fuel cap release NISSAN X-TRAIL 2003 Service Repair Manual

PRECAUTIONS
EM-5
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ

Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining coolant.

Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure there are no leaks at fuel line connections.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00KN5

Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
–Balancer unit

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

INTAKE MANIFOLD
EM-17
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INTAKE MANIFOLDPFP:14003
Removal and Installation (QR20DE)EBS00KNC
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-32, "
Removal and
Installation (QR20DE)" .
4. Remove electric throttle control actuator with the following procedure:
a. Disconnect harness connector.
1. Vacuum hose 2. Intake manifold 3. PCV hose
4. Bracket 5. Gasket 6. Electric throttle control actuator
7. Gasket 8. Intake manifold support 9. Gasket
10. Vacuum hose 11.EVAP canister purge volume con-
trol solenoid valve12. Vacuum hose
13. Bracket 14. Bracket
PBIC2172E
PBIC2175E

EM-20
[QR]
INTAKE MANIFOLD

Removal and Installation (QR25DE)EBS011TH
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-37, "
Removal and
Installation (QR25DE)" .
4. Remove electric throttle control actuator with the following procedure:
1. Bracket 2. PCV hose 3. Intake manifold collector
4. Gasket 5. Electric throttle control actuator 6. Intake manifold rear support
7.EVAP canister purge volume control
solenoid valve8. Vacuum hose 9. Intake manifold
10. Vacuum reservoir tank 11. VIAS control solenoid valve 12. Vacuum hose
13. Bracket 14. Intake manifold support 15. Vacuum reservoir tank bracket
PBIC2174E
PBIC2175E

EM-32
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FUEL INJECTOR AND FUEL TUBE

FUEL INJECTOR AND FUEL TUBEPFP:16600
Removal and Installation (QR20DE)EBS00KNH
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Disconnect quick connectors at engine side and vehicle side as
follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using quick connector
release (special service tool), not by picking out retainer
tabs.
NOTE:
There is quick connector for the engine side and for the vehicle
side, and they have different shapes. But disconnection is same
procedure. The following procedure shows the engine side.
a. Remove quick connector cap (engine side).
1. Fuel feed hose 2. Quick connector cap (engine side) 3. Quick connector cap (vehicle side)
4. Centralized under-floor piping 5. Sub-harness 6. Fuel tube protector
7. Fuel tube 8. O-ring (black) 9. Clip
10. Fuel injector 11. O-ring (green)
PBIC2178E
PBIC2175E
KBIA0701E

FUEL INJECTOR AND FUEL TUBE
EM-37
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Removal and Installation (QR25DE)EBS011SY
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE CHECK" (WITHOUT EURO-OBD).
2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "
AIR
CLEANER AND AIR DUCT" .
3. Disconnect quick connectors at engine side and vehicle side as
follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using quick connector
release (special service tool), not by picking out retainer
tabs.
NOTE:
There is quick connector for the engine side and for the vehicle
side, and they have different shapes. But disconnection is same
procedure. The following procedure shows the engine side.
a. Remove quick connector cap (engine side).
1. Fuel feed hose 2. Quick connector cap (engine side) 3. Quick connector cap (vehicle side)
4. Centralized under-floor piping 5. Sub-harness 6. Fuel tube
7. O-ring (black) 8. Clip 9. Fuel injector
10. O-ring (green) 11. Insulator
PBIC2179E
PBIC2175E
KBIA0701E

EM-122
[YD22DDTi]
PRECAUTIONS

[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Draining Engine CoolantEBS00LQZ
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00LR0

Before starting work, make sure no fire or spark producing items are in the work area.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00LR1

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00LR2
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00LR3

Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new liquid gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, engine oil sliding surfaces well.

Release air within route when refilling after draining coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00LR4

Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

PREPARATION
EC-29
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Commercial Service ToolsEBS010L5
Tool name Description
Quick connector
releaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
Fuel filler cap adapter Checking fuel tank vacuum relief valve opening
pressure
Socket wrench Removing and installing engine coolant
temperature sensor
Oxygen sensor thread
cleaner
i.e.: (J-43897-18)
(J-43897-12)Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
Anti-seize lubricant
i.e.: (Permatex
TM
133AR or equivalent
meeting MIL
specification MIL-A-
907)Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.
PBIC0198E
S-NT653
S-NT705
AEM488
S-NT779

DTC P0420 THREE WAY CATALYST FUNCTION
EC-261
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DTC P0420 THREE WAY CATALYST FUNCTIONPFP:20905
On Board Diagnosis LogicEBS010Q8
The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 and 2.
A three way catalyst (manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (manifold)
malfunction is diagnosed.
DTC Confirmation ProcedureEBS010Q9
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:

Open engine hood before conducting the following procedure.

Do not hold engine speed for more than the specified minutes below.
1. Start Engine and warm it up to the normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,00 rpm for at least 1 minute under no load.
4. Let engine idle for 1 minute.
5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUP-
PORT” mode with CONSULT-II.
6. Start engine.
7. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecu-
tive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10
8. Wait 5 seconds at idle.
SEF484YF
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0420
0420Catalyst system efficiency
below threshold

Three way catalyst (manifold) does not operate
properly.

Three way catalyst (manifold) does not have
enough oxygen storage capacity.

Three way catalyst (manifold)

Exhaust tube

Intake air leaks

Fuel injector

Fuel injector leaks

Spark plug

Improper ignition timing
PBIB0566E

PREPARATION
EC-491
[QR (WITHOUT EURO-OBD)]
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Commercial Service ToolsEBS010WL
Tool name Description Description
Quick connector
releaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
Fuel filler cap adapter Checking fuel tank vacuum relief valve opening
pressure
Socket wrench Removing and installing engine coolant
temperature sensor
Oxygen sensor thread
cleaner
ie: (J-43897-18)
(J-43897-12)Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
Anti-seize lubricant
i.e.: (Permatex
TM
133AR or equivalent
meeting MIL
specification MIL-A-
907)Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.
PBIC0198E
S-NT653
S-NT705
AEM488
S-NT779

FUEL SYSTEM
FL-3
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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