NISSAN X-TRAIL 2001 Service Repair Manual

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
[QR]
C
D
E
F
G
H
I
J
K
L
MA
FL
Disassembly and AssemblyEBS00KOV
NOTE:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
1. Remove fuel pump removing bracket.
●Using a screwdriver, remove the snap fit portion of bracket in
the order of (1), (2), (3) and (4) as shown in the figure.
2. Disconnect fuel pump harness connector.
PBIC0241E
1. Pressure regulator 2. Fuel pump 3. Packing
4. Fuel filter 5. Rubber 6. Fuel level sensor unit
7. Bracket
PBIC0242E
PBIC0243E

FL-8
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
3. Separate the fuel filter and fuel level sensor unit.
a. Fit a used O-ring into space between fuel level sensor unit and
fuel filter. Undo catches and separate fuel level sensor unit and
fuel filter.
●For reference when reassembling, put a mating mark on outer
edges of fuel level sensor unit and fuel filter with some means
which cannot be erased by fuel.
b. Insert blade end screwdriver to the gap between the fuel filter
and fuel level sensor unit to separate them.
CAUTION:
Put cloth or similar one on the edge of screwdriver not to
damage the inserted portion.
4. Remove pressure regulator from fuel filter.
a. Open and remove the clip.
b. Pull the pressure regulator straight out during removal.
CAUTION:
●Avoid impacts such as falling during removal.
●Do not disassemble or adjust.
ASSEMBLY
Install in the reverse order of removal paying attention to the following.
●Install the fuel filter and fuel pump with the tabs aligned, Make sure a click sound of secure engagement is
heard.
●Securely connect the harness connector of the fuel pump.
●Install the pressure regulator O-ring as follows.
CAUTION:
●When replacing, always use a new O-ring.
●Handle it with bare hands. (Do not use gloves.)
●Visually check the O-ring, mounting parts and mating parts for foreign materials and flaws.
●Before installing, apply new engine oil.
●To avid damage, do not apply an excessive force (pulling or starching).
●Install the pressure regulator as follows.
1. Insert the clip to the groove of the pressure regulator.
2. With the clip installed, insert the pressure regulator straight by
matching the fuel filter protrusion and the clip notch.
3. Make sure that the fuel filter protrusion and clip notch are
securely engaged.
PBIC0244E
PBIC0245E

FUEL TANK
FL-9
[QR]
C
D
E
F
G
H
I
J
K
L
MA
FL
FUEL TANKPFP:17202
Removal and InstallationEBS00KOW
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Release fuel pressure from fuel line. Refer to EC-775, "
FUEL
PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)], EC-
11 3 9 , "FUEL PRESSURE RELEASE" [QR20DE (WITHOUT
EURO-OBD)], EC-42, "
FUEL PRESSURE RELEASE"
[QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE
RELEASE" [QR25DE (WITHOUT EURO-OBD)].
2. Open the fuel filler cap and release the pressure inside the fuel
tank.
3. Remove rear seat bottom.
4. Remove inspection hole cover, harness connector and fuel feed
hose.
5. Drain fuel from fuel tank if necessary. For the draining procedure, refer to Step 4 in removal of FL-4,
"FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
CAUTION:
For the safety work and to maintain fuel tank gravity at center, drain fuel to the level where fuel
tank weight at left and right becomes equal.
6. Disconnect the quick connector.
●Put mating marks on hoses for correct installation.
PBIC0246E
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Vent hose 5. Vent tube 6. Fuel tank
7. Fuel filler hose 8. Fuel tank band 9. Fuel tank protector
KBIA0280E

