NISSAN X-TRAIL 2003 Electronic Repair Manual

SECONDARY TIMING CHAIN
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INSTALLATION
1. Install secondary timing chain.
lWhen installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
2. Install timing chain tension guide.
lThe upper bolt has a longer shank than the lower bolt.
3. Using a hexagon-head wrench [face to face: 6 mm (0.24 in),
SST], install timing chain slack guide.
4. Install chain tensioner.
a. Push the plunger of the chain tensioner. While holding it with a
push pin, install the chain tensioner.
b. Using a hexagon-head wrench [face to face: 5 mm (0.20 in),
SST], tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
lCheck again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.
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EM-162
[YD22DDTi]
SECONDARY TIMING CHAIN
5. Install front chain case.
a. Install tension guide on the back surface of front chain case.
lHold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
b. Apply Genuine Liquid Gasket or equivalent (Refer toEM-103,
"Precautions for Liquid Gasket".) on both ends of arched area
(locations where rear chain case is adjoined) as shown in the
figure.
c. Install front chain case.
lWhen installing, align dowel pin on oil pump case with the pin
hole.
lInstall No. 6, 10 and 11 bolts with the rubber washer to the
front chain case.
d. Tighten fixing bolts in the numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
6. Hereafter, install in the reverse order of removal.
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PRIMARY TIMING CHAIN
EM-163
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PRIMARY TIMING CHAINPFP:13028
Removal and InstallationEBS00BR5
CAUTION:
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.

EM-164
[YD22DDTi]
PRIMARY TIMING CHAIN
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1. Fuel supply pump 2. Chain tensioner 3. Slack guide
4. Camshaft sprocket 5. Fuel supply pump sprocket 6. Tension guide

PRIMARY TIMING CHAIN
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REMOVAL
1. Remove coolant reservior tank.
2. Remove charge air cooler. Refer toEM-114, "
Removal and Installation".
3. Remove oil cleaner and air duct. Refer toEM-112, "
Removal and Installation".
4. Remove rocker cover. Refer toEM-147, "
Removal and Installation".
5. Remove RH engine mount insulator and bracket. Refer toEM-184, "
Removal and Installation".
6. 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.
7. Remove oil pan. Refer toEM-125, "
Removal and Installation".
8. Remove oil filter bracket. Refer toLU-22, "
Removal and Installation".
9. Remove injection tube and fuel injector. Refer toEM-135, "
Removal and Installation".
10. Remove secondary timing chain and associated parts. Refer toEM-158, "
Removal and Installation".
11. When removing rear chain case, remove camshaft sprockets. Refer toEM-149, "
Removal and Installa-
tion".
12. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
c. Using pulley puller (SST), remove crankshaft pulley.
lUse two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
7. Chain guide 8. Spacer 9. Front chain case
10. Crankshaft pully 11. Front oil seal 12. Oil pump
13. Primary timing chain 14. Oil pump drive sprocket 15. Crankshaft sprocket
16. Secondary timing chain 17. Rear chain case 18. Power steering pump
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EM-166
[YD22DDTi]
PRIMARY TIMING CHAIN
13. Remove oil pump.
lLoosen bolts in the reverse order of that shown in the figure
and remove them.
lUse seal cutter (SST) etc. for removal.
14. Remove front oil seal from oil pump.
lPunch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
lBe careful not to damage the oil pump.
15. Remove chain tensioner.
lWhen removing chain tensioner, push the sleeve of chain ten-
sioner and keep it pressed with a push pin, etc.
16. Remove timing chain slack guide.
17. Hold fuel supply pump sprocket and remove bolt.
a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24 in)
in the diameter on the fuel supply pump sprocket.
b. UsingaTORXwrench(SST),turnpumpshaftlittlebylittleto
adjust the position of fuel supply pump sprocket so that the
holes align.
c. Push positioning stopper pin (SST) through pump sprocket to
fuel supply pump body to hold pump sprocket, and remove bolt.
18. Remove primary timing chain with fuel supply pump sprocket
and crankshaft sprocket.
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PRIMARY TIMING CHAIN
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19. Remove chain guide and tension guides.
20. Remove fuel supply pump.
21. Remove power steering pump.
22. Remove camshaft sprockets.
lLoosen the camshaft sprockets installation bolts by fixing the
hexagonal portion of the camshaft.
23. Remove rear chain case.
lLoosen fixing bolts in the reverse order of that shown in the
figure and remove them.
lUsesealcutter(SST)forremoval.
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EM-168
[YD22DDTi]
PRIMARY TIMING CHAIN
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Install rear chain case.
a. Apply a continuous bead of Genuine Liquid Gasket or eqivalent
on locations shown in the figure. Refer toEM-103, "
Precautions
for Liquid Gasket".
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
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PRIMARY TIMING CHAIN
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b. Install four O-rings to the grooves of the cylinder block and fuel
supply pump bracket.
c. Install rear chain case.
lWhen installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
lInstall the following four types of bolts, referring to the figure.
lThe shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
2. Install power steering pump.
3. Install fuel supply pump.
lBefore installing, make sure the notch on the fuel supply
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with the crankshaft key on
the far side.
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16 mm (0.63 in) : Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in) : Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25mm(0.98in) :BoltNo.12,15
35mm(1.38in) :BoltNo.5,7,8
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EM-170
[YD22DDTi]
PRIMARY TIMING CHAIN
6. Install primary timing chain with fuel supply pump sprocket.
lWhen installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
lInstall fuel supply pump sprocket washer with the surface
marked “F” (front mark) facing the front of the engine.
7. Install timing chain onto power steering pump sprocket and
through chain guide.
8. Use the positioning stopper pin (SST) to hold the fuel supply
pump sprocket and install the bolt.
lUsing a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel supply pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pinisinplace,installthebolt.
9. Install timing chain slack guide.
10. Install chain tensioner.
lPush the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install the chain
tensioner.
lAfter installation, pull out the push pin holding the plunger.
lCheck again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
11. Install front oil seal to oil pump.
lUsing a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
lDo not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
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