NISSAN X-TRAIL 2003 Electronic Repair Manual

FL-6
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
7. Using a lock ring wrench, remove the lock ring.
8. Remove main fuel level sensor unit, fuel filter and fuel pump
assembly, and sub fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling compo-
nents.
lRemoval of main fuel level sensor unit, fuel filter, fuel pump
assembly.
lRaise the sender unit, and remove the jet pump to remove the
sender unit.
lLeave the jet pump on the fuel tank with the fuel hose.
lIf necessary, remove the chamber from the bottom of the fuel tank.
lRemove the chamber by sliding toward the rear of the vehicle.
Removal of sub fuel level sensor unit.
lRaise and release the sub fuel level sensor unit to remove.
lIf necessary, remove the jet pump inlet from the bottom of the fuel tank.
To remove it, pinch the tabs (2 places).
INSPECTION AFTER REMOVAL
Make sure the fuel pump strainer is free from foreign materials, If any are found, remove them.
INSTALLATION
Install in the reverse order of removal paying attention to the follow-
ing.
lWhen installing the chamber and jet pump, insert them fully until
a click sound of full stopper engagement is heard (Ditto for jet
pump inlet).
lConnect the quick connector as follows.
1. Check the connection for damage and foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
lVisually confirm that the two retainer tabs are connected to the connector.
lPull the tube and the connector to make sure they are securely connected.
PBIC0240E
KBIA0281E
KBIA0302E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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lInstall fuel level sensor unit with mating mark (triangular protru-
sion) facing between two carved lines on fuel tank.(Figure
shows left side of fuel tank.)
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
lInstall the inspection hole cover with the front mark (arrow) fac-
ing front of the vehicle (Both for RH and LH).
INSPECTION AFTER INSTALLATION
Start the engine and rev it up and make sure there is no fuel leakage at connections.
Disassembly and AssemblyEBS00BKS
NOTE:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
1. Remove fuel pump removing bracket.
lUsing a screwdriver, remove the snap fit portion of bracket in the
order of (1), (2), (3) and (4) as shown in the figure.
KBIA0282E
PBIC0241E
1 Pressure regulator 2 Fuel pump 3 Packing
4 Fuel filter 5 Rubber 6 Fuel level sensor unit
7 Bracket
PBIC0242E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
2. Disconnect fuel pump harness connector.
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.
lFor 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:
lAvoid impacts such as falling during removal.
lDo not disassemble or adjust.
ASSEMBLY
Install in the reverse order of removal paying attention to the following.
lInstall the fuel filter and fuel pump with the tabs aligned, Make sure a click sound of secure engagement
is heard.
lSecurely connect the harness connector of the fuel pump.
lInstall the pressure regulator O-ring as follows.
CAUTION:
lWhen replacing, always use a new O-ring.
lHandle it with bare hands. (Do not use gloves.)
lVisually check the O-ring, mounting parts and mating parts for foreign materials and flaws.
lBefore installing, apply new engine oil.
lTo avid damage, do not apply an excessive force (pulling or starching).
lInstall the pressure regulator as follows.
1. Insert the clip to the groove of the regulator.
2. With the clip installed, insert the 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.
PBIC0243E
PBIC0244E
PBIC0245E

FUEL TANK
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FUEL TANKPFP:17202
Removal and InstallationEBS00BKT
REMOVAL
WA RN ING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Release fuel pressure from fuel line, Refer toEC-34, "
FUEL
PRESSURE RELEASE",EC-399, "FUEL PRESSURE
RELEASE".
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 proce-
dure, refer to Step 4 in removal ofFL-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. Remove the quick connector.
lPut mating marks on hoses for correct installation.
7. Remove exhaust center tube and insulator.
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

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FUEL TANK
8. Remove propeller shaft. Refer toPR-3, "Removal and Installation".
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 toFL-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.
lSurely clamp fuel hoses and insert hose to the length below.
lBe sure hose clamp is not placed on swelled area of fuel tube.
lTighten fuel hose clamp so that the distance between its lugs becomes to the following.
lPush the mounting band pin to the vehicle side securely.
lBefore 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.
lTo connect the quick connector, refer toFL-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
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Inspection After InstallationEBS00BM3
Run engine and check for fuel leaks at connections.

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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00BKV
Tightening TorqueEBS00BKW
Unit: N·m (kg-m, ft-lb) N·m (kg-m, in-lb)* Fuel tank capacity
Approx. 60 (13-1/4 Imp gal)
Fuel tank band 27.4 - 35.3 (2.8 - 3.6, 21 - 26)
Fuel filler tube 7.8 - 10.4 (0.80 - 1.1, 69 - 92)*
Lock ring.30.4 - 35.3 (3.1- 3.6, 23 - 26)*

PREPARATION
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[YD22DDTi]PREPARATIONPFP:00002
Commercial Service ToolEBS00BKG
Tool number
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D

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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 faulty parts.
General PrecautionsEBS00BKI
WAR NIN G:
When replacing fuel line parts, be sure to observe the following.
lPut a “CAUTION: FLAMMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
lBefore 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.
lAlways replace O-ring and clamps with new ones.
lDo not kink or twist tubes when they are being installed.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lAfter installing tubes, run engine and check for fuel leaks at connections.
SMA803A

FUEL FILTER
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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:
lReplace O-ring on drain plug with new one.
lScrew the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.
lAfter installation, bleed air from fuel path. Refer toFL-16, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Run engine and check for fuel leakage at connections.
SBIA0134E
SBIA0135E
SBIA0136E
: 3.9 - 5.9 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb)