fuel pump NISSAN X-TRAIL 2003 Electronic Manual PDF

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EMA ALTERNATOR AND WATER PUMP BELT ....... . 111
Removal and Installation ...................................... . 111
REMOVAL ......................................................... . 111
INSTALLATION ................................................. . 111
AIR CLEANER AND AIR DUCT .............................. 112
Removal and Installation ....................................... 112
REMOVAL .......................................................... 112
INSTALLATION .................................................. 112
CHANGING AIR CLEANER ELEMENT ............. 112
CHARGE AIR COOLER .......................................... 114
Removal and Installation ....................................... 114
REMOVAL .......................................................... 114
INSPECTION AFTER REMOVAL ...................... 114
INSTALLATION .................................................. 114
INTAKE MANIFOLD ................................................ 115
Removal and Installation ....................................... 115
REMOVAL .......................................................... 115
INSPECTION AFTER REMOVAL ...................... 116
INSTALLATION .................................................. 116
INSPECTION AFTER INSTALLATION .............. 117
CATALYST ............................................................... 118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
EXHAUST MANIFOLD AND TURBOCHARGER ... 119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION ................................................. 120
INSPECTION AFTER INSTALLATION ............. 120
Disassembly and Assembly ................................. 121
REMOVAL ......................................................... 121
INSPECTION AFTER REMOVAL ..................... 121
Turbocharger ........................................................ 122
ROTOR SHAFT CLEARANCE ......................... 122
ROTOR SHAFT END PLAY .............................. 122
TURBINE WHEEL ............................................. 123
COMPRESSOR WHEEL .................................. 123
WASTEGATE VALVE ACTUATOR ................... 123
TROUBLE DIAGNOSIS OF TURBOCHARGER. 123
OIL PAN AND OIL STRAINER ............................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSPECTION AFTER REMOVAL ..................... 127
INSTALLATION ................................................. 127
INSPECTION AFTER INSTALLATION ............. 129
GLOW PLUG .......................................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130
VACUUM PUMP ..................................................... 131
Removal and Installation ...................................... 131
INSPECTION BEFORE REMOVAL .................. 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
INSPECTION AFTER INSTALLATION ............. 132
Disassembly and Assembly ................................. 133
DISASSEMBLY ................................................. 133
ASSEMBLY ....................................................... 133INJECTION TUBE AND FUEL INJECTOR ............135
Removal and Installation ......................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
INSPECTION AFTER INSTALLATION ..............137
FUEL SUPPLY PUMP .............................................138
Removal and Installation ......................................138
REMOVAL .........................................................138
INSPECTION AFTER REMOVAL .....................143
INSTALLATION .................................................143
ROCKER COVER ...................................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSTALLATION .................................................148
INSPECTION AFTER INSTALLATION ..............148
CAMSHAFT ............................................................149
Removal and Installation ......................................149
REMOVAL .........................................................149
INSPECTION AFTER REMOVAL .....................150
INSTALLATION .................................................153
Valve Clearance ...................................................154
INSPECTION ....................................................154
ADJUSTMENTS ................................................155
SECONDARY TIMING CHAIN ................................158
Removal and Installation ......................................158
REMOVAL .........................................................158
INSPECTION AFTER REMOVAL .....................160
INSTALLATION .................................................161
PRIMARY TIMING CHAIN ......................................163
Removal and Installation ......................................163
REMOVAL .........................................................165
INSPECTION AFTER REMOVAL .....................168
INSTALLATION .................................................168
CYLINDER HEAD ...................................................173
On-Vehicle Service ...............................................173
CHECKING COMPRESSION PRESSURE .......173
Removal and Installation ......................................174
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
Disassembly and Assembly ..................................178
DISASSEMBLY .................................................178
ASEMBLY ..........................................................179
INSPECTION AFTER DISASSEMBLY ..............179
ENGINE ASSEMBLY ..............................................184
Removal and Installation ......................................184
REMOVAL .........................................................184
INSTALLATION .................................................186
INSPECTION AFTER INSTALLATION ..............186
CYLINDER BLOCK ................................................188
Disassembly and Assembly ..................................188
DISASSEMBLY .................................................189
ASSEMBLY .......................................................193
How to Select Piston and Bearing ........................197
DESCRIPTION ..................................................197
HOW TO SELECT PISTON ..............................197
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................198

