fuel tank removal INFINITI QX56 2004 Factory Service Manual

COMBINATION METERS
DI-23
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Revision: August 20072004 QX56
4. CHECK HARNESS FOR OPEN OR SHORT CIRCUIT
1. Turn the ignition switch OFF.
2. Disconnect combination meter connector M24.
3. Check continuity between combination meter harness connector
M24 terminal 15 (Y/L) and fuel level sensor unit and fuel pump
harness connector C5 terminal 2 (Y/L).
4. Check continuity between fuel level sensor unit and fuel pump
harness connector C5 terminal 2 (Y/L) and ground.
OK or NG
OK >> GO TO 5.
NG >> Repair harness or connector.
5. CHECK FUEL LEVEL SENSOR CIRCUIT
1. Check continuity between combination meter harness connector
M24 terminal 16 (B/P) and fuel level sensor unit and fuel pump
harness connector C5 terminal 5 (B/P).
2. Check continuity between fuel level sensor unit and fuel pump
harness connector C5 terminal 5 (B/P) and ground.
OK or NG
OK >> GO TO 6.
NG >> Repair harness or connector.
6. CHECK FUEL LEVEL SENSOR UNIT
Check the fuel level sensor unit. Refer to DI-25, "
FUEL LEVEL SENSOR UNIT CHECK" .
OK or NG
OK >> GO TO 7.
NG >> Replace the fuel level sensor unit. Refer to FL-5, "
Removal and Installation" .
7. CHECK INSTALLATION CONDITION
Check fuel level sensor unit installation, and determine whether the float arm interferes or binds with any of the
internal components in the fuel tank.
OK or NG
OK >> Replace the combination meter. Refer to IP-13, "Combination Meter" .
NG >> Install the fuel level sensor unit properly.Continuity should exist.
Continuity should not exist.
WKIA2070E
Continuity should exist.
Continuity should not exist.
WKIA2071E

EC-230Revision: August 2007
DTC P0181 FTT SENSOR
2004 QX56
2. Check resistance between “fuel level sensor unit and fuel pump”
terminals 4 and 5 by heating with hot water or heat gun as
shown in the figure.
Removal and InstallationUBS00H3A
FUEL TANK TEMPERATURE SENSOR
Refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
Temperature °C (°F) Resistance kΩ
20 (68) 2.3 - 2.7
50 (122) 0.79 - 0.90
PBIB0931E

DTC P0182, P0183 FTT SENSOR
EC-235
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Revision: August 20072004 QX56
2. Check resistance between “fuel level sensor unit and fuel pump”
terminals 4 and 5 by heating with hot water or heat gun as
shown in the figure.
Removal and InstallationUBS00H3H
FUEL TANK TEMPERATURE SENSOR
Refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
Temperature °C (°F) Resistance kΩ
20 (68) 2.3 - 2.7
50 (122) 0.79 - 0.90
PBIB0931E

DTC P0455 EVAP CONTROL SYSTEM
EC-319
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Revision: August 20072004 QX56
5. CHECK EVAP PURGE LINE
Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks, improper connection or
disconnection.
Refer to EC-634, "
EVAPORATIVE EMISSION LINE DRAWING" .
OK or NG
OK >> GO TO 6.
NG >> Repair or reconnect the hose.
6. CLEAN EVAP PURGE LINE
Clean EVAP purge line (pipe and rubber tube) using air blower.
>> GO TO 7.
7. CHECK EVAP CANISTER VENT CONTROL VALVE
Check the following.

EVAP canister vent control valve is installed properly.
Refer to EC-637, "
Removal and Installation" .

