NISSAN X-TRAIL 2005 Service Repair Manual

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.

Remove cover by pushing it, then by turning clips clockwise
by 90 degrees and by matching both cover hole and clip
shape.
7. Disconnect harness connector and fuel feed hose.

Disconnect quick connector as follows:
–Hold the sides of connector, push in tabs and pull out fuel feed
hose.
–If quick connector sticks to tube of fuel level sensor unit, push
and pull quick connector several times until it starts to move.
Then disconnect quick connector by pulling.
PBIC2258E
KBIA0280E
SFE562A

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:

Quick connector can be disconnected when the tabs
are completely depressed. Do not twist it more than
necessary.

Do not use any tools to disconnect quick connector.

Keep resin tube away from heat. Be especially careful
when welding near the resin 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
the equivalent) except when resin tube or retainer is
replaced.

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

Replace same color retainer as before replacing.

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 polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with
a cloth.

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
1. Install seal packing to fuel tank without any twist.
2. Face fuel level sensor unit, fuel filter and fuel pump assembly as
shown in the figure, and install it to fuel tank. (Figure shows left
side of fuel tank.)
CAUTION:
Do not bend float arm during installing.
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
3. Tighten rock ring with rock ring wrench (commercial service tool).
CAUTION:
Install rock ring horizontally.
Quick Connector
Connect quick connector as follows:
1. Check the connection for damage and foreign materials.
KBIA0281E
KBIA0302E
KBIA0282E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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.

Pull the tube and the connector to make sure they are
securely connected.
Inspection Hole Cover
1. Install inspection hole covers with the front mark (arrow) facing front of the vehicle.
2. Lock clips by turning counterclockwise by 90 degrees.
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. Separate fuel pump and bracket from fuel filter 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.
Fuel Filter and Fuel Pump

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.
Pressure Regulator
Install pressure regulator as follows:
1. Install O-ring.
CAUTION:

Do not reuse O-ring. Replace it with a new one.

Handle O-ring with bare hands. Do not wear gloves.
PBIC0242E
PBIC0243E
PBIC0244E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Visually check O-ring, mounting parts and mating parts for foreign materials and flaws.

Before installing, lubricate new engine oil.

To avoid damage, do not apply an excessive force (pulling or stretching).
2. Insert the clip to the groove of pressure regulator.
3. With the clip installed, insert pressure regulator straight by matching the fuel filter lug and the clip notch.
4. Make sure that the fuel filter lug and 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. (4WD models) 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 (4WD models) or rear suspension member (2WD
models).
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)

FUEL TANK
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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.

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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)
Fuel recommendationRefer to GI-5
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)*