fuel pump NISSAN X-TRAIL 2003 Service User Guide

FUEL PUMP
EM-161
[YD22DDTi]
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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-34, "RADIATOR" .
2. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
3. Remove RH engine mounting insulator and bracket. Refer to EM-208, "
Removal and Installation" .
4. Pull power steering reservoir tank out of brackets to move power steering piping. Refer to PS-34,
"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
PBIC2317E

EM-162
[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:
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-157, "
INJECTION TUBE AND FUEL
INJECTOR" .
CAUTION:
Be careful not to spill fuel in the engine component.
11. Remove secondary timing chain. Refer to EM-180, "
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-163
[YD22DDTi]
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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-164
[YD22DDTi]
FUEL PUMP

15. Using the extension bar and the TORX socket (size: E10),
remove the tightening bolts.
CAUTION:
Do not disassemble or adjust fuel pump.
16. Remove the fuel pump toward the rear of engine.
CAUTION:
For removal, be careful not to drop the seal washer into the engine.
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-165
[YD22DDTi]
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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-166
[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

FUEL PUMP
EM-167
[YD22DDTi]
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11. Using the hexagon wrench (special service tool), tighten the
sprocket tightening bolt.

When the washer of the fuel pump sprocket is removed,
install it with the marking “F” (front) facing the front of the
engine.
12. Pull out the positioning stopper pin (special service tool).
13. Install secondary timing chain. Refer to EM-180, "
Removal and Installation" .
14. Following steps below, install injection tube center. Refer to EM-157, "
INJECTION TUBE AND FUEL
INJECTOR" .
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool.
15. Connect the harness connector to fuel pump.
16. Install fuel hoses.
17. Hereafter, install in the reverse order of removal.
PBIC2404E

EM-170
[YD22DDTi]
CAMSHAFT

CAMSHAFTPFP:13001
Removal and InstallationEBS00LRR
CAUTION:

This engine will have a different valve arrangement from
normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust camshafts, in this
chapter they are named as follows:

Refer to the figure for intake and exhaust valve arrange-
ment.
(The camshafts have, alternately, either intake valve or an
exhaust valve.)
REMOVAL
1. Drain engine coolant. Refer to CO-31, "Changing Engine Coolant" .
2. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
3. Remove air duct. Refer to EM-133, "
Removal and Installation" .
4. Remove air inlet pipe. Refer to EM-141, "
EXHAUST MANIFOLD AND TURBOCHARGER" .
5. Remove rocker cover. Refer to EM-168, "
Removal and Installation" .
6. Remove vacuum pump. Refer to EM-153, "
Removal and Installation" .
7. Remove fuel injector. Refer to EM-157, "
Removal and Installation" .
8. Remove secondary timing chain. Refer to EM-180, "
Removal and Installation" .
9. Remove camshaft sprockets.
1. Camshaft bracket 2. Camshaft (right side) 3. Camshaft (left side)
4. Camshaft sprocket (right side) 5. Camshaft sprocket (left side) 6. Adjusting shim
7. Valve lifter 8. Cylinder head
Camshaft (right side) : Intake manifold side
Camshaft (left side) : Exhaust manifold side
PBIC2319E
SBIA0178E

EM-176
[YD22DDTi]
CAMSHAFT


Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
1. Remove charge air cooler. Refer to EM-135, "
Removal and Installation" .
2. Remove air duct. Refer to EM-133, "
Removal and Installation" .
3. Remove rocker cover. Refer to EM-168, "
Removal and Installation" .
4. Remove fuel injector. Refer to EM-157, "
Removal and Installation" .
5. Set the No. 1 piston to TDC on its compression stroke.

Turn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
6. Put an alignment mark with paint, etc. on crankshaft pulley and
on oil pump housing as an angle indicator.
7. While referring to the figure, measure the valve clearance
marked in the table below.
NOTE:

The injection order is 1-3-4-2.
SBIA0178E
PBIC2533E
JEM177G
Measuring pointNo. 1No. 2No. 3No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCXXX X
SBIA0180E

EM-180
[YD22DDTi]
SECONDARY TIMING CHAIN

SECONDARY TIMING CHAINPFP:13028
Removal and InstallationEBS00LRT
CAUTION:

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

For preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to
EM-161, "
FUEL PUMP" .

To prepare for removing/installing secondary timing chain to remove/install camshaft, refer to EM-170,
"Removal and Installation" .
1. Remove engine coolant reservoir tank. Refer to CO-34, "
RADIATOR" .
2. Remove RH engine mounting insulator and bracket. Refer to EM-208, "
Removal and Installation" .
3. Pull power steering reservoir tank out of brackets to move power steering piping. Refer to PS-34,
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets, move it with power steering pip-
ing aside.
4. Remove front chain case.
1. Chain tensioner 2. Spring 3. Plunger
4. Slack guide 5. Front chain case 6. Rubber washer
7. Tension guide 8. Gasket 9. Secondary timing chain
PBIC2326E