necessary y. A

INSPECTION AFTER REMOVAL REMOVAL Inspect air duct assembly for cracks or tear. Replace air duct assembly, if necessary. q

EM

INSTALLATION Note the following, and install in the reverse order of removal. q Align marks. Attach each joint. Screw clamps firmly. firmly.

Changing Air Cleaner Filter

C ABS00CJ1

REMOVAL 1. 2.

D

Unfasten Unfaste n clips clips and and lift lift up air cleaner cleaner case case upper upper. Remo Re move ve air air cle clean aner er filt filter er..

E

F

G PBIC2749E

INSTALLATION H

Install in the reverse order of removal.

I

J

K

L

M


EM-15

2005 X-Trail

INTAKE MANIFOLD INTAKE MANIFOLD Removal and Installation

PFP:14003 ABS00E9L

PBIC2698E

1.

Vacuum hose

2.

Harness bracket

3.

Vacuum hose

4.

EVAP canister purge volume control solenoid valve

5.

Vacuum hose

6.

PCV hose

7.

Harness bracket

8.

Intake manifold collector

9.

O-ring

10. Hose connector

11. Hose bracket

12. Gasket

13. Water hose

14. Water hose

15. Electric throttle control actuator

16. Intake manifold rear support

17. Gasket

18. Intake manifold

19. Gasket

20. Intake manifold support

21. Vacuum hose

22. Vacuum hose

23. Vacuum hose

24. Vacuum reservoir tank

25. VIAS control solenoid valve

26. Vacuum reservoir tank bracket

27. Filter

CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL 1.

Rele Re leas ase e fuel fuel pre press ssur ure. e. Ref Refer er to to EC-90, "FUEL PRESSURE RELEASE" .


EM-16

2005 X-Trail

INTAKE MANIFOLD 2.

Remove Remo ve engi engine ne cove coverr. CAUTION: Be careful not to damage or scratch engine cover.

A

EM

C

D

E

F

G PBIC2602E

3. 4.

Remove Remove air cleaner cleaner case case upper upper,, mass air flow flow sensor sensor and air air duct assembl assembly y. Refer to EM-14, "AIR CLEANER AND AIR DUCT" . Remove Rem ove quick quick conne connecto ctorr caps, caps, and disconn disconnect ect quick quick conne connecto ctorr at the engine side. Refer to EM-30, "FUEL INJECTOR AND FUEL TUBE" .

H

I

J

K PBIC2175E

5. a. b.

L

Remove Remove electric electric throttle throttle control control actuator actuator with with the the following following procedu procedure: re: Disc Discon onnec nectt harn harnes ess s conn connec ecto torr. Loosen mounting mounting bolts bolts in revers reverse e order order as as shown shown in in the figure, figure, and remove electric throttle control actuator and gasket. CAUTION: q Handle carefully to avoid any shock to electric throttle control actuator. q Do not disassemble.

M

EMJ1612D

6. 7.

Disconnect Disconnect harness, harness, vacuum vacuum hoses hoses and PCV hose from from intake intake manifold manifold collector collector,, and move them aside. aside. Remove Rem ove intake intake manifo manifold ld rear rear suppor support. t.


EM-17

2005 X-Trail

INTAKE MANIFOLD 8.

Loosen mount Loosen mounting ing nuts nuts and and bolts bolts in rever reverse se order order as show shown n in the figure, and remove intake manifold collector and gasket. CAUTION: Cover engine openings to avoid entry of foreign materials. NOTE: Disregard No. 8 when loosening.

SBIA0230E

9. 10. 11. 12. 13.

Disconnect Disconnect power power steeri steering ng piping piping from intake intake manifold, manifold, and move move them them aside. aside. Refer toPS-33, to PS-33, "HYDRAU"HYDRAULIC LINE" . Remove Remove intake intake manifol manifold d support. support. Disconnect Disconnect sub-harn sub-harness ess from fuel injecto injector. r. Refer Refer to EM-30, "FUEL INJECTOR AND FUEL TUBE" . Remove fuel tube and fuel injector assembly from intake intake manifold. Refer to EM-30, "FUEL INJECTOR AND FUEL TUBE" . Loosen Loosen mounting mounting nuts and bolts bolts in reverse reverse order as shown shown in the figure, and remove intake manifold and gasket. CAUTION: q Cover engine openings to avoid entry of foreign materials. q Do not disassemble intake manifold. NOTE: Disregard No. 6 when loosening. PBIC2699E

14. Remove EVAP EVAP canister purge volume control solenoid valve from from intake manifold collector, collector, if necessary. necessary. 15. Remove vacuum reservoir reservoir tank and VIAS VIAS control solenoid valve from from intake manifold, if necessary. necessary.

INSPECTION AFTER REMOVAL REMOVAL Surface Distortion q

Using a straightedge and a feeler gauge, check the surface distortion of both the intake manifold collector mating surface and the intake manifold mating surfaces. Limit

q

: 0.1 mm (0.004 in)

If it exceeds the limit, replace intake manifold and/or intake manifold collector. collector.

KBIA0235E

INSTALLATION Note the following, and install in the reverse order of removal.

Intake Manifold q

If stud bolts were removed, install them and tighten to the specified torque below. : 10.8 N·m (1.1 kg-m, 8 ft-lb)


EM-18

2005 X-Trail

INTAKE MANIFOLD q

Tighten in numerical order as shown in the figure. NOTE: No. 6 means double tightening of bolt No. 1.

A

EM

C PBIC2699E

D

Intake Manifold Collector q

If stud bolts were removed, install them and tighten to the specified torque below. E

: 10.8 N·m (1.1 kg-m, 8 ft-lb) q

Tighten in numerical order as shown in the figure. NOTE: No. 8 means double tightening of bolt No. 1.

F

G

H SBIA0230E

Electric Throttle Control Actuator q

q

q

I

Tighten mounting bolts equally and diagonally in several steps and in numerical order as shown in the figure. Perform the “Throttle Valve Closed Position Learning” when harha rness connector of electric throttle control actuator is disconnected. Refer to EC-88, "Throttle Valve Closed Position Learning" . Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced. Refer to EC-88, "Idle Air Volume Learning" .

J

K

L EMJ1612D

INSPECTION AFTER INSTALLA INSTALLATION TION Make sure there are no fuel leaks at connections before installing engine cover with the following procedure: 1. Apply fuel fuel pressure pressure to fuel lines lines with turning turning ignition ignition switch switch “ON” “ON” (with the the engine stopped). stopped). Then Then make sure there are no fuel leaks at connections. NOTE: Use mirrors for checking on invisible points. po ints. 2. Start Start the engine. engine. With With engine engine speed increas increased, ed, make sure again again there are are no fuel leaks leaks at connection connections. s. CAUTION: Do not touch the engine immediately after stopped as the engine becomes extremely hot.


EM-19

2005 X-Trail

M

EXHAUST MANIFOLD AND THREE WAY CATALYST EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation

PFP:14004 ABS00CJ4

PBIC2750E

1.

Heated oxygen sensor 1

2.

Exhaust manifold and three way cat3. alyst assembly

Gasket

4.

Three way catalyst cover

5.

Exhaust manifold cover (lower)

Heated oxygen sensor 2

7.

Exha Exhaus ustt man manif ifol old dc cov over er (upp (upper er))

6.

REMOVAL 1. a. b.

Remove heated Remove heated oxyge oxygen n sensors sensors with with the the followi following ng proced procedure ure:: Disconnect Disconnect harness harness connecto connectorr of each heated heated oxygen oxygen sensor, sensor, and and harness harness from bracke brackett and middle middle clamp. Using Using the the heated heated oxygen oxygen senso sensorr wrench wrench [SST] [SST],, remove remove heated heated oxygen sensors. CAUTION: q Be careful not to damage heated oxygen sensor. q Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new one.

PBIC2700E

2. 3. 4. 5.

Remove Remo ve exha exhaus ustt fron frontt tube tube.. Refer Refer to EX-2, "EXHAUST SYSTEM" . Remo Re move ve driv drive e bel belt. t. Re Refe ferr to to EM-11, "DRIVE BELTS" . Remo Re move ve alte altern rnato atorr. Refe Referr to to SC-20, "CHARGING SYSTEM" . Remove Rem ove exhaus exhaustt manif manifold old cover cover (upper (upper). ).


EM-20

2005 X-Trail

EXHAUST MANIFOLD AND THREE WAY CATALYST 6.

Loosen Loosen nuts nuts in reve reverse rse orde orderr as shown shown iin n the figur figure e to remove remove exhaust manifold and three th ree way catalyst assembly. NOTE: Disregard No. 6 and 7 when loosening.

A

EM

C PBIC2701E

D

7.

8.

Rem emo ove gas gasket ket. CAUTION: Cover engine openings to avoid entry of foreign materials. Remove Remove exhaust exhaust manifold manifold cover (lower) (lower) and three three way catalyst catalyst cover cover from from exhaust exhaust manifold manifold and three three way catalyst assembly.

INSPECTION AFTER REMOVAL REMOVAL Surface Distortion q

q

F

Using a straightedge and a feeler gauge, check the surface distortion of exhaust manifold and three way catalyst assembly mating surface. Limit

E

G

: 0.3 mm (0.012 in)

H

If it exceeds the limit, replace exhaust manifold and three way catalyst assembly. I

KBIA0046E

INSTALLATION

J

Note the following, and install in the reverse order of removal. K

Exhaust Manifold q

If stud bolts were removed, install them and tighten to the specified torque below. : 14.7 N·m (1.5 kg-m, 11 ft-lb)

q

L

Tighten nuts in numerical order as shown in the figure. NOTE: No. 6 and 7 mean double dou ble tightening of bolts No. 1 and 3.

M

PBIC2701E

Heated Oxygen Sensor CAUTION: Before installing new heated oxygen sensor, clean exhaust system threads using a heated oxygen q sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant (commercial service tool). Do not over torque heated oxygen sensor. Doing so may cause damage to heated oxygen sensor, q resulting in the “MIL” coming on.


EM-21

2005 X-Trail

OIL PAN AND OIL STRAINER OIL PAN AND OIL STRAINER Removal and Installation

PFP:11110 ABS00CJ5

PBIC2702E

1.

Oil level gauge

2.

Oil level gauge guide

3.

O-ring

4.

Oil pan (upper)

5.

Cylinder block

6.

O-ring

7.

Oil filter

8.

O-ring

9.

Drain plug washer

10. Oil strainer

11. Drain plug

12. Oil pan (lower)

13. 13. Rear Rear plat plate e cove coverr

REMOVAL WARNING: To avoid the danger of being scalded, do not drain the engine e ngine oil when the engine is hot. 1. Re Remo move ve RH and and LH LH und under erco cove vers rs.. NOTE: When removing oil pan (lower) or oil strainer only, this step is unnecessary. 2. Drai Drain n engi engine ne oil. oil. Re Refer fer to LU-7, "Changing Engine Oil" . CAUTION: q Perform this step when the engine is cold. q Do not spill engine oil on drive belt. 3. Rem Remove ove oil oil pan (low (lower) er) with with the the followi following ng proced procedure ure::


EM-22

2005 X-Trail

OIL PAN AND OIL STRAINER a.

Loosen mount Loosen mounting ing bolt bolts s in revers reverse e order order as shown shown iin n the figur figure e with power tool.

A

EM

C PBIC2703E

D

b.

c.

Insert Insert the seal cutter [SST] between between oil oil pan pan (upper) (upper) and oil oil pan pan (lower). CAUTION: q Be careful not to damage the mating surfaces. q Do not insert a screwdriver, this will damage the mating surfaces. Slide Slide seal seal cutter cutter by tap tapping ping on on the side side of tthe he tool tool with with a hammer. mer. Remove oil pan (lower).

E

F

G SEM365E

4. 5. a. b. c.

d. e. f.

Remove Remo ve oil oil str strai aine nerr. Remove Rem ove oil oil pan pan (upper (upper)) with with the the follow following ing proc procedu edure: re: Remo Re move ve dri drive ve bel belt. t. Ref Refer er to EM-11, "DRIVE BELTS" . Remo Re move ve oil oil fil filter ter.. Ref Refer er to LU-9, "OIL FILTER" . Remove Remove A/C compress compressor or with piping piping connected. connected. And And locate it aside aside temporari temporarily ly with ropes ropes or equivalen equivalentt not to disturb the following work. Refer to AT ATC-122, C-122, "Removal and Installation of Compressor" (Automatic A/C models) or MTC-82, "Removal and Installation of Compressor" (Manual A/C models). Remo Re move ve oil oil lev level el gaug gauge e gui guide de.. Remove Rem ove exhaust exhaust front front tube tube and and its its suppor support. t. Refer Refer to EX-2, "EXHAUST SYSTEM" . Set a suit suitabl able e transm transmiss ission ion jack jack under under transa transaxle xle and ho hoist ist the the engine with engine slinger, and then remove center member with power tool. Refer to EM-74, "Removal and Installation (2WD Models)" (2WD models) or EM-78, "Removal and Installation (AWD Models)" (AWD models).

H

I

J

K

L

M

PBIC0257E

g. h.

Remove rear Remove rear engine engine mount mounting ing brack bracket et (2WD (2WD models models). ). Refer Refer to EM-74, "Removal and Installation (2WD Models)" . Remove Remove rear plate plate cover cover, and four transax transaxle le joint bolts bolts which which pierce pierce oil pan pan (upper). (upper). Refer Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-269, "TRANSAXLE ASSEMBLY" (A/T models).


EM-23

2005 X-Trail

OIL PAN AND OIL STRAINER i.

Loosen bolt Loosen bolts s in revers reverse e order order as show shown n in the the figur figure e with with powe powerr tool. NOTE: Disregard No.12 and 17 when loosening.

PBIC2704E

j.

Insert the seal cutter [SST] between oil pan (upper) and cylinder block, and slide it by tapping on the side of the tool with a hammer. mer. Remove oil pan (upper). CAUTION: q Be careful not to damage the mating surfaces. q Do not insert a screwdriver, this will damage the mating surfaces.

SEM365E

6.

Remo Re move ve O-r O-rin ings gs at at fron frontt cove coverr side side..

INSPECTION AFTER REMOVAL REMOVAL Clean oil strainer if any object attached.

INSTALLATION 1. a.

Instal Installl oil pan pan (upper (upper)) with with the follow following ing proce procedur dure: e: Use a scraper scraper to remove remove old liquid liquid gasket gasket from from mating mating surfaces. surfaces. q Also remove the old liquid gasket from mating surface of cylinder block. q Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

MEM108A

b.

Apply Apply a contin continuous uous bead bead of liqu liquid id gasket gasket with with the the tube tube presse presserr [SST [SST:: WS3 WS399 9930 3000 000 0 ( — )] as show shown n in in the the figu figure re.. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: q Apply liquid gasket to outside of bolt hole for the positions shown by arrows. q Attaching should be done within 5 minutes after coating. SBIA0253E

c.

Instal Installl new new O-ring O-rings s at at fron frontt cover cover side. side.


EM-24

2005 X-Trail

OIL PAN AND OIL STRAINER d.

Tight Tighten en bolts bolts in nume numeri rical cal order order as as shown shown in the figur figure. e. NOTE: q No. 12 and 17 mean double tightening of bolts No. 1 and 2. q Refer to the following for locating bolts.

A

EM

M6 × 20 mm (0.79 in)

: No. 18, 19

M8 × 25 mm (0.9 .98 8 in in)

: No. 1, 2, 3, 11

M8 × 45 mm (1. 1.7 77 in in)

: No No. 4, 4, 10 10, 13, 13, 14 14,, 15, 15, 16

M8 × 10 100 0 mm mm (3. (3.97 97 in in))

: No. No. 5, 6, 7, 8, 9

C PBIC2704E

e. f. 2. 3. a.

Tight Tighten en tran transax saxle le joint joint bolts. bolts. Ref Refer er to MT-17, "TRANSAXLE ASSEMBLY" "TRANSAXLE ASSEMBLY" (A/T models). Inst Instal alll rear rear plat plate e cove coverr. Inst Instal alll oil oil stra strain iner er.. Instal Installl oil pan pan (lowe (lower) r) with with the follo followin wing g procedur procedure: e: Use a scraper scraper to remove remove old liquid liquid gasket gasket from from mating mating surfaces. surfaces. q Also remove old liquid gasket from mating surface of oil pan (upper). q Remove old liquid gasket from the bolt holes and thread. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

(M/T models) or AT-269,

E

F

G

H

SEM958F

b.

D

Apply Apply a contin continuous uous bead bead of liqui liquid d gasket gasket with with the tube tube presse presserr [SST [SST:: WS3 WS399 9930 3000 000 0 ( — )] as show shown n in in the the figu figure re.. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: Attaching should be done within 5 minutes after coating.

I

J

K

L SBIA0254E

c.

M

Tight Tighten en bolts bolts in in numeri numerical cal order order as as shown shown in the the figure figure..

PBIC2703E

4.

5.

Inst Instal alll oil oil pan pan drai drain n plu plug. g. q Refer to the figure of components of former page for installation direction of washer. Refer to EM-22, "Removal and Installation" . Instal Installl in the the revers reverse e order order of remo removal val afte afterr this this step. step.


EM-25

2005 X-Trail

OIL PAN AND OIL STRAINER NOTE: Pour engine oil at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check the Check the engine engine oil oil level, level, and and adjust adjust the the level level.. Refer Refer toLU-6, to LU-6, "ENGINE OIL" . Start Start the engine, engine, and make make sure sure there there is no no leaks leaks of engine oil. Stop the engine engine and and wait wait for 10 minu minutes tes.. Check Che ck the eng engine ine oil level level agai again. n. Refe Referr to to LU-6, "ENGINE OIL" .


EM-26

2005 X-Trail

IGNITION COIL IGNITION COIL Removal and Installation

PFP:22448

A ABS00CJ6

EM

C

D

E

F

G KBIA1974J

1.

Ignition coil

2.

Spark plug

3.

Rocker cover

REMOVAL

H

1. 2. 3.

I

Remove Remo ve eng engin ine e cov cover er.. Ref Refer er to to EM-16, "INTAKE MANIFOLD" . Disconn Disconnect ect harn harness ess conne connecto ctorr from from igniti ignition on coil. coil. Remo Re move ve igni igniti tion on coil coil.. CAUTION: Do not drop or shock it.

J

INSTALLATION Install in the reverse order of removal.

K

L

M


EM-27

2005 X-Trail

SPARK PLUG (PLATINUM-TIPPED TYPE) SPARK PLUG (PLATINUM-TIPPED TYPE) Removal and Installation

PFP:22401 ABS00DCN

KBIA1974J

1.

Ignition coil

2.

Spark plug

3.

Rocker cover

REMOVAL 1. 2. 3.

Remove Remo ve eng engin ine e cove coverr. Refer Refer to EM-16, "INTAKE MANIFOLD" . Remo Re move ve igni igniti tion on coi coil. l. Ref Refer er to EM-27, "IGNITION COIL" . Remove Remove spark spark plug plug with with a spark plug wrench wrench (commer (commercial cial service tool). CAUTION: Do not drop or shock it.

SEM294A

INSPECTION AFTER REMOVAL REMOVAL Use standard type spark plug for normal condition. Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such a s: Frequent engine starts q q Low ambient temperatures Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions such as: Extended highway driving q Frequent high engine revolution q Make

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap Ga p (No (Nomi mina nal) l)


: 1.1 1.1 mm mm (0. (0.043 043 in in))

EM-28

2005 X-Trail

SPARK PLUG (PLATINUM-TIPPED TYPE) CAUTION: q Do not drop or shock spark plug. q Do not use wire brush for cleaning. c arbon, spark plug cleaner may q If plug tip is covered with carbon, be used.

A

EM

Cleaner air pressure: Less than 588 kPa (6 kg/cm2 , 85 psi)

C

Cleaning time: Less than 20 seconds

D SMA773C

q

Checking and adjusting plug gap is not required between change intervals.

E

F

G

SMA806CA

H

INSTALLATION Install in the reverse order of removal. I

J

K

L

M


EM-29

2005 X-Trail

FUEL INJECTOR AND FUEL TUBE FUEL INJECTOR AND FUEL TUBE Removal and Installation

PFP:16600 ABS00CJ9

PBIC2179E

1.

Fuel feed hose

2.

Quick connector cap (engine side)

3.

Quick connector cap (vehicle side)

4.

Centralized under-floor piping

5.

Sub-harness

6.

Fuel tube

7.

O-ring (black)

8.

Clip

9.

Fuel injector

10. O-ring (green)

11. Insulator

CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL WARNING: Put a “CAUTION: INFLAMMABLE” sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. extinguisher. q Do not smoke while servicing fuel system. s ystem. Keep open flames and sparks away from the work area. q 1. Re Rele leas ase e fuel fuel pre press ssur ure. e. Ref Refer er to to EC-90, "FUEL PRESSURE RELEASE" . 2. Re Remo move ve eng engin ine e cove coverr. Refer Refer to EM-16, "INTAKE MANIFOLD" . 3. Remove Remove air cleaner cleaner case upper upper,, mass air air flow flow sensor sensor and air air duct assembl assembly y. Refer to to EM-14, "AIR CLEANER AND AIR DUCT" . 4. Disco Disconne nnect ct quick quick connec connector tors s at the engine engine side side and the vehi vehicle cle side as follows, and remove fuel feed hose. CAUTION: Disconnect quick connector by using the quick connector release [SST: J-45488], not by picking out retainer tabs. NOTE: There is quick connector for the engine side and for the vehicle side, and they have different shapes. But disconnection is same procedure. The following procedure shows the engine side. q

PBIC2175E


EM-30

2005 X-Trail

FUEL INJECTOR AND FUEL TUBE a.

Remove Rem ove quick quick connecto connectorr cap cap (eng (engine ine side). side). A

EM

C KBIA0701E

D

b. c.

d.

With the sleeve sleeve side side of quick connecto connectorr release release facing facing quick connecto connectorr, install install quick quick connector connector release release onto fuel tube. Insert Insert quick quick connector connector release release into into quick quick connector connector until sleeve sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw Draw and pull pull out quic quick k connect connector or strai straight ght from from fuel fuel tube. tube. CAUTION: q Pull quick connector holding “A” position in the figure. KBIA0702E q Do not pull with lateral force applied. O-ring inside quick connector may be damaged. q Prepare container and cloth beforehand as fuel will leak out. q Avoid fire and sparks. q Keep parts away from heat source. Especially, be careful when welding is performed around them. q Do not expose parts to battery electrolyte or other acids. q Do not bend or twist connection between quick connector and fuel feed hose during installation/removal. q To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.

E

F

G

H

I

J

K

L

M

PBIC2205E

5. 6.

Remove intake Remove intake mani manifol fold d collec collector tor.. Refer Refer to to EM-16, "INTAKE MANIFOLD" . Disconn Disconnect ect sub-ha sub-harne rness ss for for fuel fuel inject injector or..


EM-31

2005 X-Trail

FUEL INJECTOR AND FUEL TUBE 7. 8.

Loosen Loosen mounting mounting bolts in reverse reverse order as shown shown in the the figure. figure. Remove Remove fuel fuel tube and fuel injector injector assembly assembly and insulat insulators. ors. CAUTION: q When removing, be careful to avoid any interference with fuel injector. q Use a shop cloth to absorb any fuel leaks from fuel tube.

KBIA0239E

9. a. b.

Remove Remove fuel fuel inject injector or from from fuel fuel tube tube with with the the followi following ng procedur procedure: e: Open Open and and rem remove ove clip clip.. Remov Re move e fuel inje injecto ctorr from from fuel fuel tube by pull pulling ing strai straight ght.. CAUTION: q Be careful with remaining fuel that may go out from fuel tube. q Be careful not to damage fuel injector nozzle during removal. q Do not bump or drop fuel injector. q Do not disassemble fuel injector.

SBIA0364E

INSTALLATION 1.

Note the follow following, ing, and insta installll O-rings O-rings to fuel fuel injector injector.. CAUTION: q Upper and lower O-rings are different. Be careful not to confuse them.

q q q q q

q

Fue uell tu tub be si sid de

: Blac ack k

Nozzle side

: Green

Handle O-ring with bare hands. Do not wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not decenter or twist it.


EM-32

2005 X-Trail

FUEL INJECTOR AND FUEL TUBE 2. a.

b.

c.

Install Install fuel fuel injecto injectorr to fuel tube with with the the followi following ng procedur procedure: e: Insert Insert clip clip into into clip clip attachment attachment groove groove on fuel injector injector.. q Insert clip so that protrusion “A” of fuel injector matches cutout “A” of clip. CAUTION: q Do not reuse clip. Replace it with a new one. q Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert Insert fuel fuel inje injecto ctorr into into fuel fuel tube with with clip clip atta attache ched. d. q Insert it while matching it to the axial center. q Insert fuel injector so that protrusion “B” of fuel tube matches cutout “B” of clip. q Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make Make sure that that insta installa llatio tion n is compl complete ete by check checking ing that that fue fuell injector does not rotate or come off. q Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.

A

EM

C

D

E

F

G PBIC2651E

3.

a. b.

Install Install fuel fuel tube tube and fuel fuel injecto injectorr assembly assembly with the followi following ng procedure procedure:: CAUTION: When installing, be careful to avoid any interference with fuel injector. Insert Insert the the tip tip of each each fuel fuel injecto injectorr into into intake intake mani manifol fold. d. Tighten Tighten mounting mounting bolts bolts evenly evenly in two two steps steps in numerical numerical order order as shown in the figure.

H

I

1st step

J

: 10.1 N·m (1.0 kg-m, 7 ft-lb) 2nd step

K

: 23.6 N·m (2.4 kg-m, 17 ft-lb)

L KBIA0239E

4. 5. 6.

a.

Connect sub-ha Connect sub-harne rness ss for for fuel fuel inject injector or.. M Instal Installl intak intake e manif manifold old coll collect ector or.. Refer Refer to EM-16, "INTAKE MANIFOLD" . Note th the e following, following, and connect connect quick quick connector connectors s at the engine engine side side and the vehicl vehicle e side to insta installll fuel feed hose. NOTE: There is quick connector for the engine side and for the vehicle side, and they have different shapes. But connection is same procedure. The following procedure shows the engine side. Check Che ck the the connect connection ion for for forei foreign gn materi material al and dama damage. ge.


EM-33

2005 X-Trail

FUEL INJECTOR AND FUEL TUBE b.

c. d.

7. 8.

Align center to insert insert quick connector connector straigh straightly tly into into fuel fuel tube. tube. NOTE: The figure shows the engine side as an example. q Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end. CAUTION: q Hold “A” position in the figure when inserting fuel tube into quick connector. connector. q Carefully align center to avoid inclined insertion to preKBIA0272E vent damage to O-ring inside quick connector. q Insert until you hear a “click” sound and actually feel the engagement. q To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Before Before clamping clamping fuel feed hose with hose hose clamps, clamps, pull pull quick connect connector or hard hard by hand holding holding “A” “A” position. position. Make sure it is completely engaged (connected) so that it does d oes not come out from fuel feed tube. Install Install quick quick connector connector cap cap to quick connector connector connection. connection. (Both on the engine side and the vehicle side) q Install so that the arrow mark on the side faces up. CAUTION: q Make sure that quick connector and fuel tube are securely fit into quick connector cap installation groove. q If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again. NOTE: PBIC2348E There is quick connector cap for the engine side and for the vehicle side, and they have different shapes. The figure shows the t he engine side as an example. Inst Instal alll fuel fuel feed feed hose hose to to hose hose clam clamp. p. Instal Installl in the reve reverse rse order order of remo removal val after after this this step step..

INSPECTION AFTER INSTALLATION Check on Fuel Leaks 1.

2.

Apply fuel fuel pressure pressure to fuel lines lines with turning turning ignition ignition switch switch “ON” “ON” (with the engine engine stopped). stopped). Then Then make sure there are no fuel leaks at connections. con nections. NOTE: Use mirrors for checking on invisible points. Start Start the engine. engine. With With engine engine speed increas increased, ed, make make sure again again there there are no fuel leaks leaks at connecti connections. ons. CAUTION: Do not touch the engine immediately after stopped as the engine becomes extremely hot.


EM-34

2005 X-Trail

ROCKER COVER ROCKER COVER Removal and Installation

PFP:13264

A ABS00CJA

EM

C

D

E

F

G PBIC2705E

1.

PCV hose

2.

O-ring

3.

PCV valve

4.

PCV hose

5.

Oil filler cap

6.

Rocker cover

7.

Rock Rocker er cove coverr gask gasket et

H

REMOVAL 1. 2. 3. 4. 5. 6.

I

Remove Remo ve eng engin ine e cov cover er.. Ref Refer er to to EM-16, "INTAKE MANIFOLD" . Disconn Disconnect ect PCV hose hose from from rock rocker er cover cover.. Remo Re move ve igni igniti tion on coil coil.. Ref Refer er to EM-27, "IGNITION COIL" . Remove Remove PCV valve and O-ring O-ring from rocker rocker cover cover,, if n necessa ecessary ry.. Remove Remove oil oil filler filler cap from from rocker rocker cover cover,, if necessary necessary.. Loosen Loo sen bolt bolts s in reve reverse rse order order shown shown in in the figure figure..

J

K

L

M

PBIC2706E

7. 8.

Remove rock Remove rocker er cover cover gask gasket et from from rocke rockerr cover cover.. Use scraper scraper to remove remove all traces traces of liquid liquid gasket from from cylinder cylinder head head and camshaft camshaft bracket bracket (No. (No. 1). CAUTION: Do not scratch or damage the mating surface s urface when cleaning off old liquid gasket.


EM-35

2005 X-Trail

ROCKER COVER INSTALLATION 1. a. b.

Apply Apply liqui liquid d gasket gasket to the the positio position n shown shown in the figu figure re with with the following procedure: Refer to figure figure “a” to apply apply liquid liquid gasket to joint joint part part of of camshaft camshaft bracket (No. 1) and cylinder head. Refer to figure figure “b” “b” to apply liquid liquid gasket gasket in 90 degrees degrees to figure figure “a”. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

PBIC2635E

2. 3. 4.

Instal Installl rocke rockerr cover cover gask gasket et to rocker rocker cover cover.. Inst Instal alll roc rocke kerr cov cover er.. cover. q Check if rocker cover gasket is not dropped from the installation groove of rocker cover. Tighten Tighten bolts in two two steps steps separ separately ately in numeri numerical cal order order as shown in the figure. 1st step : 2.0 N·m (0.2 kg-m, 18 in-lb) 2nd step : 8.3 N·m (0.85 kg-m, 73 in-lb)

PBIC2706E

5.

Instal Installl in the reve reverse rse order order of remo removal val after after this this step step..


EM-36

2005 X-Trail

CAMSHAFT CAMSHAFT Removal and Installation

PFP:13001

A ABS00E9K

EM

C

D

E

F

G

H

I

J

PBIC2707E

1.

Camshaft bracket (No. 2 to 5)

2.

Seal washer

3.

Camshaft bracket (No. 1)

4.

Front cover

5.

Chain guide

6.

Chain tensioner

7.

Spring

8.

Chain tensioner plunger

9.

O-ring

L

10. Oil ring

11. O-ring

Intake valve timing control solenoid 12. valve

13. Intake valve timing control cover

14. Camshaft sprocket (INT)

15. Camshaft sprocket (EXH)

16. O-ring

17. Valve lifter

18. Camshaft (INT)

19. Camshaft (EXH)

20. O-ring

21. Camshaft position sensor (PHASE)

NOTE: This section describes removal/installation procedure of camshaft without removing front cover. If front cover is removed or installed, removal of camshaft bracket (No. 1) is easier before step 9 and installation is easier after step 4. Regarding removal and installation of front cover, refer to EM-49, "TIMING CHAIN" .

REMOVAL 1.

2. 3.

Remove Remo ve the foll follow owin ing g par parts ts.. q Engine cover; Refer to EM-16, "INTAKE MANIFOLD" . q Ignition coil; Refer to EM-27, "IGNITION COIL" . q Rocker cover; Refer to EM-35, "ROCKER COVER" . Remove Remove reservoi reservoirr tank tank of radiato radiatorr from from bracket, bracket, and move move it aside. Refer to CO-11, "RADIATOR" . Remove Remove power steering steering reservoir reservoir tank from from bracket bracket to move power steeri steering ng piping. piping. Refer Refer to PS-33, "HYDRAULIC LINE" .


EM-37

K

2005 X-Trail

M

CAMSHAFT

4. a. b. c. d. e.

CAUTION: To avoid power steering fluid leakage, temporarily fix reservoir tank of power steering oil pump vertically. Remove Remove intake intake valve valve timing timing control control cover cover with with the following following procedure: procedure: Disconnect Disconnect intak intake e valve valve timing timing control control solenoid solenoid valve valve harness harness connecto connectorr. Disco Disconne nnect ct groun ground d cables cables and and remov remove e harnes harness s clip. clip. Remove Remove intake intake valve timing timing control control solenoid solenoid valve, valve, ifif necessar necessary y. Loosen Loo sen bolt bolts s in rever reverse se order order as as shown shown in the the figur figure. e. Use the seal cutter cutter [SST [SST: KV1011 KV10111100 (J37228)] (J37228)] or suit suitable able tool to cut liquid gasket for removal. CAUTION: Be careful not to damage the mating surfaces. s urfaces.

KBIA0085E

5. 6. a. b.

Pull chain guide between between camshaft camshaft sprocke sprockets ts out out through through front front cover cover.. Set No. No. 1 cylinder cylinder at TDC on its compressi compression on stroke stroke with with the followi following ng procedure: procedure: Open Open spla splash sh gua guard rd on RH und underc ercover over.. Rotate Rota te cranksh crankshaft aft pulley pulley clockwise clockwise and align align TDC mark to timing timing indicator on front cover.

KBIA0190E

c.

At the the same same time, time, make make sure sure that tthe he matin mating g marks marks on camsh camshaft aft sprockets are located as shown in the figure. q If not, rotate crankshaft pulley one more turn to align mating marks to the positions in the figure.

PBIC2351E

7. a.

Remove cams Remove camshaf haftt sprocket sprockets s with the the followi following ng procedu procedure: re: Put indelible indelible paint paint marks marks on the timing timing chain chain link plates plates aligning aligning with the mating mating marks marks on camshaft camshaft sprockets.


EM-38

2005 X-Trail

CAMSHAFT b.

Push in chain chain tensione tensionerr plunger plunger.. Insert Insert a stopper stopper pin pin into hole on on chain tensioner body to secure chain tensioner plunger and remove chain tensioner. CAUTION: Be careful not to drop mounting bolts inside front cover. NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.

A

EM

C KBIA0048E

D

c.

8.

9.

Secure Secure hexa hexagona gonall part part of camsha camshaft ft with with a wrench wrench.. Loosen Loosen camcamshaft sprocket mounting bolts and a nd remove camshaft sprockets. CAUTION: q Do not loosen the mounting bolts with securing anything other than the camshaft hexagonal part or with tensioning timing chain. q Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. NOTE: Chain tension holding work is not necessary. Crankshaft sprocket and timing chain do not disconnect structurally while front cover is attached. Remove Remove camshaft camshaft positi position on sensor sensor (PHAS (PHASE) E) from from cylinder cylinder head back back side. side. CAUTION: q Handle carefully to avoid dropping and shocks. q Do not disassemble. q Do not allow metal powder to adhere to magnetic part at sensor tip. q Do not place the sensor in a location where it is exposed to magnetism. Loosen mounting mounting bolts bolts in revers reverse e order order as as shown shown in in the figure, figure, and remove camshaft brackets. q Remove camshaft bracket (No. 1) by slightly tapping it with a plastic hammer.

E

F

G KBIA0049E

H

I

J

K

L

M SBIA0255E

10. Remove Remove camshaf camshafts. ts. 11. Rem Remove ove valv valve e lifter lifters. s. q Identify installation positions, and store them without mixing them up.


EM-39

2005 X-Trail

CAMSHAFT INSPECTION AFTER REMOVAL REMOVAL Camshaft Runout 1.

2. 3.

Put V-bloc V-block k on a precise precise flat table, table, and support support No. 2 and 5 jourjournals of camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set a dial dial indica indicator tor vert vertica ically lly to No. No. 3 jour journal nal.. Turn cams camshaf haftt to one direct direction ion with with hands, hands, and and measur measure e the camshaft runout on the dial indicator. indicator. (Total (Total indicator reading) Standard: Stand ard: Less than 0.02 mm (0.0008 in).

4.

PBIC2499E

If out out of of the the standa standard, rd, replac replace e camsh camshaft aft..

Camshaft Cam Height 1.

Measur Measure e the camsh camshaft aft cam cam height height with with a microm micromete eterr. Standard: Intake

: 45 45.665 - 45.8 .855 55 mm (1 (1.7 .797 978 8 - 1. 1.8 805 053 3 in in)

Exha Ex haus ustt

: 43. 43.97 975 5 - 44. 44.165 165 mm (1 (1.7 .7313 313 - 1.7 1.7388 388 in in))

Cam wear limit : 0.2 mm (0.008 in) 2.

If wear wear is is beyond beyond the the limi limit, t, repl replace ace cams camshaft haft.. PBIC0039E

Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER Measure the outer diameter of o f camshaft journal with a micrometer. micrometer. Standard: No. 1

: 27.935 - 27.955 mm (1.0998 - 1.1006 in)

No. 2, 3, 3, 4, 5

: 23.435 23.435 - 23.4 23.455 55 mm (0. (0.9226 9226 - 0.9234 0.9234 in) in)

PBIC0040E

CAMSHAFT BRACKET INNER DIAMETER Tighten camshaft bracket bolts with the specified torque. Refer to EM-42, "INSTALLATION" for the tightq ening procedure. q Measure inner diameter “A” of camshaft bracket with a bore gauge. Standard: No. 1

: 28.000 - 28.021 mm (1.1024 - 1.1032 in)

No. 2, 3, 4, 5

: 23.500 23.500 - 23.52 23.521 1 mm (0. (0.925 9252 2 - 0.9260 0.9260 in)

PBIC1645E


EM-40

2005 X-Trail

CAMSHAFT CAMSHAFT JOURNAL OIL CLEARANCE q (Oil clearance) = (Camshaft bracket inner diameter) d iameter) – (Camshaft journal diameter) Stand St andard ard q

A

: 0.04 0.045 5 - 0.08 0.086 6 mm mm (0.00 (0.0018 18 - 0.00 0.0034 34 in) in)

If out of the standard, replace either or both camshaft and cylinder head. EM NOTE: Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder head. Replace whole cylinder head h ead assembly. assembly. C

Camshaft End Play 1. 2.

Instal Installl camsh camshaft aft in in cylin cylinder der hea head. d. Refe Referr to EM-42, "INSTALLATION" for tightening procedure. Install Install a dial indicator indicator in thrust thrust direct direction ion on on front front end of camshaf camshaft. t. Measure the camshaft end play on the dial indicator when camshaft is moved forward/backward (in direction to axis). Stand St andard ard

D

E

: 0.1 0.115 - 0.1 0.188 88 mm mm (0.00 (0.0045 45 - 0.0 0.0074 074 in)

F

PBIC2446E

q

–

Measure the following parts if out of the standard. Dimension “A” for camshaft No. 1 journal Stand St andard ard

–

q

H

: 25.80 25.800 0 - 25. 25.848 848 mm (1. (1.0157 0157 - 1.01 1.0176 76 in) in) I

Dimension “B” for cylinder head No. 1 journal bearing Stand St andard ard

G

: 25.660 25.660 - 25. 25.685 685 mm mm (1.01 (1.0102 02 - 1.0 1.01 112 in) in)

Refer to the standards above, and then replace camshaft and/ or cylinder head.

J

KBIA2426J

K

Camshaft Sprocket Runout 1.

2.

Put V-block V-block on precise precise flat flat table, table, and support support No. 2 an and d 5 journals journals of camshaft. camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Measur Measure e the camshaf camshaftt sprocke sprockett runout runout wit with h a dial indica indicator tor.. (Total indicator reading) Limit

q

: 0.15 mm (0.0059 in)

If it exceeds the limit, replace camshaft sprocket.

PBIC0930E


EM-41

2005 X-Trail

L

M

CAMSHAFT Valve Lifter Check if surface of valve lifter has any wear or cracks. If anything above is found, replace valve lifter. Refer to EM-46, q "Valve Clearance" .

KBIA0182E

Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER Measure the outer diameter of valve lifter with a micrometer. micrometer. q Stand St andard ard

: 33.96 33.965 5 - 33. 33.980 980 mm (1.3 (1.3372 372 - 1.337 1.3378 8 in) in)

JEM798G

VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer. Stand St andard ard

: 34.00 34.000 0 - 34. 34.021 021 mm (1.3 (1.3386 386 - 1.339 1.3394 4 in) in)

PBIC0043E

VALVE LIFTER CLEARANCE (Valve (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve (Valve lifter outer diameter) q Stand St andard ard q

: 0.020 0.020 - 0.05 0.056 6 mm mm (0.0 (0.0008 008 - 0.002 0.0022 2 in) in)

If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, diameter, replace either or both valve lifter and cylinder head.

INSTALLATION 1.

Inst Instal alll val valve ve lif lifte ters rs.. q Install them in the original positions.


EM-42

2005 X-Trail

CAMSHAFT 2.

Inst Insta all cam camsh shaf aftts. q Distinction between intake and exhaust camshafts is performed with the different shapes of rear end. Inttak In ake e

: Sig igna nall pla platte sha shap pe fo for cam camsh shaf aftt pos posit itio ion n sensor (PHASE)

Exhaust

: Cone en end sh shap ape e

A

EM

C KBIA0246E

D q

Install camshafts so that camshaft dowel pins on the front side are positioned as shown in the figure. E

F

G KBIA0051E

3. a. b.

