secure NISSAN X-TRAIL 2003 Electronic Manual PDF

EXHAUST SYSTEM
EX-3
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YD22DDTI
RREMOVAL
Separate each connection as necessity.
INSTALLATION
Install in the reverse order of removal paying attention to the following.
lIf the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insulator,
remove them.
lWhen installing the insulator avoid large gaps or interference between the insulator and each exhaust
pipe.
lRemove deposits and left over gasket material from the sealing surface of each connection. Connect
them securely to avoid gas leakage.
lTemporarily tighten the exhaust manifold side mounting nuts and the vehicle side mounting bolts. Check
each part for unusual interference, and then tighten them to the specified torque.
lWhen installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left direc-
tions.
lInstall the seal bearings at front exhaust tube and main muffler as follows.
CAUTION:
Do not mix the bolt and spring for seal bearing as the dimension is different for each seal bearing.
SBIA0121E
1 Main muffler 2 Mounting rubber 3 Spring
4 Ring gasket 5 Pre-muffler 6 Exhaust front tube
7 Pre-muffler bracket 8 Mounting rubber bracket 9 Mounting bracket
10 Exhaust center tube 11 Gasket 12 Seal bearing

FAX-12
FRONT DRIVE SHAFT
lDo not allow drive shaft, with transaxle inserted, to hang down without support for counter
shaft, wheel joints, and other parts.
lWhen the drive shafts listed below have been removed, check that a circular clip is attached to the end.
lRemove installation bolt from right-side drive shaft support bearing bracket. Then remove bracket from
engine.
lRemove installation bolt from right-side drive shaft and remove drive shaft from side shaft.
INSPECTION AFTER REMOVAL
lMove joint in up/down, left/right, and axial directions. Check for
motion that is not smooth and for significant looseness.
lCheck for cracking and damage of boots, and for grease leak-
age.
INSTALLATION
lInstall support bearing bracket onto engine and tighten installation bolts to specified torque.
lInstall drive shaft to side shaft and tighten installation bolts to specified torque.
1. In order to prevent damage to differential side oil seal, first fit a
protector onto oil seal before inserting drive shaft. Slide drive
shaft slide joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circular clip is securely fastened.
2. Insert drive shaft into steering knuckle. Install washers and tem-
porarily tighten lock nuts.
3. Install installation bolt for steering knuckle and strut.
4. Use lock plate to fix brake hose to strut.
5. Install tie rod to steering knuckle.
6. Install ABS wheel speed sensor.
7. Tighten lock nuts to specified torque.
8. Install cotter pin.
CAUTION:
Discard the old cotter pin; replace with a new one.
Engine typeDrive shaft with circular clip
Right Left
QR20DE —m
YD22ET —m
RAA0030D
Model type Protector SST No.
RH KV38107800
LH KV38105500
SDIA0593E
SDIA0603E

FRONT DRIVE SHAFT
FAX-15
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FA X
Joint Assembly (Wheel Side)
CAUTION:
Joint assembly cannot be disassembled. Do not attempt to disassemble it.
ASSEMBLY
Transaxle Side
1. Wind serrated part of drive shaft with tape. Install boot band and
boot to shaft. Be careful not to damage boot.
CAUTION:
Discard the old boot band and boot: replace with new ones.
2. Remove protective tape wound around serrated part of shaft.
3. Line up alignment marks which were made when spider assem-
bly was removed. Install spider assembly, with serration chamfer
facing drive shaft.
4. Secure spider assembly with snap ring.
CAUTION:
Discard the old snap ring: replace with new ones.
5. Apply Nissan genuine grease or equivalent to spider assembly
and sliding surface.
6. Install sliding joint housing to spider assembly. Add remaining
grease up to the amount listed below.
7. Install boot securely into grooves (indicated by * marks) shown
in the figure.
CAUTION:
If there is grease on boot mounting surfaces (indicated by *
marks) of joint, boot may come off. Remove all grease from
surfaces.
8. Check that boot installation length “L” is the length indicated
below. Insert a screwdriver or similar tool into smaller side of
boot. Remove air from boot to prevent boot deformation.
CAUTION:
lBoot may break if boot installation length is less than
standard value.
lBe careful that screwdriver tip does not contact inside
surface of boot.
SDIA0597E
Grease amount : 133 - 143 g (4.69 - 5.04 oz)
SDIA0598E
SDIA0599E
Boot installation length:
84 - 86 mm (3.31 - 3.39 in)
SDIA0600E

FAX-16
FRONT DRIVE SHAFT
9. Secure big and small ends of boot with new boot bands as
shown in figure.
CAUTION:
Rotate housing and check that boot installation position
does not change. If position changes, reinstall boot bands.
Wheel Side
1. Use a drift to press-fit sensor rotor into joint sub-assembly.
CAUTION:
lDiscard the old sensor rotor; replace with a new one.
lJoint assembly cannot be disassembled. Do not attempt
to disassemble it.
Dynamic Damper
lWhen dynamic damper has been removed, secure with bands
as shown in the figure so that measurements from fixed-joint
side are as listed below.
CAUTION:
Discard the old dynamic damper: replace with a new one.
Mounting Dimensions
SDIA0601E
SDIA0619E
FAC0156D
Drive shaft model Specification Dimension A Dimension B
ZF100SS86 Left
267 - 273 mm (10.51 - 10.75 in) 70 mm (2.76 in) ZF100SS86F
Right
ZF100SS86F+B

FUEL SYSTEM
FL-3
[QR20DE]
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS00BKP
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 PrecautionsEBS00BKQ
WA RN ING:
when replacing fuel line parts, be sure to observe the following.
lPut a “ CAUTION: FLAMABLE” 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) Release fuel pressure from fuel line, Refer toEC-34, "Fuel Pressure Check",EC-399, "Fuel
Pressure Check".
–c) Disconnect battery ground cable.
lAlways replace O-ring and clamps with new ones.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lDo not kink or twist tubes when they are being installed.
lAfter installing tubes, run engine and check for fuel leaks at connections.
SMA803A

FL-6
[QR20DE]
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

FL-8
[QR20DE]
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

FL-10
[QR20DE]
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)

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 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 LEVEL SENSOR UNIT
FL-19
[YD22DDTi]
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lTo keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
8. Using a lock ring wrench, remove the lock ring.
9. Remove main fuel level sensor unit and sub fuel level sensor
unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling components.
Removal of main fuel level sensor unit:
lRaise the fuel level sensor unit, and remove the jet pump.
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 (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 fol-
lowing the steps below.
PBIC0163E
PBIC0240E
SBIA0142E
SBIA0143E