Chain NISSAN X-TRAIL 2003 Service Service Manual

EM-184
[YD22DDTi]
SECONDARY TIMING CHAIN

a. Install tension guide on the back surface of front chain case.

Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
b. Apply a continuous bead of liquid gasket on both ends of arched
area (locations where rear chain case is adjoined) as shown in
the figure.

Use Genuine Liquid Gasket or equivalent.
c. Install front chain case.

When installing, align dowel pin on oil pump housing with the pin hole.

Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in 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.
SBIA0189E
JEF370Y
JEM121G

PRIMARY TIMING CHAIN
EM-185
[YD22DDTi]
C
D
E
F
G
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K
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MA
EM

PRIMARY TIMING CHAINPFP:13028
Removal and InstallationEBS00LRU
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.

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]
C
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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
[YD22DDTi]
C
D
E
F
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EM

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

EM-190
[YD22DDTi]
PRIMARY TIMING CHAIN

23. Remove rear chain case.

Loosen fixing 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 ) f o r
removal.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
INSTALLATION
1. Install rear chain case.
SBIA0211E
SEM984C
PBIC2256E

PRIMARY TIMING CHAIN
EM-191
[YD22DDTi]
C
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F
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EM

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

PRIMARY TIMING CHAIN
EM-193
[YD22DDTi]
C
D
E
F
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9. Install timing chain slack guide.
10. Install chain tensioner.

Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain ten-
sioner.

After installation, pull out the push pin holding the plunger.
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned.
11. Install front oil seal to oil pump housing.

Using the suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
12. Install power steering oil pump cover to oil pump housing.

Apply a continuous bead of liquid gasket with the tube presser
(special service tool: WS39930000) as shown in the figure.
Use Genuine Liquid Gasket or equivalent.

Apply liquid gasket on oil pump-side surface.
13. Install oil pump housing.
PBIC2404E
JEM134G
JEM142G
JEM143G