Instal Installl camsha camshaft ft bracke brackets ts with with the follow following ing proced procedure ure:: Remove Remove foreign foreign material material completel completely y from camshaft camshaft bracket bracket backside backside and from from cylinder cylinder head head installati installation on face. Install Install camshaf camshaftt bracket brackets s (No. (No. 2 to 5) aligning aligning the identificat identification ion marks on upper surface as shown in the figure. f igure. NOTE: Install so that identification mark can be correctly read when viewed from the exhaust side.

H

I

J

K

SBIA0256E

c. i.

Install Install camshaft camshaft brack bracket et (No. (No. 1) with with the following following procedure: procedure: Apply Apply liqu liquid id gaske gaskett to cams camshaft haft bracke brackett (No. (No. 1) as show shown n in the the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part “A”.

M

PBIC2579E


EM-43

L

2005 X-Trail

CAMSHAFT ii.

Apply Apply liqui liquid d gasket gasket to cams camshaft haft b brac racket ket (No. (No. 1) cont contact act surfa surface ce on the front cover backside. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . q Apply liquid gasket to the outside of bolt hole on front cover.

SBIA0258E

iii. Locate camshaft camshaft bracket bracket (No. (No. 1) near instal installatio lation n position, position, and install it without disturbing the liquid gasket applied to the surfaces.

PBIC2746E

4. a.

Tighten Tighten mounting mounting bolts of c camshaf amshaftt bracket brackets s in the ffollow ollowing ing steps, in numerical order as shown in the figure. Tighten ighten No. 9 to 11 in numeri numerical cal order order.. : 2.0 N·m (0.2 kg-m, 1 ft-lb)

b.

Tighten ighten No No.. 1 to to 8 in nume numeric rical al order order.. : 2.0 N·m (0.2 kg-m, 1 ft-lb)

c.

Tighten ighten all bolts bolts in in numer numerica icall order order.. : 5.9 N·m (0.6 kg-m, 4 ft-lb)

d.

SBIA0255E

Tighten ighten all bolts bolts in in numer numerica icall order order.. : 10.4 N·m (1.1 kg-m, 8 ft-lb)

5. 6.

7.

CAUTION: After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts listed below. q Mating surface of rocker cover q Mating surface of front cover (When installed without front cover) Instal Installl cams camshaf haftt positi position on sens sensor or (PHA (PHASE) SE).. Inst Instal alll cam camsha shaft ft spro sprock cket ets. s. q Install them by aligning the mating marks on each camshaft sprocket with the paint marks on the timing chain link plates during removal. CAUTION: q Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. q Before and after installing chain tensioner, make sure again that mating marks have not slipped. NOTE: Before installation of chain tensioner, it is possible to re-match PBIC2351E the marks on timing chain with the ones on each sprocket. Inst Instal alll chai chain n tens tensio ione nerr.


EM-44

2005 X-Trail

CAMSHAFT

8. 9. a. b. c.

CAUTION: After installation, pull the stopper pin off completely, and make sure that chain tensioner plunger A is released. Inst Instal alll chai chain n guid guide. e. Install Install intake intake valve timing timing control control cover cover with tthe he followin following g procedure: procedure: EM Install Install oil rings rings to the camshaft camshaft sprocket sprocket (INT) (INT) insert insertion ion points points on backside backside of intake intake valve timing timing control control cover. C Inst Instal alll O-ri O-ring ng to to fron frontt cove coverr. Apply Apply liquid liquid gasket gasket with with the tube tube presser presser [SST [SST:: WS3993000 WS39930000 0 ( — )] to int intak ake e val valve ve timi timing ng cont contro roll cov cover er as show shown n in in the the fig fig-ure. D Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . E

F SBIA0260E

d.

Tighten Tighten mounting mounting bolts in numeri numerical cal order order as shown shown in the figfigure.

G

H

I

KBIA0085E

e. f. 10. 11.

Install Install intake intake valve timing timing control control solenoid solenoid valve valve to intake intake valve timing timing control control cover cover if removed. removed. Connec Con nectt ground ground cables cables,, and and inst install all harnes harness s clip clip.. Check and and adjust adjust valve clearan clearance. ce. Refer Refer to EM-46, "Valve Clearance" . Install Install in the reverse reverse order order of removal removal after this this step. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after the engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

INSPECTION AFTER INSTALLA INSTALLATION TION Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: Perform this inspection only when DTC P0011 is detected in self-diagnostic se lf-diagnostic results of CONSULT-II CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-127, "SELF-DIAG RESULTS MODE" . Check when the engine is cold so as to prevent burns from any splashing engine oil. q 1. Ch Chec eck k the the engi engine ne oil oil lev level el.. Refe Referr to LU-6, "ENGINE OIL" . 2. Perform Perform the followi following ng procedure procedure so as to prevent prevent the engine engine from being unintenti unintentionally onally started started while while checking. a. Re Rele leas ase e fuel fuel pre press ssur ure. e. Refe Referr to to EC-90, "FUEL PRESSURE RELEASE" . b. Discon Disconnect nect ignit ignition ion coil coil and injecto injectorr harness harness connect connectors ors.. 3. Rem Remove ove intak intake e valve valve timing timing control control solen solenoid oid valve valve.. Refer Refer to EM-37, "CAMSHAFT" . q


EM-45

2005 X-Trail

J

K

L

M

CAMSHAFT 4.

q

5.

6.

Crank Crank the the engine, engine, and then then make make sure sure that engi engine ne oil comes comes out from intake valve timing control cover oil hole. End crank after checking. WARNING: Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.). CAUTION: Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle. Do PBIC2723E not allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil. Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from intake valve timing control cover oil hole. Refer to LU-4, "LUBRICATION SYSTEM" . Remove Remove components components between between intake intake valve valve timing timing control control solenoid solenoid valve valve and camshaft camshaft sprocket sprocket (INT), (INT), and then check each oil groove for clogging. necessary. Refer to LU-4, "LUBRICATION SYSTEM" . q Clean oil groove if necessary. After After insp inspecti ection, on, insta installll remo removed ved parts. parts.

Valve Clearance

ABS00CJD

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. 1. Re Remo move ve roc rocke kerr cov cover er.. Ref Refer er to to EM-35, "ROCKER COVER" . 2. Open Open spla splash sh gua guard rd on RH und underc ercover over.. 3. Measur Measure e the valve valve cleara clearance nce with with the follow following ing proced procedure ure:: a. Set No. No. 1 cylin cylinder der at at TDC of its its compre compressi ssion on strok stroke. e. q Rotate crankshaft pulley clockwise and align TDC mark to timing indicator on front cover.

KBIA0190E

q

q

At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face outside as shown in the figure. If they do not face outside, rotate crankshaft pulley once more (360 degrees) and align as shown in the figure.

KBIA0400J


EM-46

2005 X-Trail

CAMSHAFT b.

Use a feeler feeler gauge gauge,, measure measure the the clearan clearance ce betwee between n valve valve lifter lifter and camshaft.

A

EM

C SEM139D

D

Valve clearance: Unit: mm (in) Cold

Hot * (reference data)

Intake

0.24 - 0.32 (0.009 - 0.013)

0.304 - 0.416 (0.012 - 0.016)

Exhaust

0.26 - 0.34 (0.010 - 0.013)

0.308 - 0.432 (0.012 - 0.017)

E

F

*:Approximately 80°C (176°F) q

q

By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 1 cylinder compression TDC

Measuring position No. 1 cylinder at compression TDC

No. 1 CYL.

INT

×

EXH

×

No. 2 CYL.

No. 3 CYL.

G

No. 4 CYL.

H

× ×

I PBIC2624E

c.

J

Rotate cranksh Rotate crankshaft aft pulley one revolu revolution tion (360 degrees) degrees) and align align TDC mark to timing indicator on front cover.

K

L

KBIA0190E

q

q

By referring to the figure, measure the valve clearance at locations marked “×” as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 4 cylinder compression TDC

Measuring position No. 4 cylinder at compression TDC

No. 1 CYL.

No. 2 CYL.

INT EXH

No. 3 CYL.

No. 4 CYL.

×

×

×

×

PBIC2625E

4.

If out out of s stan tandar dard, d, perfo perform rm adju adjustm stment ent.. Refer Refer to to EM-47, "ADJUSTMENT" .

ADJUSTMENT q

Perform adjustment depending on selected head thickness of valve lifter.


EM-47

2005 X-Trail

M

CAMSHAFT 1. 2. 3.

Remove Remo ve cams camshaf haft. t. Re Refe ferr to EM-37, "REMOVAL" . Remove Remove valve valve lifter lifters s at the locati locations ons that that are are out of the standard. standard. Measure Measure the the center center thickne thickness ss of of the removed removed valve valve lifters lifters with with a micrometer.

KBIA0057E

4.

Use the equation equation below below tto o calculate calculate valve lifter thickness thickness for for replacem replacement. ent. Val alve ve lif lifte terr thi thick ckne ness ss cal calcu cula lati tion on::

q

t = t1 + (C1 – C2 )

t

= Va Valv lve e lif lifte terr th thic ickn knes ess s to to be re rep pla lace ced d

t1

= Removed valve lifter thickness

C1

= Measured valve clearance

C2

= Standard valve clearance: Intake

: 0.28 mm (0.011 in)

Exhaust

: 0.30 mm (0. 0.0 012 in)

Thickness of new valve lifter can be identified by stamp mark on the reverse side (inside the cylinder). Stamp Stamp mark “696” indicates 6.96 mm (0.2740 in) in thickness.

KBIA0119E

NOTE: Available thickness of valve lifter: 26 sizes range 6.96 to 7.46 mm (0.2740 to 0.2937 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-111, "Available Valve Lifter" . 5. Instal Installl the the select selected ed valve valve lifter lifter.. 6. Inst Instal alll cam camsh shaf aft. t. Re Refe ferr to to EM-42, "INSTALLATION" . 7. Manual Manually ly rotat rotate e cranksh crankshaft aft pulle pulley y a few rotat rotation ions. s. 8. Make sure sure that valve valve clearances clearances for cold engine engine are are within within specificati specifications ons by referrin referring g to the specified specified valvalues. Refer to EM-46, "INSPECTION" . 9. Install Install all all removed removed parts parts in the reverse reverse order order of removal. removal. Refer Refer to to EM-42, "INSTALLATION" . 10. Warm Warm up the engine, engine, and check for unusual unusual noise noise and vibration. vibration.


EM-48

2005 X-Trail

TIMING CHAIN TIMING CHAIN Removal and Installation

PFP:13028

A ABS00E9J

EM

C

D

E

F

G

H

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L

M

PBIC2708E

1.

O-ring

2.

Camshaft sprocket (INT)

3.

Camshaft sprocket (EXH)

4.

Chain tensioner

5.

Spring

6.

Chain tensioner plunger

7.

Timing chain slack guide

8.

Timing chain

9.

Front cover

10. Ch Chain guide

11.

Intake valve timing control solenoid valve

12. Inta Intake ke valve timing control control cover cover

13. RH engine mounting bracket

14. Crankshaft pulley bolt

15. Crankshaft pulley

16. Front oil seal

17. Balancer unit timing chain tensioner

18. Oil pump drive spacer

19. Crankshaft sprocket

20. Timing chain tension guide

21. Balancer unit timing chain

22. Balancer unit

23. Oil ring

REMOVAL 1.

Remo Re move ve the foll follow owin ing g par parts ts..


EM-49

2005 X-Trail

TIMING CHAIN Hood assembly; Refer to BL-12, "HOOD" . q RH and LH undercovers q Engine cover; Refer to EM-16, "INTAKE MANIFOLD" . " INTAKE AKE MANIFOLD" . q PCV hose; Refer to EM-16, "INT q Ignition coil; Refer to EM-27, "IGNITION COIL" . q Rocker cover; Refer to EM-35, "ROCKER COVER" . q Engine coolant reservoir tank; Refer to CO-11, "RADIATOR" . q Drive belt; Refer to EM-11, "DRIVE BELTS" . q Alternator; Refer to SC-20, "CHARGING SYSTEM" . Auto-Tensioner" . q Drive belt auto-tensioner; Refer to EM-12, "Removal and Installation of Drive Belt Auto-Tensioner" q Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" . Drai Drain n engi engine ne oil. oil. Re Refer fer to LU-7, "Changing Engine Oil" . CAUTION: Perform this step when the engine is cold. Remove Remove A/C compresso compressorr with piping piping connected. connected. Tempor Temporarily arily secure secure A/C compres compressor sor to the vehicle vehicle side with a rope to avoid putting a load on them. Refer to ATC-122, "Removal and Installation of Compressor" (Automatic A/C models) or MTC-82, "Removal and Installation of Compressor" (Manual A/C models). Remove Remove bracket bracket mounting mounting bolts bolts for fixing fixing A/C piping piping near near right strut strut housing housing and exhaust exhaust manifold manifold cover cover.. Doing so simplifies moving. Remove Remove power steeri steering ng oil pump pump with piping piping connected, connected, and secure secure it to the the vehicle vehicle side temporari temporarily ly.. Refer to PS-33, "HYDRAULIC LINE" . Remove Remove power steering steering reservoir reservoir tank tank from bracket bracket to move power power steering steering piping. piping. Refer Refer to PS-33, "HYDRAULIC LINE" . CAUTION: To avoid power steering fluid leakage, temporarily fix power steering s teering reservoir tank vertically. Install Install engine engine slinger slingers s into into front-le front-left ft of cylinder cylinder head head and rearright of cylinder head. q Use alternator bracket mounting bolt holes for the front side. q

2.

3.

4. 5. 6.

7.

Slinger bolts: Front : 57.9 N·m (5.9 kg-m, 43 ft-lb) Rear : 28.0 N·m (2.9 kg-m, 21 ft-lb) SBIA0271E

8. 9.

Lift Lift with with a ho hoist ist,, and supp support ort the engi engine ne postu posture. re. Remove Remove engine engine mountin mounting g related related parts parts below with power tool. Refer to EM-74, "Removal and Installation (2WD Models)" (2WD models) or EM-78, "Removal and Installation (AWD Models)" (AWD models). q RH engine mounting insulator q Center member q Rear engine mounting bracket (2WD models) 10. Remove oil pan (upper and lower) lower) with power power tool, and oil strainer. Refer to EM-22, "OIL PAN AND OIL STRAINER" . 11. Remove intake intake valve timing control cover with with the following following procedure: a. Disconnect Disconnect intak intake e valve valve timing timing control control solenoid solenoid valve valve harness harness connecto connectorr. b. Disco Disconne nnect ct groun ground d cables cables and and remov remove e harnes harness s clip. clip. c. Remove Remove intake intake valve timing timing control control solenoid solenoid valve, valve, ifif necessar necessary y.


EM-50

2005 X-Trail

TIMING CHAIN d. e.

Loosen bolt Loosen bolts s in reve reverse rse order order as shown shown in in the ffigu igure. re. Use the seal seal cutter cutter [SST [SST: KV1011 KV10111100 (J37228)] (J37228)] or or suitable suitable tool tool to cut liquid gasket for removal. CAUTION: Be careful not to damage the mating surfaces.

A

EM

C KBIA0085E

D

12. Pull chain guide between between camshaft camshaft sprockets sprockets out through front cover. cover. 13. Set No. 1 cylinder at TDC on its its compression stroke with the following procedure: procedure: a. Rota Rotate te cranksha crankshaft ft pulley pulley clockwise clockwise and and align align TDC TDC mark mark to to timing timing indicator on front cover.

E

F

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KBIA0190E

b.

At the same same time time,, make make sure that that the the mating mating marks marks on on camshaft camshaft sprockets are located as shown in the figure. q If not, rotate crankshaft pulley once more (360 degrees) to align mating marks to the positions in the figure.

H

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K PBIC2351E

L

14. Remove Remove crankshaft crankshaft pulley pulley with the following following procedure: procedure: a. Fix crankshaft crankshaft pulley with a pulley pulley holder (commerc (commercial ial servic service e tool), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.

M

PBIC2434E


EM-51

2005 X-Trail

TIMING CHAIN b.

Attach Attach a pulley pulley puller (commerci (commercial al service service tool) tool) in in the M 6 thread thread hole on crankshaft pulley, and remove crankshaft pulley p ulley..

PBIC2709E

15. Remove front cover and RH engine mounting bracket with the following following procedure: a. Loo Loosen sen mounti mounting ng bolts bolts in rever reverse se order order as shown shown in the the figure, figure, and remove RH engine mounting bracket. b. Use the seal cutter cutter [SST [SST: KV1011 KV10111100 (J37228)] (J37228)] or suit suitable able tool to cut liquid gasket for removing front cover. CAUTION: Be careful not to damage the mating surfaces. s urfaces. c. Pull Pull out dow downw nwar ard d front front cove coverr. CAUTION: Do not let A/C and power steering pipings interfere with upper part of front cover.

KBIA0083E

16. Remove Remove front oil seal from from front cover using using suitable suitable tool. CAUTION: Be careful not to damage front cover. 17. Remove Remove timing timing chain with with the following following procedure: procedure: a. Push in chain chain tensione tensionerr plunger plunger.. Insert Insert a stopper stopper pin pin into hole on chain tensioner body to secure chain tensioner plunger and remove chain tensioner. NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.

KBIA0048E

b.

Remove Remo ve timi timing ng chai chain. n. CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. 18. Remove Remove camshaft camshaft sprocke sprockets. ts. Refer Refer to to EM-37, "CAMSHAFT" . Revision: 2005 March

EM-52

2005 X-Trail

TIMING CHAIN 19. Remove timing chain slack guide, guide, timing chain tension guide and oil pump drive spacer. spacer. 20. a. b. c.

d.

A

Remove Remove balancer unit timing timing chain tensioner tensioner with the following following procedure: procedure: Lift Lift lever lever up, up, and releas release e ratche ratchett claw claw for retu return rn proof. proof. Push Push ten tensi sion oner er sle sleev eve e in, and hol hold d it. it. Matchi Mat ching ng the hole hole on leve leverr with with the one on on body, body, insert insert a stopper stopper pin to secure tensioner sleeve. NOTE: Use approximately 1 mm (0.04 in) dia. hard metal pin as a stopper pin. Remove Rem ove balance balancerr unit unit timing timing chai chain n tensio tensioner ner..

EM

C

D KBIA0121E

E

21. Remove Remove balancer balancer unit timing timing chain and crankshaft crankshaft sprocket. sprocket. 22. Loosen mounting mounting bolts bolts in reverse reverse order as shown shown in the figure, figure, and remove balancer unit. CAUTION: Do not disassemble balancer unit. NOTE: Use TORX socket (size E14).

F

G

H KBIA0122E

I

INSPECTION AFTER REMOVAL REMOVAL Timing Chain Check timing chain for cracks and any excessive wear at the roller links of timing chain. Replace timing chain if necessary.

J

K

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PBIC0282E

Balancer Unit Mounting Bolt Outer Diameter q

q

Measure outer diameters (“d1”, “d2”) at two positions as shown in the figure. If reduction appears in “A” range, regard it as “d2”. Limit Lim it (“d (“d1” 1” – “d2 “d2”) ”) : 0.15 0.15 mm mm (0.0 (0.0059 059 in)

q

If it exceeds the limit (large difference in dimensions), replace balancer unit mounting bolt with a new one.

PBIC1137E


EM-53

2005 X-Trail

M

TIMING CHAIN INSTALLATION NOTE: The figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed. 1. Make Make sure sure that that cran cranksh kshaft aft key key point points s strai straight ght up. up.

PBIC2182E

2.

a. b.

Tighten Tighten mounting mounting bolts bolts in in numerical numerical order as shown shown in in the figure with the following procedure to install balancer unit. CAUTION: If mounting bolts are re-used, check their outer diameter before installation. Refer to EM-53, "Balancer Unit Mounting Bolt Outer Diameter" . Apply Apply new engi engine ne oil to to threads threads and and seat surf surface aces s of mounti mounting ng bolts. Tighte ghten n all all bolt bolts s. : 48.1 N·m (4.9 kg-m, 35 ft-lb)

c.

d.

KBIA0122E

Turn all all bolts bolts 90 degree degrees s clockw clockwise ise (angl (angle e tighteni tightening) ng).. CAUTION: Check tightening angle with the angle wrench [SST] or a protractor. protractor. Do not make judgment by visual check alone. Com ompl plet etel ely y loos loosen en.. : 0 N·m (0 kg-m, 0 ft-lb)

e.

CAUTION: In this step, loosen bolts in reverse order as shown in the figure. Tighte ghten n all all bolt bolts s.

PBIC2710E

: 48.1 N·m (4.9 kg-m, 35 ft-lb) f.

Turn the them m another another 90 degre degrees es clock clockwis wise e (angl (angle e tighten tightening ing). ).


EM-54

2005 X-Trail

TIMING CHAIN 3.

Instal Installl cranksh crankshaft aft sproc sprocket ket and balan balancer cer unit unit timing timing chain. chain. q Make sure that crankshaft sprocket is positioned with mating marks on cylinder block and crankshaft sprocket meeting at the top. q Install it by aligning mating marks on each sprocket and balancer unit timing chain.

A

EM

C PBIC2183E

D

4.

