2001 NISSAN X-TRAIL fuel tank removal

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION
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FUEL SYSTEM
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PREPARATION ........................................................... 2
Commercial Service Tool ......................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ............................................ ..... 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6
INSPECTION AFTER INSTALLATION ................. 6
Disassembly and Assembly ..................................... 7
DISASSEMBLY ..................................................... 7
ASSEMBLY ........................................................... 8
FUEL TANK ................................................................ 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 10
INSPECTION AFTER INSTALLATION ................ 11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12
Standard and Limit ................................................. 12
FUEL TANK ......................................................... 12
Tightening Torque ................................................... 12
YD22DDTi
PREPARATION ......................................................... 13
Commercial Service Tool ........................................ 13
FUEL SYSTEM ......................................................... 14
Checking Fuel Lines ............................................ ... 14
General Precautions ............................................... 14
FUEL FILTER ............................................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Air Bleeding ............................................................ 16
Draining Water from Fuel Filter .............................. 16
FUEL LEVEL SENSOR UNIT ................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
FUEL TANK .............................................................. 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 24
Standard and Limit .................................................. 24
Tightening Torque ................................................... 24

FL-4
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
PFP:17042
Removal and InstallationEBS00KOU
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Release fuel pressure from fuel line. Refer to EC-775, "
FUEL
PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)], EC-
11 3 9 , "FUEL PRESSURE RELEASE" [QR20DE (WITHOUT
EURO-OBD)],EC-42, "
FUEL PRESSURE RELEASE"
[QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE
RELEASE" [QR25DE (WITHOUT EURO-OBD)].
2. Open fuel filer lid.
3. Open the filler cap and release the pressure inside the fuel tank.
4. 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.
In case of fuel pump does not operate, take 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.
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 fuel tank.
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit, fuel filter and fuel pump
assembly is removed.
KBIA0278E
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
KBIA0280E
FEL0403D

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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5. Remove rear seat bottom.
6. Remove inspection hole cover, harness connector and fuel feed hose.
●Disconnect the quick connector as follows.
●Remove the quick connector cap.
●Hold the sides of the connector, push in tubs and pull out the
tube. (The figure is shown for reference only.)
●If the connector and the tubs are stuck together, push and pull
several times until they start to move. Then disconnect them
by pulling.
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 remove the 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 the resin tube.
●Do not bend or twist the tube during installation and disconnection.
●Do not remove the remaining retainer on tube.
●When the tube is replaced, also replace the retainer with a new one.
Retainer color: Green.
●To keep clean the connecting portion and to avoid
damage and foreign materials, cover them completely
with plastic bags or something similar.
7. Using a fuel tank lock ring wrench, remove the lock ring.
8. Remove main fuel level sensor unit, fuel filter, fuel pump assem-
bly and sub fuel level sensor unit.
CAUTION:
●Do not bend the float arm during removal.
●Avoid impacts such as falling when handling compo-
nents.
●Removal of main fuel level sensor unit, fuel filter, fuel pump
assembly.
●Raise the sender unit, and remove the jet pump to remove the
sender unit.
●Leave the jet pump on the fuel tank with the fuel hose.
SFE562A
PBIC0163E
PBIC0240E
KBIA0281E

FL-6
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
●If necessary, remove the chamber from the bottom of the fuel tank.
●Remove the chamber by sliding toward the rear of the vehicle.
Removal of sub fuel level sensor unit.
●Raise and release the sub fuel level sensor unit to remove.
●If necessary, remove the jet pump inlet from the bottom of the fuel tank.
To remove it, pinch the tabs (2 places).
INSPECTION AFTER REMOVAL
Make sure the fuel pump strainer is free from foreign materials, If any are found, remove them.
INSTALLATION
Install in the reverse order of removal paying attention to the follow-
ing.
●When installing the chamber and jet pump, insert them fully until
a click sound of full stopper engagement is heard (Ditto for jet
pump inlet).
●Connect the 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 is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
●Visually confirm that the two retainer tabs are connected to the connector.
●Pull the tube and the 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 the inspection hole cover with the front mark (arrow)
facing front of the vehicle (Both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel
leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
KBIA0302E
KBIA0282E

