fuel cap release NISSAN TEANA 2003 Service Manual

PREPARATION
EC-19
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Commercial Service ToolsBBS005BD
Tool name Description
Quick connector
releaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
Fuel filler cap adapter Checking fuel tank vacuum relief valve opening
pressure
Socket wrench Removing and installing engine coolant
temperature sensor
Oxygen sensor thread
cleanerReconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
Anti-seize lubricant
i.e.: (Permatex
TM
133AR or equivalent
meeting MIL
specification MIL-A-
907)Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.
PBIC0198E
S-NT653
S-NT705
AEM488
S-NT779

EVAPORATIVE EMISSION SYSTEM
EC-29
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Component InspectionBBS005BL
EVAP CANISTER
Check EVAP canister as follows:
1. Block port B .
2. Blow air into port A and check that it flows freely out of port C .
3. Release blocked port B .
4. Apply vacuum pressure to port B and check that vacuum pres-
sure exists at the ports A and C .
5. Block port A and B .
6. Apply pressure to port C and check that there is no leakage.
FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum.
3. If out of specification, replace fuel filler cap as an assembly.
EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-288, "Component Inspection" .
PBIB0663E
SEF989X
Pres-
sure:15.3 - 20.0 kPa (0.153 - 0.200 bar,
0.156 - 0.204 kg/cm
2 , 2.22 - 2.90 psi)
Va c u u m :−6.0 to −3.4 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm
2 , −0.87 to −0.49 psi)
SEF943S

EM-6
[QR]
PRECAUTIONS


When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Dowel pins are used for several parts alignment. When replacing and reassemling with dowel pins, make
sure that dowel pins are installed in the original portion.

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining coolant.

Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure that there are no leaks at fuel line connections.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle TighteningBBS005KN

Use angle wrench [SST: KV10112100] for the final tightening of the following engine parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
–Balancer unit

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions For Liquid GasketBBS005KO
REMOVAL OF LIQUID GASKET

After removing the mounting nuts and bolts, separate the mating
surface using seal cutter (SST) and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.

Tap seal cutter to insert it, and then slide it by tapping on the
side as shown in the figure.

In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.

Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0275E
PBIC0003E

EM-34
[QR]
FUEL INJECTOR AND FUEL TUBE

FUEL INJECTOR AND FUEL TUBEPFP:16600
Removal and InstallationBBS00593
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
WARNING:

Put a “CAUTION: FLAMMABLE” sign in the workshop.

Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
1. Release fuel pressure. Refer to EC-49, "
FUEL PRESSURE RELEASE" .
2. Remove air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to EM-17, "
AIR
CLEANER AND AIR DUCT" .
3. Disconnect quick connectors at engine side and vehicle side as
follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using quick connector
release (SST), not by picking out retainer tabs.
NOTE:
There is quick connector for the engine side and for the vehicle
side, and they have different shapes. But disconnection is same
procedure. The following procedure shows the engine side.
1. Fuel feed hose 2. Quick connector cap (engine side) 3. Quick connector cap (vehicle side)
4. Centralized under-floor piping 5. Sub-harness 6. Fuel tube protector
7. Fuel tube 8. O-ring (black) 9. Clip
10. Fuel injector 11. O-ring (green)
PBIC2178E
PBIC2175E

FUEL INJECTOR AND FUEL TUBE
EM-35
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a. Remove quick connector cap (engine side).
b. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
c. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube.
CAUTION:

Pull quick connector holding “A” position in the figure.

Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Keep parts away from heat source. Especially, be careful when welding is performed around
them.

Do not expose parts to battery electrolyte or other acids.

Do not bend or twist connection between quick connector and fuel feed hose during installa-
tion/removal.

To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
4. Remove PCV hose. Refer to EM-19, "
INTAKE MANIFOLD" .
5. Disconnect harness connector from ignition coil.
6. Remove sub-harness for fuel injector.
7. Remove electric throttle control actuator and intake manifold support. Refer to EM-19, "
INTAKE MANI-
FOLD" .
KBIA0701E
KBIA0702E
PBIC2205E

EM-120
[VQ]
PRECAUTIONS


When tightening bolts and nuts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining engine coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle TighteningBBS007TV

Use angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts (VQ23DE)
–Connecting rod cap bolts (VQ35DE)
–Crankshaft pulley bolt

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions for Liquid GasketBBS007TW
REMOVAL OF LIQUID GASKET SEALING

After removing mounting nuts and bolts, separate the mating
surface using seal cutter (SST) and remove old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.

Tap seal cutter to insert it, and then slide it by tapping on the
side as shown in the figure.

In areas where seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the gasket
application surface and the mating surface.

Remove liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0275E
PBIC0003E

FUEL INJECTOR AND FUEL TUBE
EM-155
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FUEL INJECTOR AND FUEL TUBEPFP:16600
Removal and InstallationBBS004VX

Refer to GI-10, "Components" for symbol marks in the figure.
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
WARNING:

Put a “CAUTION FLAMMABLE” sign in the workshop.

Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Remove engine cover. Refer to EM-133, "
INTAKE MANIFOLD COLLECTOR" .
2. Release the fuel pressure. Refer to EC-392, "
FUEL PRESSURE RELEASE" .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-34, "
Changing Engine Coolant" and EM-133, "INTAKE MANIFOLD COLLECTOR" .
CAUTION:
Perform this step when engine is cold.
1. Fuel feed hose (with damper) 2. Quick connector cap 3. Centralized under-floor piping
4. Fuel tube 5. Spacer 6. Clip
7.O-ring (black) (VQ23DE)
O-ring (blue) (VQ35DE)8. Fuel injector 9.O-ring (green) (VQ23DE)
O-ring (brown) (VQ35DE)
10. O-ring 11. Fuel damper
A. Refer to EM-157
PBIC4686E

EM-156
[VQ]
FUEL INJECTOR AND FUEL TUBE

4. Remove air duct (inlet), air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to
EM-131, "
AIR CLEANER AND AIR DUCT" .
5. Remove intake manifold collectors (upper and lower). Refer to EM-133, "
INTAKE MANIFOLD COLLEC-
TOR" .
6. Remove fuel feed hose (with damper) from fuel tube.
CAUTION:

While hose disconnected, plug it to prevent fuel from
draining.

Do not separate fuel damper and fuel feed hose.
7. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect
quick connector as follows:
a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from centralized under-floor piping as follows:
CAUTION:
Disconnect quick connector by using quick connector release (SST), not by picking out retainer
tabs.
i. With the sleeve side of quick connector release facing to quick connector, install quick connector release
onto fuel tube.
ii. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
iii. Draw and pull out quick connector straight from centralized
under-floor piping.
CAUTION:

Pull quick connector holding “A” position as shown in
the figure.

Do not pull with lateral force applied. O-ring inside quick connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Keep parts away from heat source. Especially, be careful when welding is performed around
them.

Do not expose parts to battery electrolyte or other acids.

Do not bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.

To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
PBIC2468E
PBIC1898E
PBIC1899E

FUEL SYSTEM
FL-3
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FUEL SYSTEMPFP:17503
Checking Fuel LinesBBS005AE
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsBBS005AF
WARNING:
When replacing fuel line parts, be sure to observe the following.

Put a “CAUTION: FLAMMABLE” sign in the workshop.

Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
CAUTION:

Use gasoline required by the regulations for octane number. Refer to GI-6, "Precautions for Fuel" .

Before removing fuel line parts, perform the following procedures:
–Release fuel pressure from the fuel lines. Refer to EC-49, "FUEL PRESSURE RELEASE"
(QR20DE), or EC-392, "FUEL PRESSURE RELEASE" (VQ23DE and VQ35DE).
–Disconnect the battery cable from negative terminal.

Always replace clamps with new ones.

Do not kink or twist tubes when they are being installed.

Perform work on level place.

Do not tighten hose clamps excessively to avoid damaging hoses.

After connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.

After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Apply fuel pressure to fuel lines with turning ignition switch
“ON” (with engine stopped). Then check for fuel leaks at
connections.
–Start engine and rev it up and check for fuel leaks at con-
nections.

Use only a genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the “MIL” may come
on.

For servicing “Evaporative Emission System” parts, refer to
EC-27, "
EVAPORATIVE EMISSION SYSTEM" (QR20DE), or
EC-366, "
EVAPORATIVE EMISSION SYSTEM" (VQ23DE
and VQ35DE).
SMA803A
SBIA0504E

FL-4
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationBBS005AG
REMOVAL
WARNING:
Be sure to read “General Precautions” before working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Check fuel level on fuel gauge. If fuel gauge indicates more than
the level as shown in the figure (full or almost full), drain fuel
from fuel tank until fuel gauge indicates level as shown in the fig-
ure or below.
NOTE:
Because fuel will be spilled when removing fuel level sensor unit
for the top of fuel is above the fuel level sensor unit installation
surface.

As a guide, fuel level becomes the position as shown in the
figure or below when approximately 10 (2-1/4 Imp gal) of
fuel are drained from fuel tank.

In a case that fuel pump does not operate, perform the follow-
ing procedure.
a. Insert hose of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to draw
fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-8, "
FUEL TANK" .
c. Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-49, "
FUEL PRESSURE RELEASE" (QR20DE
), or EC-392, "
FUEL PRESSURE RELEASE" (VQ23DE and VQ35DE).
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside fuel tank.
5. Remove rear seat cushion. Refer to SE-112, "
REAR SEAT" .
1. Lock ring 2.Fuel level sensor unit, fuel filter and
fuel pump assembly3. Seal packing
PBIC2519E
KBIA1942J