NISSAN X-TRAIL 2003 Service Repair Manual

FUEL SYSTEM
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS00KOS
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 PrecautionsEBS011T7
WARNING:
When replacing fuel line parts, be sure to observe the following.

Put a “CAUTION: INFLAMMABLE” 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.
CAUTION:

Before removing fuel line parts, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Release fuel pressure from the fuel lines. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-510, "
FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
–Disconnect negative battery terminal.

Always replace O-rings 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 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, check if there are no fuel leaks at con-
nections 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.

For servicing “Evaporative Emission System” parts, refer to
EC-473, "
EVAPORATIVE EMISSION SYSTEM" (WITH EURO-
ODB) or EC-865, "
EVAPORATIVE EMISSION SYSTEM"
(WITHOUT EURO-OBD).
SMA803A
SBIA0504E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationEBS00KOU
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Check fuel level on fuel gauge. If gauge indicates more than the
level as shown in the figure (full or almost full), drain fuel from
fuel tank until gauge indicates level as shown in the figure or
below.
NOTE:
Fuel will be spilled when removing main and sub fuel level sen-
sor units for the top of the fuel is above the main and sub fuel
level sensor units installation surface.

As a guide, fuel level becomes the position as shown in the
figure or below when approximately 15 (13-1/4 Imp qt) of
fuel are drained from fuel tank.

In case fuel pump does not operate, perform the following
procedure.
a. Insert fuel tube 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-11, "
FUEL TANK" .
c. Insert fuel tube 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-48, "
FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-510, "
FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside fuel tank.
5. Lift to hold rear seat cushion up. Refer to SE-31, "
REAR SEAT" .
1. Lock ring 2.Main fuel level sensor unit, fuel filter
and fuel pump assembly3.Jet pump, fuel hose and jet pump
inlet assembly
4. Chamber 5. Seal packing 6. Sub fuel level sensor unit
PBIC2257E
FEL0403D

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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6. Remove inspection hole cover for main and sub fuel level sen-
sor units by turning clips clockwise by 90 degrees.
7. Disconnect harness connector and fuel feed hose.

Disconnect quick connector as follows:
–Hold the sides of connector, push in tabs and pull out tube.
–If connector and tube are stuck together, push and pull sev-
eral times until they start to move. Then disconnect them by
pulling.
PBIC2258E
KBIA0280E
SFE562A

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:

Quick connector can be removed when the tabs are
completely depressed. Do not twist it more than neces-
sary.

Do not use any tools to disconnect quick connector.

Keep resin tube away from heat. Be especially careful
when welding near the tube.

Prevent acid liquid such as battery electrolyte, etc.
from getting on resin tube.

Do not bend or twist resin tube during installation and
disconnection.

Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is
replaced.

When resin tube or hard tube (or equivalent) is
replaced, also replace retainer with a new one.

To keep the connecting portion clean and to avoid
damage and foreign materials, cover them completely
with plastic bags or something similar.
8. Using a fuel tank lock ring wrench (commercial service tool),
remove lock ring.
9. Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as
follows.
CAUTION:

Do not bend float arm during removal.

Avoid impacts such as falling when handling components.Retainer color: Green
SBIA0504E
PBIC0163E
PBIC0240E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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a. Removal of main fuel level sensor unit, fuel filter and fuel pump
assembly:
i. Raise main fuel level sensor unit, fuel filter and fuel pump
assembly, and disconnect jet pump.
ii. Leave jet pump on fuel tank with fuel hose.
CAUTION:
Do not disconnect jet pump and fuel hose.
iii. If necessary, remove chamber from the bottom of fuel tank by
sliding toward the rear of the vehicle.
b. Removal of sub fuel level sensor unit:
i. Raise and release sub fuel level sensor unit to remove.
ii. If necessary, remove jet pump inlet from the bottom of fuel tank by pinching tabs.
CAUTION:
Do not separate jet pump inlet and fuel hose.
INSPECTION AFTER REMOVAL
Make sure that fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Note the following, and install in the reverse order of removal.
Chamber and Jet Pump
When installing chamber and jet pump, insert them fully until a click
sound of full stopper engagement is heard (Ditto for jet pump inlet).
Main and Sub Fuel Level Sensor Unit
Install fuel level sensor unit with positioning 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.
Quick Connector
Connect 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 sound is
heard.
3. After connecting, make sure that the connection is secure by following method.

