NISSAN X-TRAIL 2003 Electronic Repair Manual

VACUUM PUMP
EM-131
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VACUUM PUMPPFP:41920
Removal and InstallationEBS00BO4
INSPECTION BEFORE REMOVAL
1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
lDisconnect point where vacuum from vacuum pump can be measured directly and install 3-way con-
nector.
2. Start engine and measure generated vacuum at idle speed.
lIf out of standard, check for air suction in vacuum route, and measure again.
lIf still outside of standard, replace vacuum pump.
REMOVAL
1. Drain engine coolant. Refer toCO-30, "Changing Engine Coolant".
2. Remove air duct and air cleaner case. Refer toEM-112, "
Removal and Installation".
3. Remove charge air cooler and bracket. Refer toEM-114, "
Removal and Installation".
4. Disconnect harness connector from fuel injector.
5. Remove injection tube. Refer toEM-135, "
Removal and Installation".
6. Remove fuel injector oil seal.
7. Remove rocker cover. Refer toEM-147, "
Removal and Installation".
8. Remove spill tube. Refer toEM-135, "
Removal and Installation".
9. Remove nozzle support from NO.2 cylinder and fuel injector. Refer toEM-135, "
Removal and Installation"
.
10. Remove air inlet pipes. Refer toEM-119, "
Removal and Installation".
11. Remove exhaust manifold cover.
SBIA0166E
Standard : – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to –
29.92 inHg)

EM-132
[YD22DDTi]
VACUUM PUMP
12. Disconnect electronic EGR control valve water hose and harness.
13. Disconnect heater hose.
14. Remove EGR tube.
15. Disconnect vacuum hose from vacuum pump side.
16. Remove camshaft position sensor.
17. Remove cylinder head rear cover plate.
18. Loosen and remove the installation bolts in rear cam sprocket.
lLoosen rear cam sprocket installation bolts by fixing the hexagonal portion of the camshaft.
19. Remove vacuum pump and cylinder head rear cover assembly.
lRemove and install vacuum pump, sprocket, drive chain and
chain guide as an assembly.
lLoosen mounting bolts in reverse order shown in figure.
lDo not remove any bolts not shown in figure. (Especially
never remove M6 bolts on vacuum pump.)
lUse seal cutter (special service tool) or other suitable tool to
remove.
INSTALLATION
1. Install vacuum pump and cylinder head rear cover assembly
onto cylinder head. Refer toEM-133, "
ASSEMBLY".
lApply Genuine Liquid Gasket or equivalent (Refer toEM-103,
"Precautions for Liquid Gasket".) to area shown in the figure.
lAttaching should be done with in 5 minutes after coating.
2. Tighten mounting bolts in order shown in the figure.
3. Install rear cam sprocket mounting bolts by fixing the hexagonal
portion of the camshaft. .
4. Tighten rear cam sprocket mounting bolts.
5. Install cylinder head rear cover plate.
lApply Genuine Liquid Gasket or equivalent (Refer toEM-103,
"Precautions for Liquid Gasket".) to area shown in the figure.
lAttaching should be done with in 5 minutes after coating.
CAUTION:
Never start engine with vacuum circuit being open. If
engine is started and vehicle is running while vacuum
pump is open (with vacuum hose disconnected), blow-by
flow rate will increase and engine may be damaged.
6. Install in reverse order of removal after this step.
lWhen vacuum hose is connected, insert it securely by at least
15 mm (0.59 in).
INSPECTION AFTER INSTALLATION
Check generated vacuum satisfies the specification at idle speed. Refer toEM-131, "INSPECTION BEFORE
REMOVAL".
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VACUUM PUMP
EM-133
[YD22DDTi]
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Disassembly and AssemblyEBS00BOE
DISASSEMBLY
1. Push on chain guide lightly so that clearance between chain and chain guide part reaches 0 mm (0 in).
Then loosen chain guide mounting bolts.
2. Remove chain from rear cam sprocket and vacuum pump sprocket.
3. Remove rear cam sprocket.
4. Remove vacuum pump.
CAUTION:
Do not disassemble vacuum pump.
ASSEMBLY
Follow procedure below to install each part onto cylinder head rear
cover.
1. Install vacuum pump.
2. Temporarily fit chain guide.
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1. Rear cam sprocket 2. Drive chain 3. Chain guide
4. Cylinder head rear cover 5. Vacuum pump
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EM-134
[YD22DDTi]
VACUUM PUMP
3. Install rear cam sprocket.
lSprocket can be installed in any direction.
4. Fit drive chain onto rear cam sprocket and vacuum pump
sprocket.
5. Push on chain guide lightly so that clearance between chain and
chain guide sliding part reaches 0 mm (0 in). Then tighten chain
guide mounting bolts.
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INJECTION TUBE AND FUEL INJECTOR
EM-135
[YD22DDTi]
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INJECTION TUBE AND FUEL INJECTORPFP:00018
Removal and InstallationEBS00BPY
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove charge air cooler. Refer toEM-114, "Removal and Installation".
2. Remove harness connector from fuel injector.
3. Remove spill hose.
4. Following steps below, remove injection tubes.
a. Put a paint mark or tag on injection tubes to identify each cylin-
der.
lUse a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
compartment. Especially, ensure to keep engine mount
insulator clear of fuel.
NOTE:
Removal procedure of fuel injector is shown below.
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1. Spill tube 2. Eye-bolt 3. Spill tube gasket
4. Nozzle support 5. Fuel injector 6. O-ring
7. Nozzle gasket 8. Nozzle oil seal 9. Injection tube No.1
10. Injection tube No.2 11. Injection tube No.3 12. Injection tube No.4
13. Injection tube center 14. Common rail assembly
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EM-136
[YD22DDTi]
INJECTION TUBE AND FUEL INJECTOR
5. Remove nozzle oil seal.
lUsing a slotted screwdriver, pry flange to remove oil seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.
6. Remove rocker cover. Refer toEM-147, "
Removal and Installa-
tion".
7. Remove spill tube mounting bolts and nut.
lLoosen bolts and nut to the reverse order of the shown in the
figure and remove then.
8. Following steps below, remove fuel injector.
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION:
lHandle fuel injector carefully without giving any impact.
lDo not disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a
slotted screwdriver and pull it out.
INSTALLATION
1. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Secure it with support.
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INJECTION TUBE AND FUEL INJECTOR
EM-137
[YD22DDTi]
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2. Connect spill tube.
lTighten fixing bolts and nut in the numerical order shown in
the figure.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to specified torque. It does not affect performance.
3. Carry out air tightness test for spill tube.
lConnect a vacuum handy pump to spill connector. Check that
vacuum is retained while applying following vacuum.
lIf outside of standard, reconnect spill tube. (Replace gasket in
this case.)
4. Install rocker cover. Refer toEM-147, "
Removal and Installation"
.
5. Install nozzle oil seal.
lInsert it straight until its flange fully contacts rocker cover.
CAUTION:
lCheck gutter spring in seal on fuel injector for missing.
6. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
7. Connect spill hose.
8. Install remaining parts in reverse order of removal.
9. Before starting engine, bleed air from fuel piping. Refer toFL-16, "
Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
SBIA0205E
Standard :-53 to-67 kPa (-533 to-667 mbar,-400
to-500 mmHg,-15.75 to-19.69 inHg)
JEF250Z
SBIA0203E