Instal Installl balanc balancer er unit unit timin timing g chain chain tensio tensioner ner.. NOTE: Chain guide and tensioner move freely with staking pin as the axle. Therefore, bolt hole position of the three points could be changed during removal. If points change, temporarily fix the two mounting bolts on chain guide, and move tensioner to mate the bolt holes. q Be careful not to let mating marks of each sprocket and timing chain slip. q After installation, make sure the mating marks have not slipped, then remove stopper pin and release tensioner sleeve.

E

F

G KBIA0124E

H

5.

Instal Installl timin timing g chain chain and relate related d part parts. s. q Install by aligning mating marks on each sprocket and timing chain. q Before and after installing chain tensioner, check again to make sure that mating marks have not slipped. q After installing chain tensioner, remove stopper pin, and make sure that tensioner moves freely. freely. CAUTION: q For the following note, after the mating marks are aligned, keep them aligned by holding them with a hand. q To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.

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PBIC2182E

6. 7. a.

Instal Installl front front oil oil seal seal to to front front cove coverr. Refer Refer to to EM-60, "Removal and Installation of Front Oil Seal" . Install Install front front cover cover and RH RH engine engine mounting mounting bracket bracket with with the followi following ng procedure: procedure: Instal Installl O-rin O-rings gs to cyli cylinde nderr head head and cyli cylinder nder block. block.


EM-55

2005 X-Trail

TIMING CHAIN b.

Apply Apply a contin continuous uous bead bead of liqu liquid id gasket gasket with with the the tube tube presse presserr [SST [SST:: WS3 WS3993 99300 0000 00 ( — )] to fron frontt cov cover er as show shown n in the the fig fig-ure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . NOTE: Application instruction differs depending on the position. Dettail of A De

: Cros Cross s ove overr the the st star artt of of the the ap appl plic icaation and the end.

Dettail of B De

: Appl Apply y liq liqui uid d gas gasket ket ou outtsi side de of bo bolt lt holes. (For all bolt holes other than B, apply to the inside.)

Dettai De aill of of C

: Betw Betwee een n here here onl only y, appl apply y 4.5 4.5 - 5.5 5.5 mm (0.177 - 0.217 in) dia.

SBIA0267E

c.

Make sure sure that mating mating marks marks of timing timing chain and each each sprocket sprocket are still aligned. aligned. Then Then install install front front cover. cover. q When installing, align flat faces at oil pump drive spacer and oil pump inner rotor. CAUTION: q Do not let A/C and power steering pipings interfere with upper part of front cover. q Be careful not to damage front oil seal by interference with front end of crankshaft.

d.

Tighten Tighten mountin mounting g bolts bolts in numerical numerical order order as as shown shown in the figfigure. q Refer to the following for locating M6 bolts. Bolt length:

Bolt position

45 mm (1.77 in)

: 5, 14, 17

20 mm (0 (0.7 .79 9 in) in)

: Ex Exce cept pt th the e abo above ve (Ex (Exce cept pt 1 to to 4) 4)

At the same time, install RH engine mounting bracket. (Bolt positions 1 to 4 in the figure) After all bolts bolts are tighten tightened, ed, retight retighten en them them to the specifi specified ed torque in numerical order as shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface for fitting oil pan (upper).

q

e.

KBIA0083E

8. 9. a. b.

Instal Installl chain chain guide guide betwe between en camsh camshaft aft spro sprocke ckets ts.. Install Install intake intake valve timing timing control control cover cover with with the the following following procedure: procedure: Install Install oil rings rings to the camshaft camshaft sprocke sprockett (INT) insertion insertion points points on backside backside of intake intake valve valve timing timing control cover. Inst Instal alll O-ri O-ring ng to to fron frontt cove coverr.


EM-56

2005 X-Trail

TIMING CHAIN c.

Apply Apply a contin continuous uous bead bead of liqui liquid d gasket gasket with with the tube tube presse presserr [SST [SST:: W WS3 S399 99300 30000 00 ( — )] to inta intake ke valv valve e tim timin ing g c con ontr trol ol cover as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

A

EM

C SBIA0260E

D

d.

Tighten Tighten mounting mounting bolts in numeri numerical cal order order as shown shown in the figfigure. E

F

G KBIA0085E

e. Install Install intake intake valve timing timing control control solenoid solenoid valve valve to intake intake valve timing timing control control cover cover if removed. removed. f. Con Connec nectt ground ground cables cables,, and and inst install all harnes harness s clip clip.. 10. Insert Insert crankshaft crankshaft pulley by aligning with with crankshaft crankshaft key. key. p ortion (not circumference). q When inserting crankshaft pulley with a plastic hammer, tap on its center portion CAUTION: Install protecting front oil seal lip section from any damage. 11. Tighten Tighten crankshaft crankshaft pulley pulley bolt with the following following procedure. procedure. q Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley bolt. a. Apply new engine engine oil to thread and seat seat surfaces surfaces of cranksha crankshaft ft pulley pulley bolt. bolt. b. Tight ighten en cran cranks kshaf haftt pull pulley ey bol bolt. t. : 42.1 N·m (4.3 kg-m, 31 ft-lb) c. d.

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Put a paint paint mark mark on crankshaft crankshaft pulley, pulley, mating mating with with any any one one of six easy to recognize angle marks on bolt flange. Turn Turn another another 60 60 degrees degrees cloc clockwi kwise se (angl (angle e tighteni tightening) ng).. q Check the tightening angle with movement of one angle mark.

M

SEM751G

12. Install Install all removed removed parts in the reverse reverse order order of removal. removal.


H

EM-57

2005 X-Trail

TIMING CHAIN INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required q quantity, quantity, fill to the specified level. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . q Use procedure below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start Start engine. With engine speed increased, check again for fuel leakage at connection conne ction points. – Run engine to check for unusual noise and an d vibration. q NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise no ise during and just after a fter engine start. However, this is normal. Noise will stop after hydraulic pressure rises. q Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. q Bleed air from lines and hoses of applicable lines, such as in cooling system. q After cooling down engine, again check oil/fluid levels including engine oil a nd engine coolant. Refill to the specified level, if necessary. Summary of the inspection items: Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel Exhaust gases

* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.


EM-58

2005 X-Trail

OIL SEAL OIL SEAL Removal and Installation of Valve Oil Seal

PFP:12279

A ABS00CJE

REMOVAL 1. 2. 3.

4.

Remove Remo ve cams camshaf hafts ts.. Refe Referr to EM-37, "CAMSHAFT" . EM Remo Re move ve valv valve e lif lifte ters rs.. Refe Referr to to EM-37, "CAMSHAFT" . Rotate Rota te crankshaft, crankshaft, and and set piston piston whose valve valve oil seal is to be removed removed to TDC. TDC. This will will prevent prevent valve valve from dropping into cylinder. cylinder. C CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain. Remo Re move ve valv valve e coll collet et.. D q Compress valve spring with the valve spring compressor, the attachment and the adapter [SST]. Remove valve collet with a magnet hand. E CAUTION: When working, be careful not to damage valve lifter holes. F

G PBIC1803E

5.

6.

Remove valve Remove valve sprin spring g retain retainer er and and valve valve spri spring. ng. CAUTION: Do not remove valve spring seat from valve spring. Remove Rem ove valve valve oil oil seal seal with with the valve valve oil oil seal seal puller puller [SST] [SST]..

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PBIC0072E

L

INSTALLATION 1. 2.

Apply new engine oil to to valve valve oil oil seal seal joint joint surfac surface e and seal lip. Press in valve valve oil seal seal to to the height “H” shown in the figure figure with with the valve oil seal drift [SST]. Height “H”

M

: 11.8 - 12.4 mm (0.465 - 0.488 in)

PBIC2769E

3.

Instal Installl in the the revers reverse e order order of remo removal val afte afterr this this step. step.


EM-59

2005 X-Trail

OIL SEAL Removal and Installation of Front Oil Seal

ABS00CJF

REMOVAL 1.

2.

Remove Remo ve the the fol follo lowi wing ng part parts. s. q RH undercover q RH front road wheel and tire q Drive belt; Refer to EM-11, "DRIVE BELTS" . q Crankshaft pulley; Refer to EM-49, "TIMING CHAIN" . Remov Re move e front front oil oil seal seal with with a suit suitabl able e tool. tool. CAUTION: Be careful not to damage front cover and crankshaft.

SEM829E

INSTALLATION 1. 2.

Apply new engine engine oil oil to new new front front oil seal joint surface surface and seal lip. lip. Install Install front front oil oil seal seal so that that each each seal lip is is oriented oriented as as shown shown in the figure.

SEM715A

q

Press-fit front oil seal until it is flush with front end surface of front cover with a suitable tool. CAUTION: q Be careful not to damage front cover and crankshaft. q Press-fit oil seal straight to avoid causing burrs or tilting.

SBIA0266E

3.

Instal Installl in the reve reverse rse order order of remo removal val after after this this step step..


EM-60

2005 X-Trail

OIL SEAL Removal and Installation of Rear Oil Seal

ABS00CJG

A

REMOVAL 1. 2. 3. 4.

Remove Rem ove transa transaxle xle assemb assembly ly.. Refe Referr to to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-269, "TRANSAXLE ASSEMBLY" (A/T models). Remove Remove clutch clutch cover and clutch clutch disk (M/T models). models). Refer to CL-14, "CLUTCH DISC, CLUTCH COVER EM AND FLYWHEEL" . Remove Remove drive drive plate (A/T models models)) or flywhee flywheell (M/T models) models) with with power power tool. Refer to to EM-82, "CYLINDER BLOCK" . C Remove Rem ove rear oil seal seal with with a suitab suitable le tool. tool. CAUTION: Be careful not to damage crankshaft and cylinder block. D

INSTALLATION 1. 2.

Apply new engine engine oil oil to n new ew rear rear oil seal joint joint surfac surface e and seal seal lip. lip. Install Install rear rear oil seal seal so so that that each seal lip lip is is oriented oriented as shown shown in in the figure.

E

F

G

H SEM715A

q

Press in rear oil seal to the position as shown in the figure.

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SBIA0281E

q

Press-fit rear oil seal with a suitable drift [outside diameter 102 mm (4.02 in), inside diameter 86 mm (3.39 in)]. CAUTION: q Be careful not to damage crankshaft and cylinder block. q Press-fit oil seal straight to avoid causing burrs or tilting. q Do not touch grease applied onto oil seal lip.

M

SBIA0280E

3.

Instal Installl in the the revers reverse e order order of remo removal val afte afterr this this step. step.


EM-61

L

2005 X-Trail

CYLINDER HEAD CYLINDER HEAD On-Vehicle Service

PFP:11041 ABS00CJH

CHECKING COMPRESSION PRESSURE

1. 2. 3.

Warm Warm up up engine engine tho thorou roughl ghly y. Then, Then, stop it. Rele Re leas ase e fuel fuel pre press ssur ure. e. Ref Refer er to to EC-90, "FUEL PRESSURE RELEASE" . Disco Disconne nnect ct fuel fuel pump fuse fuse to avoid avoid fuel fuel injecti injection on during during meameasurement.

PBIB0508E

4. 5. 6. 7.

Remove Remo ve eng engin ine e cove coverr. Refer Refer to EM-16, "INTAKE MANIFOLD" . Remove Remove ignition ignition coil and spark spark plug from each cylinde cylinderr. Refer Refer to EM-27, "IGNITION COIL" and EM-28, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . Connect Connect an engine engine tachome tachometer ter (not (not required required in use of CONSUL CONSULT T-II). Install Install a compressio compression n tester tester with with an adapter (commerc (commercial ial servic service e tool) onto spark plug hole.

KBIA0130E

q

Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during d uring removal.

SBIA0533E

8.

With accelera accelerator tor pedal fully fully depressed, depressed, turn turn ignition ignition switch switch to “START “START”” for cranking. cranking. When When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression pressure: Unit: kPa (kg/cm2 , psi) /rpm Standard

Minimum

1,250 (12.8, 181) / 250

1,060 (10.8, 154) / 250

Differential limit between cylinders 100 (1.0, 14) / 250

CAUTION: Always use fully a changed battery to obtain the specified engine speed. Revision: 2005 March

EM-62

2005 X-Trail

CYLINDER HEAD If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. A q If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again. EM q If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. – If the added engine oil improves the compression, piston rings may be worn out or damaged. Check C piston rings and replace if necessary. – If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. d amage. Replace valve or valve seat accordingly. accordingly. D q If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder head gasket. E 9. After After inspect inspection ion is compl complete eted, d, instal installl removed removed part parts. s. 10. Start Start the engine, and and confirm that the engine engine runs smoothly smoothly.. 11. Perform Perform trouble trouble diagnosis. diagnosis. If DTC appears, appears, erase it. Refer toEC-94, to EC-94, "TROUBLE DIAGNOSIS" . F q

Removal and Installation

ABS00CJI

G

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L PBIC2424E

1.

Cylinder head assembly

4.

Cyli Cylind nder er head head bolt bolt

2.

Cylinder head gasket

3.

Engine cover bracket

M

REMOVAL 1. 2.

3.

Releas Rele ase e fuel fuel pre press ssur ure. e. Ref Refer er to to EC-90, "FUEL PRESSURE RELEASE" . Drain Drain engi engine ne cool coolant ant and e engi ngine ne oil. oil. Refe Referr to to CO-8, "Changing Engine Coolant" and LU-7, "Changing Engine Oil" . CAUTION: q Perform this step when the engine is cold. q Do not spill engine coolant and engine oil on drive belt. Remove Rem ove the the follo followin wing g compone components nts and and relat related ed part parts. s. q Exhaust manifold and three way catalyst assembly; Refer to EM-20, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . q Intake manifold collector, intake manifold and fuel tube assembly; Refer to EM-16, "INTAKE MANIFOLD" . q Water control valve and housing (water outlet); Refer to CO-22, "THERMOSTAT AND WATER CONTROL VAL VALVE" VE" .


EM-63

2005 X-Trail

CYLINDER HEAD

4. 5. 6. 7.

NOTE: Can be removed and installed even when assembled with cylinder head. Remov Re move e front front cover cover and and tim timing ing chain chain.. Refer Refer to EM-49, "TIMING CHAIN" . Remo Re move ve cams camshaf hafts ts.. Ref Refer er to EM-37, "CAMSHAFT" . Securely Securely support support bottom bottom of cylinder cylinder block with with a jack or suitable suitable tool, tool, and release release the the hoist that that was supsupporting it. Remove Rem ove cyli cylinder nder head head loose loosening ning bolt bolts s in revers reverse e order order as shown in the figure with power tool. q Using the following tool, loosen cylinder head bolts. Bolt with washer : Cylinder Cylinder head bolt wrenc wrench h (commer (commercial cial service tool: J24239-01) Flange bolt : TOR ORX X sock socket et (si (size ze E20 E20))

8.

NOTE: There are two types of cylinder head bolt because of parallel manufacture. Remo Re move ve cyli cylind nder er head head gask gasket. et.

KBIA0058E

INSPECTION AFTER REMOVAL REMOVAL Cylinder Head Bolts Outer Diameter q

Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between “d1” and “d2” exceeds the limit, replace them with a new one. Limit (“d1” – “d2”): 0.23 mm (0.0091 in)

If reduction of outer diameter appears in a position other than “d2”, use it as “d2” point. NOTE: When replacing any cylinder head bolts, it is possible to use them with mixing flange bolt and bolt with washer. q

SBIA0269E

Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checking. Refer to EM-102, "CYLINDER BLOCK DISTORTION" . 1. Wipe off off engine oil and and remove water water scale scale (like deposit) deposit),, gasket, sealant, sealant, carbon, carbon, etc. etc. with a scraper scraper.. CAUTION: Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant. 2. At each each of several several location locations s on bottom bottom surface surface of cylinder cylinder head, measure the distortion in six directions. Limit q

: 0.1 mm (0.004 in)

If it exceeds the limit, replace cylinder head.

PBIC0075E


EM-64

2005 X-Trail

CYLINDER HEAD INSTALLATION 1. 2.

a. b.

: 50.0 N·m (5.1 kg-m, 37 ft-lb) c.

d.

A

Inst Instal alll new new cyli cylind nder er hea head d gask gasket. et. Tighten Tighten cylinder cylinder head head bolts bolts in in numerica numericall order order as shown in the the figure with the following procedure to install cylinder head. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Refer to EM-64, "Cylinder Head Bolts Outer Diameter" . Apply Apply new engi engine ne oil to thre threads ads and and seating seating surfa surfaces ces of mount mount-ing bolts. Tight ghten all all bol boltts.

EM

C

D KBIA0058E

Turn Turn all all bolts bolts 60 degree degrees s clockwi clockwise se (angle (angle tigh tighten tening) ing).. CAUTION: Check and confirm the tightening angle by using the angle wrench [SST] or protractor. Avoid judgment by visual inspection without the tool. Com ompl plet etel ely y loo loosen. sen.

E

F

: 0 N·m (0 kg-m, 0 ft-lb)

e.

G

CAUTION: In this step, loosen bolts in reverse order of that indicated in the figure. Tight ghten all all bol boltts.

PBIC2711E

: 39.2 N·m (4.0 kg-m, 29 ft-lb) f. g. 3.

I

Turn Turn all all bolt bolts s 75 deg degree rees s clock clockwis wise e (angl (angle e tight tightenin ening). g). Turn Turn all bolts 75 degrees degrees clockwise clockwise again (angle tightening) tightening).. Instal Installl in the the revers reverse e order order of remo removal val afte afterr this this step. step.

J

INSPECTION AFTER INSTALLA INSTALLATION TION Inspection for Leaks

K

The following are procedures for checking fluids leak, lubricates leak and exhaust g ases leak. q Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . Use procedure below to check for fuel leakage. q Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel – leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. q Run engine to check for unusual noise no ise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after afte r engine start. However, this is normal. Noise will stop after hydraulic pressure rises. q Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as a s in cooling system. q After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the q specified level, if necessary. necessary.


H

EM-65

2005 X-Trail

L

M

CYLINDER HEAD Summary of the inspection items: Item


Engine running


Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel Exhaust gases



EM-66

2005 X-Trail

CYLINDER HEAD Disassembly and Assembly

ABS00CJJ

A

EM

C

D

E

F

G

H

I PBIC2712E

1.

Valve collet

2.

Valve spring retainer

3.

Valve spring (with valve spring seat)

4.

Valve oil seal

5.

Valve guide

6.

Cylinder head

7.

Valve seat

8.

Valve (INT)

9.

Valve (EXH)

10. Spark plug tube

J

11. Spark plug

DISASSEMBLY 1. 2. 3.

K

Remove Remove spark spark plug plug with with a spark spark plug wrench (commerci (commercial al service service tool). tool). Remo Re move ve valv valve e lif lifte terr. q Identify installation positions, and store them without mixing them up. Remo Re move ve valv valve e coll collet et.. q Compress valve spring with the valve spring compressor, the attachment and the adapter [SST]. Remove valve collet with a magnet hand. CAUTION: When working, be careful not to damage valve lifter holes.

L

M

PBIC1803E

4.

5.

Remove Remove valve valve spring spring retain retainer er and valve spring (with (with valve valve spring spring seat). seat). CAUTION: Do not remove valve spring seat from valve spring. Push valve stem to combus combustion tion chamber chamber side, side, and remove remove valve. valve. q Identify installation positions, and store them without mixing them up.


EM-67

2005 X-Trail

CYLINDER HEAD 6.

Remove Remove valve valve oil oil seal seal with with the the valve valve oil seal puller puller [SST]. [SST].

PBIC0072E

7. 8. 9.

When When valve valve seat seat must must be be repl replace aced, d, refer refer to EM-72, "VALVE SEAT REPLACEMENT" to removal. When When valve valve guide guide must must be repl replace aced, d, refer refer to EM-70, "VALVE GUIDE REPLACEMENT" to removal. Remove Rem ove spark spark plug plug tube, tube, if nece necessa ssary ry.. q Using pliers, remove it from cylinder head. CAUTION: q Be careful not to damage cylinder head. q Do not remove spark plug tube if not necessary. Once removed, spark plug tube cannot be reused because of deformation.

ASSEMBLY 1. 2. 3.

Instal Installl valv valve e guide guide if remo removed ved.. Refer Refer to EM-70, "VALVE GUIDE REPLACEMENT" . Instal Installl valve valve seat seat if remove removed. d. Refer Refer to EM-72, "VALVE SEAT REPLACEMENT" . Inst Instal alll val valve ve oil oil sea seal. l. q Install with the valve oil seal drift [SST] to match dimension in the figure. Heig He ight ht “H “H” ”

: 11. 11.8 8 - 12 12.4 .4 mm (0 (0.4 .465 65 - 0.4 0.488 88 in in))

PBIC2769E

4. 5.

Inst nstall all val valv ve. q Install larger diameter to intake side. Instal Installl valve valve spri spring ng (wit (with h valve valve sprin spring g seat) seat).. q Install smaller pitch (valve spring seat side) to cylinder head side. q Confirm identification color of valve spring. Intake

: Blue

Exhaust

: Yellow

PBIC0525E

6. 7.

Inst Instal alll valve valve spri spring ng ret retai ainer ner.. Inst Instal alll val valve ve coll collet et..


