NISSAN X-TRAIL 2005 Service Repair Manual

INJECTION TUBE AND FUEL INJECTOR
EM-167
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INJECTION TUBE AND FUEL INJECTORPFP:00018
Removal and InstallationEBS00LRO
REMOVAL
1. Remove charge air cooler. Refer to EM-144, "Removal and Installation" .
2. Disconnect harness connector from fuel injector.
3. Remove spill hose. Refer to EM-146, "
INTAKE MANIFOLD" .
4. Remove injection tubes as follows:
a. Put a paint mark or tag on injection tubes to identify each cylinder.

Use a fuel-resistant method.
1. Spill tube 2. Eye-bolt 3. Spill tube gasket
4. Nozzle support 5. Pin 6. Fuel injector
7. O-ring 8. Nozzle gasket 9. Washer
10. Nozzle oil seal 11. Rocker cover 12. Injection tube No. 1
13. Injection tube No. 2 14. Injection tube No. 3 15. Injection tube No. 4
16. Insert rubber 17. Injection tube center 18. Clip
19. Washer 20. Spring washer 21. Fuel rail
22. Fuel rail gasket 23. Fuel hose
PBIC2584E

EM-168
[YD22DDTi]
INJECTION TUBE AND FUEL INJECTOR

b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel.
5. Remove nozzle oil seal.

Using the flat-bladed 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 to EM-178, "
Removal and Installation" .
7. Remove spill tube mounting bolts and nut.

Loosen bolts and nut to the reverse order in the figure and
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
ner.
SBIA0203E
PBIC0944E
PBIC3606E

INJECTION TUBE AND FUEL INJECTOR
EM-169
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8. Remove fuel injector as follows:
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION:

Handle fuel injector carefully without giving any impact.

Do not disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a
flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector.
INSTALLATION
1. Install fuel injector as follows:
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Tighten injection tubes temporarily in the order of 3-4-1-2.
c. Be sure to fit nozzle support without looseness.
d. Tighten nozzle support bolts.

Apply engine oil onto threaded parts of bolts and seating areas.
e. Remove injection tubes.
2. Connect spill tube.

Tighten fixing bolts and nut in numerical order shown in the
figure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.
3. Perform air tightness test for spill tube.

Connect a handy vacuum pump to spill connector. Make sure
that vacuum is retained while applying following vacuum.

If outside of standard, reconnect spill tube. (Replace gasket in
this case.)
4. Install rocker cover. Refer to EM-178, "
Removal and Installation"
.
5. Install nozzle oil seal.

Insert it straight until its flange fully contacts rocker cover.
PBIC0759E
PBIC3606E
Standard:
– 53.3 to – 66.7 kPa (– 533 to – 667 mbar, – 400 to
– 500 mmHg, – 15.75 to – 19.69 inHg)
JEF250Z

EM-170
[YD22DDTi]
INJECTION TUBE AND FUEL INJECTOR

CAUTION:

Check gutter spring in nozzle oil 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. Refer to EM-146, "
INTAKE MANIFOLD" .
8. Install remaining parts in the reverse order of removal.
9. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
SBIA0203E

FUEL PUMP
EM-171
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FUEL PUMPPFP:17042
Removal and InstallationEBS00LRP
CAUTION:

Before removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.

After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.

When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
1. Remove engine coolant reservoir tank. Refer to CO-35, "RADIATOR" .
2. Remove charge air cooler. Refer to EM-144, "
Removal and Installation" .
3. Remove RH engine mounting insulator and bracket. Refer to EM-222, "
ENGINE ASSEMBLY" .
4. Pull power steering reservoir tank out of brackets to move power steering piping. Refer to PS-37,
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets, move it with power steering pip-
ing aside.
5. Remove RH front wheel.
1. Washer 2. Fuel pump sprocket 3. Seal washer
4. O-ring 5. Adjust shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Key
10. Fuel hose 11. Fuel pump 12. Spacer
PBIC2639E

EM-172
[YD22DDTi]
FUEL PUMP

6. Remove RH engine undercover.
7. Remove front exhaust tube. Refer to EX-2, "
EXHAUST SYSTEM" .
8. Remove fuel hoses from fuel pump.
CAUTION:

While hoses are disconnected, plug them to prevent fuel from draining.

