fuel pump NISSAN X-TRAIL 2003 Service Owner's Manual

SECONDARY TIMING CHAIN
EM-181
[YD22DDTi]
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Loosen fixing bolts in reverse order of that shown in the figure
and remove them.

Remove No. 6, 10 and 11 bolts with the rubber washer as
space is limited for pulling them out.
CAUTION:

While front chain case is removed, cover openings to
prevent entry of foreign material into engine.

Do not remove two mass dampers on the back of
cover.
5. Set the No. 1 piston to TDC on its compression stroke.

Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.

No position indicator is provided on crankshaft pulley.

When installing, color coded links on secondary timing
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
pump sprocket may not be easy to see.
6. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
JEM121G
SBIA0189E
SEM515G
JEM124G

EM-186
[YD22DDTi]
PRIMARY TIMING CHAIN

1. Fuel pump 2. Seal washer 3. Chain tensioner
4. Spring 5. Slack guide 6. Plunger
7. Camshaft sprocket 8. Washer 9. Fuel pump sprocket
PBIC2327E

PRIMARY TIMING CHAIN
EM-187
[YD22DDTi]
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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 air cleaner and air duct. Refer to EM-133, "
Removal and Installation" .
4. Remove rocker cover. Refer to EM-168, "
Removal and Installation" .
5. Remove RH engine mounting insulator and bracket. Refer to EM-208, "
Removal and Installation" .
6. 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.
7. Remove oil pan (upper and lower). Refer to EM-147, "
Removal and Installation" .
8. Remove oil filter bracket. Refer to LU-26, "
OIL FILTER BRACKET" .
9. Remove fuel injector. Refer to EM-157, "
Removal and Installation" .
10. Remove secondary timing chain and associated parts. Refer to EM-180, "
Removal and Installation" .
11. When removing rear chain case, remove camshaft sprockets. Refer to EM-170, "
Removal and Installa-
tion" .
12. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (special service
tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
c. Using the pulley puller (special service tool), remove crankshaft
pulley.

Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
13. Remove oil pump housing.
10. O-ring 11. Chain guide 12. Tension guide
13. Spacer 14. Gasket 15. Front chain case
16. Rubber washer 17. Crankshaft pulley 18. Front oil seal
19. Power steering oil pump cover 20. Oil pump housing 21. Primary timing chain
22. Oil pump drive spacer 23. Crankshaft sprocket 24. Secondary timing chain
25. Rear chain case 26. Power steering oil pump 27. Key
JEM131G
JEM132G

EM-188
[YD22DDTi]
PRIMARY TIMING CHAIN


Loosen bolts in reverse order of that shown in the figure and
remove them.

U s e t h e s e a l c u t t e r ( s p e c i a l s e r v i c e t o o l : K V 1 0 1111 0 0 ) e t c . f o r
removal.
14. Remove front oil seal from oil pump housing.

Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage oil pump housing.
15. Remove chain tensioner.

When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin, etc.
16. Remove slack guide.
17. Hold fuel pump sprocket and remove bolt.
a. Insert positioning stopper pin (special service tool) into the hole
6 mm (0.24 in) in the diameter on fuel pump sprocket.
b. Using the TORX wrench, turn pump shaft little by little to adjust
the position of fuel pump sprocket so that the holes align.
c. Push positioning stopper pin through fuel pump sprocket to fuel
pump body to hold fuel pump sprocket.

Insert the positioning stopper pin until its flange contacts fuel
pump sprocket.
JEM133G
JEM134G
MBIA0049E
PBIC2535E

PRIMARY TIMING CHAIN
EM-189
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18. Using the hexagon wrench (special service tool) remove tighten-
ing bolts to fuel pump sprocket.
19. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
20. Remove chain guide and tension guides.
21. Remove fuel pump. Refer to EM-161, "
FUEL PUMP" .
22. Remove power steering oil pump.
PBIC2404E
MBIA0074E
MBIA0079E
PBIC2498E

PRIMARY TIMING CHAIN
EM-191
[YD22DDTi]
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a. Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) on locations shown in the
figure.
Use Genuine Liquid Gasket or equivalent.
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.
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
c. Install rear chain case.

When installing, align the dowel pin with the pin hole.
PBIC1255E
JEM141G

EM-192
[YD22DDTi]
PRIMARY TIMING CHAIN

d. Tighten bolts in numerical order shown in the figure.

