NISSAN X-TRAIL 2003 Service Repair Manual

FUEL TANK
FL-13
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CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.

To connect quick connector, refer to FL-7, "Quick Connector" .
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), and 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 tube and hose connec-
tions.

FL-14
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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 ring32.9 (3.4, 24)
Fuel tank band 27.4 - 35.3 (2.8 - 3.6, 21 - 26)
Fuel tank protector 4.3 - 5.8 (0.43 - 0.59, 38 - 51)*
Fuel filler tube 7.8 - 10.4 (0.80 - 1.0, 69 - 92)*
Vent tube7.8 - 10.4 (0.80 - 1.0, 69 - 92)*

PREPARATION
FL-15
[YD22DDTi]
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[YD22DDTi]PREPARATIONPFP:00002
Commercial Service ToolsEBS00BKG
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D

FL-16
[YD22DDTi]
FUEL SYSTEM

FUEL SYSTEMPFP: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, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Disconnect negative battery terminal.

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 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.
–Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
SBIA0504E

FUEL FILTER
FL-17
[YD22DDTi]
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FUEL FILTERPFP:16400
Removal and InstallationEBS00BLA
REMOVAL
1. Remove air duct, air cleaner case and mass air flow sensor assembly. Refer to EM-133, "AIR CLEANER
AND AIR DUCT" .
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 fuel filter bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type fuel 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
Note the following, and install in the reverse order of removal.

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 line. Refer to FL-18, "Air Bleeding" .
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start the engine and rev it up and make sure there is no fuel leakage at connections.
PBIC2501E
SBIA0135E
SBIA0136E
Drain plug
: 4.9 N·m (0.5 kg-m, 43 in-lb)

FL-18
[YD22DDTi]
FUEL FILTER

Air BleedingEBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel line as follows:

Move priming pump up and down to bleed air from fuel path.

When air is bled, pumping of priming pump becomes heavy stop
operation at that time.

Crank engine until it starts. Do not crank engine for more than
30 seconds.

If engine does not start, stop cranking and repeat step 1 above.

If engine does not operate smoothly after it has started, race it
two or three times.

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 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
mounting 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 mounting 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-18, "
Air Bleeding" .
5. Start engine and make sure there is no fuel leakage.
SBIA0137E
SBIA0138E

FUEL LEVEL SENSOR UNIT
FL-19
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FUEL LEVEL SENSOR UNITPFP:17042
Removal and InstallationEBS00BLD
REMOVAL
WARNING:
Be sure to read “General Precautions” When working on fuel system. Refer to FL-16, "
General Precau-
tions" .
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank.
3. Check fuel level on level place. If gauge indicates more than the
level shown in figure (full or almost full), drain fuel from fuel tank
until gauge indicates level shown in figure or below.

Refer to the following for draining fuel.
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.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel
from fuel tank.

As a guide, fuel level becomes the position shown in figure or
below when approximately 15 liter (13-1/4 lmp qt) of fuel are drained from full tank.
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit is removed.
4. Disconnect negative battery terminal.
5. Lift to fold rear seat cushion up. Refer to SE-31, "
REAR SEAT" .
6. Peel off floor carpet, then remove inspection hole cover.
1. Lock ring 2. Main fuel level sensor unit 3. Seal packing
4. Chamber 5. Sub fuel level sensor unit
PBIC2031E
FEL0403D

FL-20
[YD22DDTi]
FUEL LEVEL SENSOR UNIT


Remove clip by turning it about 90 degrees clockwise.
7. Disconnect harness connector, fuel feed tube, fuel return tube
and fuel hose. (Figure shows left side of fuel tank.)

For the right, disconnect harness connector and fuel hose.

Disconnect quick connector of fuel feed tube and fuel return
tube as follows.
NOTE:

Hold the sides of the connector, push in tubs and pull out the
tube.

If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them
by pulling.Left hand : Main fuel level sensor unit
Right hand : Sub fuel level sensor unit
SBIA0140E
PBIC2034E
SFE562A

FUEL LEVEL SENSOR UNIT
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CAUTION:

The 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 the 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 the tube during installation and
removal.

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

When resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one.

To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
8. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
9. Remove main fuel level sensor unit (Left hand) and sub fuel level sensor unit (Right hand).
CAUTION:

Do not bend the float arm during removal.

Avoid impacts such as falling when handling components.
Left hand (main fuel level sensor unit):

If necessary, remove the chamber from the bottom of the fuel tank.

Remove the chamber by sliding toward the rear of the vehicle.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC0240E

FL-22
[YD22DDTi]
FUEL LEVEL SENSOR UNIT

INSPECTION AFTER REMOVAL
Make sure 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.

Connect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.

Visually confirm that the two tabs are connected to connector.

Pull the tube and connector to make sure they are securely
connected.

Install fuel level sensor unit with mating mark (triangular pro-
trusion) 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.

Install inspection hole cover with the front mark (arrow) facing front of vehicle (both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start engine and rev it up and make sure there is no fuel leakage at connections.
PBIC1653E
PBIC2032E