Be careful not to spill fuel in the engine component.
9. Disconnect harness connector from fuel pump.
10. Remove injection tube center, clip and insert rubber. Refer to EM-167, "
INJECTION TUBE AND FUEL
INJECTOR" .
CAUTION:
Be careful not to spill fuel in the engine component.
11. Remove secondary timing chain. Refer to EM-193, "
Removal and Installation" .
12. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin (special service tool) into the
hole 6 mm (0.24 in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (special service tool), turn pump shaft
little by little to adjust the position of fuel pump sprocket so that
the holes align.
c. Push the positioning stopper pin (special service tool) through
fuel pump sprocket to fuel pump body to hold fuel pump
sprocket.

Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
13. Using the hexagon wrench (special service tool) remove tighten-
ing bolts of fuel pump sprocket.
MBIA0049E
PBIC2535E
PBIC2404E

FUEL PUMP
EM-173
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14. Using the sprocket holder (special service tool), hold fuel pump
sprocket to prevent falling.

For sprocket holder, use KV11106060 machined as shown in
the figure, because the previous bore is not fitting.

When the sprocket holder is installed, if the positioning stop-
per pin (special service tool) interferes, pull out the positioning
stopper pin approximately 10 mm (0.39 in), then install it.

After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) insert into the machined bore.

The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).

Make sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket (small diameter side).
CAUTION:
Do not remove the sprocket holder (special service tool) until fuel pump is installed.

After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
MBIA0074E
SBIA0217E
PBIC2534E
MBIA0075E

EM-174
[YD22DDTi]
FUEL PUMP

15. Using the extension bar and the TORX socket (size: E10),
remove the tightening bolts.
16. Remove the fuel pump toward the rear of engine.
CAUTION:

For removal, be careful not to drop the seal washer into the engine.

Do not disassemble or adjust fuel pump.
NOTE:
The seal washer of the tightening bolts cannot be reused.
17. Remove adjust shim.
18. Attach a suitable tool in the M8 bolt hole on coupling.
19. Loosen sprocket nut with the TORX wrench (special service
tool).
20. Remove coupling with a suitable puller.
21. Remove spacer from fuel pump.
22. Remove oil seal from spacer.
PBIC2405E
MBIA0013E
MBIA0014E

FUEL PUMP
EM-175
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INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
INSTALLATION
1. Install new oil seal to spacer.
2. Install spacer to fuel pump.
3. Install coupling to fuel pump of spacer.

Using the TORX wrench (special service tool), tighten the
sprocket nut to fix the coupling.
4. Install adjust shim.

For shim adjustment, measure dimension “L” [Distance
between front surface of coupling and the fuel pump flange
(spacer)] at two opposing points near the coupling bolt center.
Use the average of these two measurements to select the
shim grade that marked on adjust shim.

The shim adjustment is required only when the fuel pump is
replaced.
SEM984C
MBIA0045E
MBIA0013E
MBIA0077E

EM-176
[YD22DDTi]
FUEL PUMP

5. Before fuel pump is installed, make sure that spacer and the 6
mm (0.24 in) dia. hole on coupling are aligned.
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
Be careful not to drop the seal washer into engine.
7. Using the extension bar and the TORX socket (size: E10),
tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (special service tool).
9. Using the TORX wrench (special service tool), turn the pump
shaft gradually to adjust the position of fuel pump sprocket.
Then, insert the positioning stopper pin (special service tool) to
the 6 mm (0.24 in) dia. hole of the fuel pump sprocket through
the pump body.
10. Remove the TORX wrench (special service tool).
Part No. of adjusting shim Grade number Measuring dimension L mm (in)
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657)
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445)
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260)
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185)
MBIA0016E
PBIC2438E
PBIC2405E
MBIA0049E