Install the following four types of bolts, referring to the figure.

The 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 oil pump.
3. Install fuel pump. Refer to EM-161, "
FUEL PUMP" .

Before installing, make sure that spacer and the hole 6 mm
(0.24 in) in diameter on coupling are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with crankshaft key on the
far side.
6. Install primary timing chain with fuel pump sprocket.

When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.

Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.
7. Install timing chain onto power steering oil pump sprocket and
through chain guide.
8. Use the positioning stopper pin (special service tool) to hold the
fuel pump sprocket and install the bolt.

Using the TORX wrench (special service tool), turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm
(0.24 in) in diameter on fuel pump sprocket so that the stop-
per pin goes through the fuel pump body. While the stopper
pin is in place, install the bolt.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
25 mm (0.98 in) : Bolt No. 12, 15
35 mm (1.38 in) : Bolt No. 5, 7, 8
SBIA0211E
PBIC2498E
MBIA0079E
MBIA0049E

EM-196
[YD22DDTi]
CYLINDER HEAD

CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00LRV
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-905,
"Basic Inspection" (WITH EURO-ODB) or EC-1231, "Basic Inspection" (WITHOUT EURO-ODB).

Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove charge air cooler. Refer to EM-135, "
Removal and Installation"
5. To prevent fuel from being injected during inspection, remove
fuel pump fuse [ENG CONT 2 (20A)] from fuse box on the left
side of engine room.

Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
pump fuse.
6. Remove glow plugs from all the cylinders. Refer to EM-152,
"Removal and Installation" .
CAUTION:

Before removal, clean the surrounding area to prevent
entry of any foreign materials into engine.

Carefully remove glow plugs to prevent any damage or
breakage.

Handle with care to avoid applying any shock to glow plugs.
7. Install compression gauge adapter (special service tool) to
installation holes of glow plugs and connect compression gauge
for diesel engine.
8. Connect battery negative terminal.
9. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.

Always use a fully-charged battery to obtain specified engine
speed.
Compression pressure
Unit: kPa (bar, kg/cm2 , psi)/rpm

When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.

If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.

If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.

If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
PBIC0680E
: 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
SEM112G
Standard Minimum Difference limit between cylinders
2,991 (29.9, 30.5, 434)/200 2,452 (24.5, 25.0, 356)/200 490 (4.9, 5.0, 71)/200

CYLINDER HEAD
EM-197
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10. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuel pump fuse [ENG CONT (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no DTC is indicated for items of self-diagnosis.
Removal and InstallationEBS00LRW
REMOVAL
1. Drain engine coolant. Refer to CO-31, "Changing Engine Coolant" .
2. Remove the following:

Charge air cooler (Refer to EM-135, "Removal and Installation" .)

Rocker cover (Refer to EM-168, "Removal and Installation" .)

Air cleaner and air duct (Refer to EM-133, "Removal and Installation" .)

Vacuum pump (Refer to EM-153, "Removal and Installation" .)

Spill tube and fuel injector (Refer to EM-157, "Removal and Installation" .)

Intake manifold (Refer to EM-136, "Removal and Installation" .)

Exhaust manifold and Turbocharger (Refer to EM-141, "Removal and Installation" .)

Secondary timing chain (Refer to EM-180, "Removal and Installation" .)

Camshaft (Refer to EM-170, "Removal and Installation" .)
3. Remove cylinder head assembly.
1. Glow plug 2. Cylinder head assembly 3. Cylinder head bolt
4. Copper washer 5. Engine coolant temperature sensor 6. Gasket
7. Water outlet 8. Dowel pin 9. Gasket
10. Glow harness 11. Glow plate 12. Cap
PBIC2437E

ENGINE ASSEMBLY
EM-211
[YD22DDTi]
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8. Remove power steering oil pump with piping connected from engine. Move it aside on suspension mem-
ber. Refer to PS-34, "
HYDRAULIC LINE" .
9. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
10. Remove starter motor. Refer to SC-21, "
STARTING SYSTEM" .
11. Separate engine and transaxle. Refer to MT-17, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.

Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-208, "
ENGINE ASSEMBLY" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION

Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than
required quantity, fill to the specified level.

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working
engine oil, fuel and exhaust gas.

Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.

After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level
Fuel — Leakage —
Exhaust gas — Leakage —