EVAP canister vent control valve.
Refer to EC-297, "
Component Inspection" .
OK or NG
OK >> GO TO 8.
NG >> Repair or replace EVAP canister vent control valve and O-ring.
8. INSTALL THE PRESSURE PUMP
To locate the EVAP leak, install EVAP service port adapter and pres-
sure pump to EVAP service port securely.
NOTE:
Improper installation of the EVAP service port adapter to the
EVAP service port may cause leaking.
With CONSULT-II>>GO TO 9.
Without CONSULT-II>>GO TO 10.
BBIA0366E
SEF 9 16 U

DTC P0461 FUEL LEVEL SENSOR
EC-337
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7. Check “FUEL LEVEL SE” output voltage and note it.
8. Select “FUEL PUMP” in “ACTIVE TEST” mode with CONSULT-
II.
9. Touch “ON” and drain fuel approximately 30 (7-7/8 US gal, 6-
5/8 Imp gal) and stop it.
10. Check “FUEL LEVEL SE” output voltage and note it.
11. Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal).
12. Check “FUEL LEVEL SE” output voltage and note it.
13. Confirm whether the voltage changes more than 0.03V during
step 7 to 10 and 10 to 12.
If NG, go to EC-337, "
Diagnostic Procedure" .
WITH GST
NOTE:
Start from step 8, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8
Imp gal) in advance.
1. Prepare a fuel container and a spare hose.
2. Release fuel pressure from fuel line. Refer to EC-46, "
FUEL PRESSURE RELEASE" .
3. Remove the fuel feed hose on the fuel level sensor unit.
4. Connect a spare fuel hose where the fuel feed hose was removed.
5. Turn ignition switch ON.
6. Drain fuel by 30 (7-7/8 US gal, 6-5/8 Imp gal) from the fuel tank using proper equipment.
7. Confirm that the fuel gauge indication varies.
8. Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal).
9. Confirm that the fuel gauge indication varies.
10. If NG, go to EC-337, "
Diagnostic Procedure" .
Diagnostic ProcedureUBS00H65
1. CHECK DTC WITH COMBINATION METER
Refer to DI-5, "
COMBINATION METERS" .
OK or NG
OK >> GO TO 2.
NG >> Go to DI-22, "
Fuel Level Sensor Unit Inspection" .
2. CHECK INTERMITTENT INCIDENT
Refer to EC-127, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>>INSPECTION END
Removal and InstallationUBS00H66
FUEL LEVEL SENSOR
Refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
SEF 1 95 Y

ENGINE ASSEMBLY
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Revision: August 20072004 QX56
5. Remove the cowl extension. Refer to EI-18, "Removal and Installation" .
6. Remove engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly. Refer to EM-14, "
REMOVAL" .
8. Disconnect vacuum hose between vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses. Refer to CO-10, "
REMOVAL" .
10. Remove the drive belts. Refer to EM-12, "
Removal" .
11. Remove the fan blade. Refer to CO-13, "
REMOVAL" .
12. Disconnect the engine room harness from the fuse box and set it aside for easier work.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside for easier work.
15. Disconnect the engine harness grounds.
16. Disconnect the reservoir tank for power steering from engine and move it aside for easier work.
17. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas-
ier work. Refer to PS-26, "
REMOVAL" .
18. Remove the A/C compressor bolts and set aside. Refer to ATC-166, "
REMOVAL" .
19. Disconnect brake booster vacuum line.
20. Disconnect EVAP line.
21. Disconnect the fuel hose at the engine side connection. Refer to EM-29, "
REMOVAL" .
22. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the A/T. Refer to AT-255, "
Removal and Installation (4x2)" , or AT-258, "Removal and Installation
(4x4)" .
25. Install engine slingers into left bank cylinder head and right bank
cylinder head.
26. Lift with hoist and secure the engine in position.
27. Remove engine assembly from vehicle, avoiding interference
with vehicle body.
CAUTION:

Before and during this lifting, always check if any har-
nesses are left connected.
28. Remove alternator. Refer to SC-27, "
REMOVAL" .
29. Remove engine mounting insulator and bracket using power tool.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.

Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-
etrain components.
WBIA0464E
Engine slinger torque: 45.0 N·m (4.6 kg-m, 33 ft-lb)
PBIC1556E

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION FL
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Revision: August 20072004 QX56 PREPARATION ........................................................... 2
Special Service Tools ............................................... 2
Commercial Service Tool ......................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 5
Removal and Installation .......................................... 5
REMOVAL ............................................................. 5
INSTALLATION ..................................................... 8
INSPECTION AFTER INSTALLATION ................. 8FUEL TANK ................................................................ 9
Removal and Installation .......................................... 9
REMOVAL ........................................................... 10
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ................ 13
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Standard and Limit .................................................. 14

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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Revision: August 20072004 QX56
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationEBS00IKP
REMOVAL
WA RN ING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
2. Check the fuel level on level gauge. If the fuel gauge indicates
more than the level as shown (full or almost full), drain the fuel
from the fuel tank until the fuel gauge indicates the level as
shown, or less.

If the fuel pump does not operate, use the following procedure
to drain the fuel to the specified level.
a. Insert a suitable hose of less than 15 mm (0.59 in) diameter into
the fuel filler pipe through the fuel filler opening to drain the fuel
from fuel filler pipe.
b. Remove the LH rear wheel and tire. Refer to WT-6, "
Rotation" .
c. Remove the four clips and remove the rear fender protector,
front.
1. Inspection hole cover 2. Inspection hole cover O-ring 3. Lock ring
4. Fuel level sensor, fuel filter, and fuel
pump assembly5. Fuel tank 6. Fuel level sensor, fuel filter, and fuel
pump assembly O-ring
LBIA0381E
WBIA0390E

FUEL TANK
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FUEL TANKPFP:17202
Removal and InstallationEBS00IKQ
1. Inspection hole cover 2. Inspection hole cover O-ring 3. Lock ring
4. Fuel level sensor, fuel filter, and fuel
pump assembly5. Fuel tank 6. Fuel tank protector
7. Fuel tank protector clips 8. Fuel tank straps 9. Fuel level sensor, fuel filter, and fuel
pump assembly O-ring
WBIA0443E

FL-10Revision: August 2007
FUEL TANK
2004 QX56
REMOVAL
WAR NIN G:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Drain the fuel from the fuel tank, if necessary.

Position the vehicle so it is level.
2. Remove the fuel filler cap to release the pressure from inside the fuel tank.
3. Check the fuel level on level gauge. If the fuel gauge indicates
more than the level as shown (full or almost full), drain the fuel
from the fuel tank until the fuel gauge indicates the level as
shown, or less.

If the fuel pump does not operate, use the following procedure
to drain the fuel to the specified level after disconnecting the
fuel filler hose from the fuel filler pipe.
a. Insert a suitable hose of less than 15 mm (0.59 in) diameter into
the fuel filler pipe through the fuel filler opening to drain the fuel
from fuel filler pipe.
b. Insert a suitable hose into the fuel tank through the fuel filler
hose to drain the fuel from the fuel tank.

As a guide, the fuel level reaches the fuel gauge position as shown, or less, when approximately 14
liters (3 3/4 US gal, 3 1/8 Imp gal) of fuel are drained from the fuel tank.
4. Remove the LH rear wheel and tire. Refer to WT-6, "
Rotation" .
5. Remove the four clips and remove the rear fender protector, front.
6. Disconnect the fuel filler hose from the fuel filler pipe and dis-
connect the vent hose quick connector.
7. Release the fuel pressure from the fuel lines. Refer to EC-46, "
FUEL PRESSURE RELEASE" .
8. Remove the second row LH rear seat and the third row rear seat. Refer to SE-103, "
REAR SEAT" .
9. Remove the second and third row rear seat belt buckles mounted on the floor. Refer to SB-3, "
SEAT
BELTS" .
10. Remove the LH center pillar trim, the LH rear trim panel, and the LH rear side door kick plate and weather
stripping. Refer to EI-34, "
BODY SIDE TRIM" .
11. Remove the second row rear center console and base. Refer to EI-36, "
FLOOR TRIM" .
12. Reposition the floor carpet out of the way to access the inspection hole cover, located under the center LH
rear seat.
10. Fuel filler hose 11. Fuel filler pipe 12. Fuel filler cup
13. Fuel filler hose grommet 14. Fuel filler cap 15. Fuel tank shield
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