EM-68

2005 X-Trail

CYLINDER HEAD q

q

Compress valve spring with the valve spring compressor, the attachment and the adapter [SST]. Install valve collet with a magnet hand. CAUTION: When working, be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.

A

EM

C PBIC1803E

D

8. 9. a. b.

c.

Inst Instal alll val valve ve lift lifter er.. Inst Instal alll spar spark k plug plug tub tube e if rem remov oved ed.. q Press-fit it into cylinder head with the following procedure: Remove Remove old old sealant sealant from cylinder cylinder head side installati installation on hole. hole. Apply sealant sealant all round on spark spark plug tube tube within within approximate approximately ly 12 mm (0.47 in) width from edge of spark plug tube on the press-fit side. Use Genuine High Strength Locking Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . Using a drift, drift, press-fit press-fit spark spark plug plug tube tube so that height height is as as same same as “H” shown in the figure.

E

F

G PBIC2713E

H

Standard Stand ard press-fit height “H”: 41.2 - 42.2 mm (1.622 - 1.661 1.66 1 in) I

CAUTION: q When press-fitting, be careful not to deform spark plug tube. q After press-fitting, wipe off any protruding sealant on top surface of cy linder head. 10. Install spark plug with a spark plug plug wrench (commercial (commercial service service tool).

Inspection After Disassembly

J ABS00CJK

VALVE DIMENSIONS q

q

K

Check dimensions of each valve. For dimensions, refer to EM110, "Valve Dimensions" . If dimensions are out of the standard, replace valve.

L

M

SEM188A


EM-69

2005 X-Trail

CYLINDER HEAD VALVE GUIDE CLEARANCE Valve Stem Diameter Measure the diameter of valve stem with a micrometer. Standard Inttake In

: 5.9 .965 65 - 5. 5.98 980 0 mm (0. 0.23 2348 48 - 0. 0.2 235 354 4 in in))

Exha Ex haus ustt

: 5.9 5.955 55 - 5.9 5.970 70 mm (0 (0.2 .2344 344 - 0.2 0.2350 350 in in))

SEM938C

Valve Guide Inner Diameter Measure the inner diameter of valve guide with a bore gauge. Standard Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 0. 2369 in)

Valve Guide Clearance (Valve (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter). Valve guide clearance: Standard Inttak In ake e

: 0.0 0.020 20 - 0. 0.05 053 3 mm mm (0. (0.00 0008 08 - 0.0 0.002 021 1 in in)

Exhaust Exh aust

: 0.030 0.030 - 0.063 0.063 mm (0.0 (0.0012 012 - 0.002 0.0025 5 in) in)

Limit

q

Intake

: 0.08 mm (0.003 in)

Exha Ex haus ustt

: 0.0 0.09 9 mm mm (0. (0.00 004 4 in) in)

If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, refer to EM70, "VALVE GUIDE REPLACEMENT" .

VALVE GUIDE REPLACEMENT When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide . 1. To remove remove valve valve guide, heat cylind cylinder er head head to 110 to 130°C (230 to 266°F) by soaking in heated oil.

SEM008A


EM-70

2005 X-Trail

CYLINDER HEAD 2.

Drive Drive out out valve valve guide guide with with a press press [unde [underr a 20 kN (2 (2 ton, 2.2 2.2 US ton, 2.0 lmp ton) force] or hammer and valve guide drift (commercial service tool). CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.

A

EM

C SEM931C

D

3.

Ream cylind Ream cylinder er head head valve valve guide guide hole hole with with a valve valve guide guide reamer reamer (commercial service tool). Valve guide hole diameter (for service parts):

E

Intake and exhaust : 10.175 - 10.196 mm (0.4006 - 0.4014 in) F

G SEM932C

4.

Heat cyl Heat cylin inde derr hea head d to 110 to to 130 130°C (230 to 266°F) by soaking in heated oil.

H

I

J

SEM008A

5.

Using a valve valve guide guide drift drift (comme (commercial rcial service service tool), tool), press press valve valve guide from camshaft side to dimensions as shown in the figure. L

Projection “H”: Intake

: 10.1 - 10.3 mm (0.398 - 0.406 in)

Exhaust

: 10.0 - 10.4 mm (0.394 - 0.409 in)

M

CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. PBIC2187E

6.

K

Apply Apply reame reamerr finish finish to valve valve guide guide w with ith a valve valve guid guide e reamer reamer (commercial service tool). Standard Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

SEM932C


EM-71

2005 X-Trail

CYLINDER HEAD VALVE SEAT CONTACT q

q

q

q

After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface. Check if the contact area band is continuous all around the circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat. Refer to EM-72, "VALVE SEAT REPLACEMENT" .

SBIA0322E

VALVE SEAT REPLACEMENT When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat. sea t. 1. Bore out old old seat until until it collapse collapses. s. Boring Boring should not not continue continue beyond the the bottom face face of the seat recess recess in cylinder head. Set the machine depth stop sto p to ensure this. Refer to EM-113, "Valve Seat" . CAUTION: Prevent to scratch cylinder head by excessive boring. 2. Ream cylinder cylinder head recess recess diamete diameterr for for servic service e valve valve seat. seat. Oversize [0.5 mm (0.020 in)]

q

Int ntak ake e

: 37. 37.00 000 0 - 37. 37.0 016 mm (1. (1.4 456 567 7 - 1.4 1.457 573 3 in in)

Exhaus Exh austt

: 32.00 32.000 0 - 32.0 32.016 16 mm mm (1.2 (1.2598 598 - 1.2605 1.2605 in)

Be sure to ream in circles concentric to the valve guide center. cente r. This will enable valve seat to fit correctly.

SEM795A

3.

Heat cyl Heat cylin inder der head head to to 110 110 to to 130 130°C (230 to 266°F) by soaking in heated oil.

SEM008A

4.

Provide Provide valve valve seats seats cooled well well with with a dry ice. ice. Press-fit Press-fit valve valve seats seats into cylinder cylinder head. CAUTION: q Avoid directly to touching cold valve seats. q Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.


EM-72

2005 X-Trail

CYLINDER HEAD 5.

Using a valve valve seat seat cutter cutter set (commerc (commercial ial servic service e tool) tool) or a valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to EM-113, "Valve Seat" . CAUTION: When using a valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with the cutter or cutting many different times may result in stage valve seat.

A

EM

C SEM934C

D

6. 7.

Using Using comp compoun ound, d, grind grind to adjus adjustt valve valve fittin fitting. g. Check Che ck agai again n for for norm normal al contact contact.. Refer Refer to EM-72, "VAL "VALVE VE SEAT S EAT CONTACT" . E

VALVE SPRING SQUARENESS q

Set a try square along the side of valve spring and rotate valve spring. Measure the maximum clearance between the top of valve spring and try square. CAUTION: Do not remove valve spring seat from valve spring. Limit

q

F

G

: 1.9 mm (0.075 in)

If it exceeds the limit, replace valve spring (with valve spring seat).

H PBIC0080E

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD q

I

Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Do not remove valve spring seat from valve spring.

J

K

L SEM113

M

Standard: Items Free height Installation height Installation load Height during valve open Load with valve open Identification color q

Intake

Exhaust

44.84 - 45.34 mm (1.7654 - 1.7850 in)

45.28 - 45.78 mm (1.7827 - 1.8024 in)

35.30 mm (1.390 in)

35.30 mm (1.390 in)

151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)

151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)

24.94 mm (0.9819 in)

26.39 mm (1.0390 in)

358 - 408 N (36.5 - 41.6 kg, 80 - 92 lb)

325 - 371 N (33.1 - 37.8 kg, 73 - 83 lb)

Blue

Yellow

If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).


EM-73

2005 X-Trail

ENGINE ASSEMBLY ENGINE ASSEMBLY ASSEMBLY Removal and Installation (2WD Models)

PFP:10001 ABS00DAN

PBIC2747E

1.

Rear engine mounting insulator

2.

Rubber seat

3.

Rear engine mounting bracket

4.

RH engine mounting insulator

5.

RH engine mounting bracket

6.

Front engine mounting bracket

7.

Front engine mounting insulator

8.

Grommet

9.

Center member

10. LH en engine mounting in insulator

11. Stopper

WARNING: q Situate the vehicle on a flat and solid surface. Place chocks at front and back of rear wheels. q Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not q equipped. CAUTION: q Always be careful to work safely, safely, avoid forceful or uninstructed operations. q Do not start working until exhaust system and coolant are cool enough. If items or work required are not covered by the engine section, refer to the applicable sections. q Always use the support point specified for lifting. q Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for q unavoidable reasons, support at the rear axle jacking jac king point with a transmission jack or similar tool before starting work, in preparation for the backward shift of center c enter of gravity. q For supporting points for lifting and jacking point at rear axle, refer to GI-40, "Garage Jack and Safety Stand" .


EM-74

2005 X-Trail

ENGINE ASSEMBLY REMOVAL Outline

A

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine e ngine and the transaxle. EM

Preparation 1. 2. 3.

4.

5. 6.

Remove Remo ve hood hood asse assemb mbly ly.. Refe Referr to BL-12, "HOOD" . Rele Re leas ase e fuel fuel pre press ssur ure.R e.Refe eferr to EC-90, "FUEL PRESSURE RELEASE" . Drain Drain engin engine e coolan coolantt from from radia radiator tor.. Refer Refer to CO-8, "Changing Engine Coolant" . CAUTION: q Perform this step when the engine is cold. q Do not spill engine coolant on drive belt. Remo Re move ve the foll follow owin ing g par parts ts.. q LH and RH undercovers q Front road wheels and tires q Battery and battery tray; Refer to SC-4, "BATTERY" . q Drive belt; Refer to EM-11, "DRIVE BELTS" . q Air duct and air cleaner case assembly; Refer to EM-14, "AIR CLEANER AND AIR DUCT" . q Alternator and alternator bracket; Refer to SC-20, "CHARGING SYSTEM" . q Radiator and radiator cooling fan assembly; Refer to CO-11, "RADIATOR" . Disconnect Disconnect engine engine room room harness harness from from the engine side and and set it aside for for easier easier work. work. Disconnect Disconnect all vacuum vacuum hoses hoses and air air hoses hoses connected connected to the the vehicle vehicle side side at the engine side.

C

D

E

F

G

H

Engine Room LH 1. 2. 3. 4.

Disconnect Disconnect fuel feed feed hoses, hoses, and plug plug them to prevent prevent fuel fuel from from draining. draining. Refer to to EM-30, "FUEL INJECTOR AND FUEL TUBE" . Disconnect Disconnect heater heater hoses, hoses, and install install plugs plugs them them to prevent prevent engine engine coolant coolant from drainin draining. g. Refer toCO-22, toCO-22, "THERMOSTAT "THERMOSTA T AND WA WATER TER CONTROL C ONTROL VALVE" . Discon Disconnect nect control control cabl cable e from from transax transaxle. le. Refe Referr to AT-251, "SHIFT CONTROL SYSTEM" . Disconnect Disconnect B termina terminall harness harness of starter starter motor. motor. Refer Refer to SC-9, "STARTING SYSTEM" .

Engine Room RH 1. 2.

3.

Remove reserv Remove reservoir oir tan tank k of engin engine e coolan coolant. t. Refe Referr to CO-11, "RADIATOR" . Remove Remove A/C compressor compressor with with piping piping connected connected from the engine. engine. Tempor Temporarily arily secure secure it on the vehicle vehicle side side with a rope to avoid putting load on it. Refer to ATC-122, "Removal and Installation of Compressor" (Automatic A/C models) or MTC-82, "Removal and Installation of Compressor" (Manual A/C models). Remove Remove power steerin steering g oil pump with with piping connected connected from from the engine. engine. Tempor Temporarily arily secure secure it on the vehicle side with a rope to avoid putting putt ing load on it. Refer to PS-33, "HYDRAULIC LINE" .

Vehicle Underbody 1. 2. 3. 4. 5. 6.

Remove Remo ve exh exhaus austt front front tube tube.. Refe Referr to EX-2, "EXHAUST SYSTEM" . Remove Remove rear plate plate cover from from oil oil pan (upper). (upper). Then Then remove bolts bolts fixing fixing drive drive plate to torque torque converter converter.. Refer to EM-22, "OIL PAN AND OIL STRAINER" and AT-269, "TRANSAXLE ASSEMBLY" . Remove Remove transaxle transaxle joint joint bolts bolts which which pierce pierce at oil pan (upper) (upper) lower lower rear rear side. side. Refer to AT-269, "TRANSAXLE ASSEMBLY" . Remove Remove front front wheel sensor (LH and and RH) for for ABS ABS from steerin steering g knuckle. knuckle. Refer Refer toBRC-36, to BRC-36, "WHEEL SENSORS" . Remove Remove brake caliper caliper assembly assembly with with piping connecte connected d from steering steering knuckle. knuckle. Tempor Temporarily arily secure secure it on the vehicle side with a rope to avoid load on it. Refer to BR-25, "FRONT DISC BRAKE" . Remove Remove LH and RH RH drive drive shafts shafts from from steerin steering g knuckle. knuckle. Refer to FAX-13, "FRONT DRIVE SHAFT" .

Removal 1.

Install Install engine engine slingers slingers into into front-left front-left of cylinder cylinder head and rearrear-right right of cylind cylinder er head.


EM-75

2005 X-Trail

I

J

K

L

M

ENGINE ASSEMBLY q

Use alternator bracket mounting bolt holes for the front side. Slinger bolts: Front : 57.9 N·m (5.9 kg-m, 43 ft-lb) Rear : 28.0 N·m (2.9 kg-m, 21 ft-lb)

SBIA0271E

2. 3.

Lift with a hoist hoist and and secure secure the the engine engine in appropr appropriate iate position. position. Use a manual manual lift lift table table caddy caddy (comm (commercia erciall service service tool) or equivequivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.

KBIA0256E

4. 5. 6.

Remove RH engi Remove engine ne mounti mounting ng insula insulator tor with with powe powerr tool. tool. Remove Rem ove LH engi engine ne mounti mounting ng through through-bol -boltt with with power power tool. tool. Remove Rem ove center center member member with with power power too tool. l.

PBIC2748E

7.

Remove Remove the engine engine and the the transaxle transaxle assembly assembly from the the vehicle vehicle downward downward by carefully carefully operatin operating g supporting tools. CAUTION: q During the operation, make sure that no part interferes with the vehicle side. q Before and during this lifting, always check if any harnesses are left connected. q During the removal operation, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. q If necessary, support the vehicle by setting jack or suitable tool at the rear. 8. Re Remo move ve sta start rter er mot motor or.. Refer Refer to SC-9, "STARTING SYSTEM" . 9. Rem Remove ove rear rear engine engine mounti mounting ng bracke bracket. t. 10. Separate Separate the engine engine and the transa transaxle. xle. Refer Refer toAT-269, to AT-269, "TRANSAXLE ASSEMBLY" .

INSTALLATION Note the following, and install in the reverse order of removal. Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting q insulator. q When installation directions are specified, install parts according to the direction marks on them referring to the figure of components. Refer to EM-74, "Removal and Installation (2WD Models)" . Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts. q


EM-76

2005 X-Trail

ENGINE ASSEMBLY INSPECTION AFTER INSTALLA INSTALLATION TION Inspection for Leaks

A

The following are procedures for checking fluids leak, lubricates leak and exhaust g ases leak. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required q EM quantity, fill to the specified level. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . q Use procedure below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel C leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points. – Run engine to check for unusual noise no ise and vibration. q D Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids q including engine oil and engine coolant. q Bleed air from lines and hoses of applicable lines, such as a s in cooling system. E q After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. necessary. Summary of the inspection items: Item

F


Engine running


Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel Exhaust gases

G

H


I

J

K

L

M


EM-77

2005 X-Trail

ENGINE ASSEMBLY Removal and Installation (AWD Models)

ABS00CJL

PBIC2392E

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

11.

Grommet

10. Stopper

WARNING: Situate the vehicle on a flat and solid surface. q q Place chocks at front and back of rear wheels. q Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped. CAUTION: Always be careful to work safely, safely, avoid forceful or uninstructed operations. q Do not start working until exhaust system and engine coolant are cool enough. q If items or work required are not covered by the engine section, refer to the applicable sections. q q Always use the support point specified for lifting. q 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 jac king point with a transmission jack or similar tool before starting work, in preparation for the backward shift of center c enter of gravity. For supporting points for lifting and jacking point at rear axle, refer to GI-40, "Garage Jack and q Safety Stand" .

REMOVAL Outline Remove the engine, the transaxle and the transfer assembly with front suspension member from the vehicle downward. Separate front suspension member, and then separate the engine and the transaxle.

Preparation 1.

Remo Re move ve hoo hood d asse assemb mbly ly.. Refer Refer to BL-12, "HOOD" .


EM-78

2005 X-Trail

ENGINE ASSEMBLY 2. 3.

4.

5. 6.

Releas Rele ase e fuel fuel pre press ssur ure. e. Ref Refer er to to EC-90, "FUEL PRESSURE RELEASE" . Drain Drain engin engine e coolan coolantt from from radia radiator tor.. Refer Refer to CO-8, "Changing Engine Coolant" . CAUTION: q Perform this step when the engine is cold. q Do not spill engine coolant on drive belt. Remo Re move ve the foll follow owin ing g par parts ts.. q LH and RH undercovers q Front road wheels and tires q Battery and battery tray; Refer to SC-4, "BATTERY" . q Drive belt; Refer to EM-11, "DRIVE BELTS" . q Air duct and air cleaner case assembly; Refer to EM-14, "AIR CLEANER AND AIR DUCT" . q Alternator; Refer to SC-20, "CHARGING SYSTEM" . q Radiator and radiator cooling fan assembly; Refer to CO-11, "RADIATOR" . Disconnect Disconnect engine engine room room harness harness from from the engine side and and set it aside for for easier easier work. work. Disconnect Disconnect all vacuum vacuum hoses hoses and air air hoses hoses connected connected to the the vehicle vehicle side side at the engine side.

2. 3. 4. 5. 6.

EM

C

D

E

F

Engine Room LH 1.

A

Disconnect Disconnect fuel feed feed hose, hose, and plug itit to preven preventt fuel from draining. draining. Refer Refer toEM-30, to EM-30, "FUEL INJECTOR AND FUEL TUBE" Disconnect Disconnect heater heater hoses, hoses, and and install install plugs plugs them to prevent prevent engine engine coolant coolant from from draining. draining. Disconnect Disconnect control control cable cable from from transax transaxle le (A/T (A/T models). models). Refer Refer to AT-251, "SHIFT CONTROL SYSTEM" . Disconnect Disconnect clutch clutch operati operating ng cylinder cylinder from from transaxle transaxle,, and move move it aside aside (M/T models) models).. Refer to to CL-10, "OPERATING CYLINDER" . Disconnect Disconnect shift and select select cable cable from from transax transaxle le (M/T (M/T models) models).. Refer Refer toMTto MT-14, 14, "CONTROL LINKAGE" . Disconnect Disconnect B termina terminall harness harness of starter starter motor. motor. Refer Refer to SC-9, "STARTING SYSTEM" .

G

H

I

Engine Room RH 1. 2.

Remove reserv Remove reservoir oir tan tank k of engin engine e coolan coolant. t. Refe Referr to CO-11, "RADIATOR" . Remove Remove A/C compressor compressor with with piping piping connected connected from the engine. engine. Tempor Temporarily arily secure secure it on the vehicle vehicle side side with a rope to avoid putting load on it. Refer to ATC-122, "Removal and Installation of Compressor" (Automatic A/C models) or MTC-82, "Removal and Installation of Compressor" (Manual A/C models).

J

Vehicle Underbody

K

1. 2. 3. 4.

L

5. 6. 7. 8. 9.

Remove Remo ve exh exhaus austt front front tube tube.. Refe Referr to EX-2, "EXHAUST SYSTEM" . Remo Re move ve pro propel pelle lerr shaf shaft. t. Ref Refer er to to PR-3, "REAR PROPELLER SHAFT" . Remove Remove steerin steering g lower lower joint from steering steering gear gear.. Refer Refer to PS-12, "STEERING COLUMN" . Disconnect Disconnect power power steerin steering g fluid piping at a point point between between the vehicl vehicle e and the engine. Refer to PS-33, "HYDRAULIC LINE" . Remove Remove rear plate plate cover from from oil pan pan (upper). (upper). Then remove remove bolts bolts fixing drive drive plate plate to torque converter converter (A/T models). Refer to EM-22, "OIL PAN AND OIL STRAINER" and AT-269, "TRANSAXLE ASSEMBLY" . Remove Remove transaxle transaxle joint bolts bolts which which pierce pierce at oil pan (upper) (upper) lower lower rear rear side. side. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-269, "TRANSAXLE ASSEMBLY" (A/T models). Remove Remove front front wheel sensor (LH and and RH) for for ABS ABS from steerin steering g knuckle. knuckle. Refer Refer toBRC-36, to BRC-36, "WHEEL SENSORS" (ABS) or BRC-96, "WHEEL SENSORS" (VDC/TCS/ABS). Remove Remove brake caliper caliper assembly assembly with with piping connecte connected d from steering steering knuckle. knuckle. Tempor Temporarily arily secure secure it on the vehicle side with a rope to avoid load on it. Refer to BR-25, "FRONT DISC BRAKE" . Remove Remove lower lower ends ends of left left and right right strut strut from from steeri steering ng knuckle. knuckle. Refer Refer to to FSU-6, "FRONT SUSPENSION ASSEMBLY" .

Removal 1.

Install Install engine engine slingers slingers into into front-left front-left of cylinder cylinder head and rearrear-right right of cylind cylinder er head.


EM-79

2005 X-Trail

M

ENGINE ASSEMBLY q

Use alternator bracket mounting bolt holes for the front side. Slinger bolts: Front : 57.9 N·m (5.9 kg-m, 43 ft-lb) Rear : 28.0 N·m (2.9 kg-m, 21 ft-lb)

SBIA0271E

2. 3.

Lift with a hoist hoist and and secure secure the the engine engine in appropr appropriate iate position. position. Use a manual manual lift lift table table caddy caddy (comm (commercia erciall service service tool) or equivequivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.

KBIA0256E

4. 5.

Remove RH engi Remove engine ne mounti mounting ng insula insulator tor with with powe powerr tool. tool. Remove Rem ove LH engi engine ne mounti mounting ng through through-bol -boltt with with power power tool. tool.

PBIC2188E

6. 7.

Remove moun Remove mountin ting g bolts bolts at front front e end nd of cente centerr member member with with power tool. Remove Rem ove front front suspe suspensi nsion on member member mount mounting ing nuts nuts and bolt bolts. s. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" .

KBIA0270E

8.

Remove Remove the engine, engine, the transaxl transaxle e and the transfer transfer assembly assembly with front front suspension suspension member member and and center member from the vehicle downward by carefully operating supporting tools. CAUTION: q During the operation, make sure that no part interferes with the vehicle side. q Before and during this lifting, always check if any harnesses are left connected. q During the removal operation, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. q If necessary, support the vehicle by setting a jack or suitable tool at the rear.


EM-80

2005 X-Trail

ENGINE ASSEMBLY 9.

Remove Remove power steeri steering ng oil pump pump with piping piping connected connected from from the engine. engine. Move Move it aside aside on front front suspensuspension member. Refer to PS-33, "HYDRAULIC LINE" . A 10. Remove front engine mounting and rear engine mounting through-bolts through-bolts to remove remove front suspension member and center member with power tool. 11. Remove Remove starter starter motor motor with power power tool. tool. Refer Refer to SC-9, "STARTING SYSTEM" . EM 12. Separate Separate the engine engine and and transaxle. transaxle. Refer Refer to to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT269, "TRANSAXLE ASSEMBL ASSEMBLY" Y" (A/T models). C

INSTALLATION Note the following, and install in the reverse order of removal. q Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator. q When installation directions are specified, install parts according to the direction marks on them referring to figure of components. Refer to EM-78, "Removal and Installation (AWD Models)" . Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts. q

INSPECTION AFTER INSTALLA INSTALLATION TION Inspection for Leaks

Summary of the inspection items: Engine running


Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Exhaust gases

H

I

J

L

M



G

K


Fuel

E

F

The following are procedures for checking fluids leak, lubricates leak and exhaust g ases leak. q Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . Use procedure below to check for fuel leakage. q Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel – leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. q Run engine to check for unusual noise no ise and vibration. q Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as a s in cooling system. q After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the q specified level, if necessary. necessary. Item

D

EM-81

2005 X-Trail

CYLINDER BLOCK CYLINDER BLOCK Disassembly and Assembly

PFP:11010 ABS00CJM

PBIC3973E

1.

Cylinder block

2.

O-ring

3.

Crankshaft position sensor (POS)

4.

Knock sensor

5.

Water drain plug

6.

Lower cylinder block

7.

Lower cylinder block mounting bolt

8.

Snap ring

9.

Connecting rod

10. Connecting rod bearing

11.

Connecting rod bearing cap

12.

Connecting rod bolt

13. Piston

14.

O Oiil ring

15.

Second ring Se

16. T To op ring

17. Piston pin

18.

Thrust bearing

19. Main bearing upper

20. Crankshaft

21.

Crankshaft key

22. Main bearing lower

23. Rear oil seal

24.

Pilot convertor (A/T models)

25. Signal plate

26. Drive plate (A/T models)

27.

Reinforce plate (A/T models)

28. Flywhee Flywheell (M/T (M/T models models))


EM-82

2005 X-Trail

CYLINDER BLOCK

A

EM

C

D

E

F

G

H

PBIC2714E

1.

Cylinder block

2.

4.

Conn Connec ecto torr p pro rote tect ctor or cap cap

Gasket

3.

I

Cylinder block heater

DISASSEMBLY

J

NOTE: Explained here is how to disassemble with an engine stand supporting mating surface of transaxle. When using different type of engine stand, note with difference in steps and etc. 1. Remove Remove the engine, engine, the transaxle transaxle and the the transfer transfer (AWD (AWD models) models) assembly assembly from from the vehicle vehicle,, and separate the transaxle and the transfer (AWD models) assembly from the engine. Refer to EM-74, "ENGINE ASSEMBLY" . 2. Remove Remove clutch clutch cover and clutch clutch disc (M/T models). models). Refer to CL-14, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" . 3. Remove Remove flywheel flywheel (M/T models) models) or drive drive plate plate (A/T (A/T models) models) with power tool. q Secure crankshaft with a stopper plate, and remove mounting bolts. q Using the following TORX socket, loosen mounting bolts. Flywheel (M/T models) : size T55 (commercial service tool) Drive plate (A/T models) : size E20

PBIC2352E

CAUTION: Be careful not to damage or scratch s cratch drive plate (A/T models) and contact surface for clutch disc of flywheel (M/T models). NOTE: The flywheel, two block construction, allows movement in response to transaxle side pressure, or when twisted in its rotational direction. Therefore, some amount of noise is normal.


EM-83

2005 X-Trail

K

L

M

CYLINDER BLOCK 4.

5. 6.

Lift the engine engine with with a hoist to install install it onto onto widely widely use use engine engine stand. CAUTION: q Use the engine stand that has a load capacity [approximately 150kg (331 lb) or more] large enough for supporting the engine weight. q Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning. NOTE: The figure shows an example of widely use engine stand that can support mating surface of transaxle with flywheel (M/T models) or drive plate (A/T models) removed. Drai Drain n engi engine ne oil. oil. Re Refer fer to LU-7, "Changing Engine Oil" . Drain Drain engine engine coolant coolant by removi removing ng water water drain plug from inside inside of the engine.

PBIC0085E

PBIC2716E

7. 8.

9.

Remove Remov e cylin cylinder der head head with with pow power er tool. tool. Ref Refer er to to EM-62, "CYLINDER HEAD" . Remo Re move ve knoc knock k sen senso sorr. CAUTION: Carefully handle knock sensor avoiding shocks. Remove Rem ove cranks crankshaf haftt posit position ion sensor sensor (POS). (POS). CAUTION: q Avoid impacts such as a dropping. q Do not disassemble. q Keep it away from metal particles. q Do not place the sensor in a location where it is exposed to magnetism.

PBIC2191E

10. Remove Remove pilot converter converter using using the pilot bushing bushing puller [SST] [SST] or suitable tool. (A/T models) NOTE: M/T models have no pilot bushing.

PBIC2717E

11. Remove piston piston and connecting rod assembly assembly with the following procedure: q Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to EM-99, "CONNECTING ROD SIDE CLEARANCE" . a. Position Position cranksha crankshaft ft pin corre correspondi sponding ng to connecti connecting ng rod to be removed removed onto onto the bottom bottom dead center center.. Revision: 2005 March

EM-84

2005 X-Trail

CYLINDER BLOCK b. c.

Remove Remo ve conne connect ctin ing g rod rod cap. cap. Using Using a hammer hammer handle handle or sim simila ilarr tool, tool, push pist piston on and connec connectting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

A

EM

C

PBIC0259E

12. Remove Remove connecti connecting ng rod rod bearings bearings.. CAUTION: Identify installation positions, and store them without mixing them up. 13. Remove Remove piston piston rings rings form form piston. piston. q Before removing piston rings, check the piston ring side clearance. Refer to EM-100, "PISTON RING SIDE CLEARANCE" . q Use a piston ring expander (commercial service tool). CAUTION: q When removing piston rings, be careful not to damage the piston. q Be careful not to damage piston rings by expanding them excessively exces sively..

D

E

F

G

H

I PBIC0087E

J

14. Remove Remove piston from connecti connecting ng rod with the following following procedure: procedure: a. Using Using snap snap ring ring plie pliers, rs, remove remove snap snap rings rings.. K

L

M PBIC1638E

b.

Heat eat pis pisto ton n to to 60 60 to to 70 70°C (140 to 158°F) with an industrial use drier or equivalent.

PBIC1639E


EM-85

2005 X-Trail

CYLINDER BLOCK c.

Push Push out piston piston pin pin with a stick stick of outer outer diame diameter ter appro approxim ximate ately ly 19 mm (0.75 in).

PBIC0262E

15. Remove Remove lower cylind cylinder er block mounting mounting bolts. bolts. q Before loosening lower cylinder block mounting bolts, measure crankshaft end play. Refer to EM-99, "CRANKSHAFT END PLAY" q Loosen them in reverse order as shown in the figure, and remove them. NOTE: Use TORX socket (size E14) for bolts No. 1 to 10.

PBIC2718E

16. Remove Remove lower lower cylinder cylinder block. block. q Use the seal cutter [SST: KV1011 KV10111100 (J37228)] or suitable tool to cut liquid gasket for removal. CAUTION: Be careful not to damage the mounting surface. 17. Rem Remove ove cran cranksh kshaft aft.. CAUTION: q Be careful not damage or deform signal plate mounted on crankshaft. q When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface. q Do not remove signal plate unless it is necessary to do so. NOTE: When removing or installing signal plate, use TORX socket (size T30). SBIA0275E 18. Pull rear rear oil seal out from from rear rear end of crankshaft. crankshaft. NOTE: When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull the oil seal installed between crankshaft and cylinder block out. CAUTION: Be careful not to damage crankshaft and cylinder cy linder block. 19. Remove main main bearings and thrust thrust bearings from cylinder block and lower cylinder cylinder block. CAUTION: Identify installation positions, and store them without mixing them up.

ASSEMBLY 1.

Fully Fully air-blow air-blow engine engine coolant coolant and engine engine oil passages passages in in cylinder cylinder block, block, cylinder cylinder bore bore and crankcase crankcase to remove any foreign material.


EM-86

2005 X-Trail

CYLINDER BLOCK

2.

CAUTION: Use a goggles to protect your eye. Instal Installl each each plug plug to cylin cylinder der bloc block k as shown shown in in the ffigu igure. re. q Apply liquid gasket to the thread of water drain plug “A”. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . NOTE: Do not apply liquid gasket to the th e thread of plug “B”.

A

EM

C

D PBIC2770E

q

3. a. b.

E

Tighten each plug as specified below. Part

Washer

Tightening torque

A

No

9.8 N·m (1.0 kg-m, 87 in-lb)

B

Yes

53.9 N·m (5.5 kg-m, 40 ft-lb)

Install Install main main bearings bearings and thrust thrust bearing bearings s with with the following following procedur procedure: e: Remove Remove dust, dirt, dirt, and engine engine oil on the the bearing mating mating surface surfaces s of cylinder cylinder block block and lower lower cylinder cylinder block. Install Install thrust thrust bearings bearings to to the both sides of the No. 3 journal journal housing on cylinder block. q Install thrust bearings with the oil groove facing crankshaft arm (outside).

F

G

H

I

J

PBIC0264E

c.

4.

Instal Installl the main main bearin bearings gs payin paying g attenti attention on to the dire directi ction. on. q Main bearing with an oil hole and groove goes on cylinder block. The one without them goes on lower cylinder block. q Only main bearing (on cylinder block) for No. 3 journal has different specifications. q Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. q When installing, align main bearing stopper to the notch. q Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

L

M

PBIC2193E

Instal Installl signal signal plate plate to cran cranksh kshaft aft ifif remov removed. ed.


EM-87

K

2005 X-Trail

CYLINDER BLOCK a.

b.

5.

6. 7. a.

b. i. ii.

Positi Position on cranks crankshaf haftt and signal signal plat plate e using using a dowel dowel pin, pin, and tighten mounting bolts. NOTE: Dowel pin of crankshaft and signal plate is provided as a set for each. If dowel pin is not available (when reusing crankshaft and signal plate), use M6 bolt [length 10 mm (0.39 in) or more] as a substitute. Rem emov ove e dow dowe el pin pin.. CAUTION: Be sure to remove dowel pin. SBIA0278E Instal Installl cran cranksh kshaft aft to cylind cylinder er block. block. smoothly. q While turning crankshaft by hand, make sure that it turns smoothly. CAUTION: Do not install rear oil seal yet. Inspect Inspect outer outer diameter diameter of lower lower cylinder cylinder block mounting mounting bolts. bolts. Refer Refer to EM-107, "LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER" . Install Install lower cylinder cylinder block with the follow following ing procedure: procedure: Apply liquid liquid gasket gasket w with ith tthe he tube tube presser presser [SST: [SST: WS3993000 WS39930000 0 ( — )] to lowe lowerr cyl cylin inde derr blo block ck as sho shown wn in the the fig figur ure. e. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly. quickly. NOTE: PBIC2719E Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block. Tighten Tighten lower lower cylind cylinder er block block mounting mounting bolts bolts with with the following following procedur procedure: e: Apply Apply new new engine engine oil oil to thre threads ads and and seat seat surfa surfaces ces of of the m mount ounting ing bolt bolts. s. Tighten Tighten M8 M8 bolts bolts in numerical numerical order from No. No. 11 11 to 22 in the figure. : 25.1 N·m (2.6 kg-m, 19 ft-lb) CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface. NOTE: There are more processes to complete the tightening of mounting bolts. However stop procedure here to install rear oil seal. PBIC2718E

c. d. i.

Inst Instal alll rear rear oil oil sea seal. l. Re Refer fer to EM-61, "Removal and Installation of Rear Oil Seal" . Restart Restart tightenin tightening g of lower cylinder cylinder block block mounting mounting bolts bolts with with the following following procedur procedure: e: Tighten ighten M10 M10 bolt bolts s in nume numeri rical cal orde orderr from from No. No. 1 tto o 10 in in the figfigure. : 39.2 N·m (4.0 kg-m, 29 ft-lb)

PBIC2718E


EM-88

2005 X-Trail

CYLINDER BLOCK ii.

Turn Turn M10 M10 bolts bolts 60 degree degrees s clockw clockwise ise (ang (angle le tight tighteni ening) ng) in in numerical order from No. 1 to 10 in the figure. CAUTION: Check and confirm the tightening angle by using the angle wrench [SST] or protractor. Avoid judgment by visual inspection without the tool.

A

EM

C PBIC2720E

D q q q

8. a. b.

c.

After installing the mounting bolts, make sure that crankshaft can be rotated smoothly by hand. Wipe off completely any protruding liquid gasket on front side of the engine. Check crankshaft end play. Refer to EM-99, "CRANKSHAFT END PLAY" . Install Install piston to connecti connecting ng rod rod with with the follow following ing procedure: procedure: Using snap ring ring pliers, pliers, instal installl new snap snap ring ring to the groove of the piston piston rear rear side. side. q Insert it fully into groove to install. Asse Assemb mble le pis pisto ton n to con connec necti ting ng rod rod.. q Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approximately 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin into piston and connecting rod. q Assemble so that the front mark on the piston head and the oil holes and the cylinder number on connecting rod are positioned as shown in the figure. Instal Installl new snap snap ring ring to the the groov groove e of the pist piston on front front side side.. q Insert it fully into groove to install. q After installing, make sure that connecting rod moves smoothly.

E

F

G

H

I

J

PBIC2194E

9.

Using a piston piston ring ring expander expander (commercia (commerciall service service tool), install install piston piston rings. rings. CAUTION: q Be careful not to damage piston. q Be careful not to damage piston rings by expanding them excessively. q Position each ring with the gap as shown in the figure referring to the piston front mark. q Install second ring with the stamped surface facing upward.

L

M

Stamped mark: Top ring

:—

Second ring

: 2F

NOTE: If there is no stamped mark on piston ring, no specific orientation is required for installation. PBIC2195E

10. Inspect Inspect outer diameter diameter of connecting connecting rod rod bolts. bolts. Refer to EM-107, "CONNECTING ROD BOLT OUTER DIAMETER" . 11. Install Install connecting connecting rod bearings bearings to connecting connecting rod and connecting connecting rod cap. q When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.


EM-89

K

2005 X-Trail

CYLINDER BLOCK q

q

When installing, align the connecting rod bearing stopper prop rotrusion with the cutout of connecting rod and connecting rod cap to install. Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.

PBIC2067E

12. Install Install piston piston and connecting connecting rod assembly assembly to crankshaft. crankshaft. q Position crankshaft pin corresponding to connecting rod to be b e installed onto the bottom dead center. q Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. q Match the cylinder position with the cylinder number on connecting rod to install. q Using the piston ring compressor [SST] or suitable tool, install piston with the front mark on the piston head facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

PBIC2721E

13. Install Install connecting connecting rod cap. q Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.

PBIC2196E

14. Tighten Tighten connecting connecting rod bolt bolt with the following following procedure: procedure: a. Apply new engine engine oil oil to tthe he threads threads and and seats seats of connec connecting ting rod rod bolts. bolts. b. Tight ighten en bol bolts ts in in seve severa rall step steps. s. : 19.6 N·m (2.0 kg-m, 14 ft-lb) c.

Then Then turn all all bolts bolts 90 degrees degrees clock clockwis wise e (angle (angle tighteni tightening) ng).. CAUTION: Check and confirm the tightening angle by using the angle wrench [SST] or protractor. Avoid judgement by visual inspection without the tool.

PBIC2722E


EM-90

2005 X-Trail

CYLINDER BLOCK q q

After tightening connecting rod bolt, make sure that t hat crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to EM-99, "CONNECTING ROD SIDE CLEARANCE" .

15. Install Install flywheel flywheel (M/T models) models) or drive drive plate (A/T models) models).. q Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times. q Install drive plate, reinforcement plate and pilot converter as shown in figure (A/T models). q Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it i t stops (A/T models).

A

EM

C

D

E KBIA0075E

F

16. Instal Installl knock knock sensor sensor. q Install knock sensor with connector facing lower left by 45 degrees as shown in the figure. CAUTION: q Do not tighten mounting bolt while holding the connector. q If any impact by dropping is applied to knock sensor, replace it with a new one. NOTE: q Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. q Make sure that knock sensor does not interfere with other parts. 17. Install Install crankshaf crankshaftt position position sensor sensor (POS). (POS). 18. Assemble Assemble in the reverse reverse order of disassembl disassembly y after this step.

G

H

I KBIA0069E

J

How to Select Piston and Bearing

ABS00CJN

K

DESCRIPTION

Selection points

Between cylinder block and crankshaft

Selection parts

Selection items

Main bearing

Selection methods

Main bearing grade (bearing thickness)

Determined by match of cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal)

Between crankshaft and connecting rod

Connecting rod bearing

Connecting rod bearing grade (bearing thickness)

Combining service grades for connecting rod big end diameter and crankshaft pin outer diameter determine connecting rod bearing selection.

Between cylinder block and piston

Piston and piston pin assembly (piston is available together with piston pin as an assembly.)

Piston grade (piston skirt diameter)

Piston grade = cylinder bore grade (inner diameter of bore)

—

—

Between piston and connecting rod*

—

*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The information at the shipment from the plant is described as a reference. q

The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts.


EM-91

2005 X-Trail

L

M

CYLINDER BLOCK 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.

q

q

HOW TO SELECT PISTON When New Cylinder Block Is Used Check the cylinder bore grade on rear-left side of cylinder cy linder block, and select piston of the same grade. If there is a corrected stamp mark on cylinder block, use it as a correct reference.

q

q

SBIA0283E

PBIC2197E

When Cylinder Block Is Reused 1. 2. 3.

Measur Measure e the cylin cylinder der bore bore inner inner diame diameter ter.. Refer Refer to EM-103, "Cylinder Bore Inner Diameter" . Determine Determine the bore bore grade grade by comparing comparing the measur measurement ement with with the values values under the the cylinder cylinder bore inner inner diameter of the “Piston Selection Table”. Table”. Sele Select ct pis pisto ton n of the the same same grad grade. e.

Piston Selection Table Unit: mm (in) Grade number (Mark)

2 (or no mark)

3

Cylinder bore Inner diameter

89.010 - 89.020 (3.5043 - 3.5047)

89.020 - 89.030 (3.5047 - 3.5051)

Piston skirt diameter

88.990 - 89.000 (3.5035 - 3.5039)

89.000 - 89.010 (3.5039 - 3.5043)

NOTE: There is no piston grade “1”. q q Piston is available together with piston pin as an assembly. assembly. q The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only grade “0” is available.)


EM-92

2005 X-Trail

CYLINDER BLOCK HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft Are Used 1.

