NISSAN X-TRAIL 2003 Service Repair Manual

FUEL TANK
FL-23
[YD22DDTi]
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FUEL TANKPFP:17202
Removal and InstallationEBS00BL3
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-16, "
General Precau-
tions" .
1. Perform the procedure from 1 to 7 in “removal” of FL-19, "
FUEL LEVEL SENSOR UNIT" .
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" .
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Vent hose 5. Vent tube 6. EVAP hose
7. Fuel filler hose 8. Fuel transport pump 9. Fuel hose
10. Fuel tube 11. Fuel tank protector 12. Fuel tank band
13. Fuel tank
PBIC2033E

FL-24
[YD22DDTi]
FUEL TANK

5. Using a transmission jack, support the bottom of final drive
assembly.
6. 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.
7. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.

Instruction for quick connector of EVAP hose. Refer to FL-19,
"FUEL LEVEL SENSOR UNIT" .
8. Disconnect connector of fuel transport pump and remove bolts
for bracket.
9. Remove fuel tank protector.
10. Remove fuel tank band mounting bolts while supporting fuel
tank.
CAUTION:
Sustain the bottom of the tank by using plate or anything
same.
11. Remove fuel tank.
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.

After lifting down the front portion of fuel tank, remove the fuel tank by pulling it from the upper front of
final drive assembly, so that the fuel tank can move forwardly.
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 positioned on swelled area of fuel tube.

Tighten fuel hose clamp so that the distance between its lugs becomes to the following.

Fit mounting band pin to the vehicle side securely.

Before fixing the fuel tank, temporarily install the fuel filler tube.
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-19, "FUEL LEVEL SENSOR UNIT" .
KBIA0285E
PBIC2035E
KBIA0290E
Fuel filler hose : 35 mm (1.38 in)
The other hose : 25 mm (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-25
[YD22DDTi]
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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.

FL-26
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00BL5
Tightening TorqueEBS00BL6
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)* Fuel tank capacity
Approx. 60 (13-1/4 Imp gal)
Fuel filter drain plug4.9 (0.50, 43)*
Fuel tank band31.4 (3.2, 23)
Fuel filler tube 9.1 (0.93, 81)*
Vent tube9.1 (0.93, 81)*
Lock ring32.9 (3.4, 24)
Fuel transport pump4.8 (0.49, 42)*

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTION
A
EX

EXHAUST SYSTEM
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2
Removal and Installation .......................................... 2
QR20DE AND QR25DE ........................................ 2
YD22DDTI ............................................................. 3
REMOVAL ............................................................. 3
INSTALLATION ..................................................... 3
INSPECTION AFTER INSTALLATION ................. 4SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5
Tightening Torque ..................................................... 5
QR20DE AND QR25DE ........................................ 5
YD22DDTI ............................................................. 5

EX-2
EXHAUST SYSTEM

EXHAUST SYSTEMPFP:20100
Checking Exhaust SystemEBS00AZ6
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.

If anything is found, repair or replace damaged parts.
Removal and InstallationEBS003DN
CAUTION:

Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.

Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.

Be careful not to cut your hand on the insulator edge.
QR20DE AND QR25DE
SMA211A
1. Main muffler 2. Mounting rubber 3. Spring
4. Gasket 5. Three way catalyst 6. Exhaust front tube
7. Seal bearing 8. Mounting rubber bracket 9. Mounting bracket
10. Exhaust center tube
SBIA0434E

EXHAUST SYSTEM
EX-3
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EX

YD22DDTI
REMOVAL
Separate each connection as necessity.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:

Always replace exhaust gaskets and seal bearings with new ones when reassembling.

If insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.

When installing insulator avoid large gaps or interference between insulator and each exhaust
pipe.

Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.

Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
cle side. Check each part for unusual interference, and then tighten them to the specified torque.

When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.

Install seal bearings at exhaust front 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.
1. Main muffler 2. Mounting rubber 3. Spring
4. Gasket 5. Exhaust tube 6. Exhaust front tube
7. Exhaust bracket 8. Mounting rubber bracket 9. Mounting bracket
10. Exhaust center tube 11. Gasket 12. Seal bearing
PBIC2440E

EX-4
EXHAUST SYSTEM

Exhaust Front Tube Side (QR20DE and QR25DE)
Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with
exhaust front tube flange.
Main Muffler Side (QR20DE, QR25DE and YD22DDTi)
Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with main
muffler flange.
INSPECTION AFTER INSTALLATION

With the engine running, check exhaust tube joints for gas leakage and unusual noises.

Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
PBIC2274E
PBIC2275E

SERVICE DATA AND SPECIFICATIONS (SDS)
EX-5
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EX

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Tightening TorqueEBS00KP4
QR20DE AND QR25DE
Unit: N·m (kg-m, ft-lb)
YD22DDTI
Unit: N·m (kg-m, ft-lb) Exhaust system connections
Exhaust manifold three way catalyst assembly to exhaust front
tube43.1 - 54.9 (4.4 - 5.5, 32 - 40)
Exhaust front tube to three way catalyst 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Three way catalyst to exhaust center tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust center tube to main muffler 43.1 - 54.9 (4.4 - 5.5, 32 - 40)
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Exhaust system connections
Catalyst rear diffuser to exhaust front tube 59.8 - 69.6 (6.1 - 7.0, 45 - 51)
Exhaust front tube to exhaust tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust tube to exhaust center tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust center tube to main muffler 43.1 - 54.9 (4.4 - 5.5, 32 - 40)
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)

EX-6
SERVICE DATA AND SPECIFICATIONS (SDS)