ENGINE ASSEMBLY
EM-63
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lUse a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
lPut a piece of wood or something similar as the support-
ing surface, secure a completely stable condition.
23. Remove RH engine mounting insulator.
24. Pull LH engine mounting through-bolt out.
25. Remove mounting bolts at front end of center member.
26. Remove front suspension member mounting bolts and nuts.
27. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
lDuring the operation, make sure that no part interferes
with body side.
lBefore and during this lifting, always check if any har-
nesses are left connected.
lDuring the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
lIf necessary, support vehicle by setting a jack or equivalent tool at the rear.
28. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
29. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
30. Remove starter motor.
31. Separate engine and transaxle.
INSTALLATION
Install in the reverse order of removal.
lDo not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
lWhen installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
lMake sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
lBefore starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
lRun engine to check for unusual noise and vibration.
lWarm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
lBleed air from passages in pipes and tubes of applicable lines.
KBIA0256E
KBIA0257E
KBIA0270E

EM-106
[YD22DDTi]
PREPARATION
Commercial Service Tools
EBS00BNW
KV11106010
Hexagon wrencha: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
KV11106020
Hexagon wrencha: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pina: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrencha: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrencha: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
Removing and installing mountingbolts of
fuel injection pump sprocket
KV11106060
Sprocket holderHolding fuel injection pump sprocket Tool number
Tool nameDescription
NT801
NT803
NT804
NT805
SBIA0224E
SBIA0225E

EM-116
[YD22DDTi]
INTAKE MANIFOLD
8. Remove EGR tube.
9. Remove vacuum hose.
10. Remove injection tube. Refer toEM-135, "
Removal and Installa-
tion".
11. Remove water pipe.
12. Remove fuel hose.
lTo prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
13. Loosen bolts and nuts in the reverse order of that shown in the
figure.
CAUTION:
Do not disassemble or adjust swirl control valve.
14. Remove electronic EGR control valve from intake manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
lConnect vacuum handy pump to actuator, and apply vacuum to close swirl control valve.
lCheck distortion on the mounting surface with a straightedge
and feeler gauge.
Swirl Control Valve
lConnect vacuum handy pump to actuator, confirm that rod
moves smoothly in accordance with the amount of vacuum
applied and vacuum is maintained.
INSTALLATION
Following instructions below, install in reverse order of removal.
1. Install EGR vacuum control valve.
lHandle with care avoiding any shocks.
SBIA0152E
SBIA0153E
Limit : 0.1 mm (0.004 in)
SBIA0154E
Vacuum reference value (Approx.)
At start of rod movement
: – 8.0 Kpa (– 80 mbar, – 60 mmHg, – 2.36 inHg)
At end of rod movementApprox.
: –26.7Kpa(–267bar,–200mmHg,–7.87inHg)
SBIA0155E

VACUUM PUMP
EM-131
[YD22DDTi]
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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)

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)
SBIA0213E

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.
SBIA0214E
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
SBIA0227E
SBIA0228E
JEM127G

FUEL SUPPLY PUMP
EM-141
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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. Using a TORX wrench (SST), turn pump shaft little by little to
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.
lInsert the positioning stopper pin until its flange contacts the fuel
supply pump sprocket.
lRemove the TORX wrench (SST).
18. Using a hexagon-head wrench [face to face 6 mm (0.24 in) SST]
remove bolts to fuel supply pump sprocket.
SBIA0208E
SBIA0215E
SBIA0209E
SBIA0216E