A

Apply Apply connec connectin ting g rod big big end diame diameter ter grade grade stamp stamped ed on conconnecting rod side face to the row in the “Connecting Rod Bearing Selection Table”.

EM

C

D PBIC2196E

2.

Apply crankshaft crankshaft pin journa journall diameter diameter grade stamped stamped on crankshaft front side to the column in the “Connecting Rod Bearing Selection Table”.

E

F

G

PBIC2198E

3. 4.

Read the symbol symbol at at the cross cross point of selected selected row and colum column n in the “Connect “Connecting ing Rod Bearing Bearing Selecti Selection on Table”. Apply the the symbol symbol obtained obtained to the “Connecti “Connecting ng Rod Bearing Bearing Grade Grade Table” Table” to select select connecting connecting rod rod bearing. bearing.

H

I

When Crankshaft and Connecting Rod Are Reused 1.

2. 3. 4.

Measure Measure the dimension dimensions s of the connectin connecting g rod big end end diameter diameter and cranksha crankshaft ft pin journal journal diameter diameter individually. Refer to EM-101, "CONNECTING ROD BIG END DIAMETER" and EM-105, "CRANKSHAFT PIN JOURNAL DIAMETER" . Apply the the measured measured dimensi dimension on to the “Connecting “Connecting Rod Bearing Bearing Selection Selection Table”. able”. Read the symbol symbol at the cross cross point of of selected selected row and column column in the “Connecti “Connecting ng Rod Bearing Bearing Selecti Selection on Table”. Apply the the symbol symbol obtained obtained to the “Connecti “Connecting ng Rod Bearing Bearing Grade Grade Table” Table” to select select connecting connecting rod rod bearing. bearing.

J

K

L

M


EM-93

2005 X-Trail

CYLINDER BLOCK Connecting Rod Bearing Selection Table

PBIC2199E

Connecting Rod Bearing Grade Table Unit: mm (in) Grade number Thickness Identification color

0

1

2

3

1.495 - 1.499 (0.0589 - 0.0590)

1.499 - 1.503 (0.0590 - 0.0592)

1.503 - 1.507 (0.0592 - 0.0593)

1.507 - 1.511 (0.0593 - 0.0595)

Black

Brown

Green

Yellow

Undersize Bearings Usage Guide q

q

When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings. When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.


EM-94

2005 X-Trail

CYLINDER BLOCK CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].

A

EM

C

PBIC2200E

D

Bearing undersize table Unit: mm (in) Size

Thickness

US 0.25 (0.0098)

1.624 - 1.632 (0.0639 - 0.0643)

E

F

HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft Are Used 1.

“Main “Main Bearing Bearing Selecti Selection on Table” Table” rows rows corres correspond pond to to main main bearing bearing housing grade on rear-left side of cylinder block. q If there is a corrected stamp mark on cylinder block, use it as a correct reference.

G

H

I

SBIA0283E

2.

Apply main journal journal diamete diameterr grade grade stamped stamped on cranksh crankshaft aft front front side to column in the “Main Bearing Bearing Selection Table”.

J

K

L

M PBIC2198E

3.

4.

Read the symbol symbol at the cross cross point of of selected selected row and and column column in the “Main “Main Bearing Bearing Selection Selection Table” Table”.. CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and the other is for even-numbered even-numbered journals (No. 2 and 4). Make certain to use the the appropriate table. table. This is due to differences in the specified clearances. Apply the the symbol symbol obtained obtained to the “Main Bearin Bearing g Grade Table” Table” to select select main main bearing. bearing. NOTE: Service part is available as a set of both upper u pper and lower.

When Cylinder Block and Crankshaft Are Reused 1.

Measure Measure the dimensi dimensions ons of the cylind cylinder er block block main bearing bearing housing housing inner inner diameter diameter and crankshaf crankshaftt main journal diameter individually. individually. Refer to EM-103, "MAIN BEARING HOUSING INNER DIAMETER" and EM104, "CRANKSHAFT MAIN JOURNAL DIAMETER" . 2. Apply the measur measured ed dimension dimension to the “Main “Main Bearing Bearing Selecti Selection on Table” Table”.. Revision: 2005 March

EM-95

2005 X-Trail

CYLINDER BLOCK 3.

4.

Read the the symbol symbol at the cross cross point of selected selected row and and column column in the “Main “Main Bearing Bearing Selection Selection Table” Table”.. CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and the other is for for even-numbered journals journals (No. 2 and 4). Make certain to use the appropriate table. table. This is due to differences in the specified clearances. Apply the the symbol symbol obtained obtained to the “Main “Main Bearing Bearing Grade Grade Table” Table” to select select main bearing bearing.. NOTE: Service part is available as a set of both upper uppe r and lower.

Main Bearing Selection Table (No. 1, 3 and 5 Journals)

PBIC2201E


EM-96

2005 X-Trail

CYLINDER BLOCK Main Bearing Selection Table (No. 2 and 4 Journals) A

EM

C

D

E

F

G

H

I

J

K

L PBIC2202E

M


EM-97

2005 X-Trail

CYLINDER BLOCK Main Bearing Grade Table (All Journals) Unit: mm (in) Grade number

Thickness

Identification color

0

1.973 - 1.976 (0.0777 - 0.0778)

Black

1

1.976 - 1.979 (0.0778 - 0.0779)

Brown

2

1.979 - 1.982 (0.0779- 0.0780)

Green

3

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

4

1.985 - 1.988 (0.0781 - 0.0783)

Blue

5

1.988 - 1.991 (0.0783 - 0.0784)

Pink

6

1.991 - 1.994 (0.0784 - 0.0785)

Purple

7

1.994 - 1.997 (0.0785 - 0.0786)

White

UPR

1.973 - 1.976 (0.0777 - 0.0778)

Black

LWR

1.976 - 1.979 (0.0778 - 0.0779)

Brown

UPR

1.976 - 1.979 (0.0778 - 0.0779)

Brown

LWR

1.979 - 1.982 (0.0779 - 0.0780)

Green

UPR

1.979 - 1.982 (0.0779- 0.0780)

Green

LWR

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

UPR

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

LWR

1.985 - 1.988 (0.0781 - 0.0783)

Blue

UPR

1.985 - 1.988 (0.0781 - 0.0783)

Blue

LWR

1.988 - 1.991 (0.0783 - 0.0784)

Pink

U PR

1.988 - 1.991 (0.0783 - 0.0784)

Pink

LWR

1.991 - 1.994 (0.0784 - 0.0785)

Purple

U PR

1.991 - 1.994 (0.0784 - 0.0785)

Purple

LWR

1.994 - 1.997 (0.0785 - 0.0786)

White

01

12

23

34

45

56

67

Remarks

Grade and color are the same for upper and lower bearings.

Grade and color are different for upper and lower bearings.

Use Undersize Bearing Usage Guide When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and q grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 0. 067 in)]. q

PBIC2200E

Bearing undersize table Unit: mm (in) Size

Thickness

US 0.25 (0.0098)

2.106 - 2.114 (0.0829 - 0.0832)


EM-98

2005 X-Trail

CYLINDER BLOCK Inspection After Disassembly

ABS00CJO

A

CRANKSHAFT END PLAY q

q

Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator ind icator.. Stan St anda dard rd

: 0.10 0.10 - 0.26 0.26 mm (0.0 (0.0039 039 - 0.01 0.0102 02 in) in)

Limit

: 0.30 mm (0.0118 in)

EM

C

If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

D PBIC2377E

CONNECTING ROD SIDE CLEARANCE q

q

E

Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge. Stan St anda dard rd

: 0.20 0.20 - 0.35 0.35 mm (0.0 (0.0079 079 - 0.01 0.0138 38 in) in)

Limit

: 0.50 mm (0.0197 in)

F

If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

G

H KBIA0071E

PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter

I

Measure the inner diameter of piston pin hole with an inside micrometer.

J

Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)

K

L PBIC0116E

Piston Pin Outer Diameter

M

Measure the outer diameter of piston pin with a micrometer. micrometer. Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)

PBIC0117E

Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter) Standard: Stand ard: 0.002 - 0.006 mm (0.0001 - 0.0002 0 .0002 in) q

If oil clearance is out of the standard, replace piston p iston and piston pin assembly.


EM-99

2005 X-Trail

CYLINDER BLOCK q

When replacing piston and piston pin assembly, refer to EM-103, "PISTON TO CYLINDER BORE CLEARANCE" . NOTE: q Piston is available together with piston pin as assembly. assembly. q Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only grade “0” is available.)

PISTON RING SIDE CLEARANCE q

Measure the side clearance of piston ring and piston ring groove with a feeler gauge. Standard: Top ri ring ng

: 0.0 0.045 45 - 0. 0.080 080 mm (0 (0.0 .0018 018 - 0.0 0.0031 031 in in))

2nd 2n d rin ring g

: 0.0 0.030 30 - 0.0 0.070 70 mm (0 (0.0 .0012 012 - 0.0 0.0028 028 in in))

Oill rin Oi ring g

: 0.0 0.065 65 - 0.1 0.135 35 mm (0 (0.0 .002 026 6 - 0. 0.00 0053 53 in in))

Limit:

q

Top rin ring g

: 0.1 0.11 1 mm mm (0. (0.00 004 43 in) in)

2nd 2n d ri rin ng

: 0. 0.10 10 mm (0 (0.0 .003 039 9 in in))

SEM024AA

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

PISTON RING END GAP q

q

Make sure that cylinder bore inner diameter is within the specification. Refer to EM-103, "Cylinder Bore Inner Diameter" . Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler fe eler gauge. Standard: Top ring

: 0.21 - 0.31 mm (0.0083 - 0.0122 in)

2nd ring

: 0.32 - 0.47 mm (0.0126 - 0.0185 in)

Oil ring (rail ring)

: 0.20 - 0.60 mm (0.0079 - 0.0236 in) SEM822B

Limit:

q

Top ring

: 0.54 mm (0.0213 in)

2nd ring

: 0.67 mm (0.0264 in)

Oil rin ring g (rai (raill ring ring))

: 0.95 0.95 mm mm (0.03 (0.0374 74 in) in)

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder inner wall and use oversized piston and piston rings.


EM-100

2005 X-Trail

CYLINDER BLOCK CONNECTING ROD BEND AND TORSION q

A

Check with a connecting rod aligner. Bend: Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

EM

Torsion: Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length q

C

If it exceeds the th e limit, replace connecting rod assembly. assembly.

D

E

F

G PBIC2077E

H

CONNECTING ROD BIG END DIAMETER q

q

Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for the tightening procedure. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)

q

I

J

If out of the standard, replace connecting rod assembly. assembly. K

PBIC1641E

CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter

M

Measure the inner diameter of connecting rod bushing bu shing with an inside micrometer. Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)

PBIC0120E


EM-101

L

2005 X-Trail

CYLINDER BLOCK Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer. Standard: Stand ard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)

PBIC0117E

Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diameter) Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) q

q

q

If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly. If replacing piston and piston pin assembly, refer to EM-103, "PISTON TO CYLINDER BORE CLEARANCE" . If replacing connecting rod assembly, refer to EM-105, "CONNECTING ROD BEARING OIL CLEARANCE" to select connecting rod bearing.

PBIC2196E

Factory installed parts grading: Service parts apply only to grade “0”. q Unit: mm (in) Grade

0

1

20.000 - 20.006 (0.7874 - 0.7876)

20.006 - 20.012 (0.7876 - 0.7879)

Piston pin hole diameter

19.993 - 19.999 (0.7871 - 0.7874)

19.999 - 20. 005 (0.7874 - 0.7876)

Piston pin outer diameter

19.989 - 19.995 (0.7870 - 0.7872)

19.995 - 20.001 (0.7872 - 0.7874)

Connecting rod bushing inner diameter

*

* : After installing in connecting rod.

PBIC2197E

CYLINDER BLOCK DISTORTION q

Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.


EM-102

2005 X-Trail

CYLINDER BLOCK q

Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge and a feeler gauge.

A

Limit: 0.1 mm (0.004 in) q

EM

If it exceeds the limit, replace cylinder block and lower cylinder block assembly. NOTE: Cylinder block cannot be replaced as a single, because it is machined together with lower cylinder block.

C PBIC0121E

D

MAIN BEARING HOUSING INNER DIAMETER q

q

Install lower cylinder block without main bearings installed, and tighten lower cylinder block mounting bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for the tightening procedure. Measure the inner diameter of main bearing housing with a bore gauge.

E

F

Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 in) q

If out of the standard, replace cylinder block and lower cylinder block assembly. NOTE: Cylinder block cannot be replaced as a single, because it is machined together with lower cylinder block.

G PBIC2012E

H

PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter q

I

Using a bore gauge, measure the cylinder bore for wear, out-ofround and taper at six different points on each cylinder. (“X” and “Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of the engine) NOTE: When determining cylinder bore grade, measure cylinder bore at “B” position.

J

K

Standard Stand ard inner diameter: L

89.010 - 89.030 mm (3.5043 - 3.5051 in) Wear limit:

SBIA0284E

0.2 mm (0.008 in)

M

Out-of-round Out-of-rou nd (Difference between “X” and “Y”): 0.015 mm (0.0006 in) Taper limit (Difference between “A” and “C”): 0.01 mm (0.0004 in) q

q

If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the cylinder inner wall. Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the piston to cylinder bore satisfies the standard. CAUTION: When using an oversize piston, use oversize pistons for all cylinders with oversize piston rings. Oversize (OS): 0.2 mm (0.008 in)


EM-103

2005 X-Trail

CYLINDER BLOCK Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer. micrometer. Measure point : Distance from the top 42.0 mm (1.654 in) Standard : 88.990 - 89.010 mm (3.5035 - 3.5043 3 .5043 in)

PBIC0125E

Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner inne r diameter (direction “X”, position “B”). (Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter) Stand St andard ard : 0.010 0.010 - 0.03 0.030 0 mm (0.00 (0.0004 04 - 0.00 0.0012 12 in) in) Limit q

: 0.08 mm (0.0031 in)

If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-92, "HOW TO SELECT PISTON" .

Re-boring Cylinder Bore 1.

Cylinder Cylinder bore size size is determined determined by adding adding piston piston to cylinder cylinder bore clearance clearance to piston piston skirt skirt diameter diameter.. Re-bored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston - to - cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in)

2. 3.

4. 5.

Install Install lower lower cylinder cylinder block, block, and tighten tighten mounting mounting bolts to to the specified specified torque. torque. Otherwise, Otherwise, cylinde cylinderr bores may be distorted in final assembly. assembly. Refer to EM-86, "ASSEMBLY" for the tightening procedure. Cutt cyli Cu cylind nder er bore bores. s. NOTE: q When any cylinder needs boring, all other cylinders must also be bored. q Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. Hone cylind cylinders ers to to obtain obtain the specified specified piston piston to cylinder cylinder bore clearanc clearance. e. Measure Measure the the finished finished cylinder cylinder bore for out-of out-of-round -round and taper taper.. NOTE: Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER q

Measure the outer diameter of crankshaft main journals with a micrometer. Standard: Stand ard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.

q

If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-106, "MAIN BEARING OIL CLEARANCE" .

PBIC0270E


EM-104

2005 X-Trail

CYLINDER BLOCK CRANKSHAFT PIN JOURNAL DIAMETER q

A

Measure the outer diameter of o f crankshaft pin journal with a micrometer. Standard: Stand ard: 44.956 - 44.974 mm (1.7699-1.7706 in) dia.

q

If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. EM Refer to EM-105, "CONNECTING ROD BEARING OIL CLEARANCE" .

OUT-OF-ROUND OUT-OF-ROUND AND TAPER OF CRANKSHAFT q

q

q

C

Measure the dimensions at four different points as shown in the figure on each main journal and pin journal jou rnal with a micrometer. micrometer. Out-of-round is indicated by the difference in dimensions between “X” and “Y” at “A” and “B”. Taper is indicated by the difference in dimension between “A” and “B” at “X” and “Y”.

D

E

Limit: Out-of-round Out-of-r ound (Difference between “X” and a nd “Y”) : 0.005 mm (0.0002 in) Taper (Difference between “A” and “B”)

PBIC2203E

: 0.005 mm (0.0002 in) q q

If the measured value exceeds the limit, correct or replace crankshaft. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing. Refer to EM-106, "MAIN BEARING OIL CLEARANCE" and/or EM-105, "CONNECTING ROD BEARING OIL CLEARANCE" .

F

G

H

CRANKSHAFT RUNOUT q

q q

Place a V-block on a precise flat table to support the journals on the both end of crankshaft. Place a dial indicator straight up on the t he No. 3 journal. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total (Total indicator reading) Limit

q

I

J

: 0. 0.05 mm (0. (0.0 002 020 0 in in)

K

If it exceeds the limit, replace crankshaft. PBIC2541E

CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation q

q

q

Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for tightening procedure. Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter) Stan anda dard rd

: 0.0 0.028 28 - 0.0 0.045 45 mm (0 (0.0 .001 011 1 - 0. 0.00 0018 18 in in))

Limit

: 0.10 mm (0.0039 in)

If the clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to EM-93, "HOW TO SELECT CONNECTING ROD BEARING" .

PBIC1642E

Method of Using Plastigage q

Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.


EM-105

2005 X-Trail

L

M

CYLINDER BLOCK q

q

q

Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for the tightening procedure. CAUTION: Do not rotate crankshaft. Remove connecting rod cap and bearing, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”.

PBIC1149E

MAIN BEARING OIL CLEARANCE Method by Calculation Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for the tightening procedure. Measure the inner diameter of main bearing with a bore gauge. q (Bearing oil clearance) = (Main bearing inner diameter) – (Crankshaft main journal diameter) q

Standard: No. 1, 3 and 5 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in) No. 2 and 4 journals : 0.018 - 0.028 mm (0.0007 - 0.0011 0 .0011 in) Limit q

: 0. 0.1 mm mm (0.00 004 4 in in)

PBIC2204E

If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-95, "HOW TO SELECT MAIN BEARING" .

Method of Using Plastigage q q

q

q

Remove engine oil and dust on crankshaft main journal and an d the surfaces of each bearing completely. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting bolts to the specified torque. Refer to EM-86, "ASSEMBLY" for the tightening procedure. CAUTION: Do not rotate crankshaft. Remove lower cylinder block and bearings, and using the scale on the plastigage bag, measure the plastigage p lastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”.

PBIC1149E


EM-106

2005 X-Trail

CYLINDER BLOCK MAIN BEARING CRUSH HEIGHT q

A

When lower cylinder block is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to EM-86, "ASSEMBLY" for the tightening procedure.

EM

Standard: Stand ard: There must be crush height. q

If the standard is not met, replace main bearings.

C

SEM502G

D

CONNECTING ROD BEARING CRUSH HEIGHT q

When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to EM-86, "ASSEMBLY" for the tightening procedure.

E

F

Standard: Stand ard: There must be crush height. q

If the standard is not met, replace connecting rod bearings. G

PBIC1646E

H

LOWER CYLINDER BLOCK MOUNTING BOLT BOLT OUTER DIAMETER q q

q

Perform only with M10 bolts. Measure the outer diameters (“d1 ”, “d2” ) at two positions as shown in the figure. If reduction appears in “A” range, regard it as “d2 ”.

I

J

Limit (“d1 ” – “d2 ”) : 0.13 mm (0.0051 in) q

If it exceeds the limit (a large difference in dimensions), replace lower cylinder block mounting bolt with a new one.

K

L PBIC0911E

CONNECTING ROD BOLT OUTER DIAMETER q

q

Measure the outer diameter “d” at position as shown in the figure. If reduction appears in a position other oth er than “d”, regard it as “d”.

M

Limit : 7.75 mm (0.3051 in) q

When “d ” falls below the limit (when it becomes thinner), replace connecting rod bolt with a new one.

PBIC0912E


EM-107

2005 X-Trail

CYLINDER BLOCK FLYWHEEL FLYWHEEL DEFLECTION (M/T MODELS) q

q

Measure the deflection of flywheel contact surface to clutch with a dial indicator. Measure the deflection at 210 mm (8.27 in) dia. Standard Stand ard

: 0.45 mm (0.0177 in) or less.

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.

q

PBIC2168E

MOVEMENT AMOUNT OF FLYWHEEL FLYWHEEL (M/T MODELS) CAUTION: Do not disassemble double mass flywheel.

Movement Amount of Thrust (Fore-and-Aft) Direction q

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. Stan St anda dard rd

q

: 1.3 1.3 mm (0 (0.0 .051 51 in in)) or or les less s

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 Install a bolt to clutch clutch cover cover mounting mounting hole, hole, and place place a torque torque wrench on on the extended extended line of the the flywheel flywheel center line. q 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 mati mating ng mark mark on circum circumfer ferenc ences es of the the two flyw flywheel heel masses without applying any load (Measurement standard points). 3. Apply a force force of 9.8 N N·m ·m (1.0 (1.0 kg-m, kg-m, 87 in-lb) in-lb) in each each directi direction, on, and mark the movement amount on the mass on the transaxle side. 4. Measur Measure e the dimen dimensio sions ns of moveme movement nt amount amounts s “A” and and “B” “B” on circumference of flywheel on the transaxle side. Standard: Stand ard: 28.3 mm (1.1 (1.114 14 in) or less. le ss. q

If measured value is out of the standard, replace flywheel.