Visually confirm that the two tabs are connected to the connector.
KBIA0281E
KBIA0302E
KBIA0282E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Pull the tube and the connector to make sure they are
securely connected.
Inspection Hole Cover
Install inspection hole covers with the front mark (arrow) facing front of the vehicle.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres-
sure to fuel piping.
2. Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.
Disassembly and AssemblyEBS00KOV
CAUTION:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
1. Remove fuel pump removing bracket as follows:
PBIC1653E
1. Fuel filter 2. O-ring 3. Clip
4. Pressure regulator 5. O-ring 6. Fuel level sensor unit
7. Bracket 8. Rubber 9. Fuel pump
10. Packing
PBIC2259E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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a. Using a screwdriver, separate the snap fit portion of bracket in
numerical order as shown in the figure.
CAUTION:
Put cloth or similar one on the edge of screwdriver not to
damage the inserted portion.
b. Pull out fuel pump, and disconnect harness connector.
2. Separate fuel filter and fuel level sensor unit as follows:
a. Fit a used O-ring into space between fuel level sensor unit and
fuel filter to release tabs.
NOTE:
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 screwdriver to the gap between 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.
3. Remove pressure regulator from fuel filter as follows:
a. Open and remove the clip.
b. Pull pressure regulator straight out during removal.
CAUTION:

Avoid impacts such as falling during removal.

Do not disassemble or adjust.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.

Install fuel filter and fuel pump with the tabs aligned. Make sure a click sound of secure engagement is
heard.

Securely connect harness connector of fuel pump.

Install pressure regulator O-ring.
CAUTION:

When replacing, always use 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).
PBIC0242E
PBIC0243E
PBIC0244E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Install pressure regulator as follows:
1. Insert the clip to the groove of pressure regulator.
2. With the clip installed, insert pressure regulator straight by
matching the fuel filter lug and the clip notch.
3. Make sure that the fuel filter lug and the clip notch are securely
engaged.
PBIC2494E

FUEL TANK
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FUEL TANKPFP:17202
Removal and InstallationEBS00KOW
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Perform the steps 1 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”. Refer to FL-4, "
REMOVAL" .
2. Drain fuel more from fuel tank if necessary.
CAUTION:
Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel should
be drained if found the remaining quantity.
3. Remove exhaust center tube and insulator. Refer to EX-2, "
EXHAUST SYSTEM" .
4. Remove propeller shaft. Refer to PR-3, "
REAR PROPELLER SHAFT" .
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

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FUEL TANK

5. Using a transmission jack, support the bottom of final drive
assembly.
6. Remove mounting nuts on rear suspension member, and lower
the transmission jack carefully until just before rear suspension
member is removed from stud bolts on the vehicle. Refer to
RSU-5, "
REAR SUSPENSION ASSEMBLY" .
7. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.

For disconnection procedure of quick connector on EVAP
hose, refer to FL-4, "
FUEL LEVEL SENSOR UNIT, FUEL FIL-
TER AND FUEL PUMP ASSEMBLY" .
8. Remove fuel tank protector.
9. Remove fuel tank band mounting bolts while supporting fuel
tank.
CAUTION:
Sustain the bottom of fuel tank by using plate or anything
same.
10. Remove fuel tank.

After lifting down the front portion of fuel tank, remove fuel
tank by pulling it from the upper front of final drive assembly,
so that fuel tank can move forwardly.
CAUTION:
Pay attention not to fall fuel tank because it forwardly
inclines and becomes unstable.
NOTE:
It is desirable that more than two technicians work together.
INSTALLATION
Note the following, and install in the reverse order of removal.

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 remaining length of screw thread becomes to the following.

Fit fuel tank band pin to the vehicle side securely.

Before fixing fuel tank, temporarily install fuel filler tube.
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)