FL-10
[QR]
FUEL TANK
7. Remove exhaust center tube and insulator. Refer to EX-2, "EXHAUST SYSTEM" .
8. Remove propeller shaft. Refer to PR-2, "
REAR PROPELLER SHAFT" .
9. Using a transmission jack, support the bottom of the rear final
drive.
10. Remove the mounting nuts on the rear suspension member, and
lower the transmission jack carefully until just before the rear
suspension member is removed from the stud bolts on the vehi-
cle.
11. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.
12. For disconnection procedure of the quick connector on the
evaporator hose, Refer to FL-4, "
FUEL LEVEL SENSOR UNIT,
FUEL FILTER AND FUEL PUMP ASSEMBLY" .
13. Remove fuel tank protector.
14. Remove fuel tank band mounting bolts while supporting fuel
tank.
15. Remove fuel tank.
INSTALLATION
Install in the reverse order of removal paying attention to the following.
●Surely clamp fuel hoses and insert hose to the length below.
●Be sure hose clamp is not placed on swelled area of fuel tube.
●Tighten fuel hose clamp so that the distance between its lugs becomes to the following.
●Push the mounting band pin to the vehicle side securely.
●Before fixing the fuel tank, temporarily install the filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.
●To connect the quick connector, refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY" .
KBIA0285E
KBIA0286E
KBIA0290E
Fuel filler hose : 35mm (1.38 in)
The other hoses : 25mm (0.98 in)
Fuel tank side : 5 - 9 mm (0.20 - 0.35 in)
Fuel filler tube side : 7 - 11 mm (0.28 - 0.43 in)

FUEL TANK
FL-11
[QR]
C
D
E
F
G
H
I
J
K
L
MA
FL
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel
leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.

FL-12
[QR]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00KOX
FUEL TANK
Tightening TorqueEBS00KOY
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)* Fuel tank capacity
Approx. 60 (13-1/4 Imp gal)
Lock ring30.4 - 35.3 (3.1- 3.6, 23 - 26)
Fuel tank band 27.4 - 35.3 (2.8 - 3.6, 21 - 26)
Fuel tank band to fuel tank protector 4.3 - 5.8 (0.43 - 0.59, 38 - 51)*
Fuel filler tube 7.8 - 10.4 (0.80 - 1.1, 69 - 92)*
Ve n t t u b e7.8 - 10.4 (0.80 - 1.1, 69 - 92)*

PREPARATION
FL-13
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
FL
[YD22DDTi]PREPARATIONPFP:00002
Commercial Service ToolEBS00BKG
To o l n a m eDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D

FL-14
[YD22DDTi]
FUEL SYSTEM
FUEL SYSTEM
PFP:17503
Checking Fuel LinesEBS00BKH
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS00BKI
WARNING:
When replacing fuel line parts, be sure to observe the following.
●Put a “CAUTION: INFLAMMABLE” sign in 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 spark away from work area.
CAUTION:
●Before removing fuel line parts, carry out the following procedures:
–a) Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container
in safe area.
–b) Disconnect battery ground cable.
●Always replace O-ring and clamps with new ones.
●Do not kink or twist tubes when they are being installed.
●Do not tighten hose clamps excessively to avoid damaging hoses.
●After installing tubes, make sure there is no fuel leakage at connections in the following steps.
–a) Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then
check for fuel leaks at connections.
–b) Start the engine and rev it up and check for fuel leaks at connections.
SMA803A

FUEL FILTER
FL-15
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
FL
FUEL FILTERPFP:16400
Removal and InstallationEBS00BLA
REMOVAL
1. Remove air duct and upper air cleaner case.
2. Remove fuel filter protector.
3. Disconnect fuel hoses at fuel filter bracket.
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type filter wrench (commercial service tool), remove
fuel filter.
6. Turn fuel filter upside down to drain fuel.
7. Remove drain plug from fuel filter.
INSTALLATION
Install in reverse order of removal, paying attention to following:
●Replace O-ring on drain plug with new one.
●Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.
●After installation, bleed air from fuel path. Refer to FL-16, "Air Bleeding" .
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check for
fuel leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
SBIA0134E
SBIA0135E
SBIA0136E
Drain plug
: 3.9 - 5.9 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb)

FL-16
[YD22DDTi]
FUEL FILTER
Air Bleeding
EBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel path as follows:
1. Move priming pump up and down to bleed air from fuel path.
2. When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
3. Crank the engine until it starts. Do not crank the engine for more
than 30 seconds.
4. If the engine does not starts, stop cranking and repeat step 1
above.
5. If the engine does not operate smoothly after it has started, race
it two or three times.
6. If air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel injection pump. After that, operate priming pump
and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mount insulator.
Draining Water from Fuel FilterEBS00MRU
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:
●Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
●Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mount insulator.
3. After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged
and fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer to FL-16, "
Air Bleeding" .
5. Start engine and check for fuel leakage.
SBIA0137E
SBIA0138E