EM-138
[YD22DDTi]
FUEL SUPPLY PUMP
FUEL SUPPLY PUMP
PFP:00018
Removal and InstallationEBS00CBL
CAUTION:
lbefore removing and installing fuel supply pump, be sure to remove sprocket. Do not loosen or
remove installation nut in the center of fuel supply pump. If loosened or removed, replace fuel
supply pump.
lAfter removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
lWhen installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
lApply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove coolant reservoir tank.
2. Remove charge air cooler. Refer toEM-114, "
Removal and Installation".
3. Remove RH engine mount insulator and bracket. Refer toEM-184, "
Removal and Installation".
4. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
To avoid removing power steering reservoir tank out of brackets move it with power steering pip-
ing aside.
1. Washer 2. Fuel supply pump sprocket 3. Fuel supply pump
4. Fuel supply pump rear bracket 5. Fuel connector (Feed side) 6. Fuel connector (Return side)
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FUEL SUPPLY PUMP
EM-139
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5. Remove RH front wheel.
6. Remove RH splash cover (combined with under cover)
7. Remove fuel hose from fuel supply pump.
8. Remove the harness connector from the fuel supply pump.
9. Remove the fuel supply pump rear bracket.
lLoosen the fuel bolts in the reverse order of that show in the
figure and remove them.
10. Remove fuel supply pump center spill tube.
11. Remove front chain case.
lLoosen fixing bolts in the reverse order of that shown in the
figure and remove them.
lRemove No. 6, 10 and 11 bolts with the rubber washer as
space is limited for pulling them out.
CAUTION:
lWhile front chain case is removed, cover openings to
prevent entry of foreign material into engine.
lDo not remove two mass dampers on the back of cover.
12. Set the No. 1 piston to TDC on its compression stroke.
lTurn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
showninthefigure.
lNo position indicator is provided on the crankshaft pul-
ley.
lWhen installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
supply pump sprocket may not be easy to see.
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JEM121G
SBIA0189E
SEM515G

EM-140
[YD22DDTi]
FUEL SUPPLY PUMP
13. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
b. Using a hexagon-head wrench [face to face: 5 mm (0.20 in),
SST], remove bolts to remove chain tensioner.
14. Remove timing chain slack guide.
lUsing a hexagon-head wrench [face to face: 6 mm (0.24 in),
SST], remove bolt to remove timing chain slack guide.
15. Remove timing chain tension guide.
16. Remove secondary timing chain.
lTiming chain alone can be removed without removing sprock-
ets.
JEM124G
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