engine NISSAN X-TRAIL 2003 Electronic Repair Manual

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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INJECTION TUBE AND FUEL INJECTOR
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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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INJECTION TUBE AND FUEL INJECTOR
EM-137
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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.
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Standard :-53 to-67 kPa (-533 to-667 mbar,-400
to-500 mmHg,-15.75 to-19.69 inHg)
JEF250Z
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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
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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
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SEM515G

EM-142
[YD22DDTi]
FUEL SUPPLY PUMP
19. Using the sprocket holder (SST), hold the fuel supply pump
sprocket to prevent falling.
lAs for the sprocket holder, install fuel supply pump mounting
bolt through hole of KV11106060 as shown in figure.
lWhen the sprocket holder is installed, if the positioning stop-
per pin interferes, pull out the stopper pin approximately 10
mm (0.39 in), then install it.
lAfter the sprocket holder is installed temporarily, insert the
extension bar (SST) and TORX socket in the three holes A.
After positioning the holes, tighten the holder mounting bolts.
lThe length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
lMake 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 until the fuel supply
pump is installed.
lAfter the sprocket holder is installed, pull out the positioning
stopper pin (SST) from the fuel supply pump sprocket.
20. Using the extension bar [SST: whole length 43 mm (1.69 in)] and
the TORX socket (Q6-E12: commercially available), remove the
mounting bolts, them remove the fuel supply pump toward the
rear of the engine
CAUTION:
Do not disassemble or adjust the fuel supply pump.
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FUEL SUPPLY PUMP
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21. Remove the fuel supply pump mounting bolts.
NOTE:
The seal washer of the mounting bolts cannot be reused.
CAUTION:
For removal, be careful not to drop the seal washer into the
engine.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Before the fuel supply pump is installed, check that the notch of
its flange and the 6 mm (0.24 in) dia. hole on the body are
aligned.
2. Insert the fuel supply pump to the mounting position from the
rear side of the engine.
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SEM984C
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EM-144
[YD22DDTi]
FUEL SUPPLY PUMP
3. Using the extension bar (SST) and the TORX socket, tighten the
mounting bolts of the fuel supply pump.
4. Remove the sprocket holder (SST).
5. Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of the flange. Then, insert the positioning
stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the fuel sup-
ply pump sprocket through the pump flange and the pump body.
6. Remove the TORX wrench (SST)
7. Using the hexagon wrench [face to face: 6 mm (0.24 in), long-
type}](SST), tighten the sprocket mounting bolt.
lWhen the washer of the fuel supply pump sprocket is
removed, install it with the marking “F” (front) facing the front
of the engine.
8. Pull out the positioning stopper pin (SST).
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ROCKER COVER
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ROCKER COVERPFP:13264
Removal and InstallationEBS00BOF
REMOVAL
1. Remove charge air cooler cover. Refer toEM-114, "Removal and Installation".
2. Remove charge air cooler and bracket.
3. Remove harness connector from injection nozzle. Refer toEM-135, "
Removal and Installation".
4. Following steps below, remove injection tube.
a. Put a paint mark or tag on injection tubes to identify each cylinder.
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.
5. Remove injection nozzle oil seal.
lUsing a slotted screwdriver, pry flange to remove oil seal.
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1. Nozzle oil seal 2. Oil filler cap 3. Gasket
4. Rocker cover
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EM-148
[YD22DDTi]
ROCKER COVER
6. Remove rocker cover.
lLoosen holding bolts in the reverse order of that shown in the
figure and remove.
INSTALLATION
1. Apply 3.0 mm (0.118 in) dia. of Genuine Liquid Gasket or equiv-
alent (Refer toEM-103, "
Precautions for Liquid Gasket".) on
locactions shown in the figure.
2. Tighten holding bolts in the numerical order shown in the figure.
lRe-tighten to the same torque in the same order as above.
3. Install nozzle oil seal.
lInsert it straight until flange fully contacts cylinder head.
4. Install remaining parts in reverse order removal.
5. Before starting engine, bleed air from fuel piping. ReferFL-16,
"Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
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JEM248G
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