FUEL TANK
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FUEL TANKPFP:17202
Removal and InstallationEBS00KOW
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Release fuel pressure from fuel line. Refer to EC-775, "
FUEL
PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)], EC-
11 3 9 , "FUEL PRESSURE RELEASE" [QR20DE (WITHOUT
EURO-OBD)], EC-42, "
FUEL PRESSURE RELEASE"
[QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE
RELEASE" [QR25DE (WITHOUT EURO-OBD)].
2. Open the fuel filler cap and release the pressure inside the fuel
tank.
3. Remove rear seat bottom.
4. Remove inspection hole cover, harness connector and fuel feed
hose.
5. Drain fuel from fuel tank if necessary. For the draining procedure, refer to Step 4 in removal of FL-4,
"FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
CAUTION:
For the safety work and to maintain fuel tank gravity at center, drain fuel to the level where fuel
tank weight at left and right becomes equal.
6. Disconnect the quick connector.
●Put mating marks on hoses for correct installation.
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
KBIA0280E

FL-10
[QR]
FUEL TANK
7. Remove exhaust center tube and insulator. Refer to EX-2, "EXHAUST SYSTEM" .
8. Remove propeller shaft. Refer to PR-2, "
REAR PROPELLER SHAFT" .
9. Using a transmission jack, support the bottom of the rear final
drive.
10. 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.
11. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.
12. For disconnection procedure of the quick connector on the
evaporator hose, Refer to FL-4, "
FUEL LEVEL SENSOR UNIT,
FUEL FILTER AND FUEL PUMP ASSEMBLY" .
13. Remove fuel tank protector.
14. Remove fuel tank band mounting bolts while supporting fuel
tank.
15. Remove fuel tank.
INSTALLATION
Install in the reverse order of removal paying attention to the following.
●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 distance between its lugs becomes to the following.
●Push the mounting band pin to the vehicle side securely.
●Before fixing the fuel tank, temporarily install the filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.
●To connect the quick connector, refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY" .
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 LEVEL SENSOR UNIT
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[YD22DDTi]
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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-14, "
General Precau-
tions" .
1. Disconnect battery ground cable.
2. Open fuel filler lid.
3. Open the filler cap and release the pressure inside the fuel tank.
4. 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.
In case of fuel pump does not operate, take 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.
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.
SBIA0139E
1. Lock ring 2. Main fuel level sensor unit 3.Jet pump, fuel hose and jet pump
inlet assembly
4. Chamber 5. Seal packing 6. Sub fuel level sensor unit
SBIA0140E
FEL0403D

FUEL LEVEL SENSOR UNIT
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[YD22DDTi]
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●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, remove the lock ring.
9. Remove main fuel level sensor unit and sub fuel level sensor
unit.
CAUTION:
●Do not bend the float arm during removal.
●Avoid impacts such as falling when handling compo-
nents.
Removal of main fuel level sensor unit:
●Raise the fuel level sensor unit, and remove the jet pump.
●Leave the jet pump on the fuel tank with the fuel hose.
●If necessary, remove the chamber from the bottom of the fuel
tank.
●Remove the chamber by sliding toward the rear of the vehicle.
Removal of sub fuel level sensor unit:
●Raise and release the sub fuel level sensor unit to remove.
●If necessary, remove the jet pump inlet from the bottom of the fuel tank.
To remove it, pinch the tabs (2 places).
INSPECTION AFTER REMOVAL
Make sure the fuel pump strainer is free from foreign materials, If any are found, remove them.
INSTALLATION
Install in the reverse order of removal paying attention to the follow-
ing.
●When installing the chamber and jet pump, insert them fully until
a click sound of full stopper engagement is heard (for jet pump
inlet).
●Connect the 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 is heard.
3. After connecting, make sure that the connection is secure by fol-
lowing the steps below.
PBIC0163E
PBIC0240E
SBIA0142E
SBIA0143E