EM-108

PBIC1263E

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA DATA AND SPECIFICATIONS (SDS) Standard and Limit

PFP:00030

A ABS00CJP

GENERAL SPECIFICATIONS SPECIFICATIONS Cylinder arrangement

In-line 4 3

Displacement

cm

Bore and stroke

2,488 (151.82)

(cu in)

mm (in)

89.0 x 100.0 (3.504 x 3.937)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings

Compression

2

Oil

1

Compression ratio Compression pressure kPa (kg/cm2 , psi) / 250 rpm

EM

C

D

9.5 Standard

1,250 (12.8, 181)

Minimum

1,060 (10.8, 154)

Differential limit between cylinders

E

100 (1.0, 14)

F

DRIVE BELT Tension of drive belt

Auto adjustment by auto-tensioner

G

INTAKE INTAKE MANIFOLD AND EXHAUST MANIFOLD Unit: mm (in) Items

Surface distortion

Limit Intake manifold collector

0.1 (0.004)

Intake manifold

0.1 (0.004)

Exhaust manifold and three way catalyst assembly

0.3 (0.012)

H

I

SPARK PLUG Make

J

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap (nominal)

K

1.1 mm (0.043 in)

L

CYLINDER HEAD Unit: mm (in) Items

Limit

Head surface distortion

M

0.1 (0.004)

PBIC0283E


EM-109

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) VALVE Valve Timing

Valve timing

PBIC0187E

Unit: degree

(

a

b

c

d

e

f

22 4

244

0 (30)

64 (27)

3

41

): Val Valve ve tim timin ing g cont contro roll “ON” “ON”

Valve Dimensions Unit: mm (in)

SEM188A

Valve head diameter “D”

Valve length “L”

Valve stem diameter “d”

Valve seat angle “ α”

Valve margin “T”

Intake

35.5 - 35.8 (1.398 - 1.409)

Exhaust

30.5 - 30.8 (1.201 - 1.213)

Intake

97.16 (3.8252)

Exhaust

98.82 (3.8905)

Intake

5.965 - 5.980 (0.2348 - 0.2354)

Exhaust

5.955 - 5.970 (0.2344 - 0.2350)

Intake

45°15′ - 45°45′

Exhaust Intake

1.1 (0.043)

Exhaust

1.3 (0.051)

Valve Clearance Unit: mm (in) Items

Cold

Hot* (reference data)

Intake

0.24 - 0.32 (0.009 - 0.013)

0.304 - 0.416 (0.012 - 0.016)

Exhaust

0.26 - 0.34 (0.010 - 0.013)

0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)


EM-110

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) Available Valve Lifter Thickness

mm (in)

A

Identification mark

EM

C

D KBIA0119E

6.96 (0.2740)

696

6.98 (0.2748)

698

7.00 (0.2756)

700

7.02 (0.2764)

702

7.04 (0.2772)

704

7.06 (0.2780)

706

7.08 (0.2787)

708

7.10 (0.2795)

710

7.12 (0.2803)

712

7.14 (0.2811)

714

7.16 (0.2819)

716

7.18 (0.2827)

718

7.20 (0.2835)

720

7.22 (0.2843)

722

7.24 (0.2850)

724

7.26 (0.2858)

726

7.28 (0.2866)

728

7.30 (0.2874)

730

7.32 (0.2882)

732

7.34 (0.2890)

734

7.36 (0.2898)

736

7.38 (0.2906)

738

7.40 (0.2913)

740

7.42 (0.2921)

742

744 (0.2929)

744

7.46 (0.2937)

746

E

F

G

H

I

J

K

L

M

Valve Spring Items Free height Installation height Installation load Height during valve open Load with valve open Identification color


Intake

Exhaust

44.84 - 45.34 mm (1.7654 - 1.7850 in)

45.28 - 45.78 mm (1.7827 - 1.8024 in)

35.30 mm (1.390 in)

35.30 mm (1.390 in)

151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)

151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)

24.94 mm (0.9819 in)

26.39 mm (1.0390 in)

358 - 408 N (36.5 - 41.6 kg, 80 - 92 lb)

325 - 371 N (33.1 - 37.8 kg, 73 - 83 lb)

Blue

Yellow

EM-111

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) Valve Lifter Unit: mm (in) Items

Standard

Valve lifter outer diameter

33.965 - 33.980 (1.3372 - 1.3378)

Valve lifter hole diameter

34.000 - 34.021 (1.3386 - 1.3394)

Valve lifter clearance

0.020 - 0.056 (0.0008 - 0.0022)

Valve Guide Unit: mm (in)

PBIC0184E

Items Valve guide

Outer diameter

Standard part

Service part

10.023 - 10.034 (0.3946 - 0.3950)

10.223 - 10.234 (0.4025 - 0.4029)

Inner diameter (Finished size)

Cylinder head valve guide hole diameter

6.000 - 6.018 (0.2362 - 0.2369) 9.975 - 9.996 (0.3927 - 0.3935)

Interference fit of valve guide

0.027 - 0.059 (0.0011 - 0.0023)

Items Valve guide clearance

Projection length “L”


10.175 - 10.196 (0.4006 - 0.4014)

Standard

Limit

Intake

0.020 - 0.053 (0.0008 - 0.0021)

0.08 (0.003)

Exhaust

0.030 - 0.063 (0.0012 - 0.0025)

0.09 (0.004)

Intake

10.1 - 10.3 (0.398 - 0.406)

Exhaust

10.0 - 10.4 (0.394 - 0.409)

EM-112

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) Valve Seat Unit: mm (in)

A

EM

C

D PBIC2745E

Items Cylinder head seat recess diameter “D”

Valve seat outer diameter “d”

Valve seat interference fit

Diameter “d1”*1

Diameter “d2”*2

Angle “α1”

Angle “α2”

Angle “α3”

Contacting width “W”*3

Height “h”

Standard

Oversize [0.5 (0.02)] (Service)

Intake

36.500 - 36.516 ((1 1.4370 - 1.4376)

37.000 - 37.016 ((1 1.4567 - 1.4573)

Exhaust ust

31. 31.500 - 31.516 ((1 1.2402 - 1.2 1.2408)

32.000 000 - 32.016(1.2598 - 1.26 .2605)

Intake

36.597 - 36.613 ((1 1.4408 - 1.4415)

37.097 - 37.113 ((1 1.4605 - 1.4611)

Exhaust ust

31. 31.600 - 31.616 (1 (1.2441 - 1.2 1.2447)

32.100 - 32 32.116 (1 (1.2638 - 1.2644)

Intake

0.081 - 0.113 (0.0032 - 0.0044)

Exhaust

0.084 - 0.116 (0.0033 - 0.0046)

Intake

33.5 (1.319)

Exhaust

28.0 (1.102) 35.1 - 35.3 (1.382 - 1.390)

Exhaust

29.9 - 30.1 (1.177 - 1.185) 60 °

Exhaust

60 °

Intake

88°45′ - 90°15′

Exhaust

88°45′ - 90°15′

Intake

120°

Exhaust

120°

I

K

1.05 - 1.35 (0.0413 - 0.0531)

Exhaust

1.25 - 1.55 (0.0492 - 0.0610)

L

Intake

5.9 - 6.0 (0.232 - 0.236)

5.0 - 5.1 (0.197 - 0.201)

Exhaust

5.9 - 6.0 (0.232 - 0.236)

4.91 - 5.01 (0.1933 - 0.1972)

*1 : Diameter made by intersection point of conic angles *

2

: Diameter made by intersection point of conic angles

*

3

: Machining data


G

J

Intake

Depth “H”

M

6.0 (0.236) α1

and α2

α2

and α3

EM-113

F

H

Intake

Intake

E

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) CAMSHAFT AND CAMSHAFT BEARING Unit: mm (in) Items

Standard

Limit

0.045 - 0.086 (0.0018 - 0.0034)

—

No. 1

28.000 - 28.021 (1.1024 - 1.1032)

—

No. 2, 3, 4, 5

23.500 - 23.521 (0.9252 - 0.9260)

—

No. 1

27.935 - 27.955 (1.0998 - 1.1006)

—

No. 2, 3, 4, 5

23.435 - 23.455 (0.9226 - 0.9234)

—

0.115 - 0.188 (0.0045 - 0.0074)

—

Camshaft journal oil clearance Camshaft bracket inner diameter

Camshaft journal outer diameter Camshaft end play Camshaft cam height “A”

Intake

45.665 - 45.855 (1.7978 - 1.8053)

Exhaust

43.975 - 44.165 (1.7313 - 1.7388)

Camshaft runout [TIR* 2 ]

0.2 (0.008)* 1

Less than 0.02 (0.0008)

—

—

0.15 (0.0059)

Camshaft sprocket runout [TIR*2 ]

SEM671

*1 : Cam wear limit *2 : Total indicator reading

CYLINDER BLOCK Unit: mm (in)

PBIC0281E

Surface distortion

Cylinder bore

Limit

Inner diameter

Standard

0.1 (0.004) Grade No. 2

89.010 - 89.020 (3.5043 - 3.5047)

Grade No. 3

89.020 - 89.030 (3.5047 - 3.5051)

Wear limit Out-of-round (Difference between “X” and “Y”) Taper (Difference between “A” and “C”)


0.2 (0.008) 0.015 (0.0006)

Limit

0.01 (0.0004)

EM-114

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7

Main bearing housing inner diameter grade

Difference in inner diameter between cylinders

Standard

58.944 - 58.945 (2.3206 - 2.3207) 58.945 - 58.946 (2.3207 - 2.3207) 58.946 - 58.947 (2.3207 - 2.3207) 58.947 - 58.948 (2.3207 - 2.3208) 58.948 - 58.949 (2.3208 - 2.3208) 58.949 - 58.950 (2.3208 - 2.3209) 58.950 - 58.951 (2.3209 - 2.3209) 58.951 - 58.952 (2.3209 - 2.3209) 58.952 - 58.953 (2.3209 - 2.3210) 58.953 - 58.954 (2.3210 - 2.3210) 58.954 - 58.955 (2.3210 - 2.3211) 58.955 - 58.956 (2.3211 - 2.3211) 58.956 - 58.957 (2.3211 - 2.3211) 58.957 - 58.958 (2.3211 (2.3211 - 2.3212) 58.958 - 58.959 (2.3212 - 2.3212) 58.959 - 58.960 (2.3212 - 2.3213) 58.960 - 58.961 (2.3213 - 2.3213) 58.961 - 58.962 (2.3213 - 2.3213) 58.962 - 58.963 (2.3213 - 2.3214) 58.963 - 58.964 (2.3214 - 2.3214) 58.964 - 58.965 (2.3214 - 2.3215) 58.965 - 58.966 (2.3215 - 2.3215) 58.966 - 58.967 (2.3215 - 2.3215) 58.967 - 58.968 (2.3215 - 2.3216) Less than 0.03 (0.0012)

A

EM

C

D

E

F

G

H

I

J

K

L

M


EM-115

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) PISTON, PISTON RING AND PISTON PIN Available Piston Unit: mm (in)

PBIC0188E

Piston skirt diameter “A”

Standard

Grade No. 2

88.990 - 89.000 (3.5035 - 3.5039)

Grade No. 3

89.000 - 89.010 (3.5039 - 3.5043)

0.20 (0.008) oversize (Service)

89.180 - 89.210 (3.5110 - 3.5122)

Piston height “H” dimension Piston pin hole diameter

Piston to cylinder bore clearance

42.0 (1.654) Grade No. 0

19.993 - 19.999 (0.7871 - 0.7874)

Grade No. 1

19.999 - 20.005 (0.7874 - 0.7876)

Standard

0.010 - 0.030 (0.0004 - 0.0012)

Limit

0.08 (0.0031)

Piston Ring Unit: mm (in) Items

Side clearance

End gap

Standard

Limit

Top

0.045 - 0.080 (0.0018 - 0.0031)

0.11 (0.0043)

2 nd

0.030 - 0.070 (0.0012 - 0.0028)

0.10 (0.0039)

Oil ring

0.065 - 0.135 (0.0026 - 0.0053)

—

Top

0.21- 0.31 (0.0083 - 0.0122)

0.54 (0.0213)

2 nd

0.32 - 0.47 (0.0126 - 0.0185)

0.67 (0.0264)

Oil (rail ring)

0.20 - 0.60 (0.0079 - 0.0236)

0.95 (0.0374)

Piston Pin Unit: mm (in) Grade No. 0

19.989 - 19.995 (0.7870 - 0.7872)

Grade No. 1

19.995 - 20.001 (0.7872 - 0.7874)

Piston to piston pin oil clearance

Standard

0.002 - 0.006 (0.0001 - 0.0002)

Connecting rod bushing oil clearance

Standard

0.005 - 0.017 (0.0002 - 0.0007)

Piston pin outer diameter


EM-116

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) CONNECTING ROD Unit: mm (in) Center distance

143.00 - 143.10 (5.630 - 5.634)

Bend [per 100 (3.94)]

Limit

0.15 (0.0059)

Torsion [per 100 (3.94)]

Limit

0.30 (0.0118)

Connecting rod bushing inner diameter*

Side clearance

Connecting rod big end diameter

A

EM

Grade No. 0

20.000 - 20.006 (0.7874 - 0.7876)

Grade No. 1

20.006 - 20.012 (0.7876 - 0.7879)

Standard

C

0.20 - 0.35 (0.0079 - 0.0138)

Limit

0.50 (0.0197)

Grade No. 0 Grade No. 1 Grade No. 2 Grade No. 3 Grade No. 4 Grade No. 5 Grade No. 6 Grade No. 7 Grade No. 8 Grade No. 9 Grade No. A Grade No. B Grade No. C

D

48.000 - 48.001 (1.8898 - 1.8898) 48.001 - 48.002 (1.8898 - 1.8898) 48.002 - 48.003 (1.8898 - 1.8899) 48.003 - 48.004 (1.8899 - 1.8899) 48.004 - 48.005 (1.8899 - 1.8900) 48.005 - 48.006 (1.8900 - 1.8900) 48.006 - 48.007 (1.8900 - 1.8900) 48.007 - 48.008 (1.8900 - 1.8901) 48.008 - 48.009 (1.8901 - 1.8901) 48.009 - 48.010 (1.8901 - 1.8902) 48.010 - 48.011 (1.8902 - 1.8902) 48.011 48.011 - 48.012 (1.8902 - 1.8902) 48.012 - 48.013 (1.8902 - 1.8903)

E

F

G

*: After installing in connecting rod

H

CRANKSHAFT Unit: mm (in)

I

J

K

SBIA0535E

SEM645

Center distance “r”

49.96 - 50.04 (1.9669 - 1.9701)

Out-of-round (Difference between “X” and “Y”)

Limit

0.005 (0.0002)

Taper (Difference between “A” and “B”)

Limit

0.005 (0.0002)

Runout [TIR*]

Limit

0.05 (0.0020)

Crankshaft end play


L

Standard

M

0.10 - 0.26 (0.0039 - 0.0102)

Limit

0.30 (0.0118)

EM-117

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS)

Pin journal diameter grade. “DP”

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U

44.974 - 44.973 (1.7706 - 1.7706) 44.973 - 44.972 (1.7706 - 1.7705) 44.972 - 44.971 (1.7705 - 1.7705) 44.971 - 44.970 (1.7705 - 1.7705) 44.970 - 44.969 (1.7705 - 1.7704) 44.969 - 44.968 (1.7704 - 1.7704) 44.968 - 44.967 (1.7704 - 1.7704) 44.967 - 44.966 (1.7704 - 1.7703) 44.966 - 44.965 (1.7703 - 1.7703) 44.965 - 44.964 (1.7703 - 1.7702) 44.964 - 44.963 (1.7702 - 1.7702) 44.963 - 44.962 (1.7702 - 1.7702) 44.962 - 44.961 (1.7702 - 1.7701) 44.961 - 44.960 (1.7701 - 1.7701) 44.960 - 44.959 (1.7701 - 1.7700) 44.959 - 44.958 (1.7700 - 1.7700) 44.958 - 44.957 (1.7700 - 1.7700) 44.957 - 44.956 (1.7700 - 1.7699)

Main journal diameter grade. “Dm”

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7

54.979 - 54.978 (2.1645 - 2.1645) 54.978 - 54.977 (2.1645 - 2.1644) 54.977 - 54.976 (2.1644 - 2.1644) 54.976 - 54.975 (2.1644 - 2.1644) 54.975 - 54.974 (2.1644 - 2.1643) 54.974 - 54.973 (2.1643 - 2.1643) 54.973 - 54.972 (2.1643 - 2.1642) 54.972 - 54.971 (2.1642 - 2.1642) 54.971 - 54.970 (2.1642 - 2.1642) 54.970 - 54.969 (2.1642 - 2.1641) 54.969 - 54.968 (2.1641 - 2.1641) 54.968 - 54.967 (2.1641 - 2.1641) 54.967 - 54.966 (2.1641 - 2.1640) 54.966 - 54.965 (2.1640 - 2.1640) 54.965 - 54.964 (2.1640 - 2.1639) 54.964 - 54.963 (2.1639 - 2.1639) 54.963 - 54.962 (2.1639 - 2.1639) 54.962 - 54.961 (2.1639 - 2.1638) 54.961 - 54.960 (2.1638 - 2.1638) 54.960 - 54.959 (2.1638 - 2.1637) 54.959 - 54.958 (2.1637 - 2.1637) 54.958 - 54.957 (2.1637 - 2.1637) 54.957 - 54.956 (2.1637 - 2.1636) 54.956 - 54.955 (2.1636 - 2.1636)

*: Total indicator reading


EM-118

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) MAIN BEARING Unit: mm (in)

A

EM

C

D SEM685D

Grade number

Thickness


0

1.973 - 1.976 (0.0777 - 0.0778)

Black

1

1.976 - 1.979 (0.0778 - 0.0779)

Brown

2

1.979 - 1.982 (0.0779 - 0.0780)

Green

3

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

4

1.985 - 1.988 (0.0781 - 0.0783)

B l ue

5

1.988 - 1.991 (0.0783 - 0.0784)

Pink

6

1.991 - 1.994 (0.0784 - 0.0785)

Purple

7

1.994 - 1.997 (0.0785 - 0.0786)

White

UPR

1.973 - 1.976 (0.0777 - 0.0778)

Black

LWR

1.976 - 1.979 (0.0778 - 0.0779)

Brown

UPR

1.976 - 1.979 (0.0778 - 0.0779)

Brown

LWR

1.979 - 1.982 (0.0779 - 0.0780)

Green

UPR

1.979 - 1.982 (0.0779 - 0.0780)

Green

LWR

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

UPR

1.982 - 1.985 (0.0780 - 0.0781)

Yellow

LWR

1.985 - 1.988 (0.0781 - 0.0783)

B l ue

UPR

1.985 - 1.988 (0.0781 - 0.0783)

B l ue

LWR

1.988 - 1.991 (0.0783 - 0.0784)

Pink

UPR

1.988 - 1.991 (0.0783 - 0.0784)

Pink

LWR

1.991 - 1.994 (0.0784 - 0.0785)

Purple

UPR

1.991 - 1.994 (0.0784 - 0.0785)

Purple

LWR

1.994 - 1.997 (0.0785 - 0.0786)

White

01

12

23

34

45

56

67

Remarks

F Grade and color are the same for upper and lower bearings.

G

H

I

J Grade and color are different for upper and lower bearings.

M

Unit: mm (in) Item

Thickness

Main journal diameter

US 0. 0.25 (0 (0.0098)

2.106 - 2.114 (0 (0.0829 - 0. 0.0832)

Grind so so th that bearing clearance is is th the sp specified va value.

Bearing Oil Clearance Unit: mm (in)

Main bearing oil clearance

No. 1, 3 and 5

0.012 - 0.022 (0.0005 - 0.0009)

No. 2 and 4

0.018 - 0.028 (0.0007 - 0.0011)

Limit


0.1 (0.004)

EM-119

K

L

Undersize

Standard

E

2005 X-Trail

SERVICE DATA AND SPECIFICATIONS (SDS) CONNECTING ROD BEARING Grade number

Thickness

mm (in)


0

1.495 - 1.499 (0.0589 - 0.0590)

Black

1

1.499 - 1.503 (0.0590 - 0.0592)

Brown

2

1.503 - 1.507 (0.0592 - 0.0593)

Green

3

1.507 - 1.511(0.0593 - 0.0595)

Yellow

Undersize Unit: mm (in) Item

Thickness

Crank pin journal diameter

US 0.25 (0.0098)

1.624 - 1. 1.632 (0.0639 - 0. 0.0643)

Grind so that be bearing clearance is the specified value.

Bearing Oil Clearance Unit: mm (in) Connecting rod bearing oil clearance


Standard

0.028 - 0.045 (0.0011 - 0.0018)

Limit

0.10 (0.0039)

EM-120

2005 X-Trail

manual taller nissan QR25 (EM)

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