2003 NISSAN X-TRAIL fuel tank removal

FUEL TRANSPORT PUMP
EC-1495
[YD (WITHOUT EURO-OBD)]
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FUEL TRANSPORT PUMP
1. Remove fuel transport pump.
2. Apply battery voltage between fuel transport pump terminal 1 and 2.
3. Check operating sound of fuel transport pump under the following conditions.
4. Listen fuel transport pump operating sound.
FUEL LEVEL SWITCH
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
2. Check continuity between sub fuel level sensor unit terminal 2
and 4 under the following conditions.
Removal and InstallationEBS0126L
FUEL TRANSPORT PUMP
Refer to FL-23, "FUEL TANK" .
SUB FUEL LEVEL SENSOR UNIT
Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
Conditions Operating sound
12V direct current supply between fuel transport pump
terminals 1 and 2Ye s
No current supply No
Conditions Continuity
Fuel level switch is soaked in fuel. Yes
Fuel level switch is not soaked in fuel. No
PBIB2015E

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION
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FUEL SYSTEM
QR
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 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 ......................... 7
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION ................. 8
Disassembly and Assembly ..................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK ...............................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Standard and Limit ................................................. 14
FUEL TANK ......................................................... 14
Tightening Torque ................................................... 14
YD22DDTi
PREPARATION ......................................................... 15
Commercial Service Tools ...................................... 15
FUEL SYSTEM ......................................................... 16
Checking Fuel Lines ............................................... 16
General Precautions ............................................... 16
FUEL FILTER ............................................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 17
Air Bleeding ............................................................ 18
Draining Water from Fuel Filter .............................. 18
FUEL LEVEL SENSOR UNIT ................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
FUEL TANK .............................................................. 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
Tightening Torque ................................................... 26

FL-4
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationEBS00KOU
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Check fuel level on fuel gauge. If gauge indicates more than the
level as shown in the figure (full or almost full), drain fuel from
fuel tank until gauge indicates level as shown in the figure or
below.
NOTE:
Fuel will be spilled when removing main and sub fuel level sen-
sor units for the top of the fuel is above the main and sub fuel
level sensor units installation surface.

As a guide, fuel level becomes the position as shown in the
figure or below when approximately 15 (13-1/4 Imp qt) of
fuel are drained from fuel tank.

In case fuel pump does not operate, perform the 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. Refer to FL-11, "
FUEL TANK" .
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the 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).
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside fuel tank.
5. Lift to hold rear seat cushion up. Refer to SE-31, "
REAR SEAT" .
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
PBIC2257E
FEL0403D

FL-6
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:

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 disconnect quick connector.

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

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

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 impacts such as falling when handling components.Retainer color: Green
SBIA0504E
PBIC0163E
PBIC0240E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
[QR]
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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
Install fuel level sensor unit with positioning 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.
Quick Connector
Connect 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 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.
KBIA0281E
KBIA0302E
KBIA0282E

FUEL TANK
FL-11
[QR]
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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. 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

FL-12
[QR]
FUEL TANK

5. Using a transmission jack, support the bottom of final drive
assembly.
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 LEVEL SENSOR UNIT
FL-19
[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-16, "
General Precau-
tions" .
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank.
3. 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.

Refer to the following for draining fuel.
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.
4. Disconnect negative battery terminal.
5. Lift to fold rear seat cushion up. Refer to SE-31, "
REAR SEAT" .
6. Peel off floor carpet, then remove inspection hole cover.
1. Lock ring 2. Main fuel level sensor unit 3. Seal packing
4. Chamber 5. Sub fuel level sensor unit
PBIC2031E
FEL0403D