2003 NISSAN X-TRAIL fuel filter

FL-4
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
PFP:17042
Removal and InstallationEBS00BKR
REMOVAL
WAR NIN G:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions"
1. Release fuel pressure from fuel line.
Refer toEC-34, "
FUEL PRESSURE RELEASE"(WITH EURO-
OBD),EC-399, "
FUEL PRESSURE RELEASE"(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.
lAs 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 position.
KBIA0278E
1Lockring 2Main fuel level sensor unit, fuel filter
and fuel pump assembly3Jet 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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NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit, fuel filter and fuel pump
assembly is removed.
5. Remove rear seat bottom.
6. Remove inspection hole cover, harness connector and fuel feed hose.
lRemove the quick connector as follows.
NOTE:
lHold the sides of the connector, push in tubs and pull out the
tube.
lIf the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them by
pulling.
CAUTION:
lThe tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
lDo not use any tools to remove the quick connector.
lKeep the resin tube away from heat. Be especially careful
when welding near the tube.
lPrevent acid liquid such as battery electrolyte etc. from get-
ting on the resin tube.
lDo not bend or twist the tube during installation and
removal.
lDo not remove the remaining retainer on tube or fuel level
sensor unit.
lWhen the tube or fuel level sensor unit is replaced, also
replace the retainer with a new one.
Retainer color: Green.
lTo keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
SFE562A
PBIC0199E
PBIC0163E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
7. Using a lock ring wrench, remove the lock ring.
8. Remove main fuel level sensor unit, fuel filter and fuel pump
assembly, and sub fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling compo-
nents.
lRemoval of main fuel level sensor unit, fuel filter, fuel pump
assembly.
lRaise the sender unit, and remove the jet pump to remove the
sender unit.
lLeave the jet pump on the fuel tank with the fuel hose.
lIf necessary, remove the chamber from the bottom of the fuel tank.
lRemove the chamber by sliding toward the rear of the vehicle.
Removal of sub fuel level sensor unit.
lRaise and release the sub fuel level sensor unit to remove.
lIf 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.
lWhen installing the chamber and jet pump, insert them fully until
a click sound of full stopper engagement is heard (Ditto for jet
pump inlet).
lConnect 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.
lVisually confirm that the two retainer tabs are connected to the connector.
lPull the tube and the connector to make sure they are securely connected.
PBIC0240E
KBIA0281E
KBIA0302E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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lInstall fuel level sensor unit with mating mark (triangular protru-
sion) 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.
lInstall the inspection hole cover with the front mark (arrow) fac-
ing front of the vehicle (Both for RH and LH).
INSPECTION AFTER INSTALLATION
Start the engine and rev it up and make sure there is no fuel leakage at connections.
Disassembly and AssemblyEBS00BKS
NOTE:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
1. Remove fuel pump removing bracket.
lUsing a screwdriver, remove the snap fit portion of bracket in the
order of (1), (2), (3) and (4) as shown in the figure.
KBIA0282E
PBIC0241E
1 Pressure regulator 2 Fuel pump 3 Packing
4 Fuel filter 5 Rubber 6 Fuel level sensor unit
7 Bracket
PBIC0242E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
2. Disconnect fuel pump harness connector.
3. Separate the fuel filter and fuel level sensor unit.
a. Fit a used O-ring into space between fuel level sensor unit and
fuel filter. Undo catches and separate fuel level sensor unit and
fuel filter.
lFor 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 blade end screwdriver to the gap between the 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.
4. Remove pressure regulator from fuel filter.
a. Open and remove the clip.
b. Pull the pressure regulator straight out during removal.
CAUTION:
lAvoid impacts such as falling during removal.
lDo not disassemble or adjust.
ASSEMBLY
Install in the reverse order of removal paying attention to the following.
lInstall the fuel filter and fuel pump with the tabs aligned, Make sure a click sound of secure engagement
is heard.
lSecurely connect the harness connector of the fuel pump.
lInstall the pressure regulator O-ring as follows.
CAUTION:
lWhen replacing, always use a new O-ring.
lHandle it with bare hands. (Do not use gloves.)
lVisually check the O-ring, mounting parts and mating parts for foreign materials and flaws.
lBefore installing, apply new engine oil.
lTo avid damage, do not apply an excessive force (pulling or starching).
lInstall the pressure regulator as follows.
1. Insert the clip to the groove of the regulator.
2. With the clip installed, insert the regulator straight by matching
the fuel filter protrusion and the clip notch.
3. Make sure that the fuel filter protrusion and clip notch are
securely engaged.
PBIC0243E
PBIC0244E
PBIC0245E

FUEL TANK
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FUEL TANKPFP:17202
Removal and InstallationEBS00BKT
REMOVAL
WA RN ING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Release fuel pressure from fuel line, Refer toEC-34, "
FUEL
PRESSURE RELEASE",EC-399, "FUEL PRESSURE
RELEASE".
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 proce-
dure, refer to Step 4 in removal ofFL-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. Remove the quick connector.
lPut mating marks on hoses for correct installation.
7. Remove exhaust center tube and insulator.
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

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FUEL TANK
8. Remove propeller shaft. Refer toPR-3, "Removal and Installation".
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 toFL-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.
lSurely clamp fuel hoses and insert hose to the length below.
lBe sure hose clamp is not placed on swelled area of fuel tube.
lTighten fuel hose clamp so that the distance between its lugs becomes to the following.
lPush the mounting band pin to the vehicle side securely.
lBefore 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.
lTo connect the quick connector, refer toFL-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)

PREPARATION
FL-13
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[YD22DDTi]PREPARATIONPFP:00002
Commercial Service ToolEBS00BKG
Tool number
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D