2003 NISSAN X-TRAIL fuel tank removal

FUEL LEVEL SENSOR UNIT
FL-21
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
FL

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 disconnect 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 resin tube.

Do not bend or twist the tube during installation and
removal.

Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is
replaced.

When resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one.

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 (commercial service tool),
remove the lock ring.
9. Remove main fuel level sensor unit (Left hand) and sub fuel level sensor unit (Right hand).
CAUTION:

Do not bend the float arm during removal.

Avoid impacts such as falling when handling components.
Left hand (main fuel level sensor unit):

If necessary, remove the chamber from the bottom of the fuel tank.

Remove the chamber by sliding toward the rear of the vehicle.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC0240E

FL-22
[YD22DDTi]
FUEL LEVEL SENSOR UNIT

INSPECTION AFTER REMOVAL
Make sure 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.

Connect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into 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 tabs are connected to connector.

Pull the tube and 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 inspection hole cover with the front mark (arrow) facing front of vehicle (both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start engine and rev it up and make sure there is no fuel leakage at connections.
PBIC1653E
PBIC2032E

FUEL TANK
FL-23
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
FL

FUEL TANKPFP:17202
Removal and InstallationEBS00BL3
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-16, "
General Precau-
tions" .
1. Perform the procedure from 1 to 7 in “removal” of FL-19, "
FUEL LEVEL SENSOR UNIT" .
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" .
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Vent hose 5. Vent tube 6. EVAP hose
7. Fuel filler hose 8. Fuel transport pump 9. Fuel hose
10. Fuel tube 11. Fuel tank protector 12. Fuel tank band
13. Fuel tank
PBIC2033E

FL-24
[YD22DDTi]
FUEL TANK

5. Using a transmission jack, support the bottom of final drive
assembly.
6. 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.
7. Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.

Instruction for quick connector of EVAP hose. Refer to FL-19,
"FUEL LEVEL SENSOR UNIT" .
8. Disconnect connector of fuel transport pump and remove bolts
for bracket.
9. Remove fuel tank protector.
10. Remove fuel tank band mounting bolts while supporting fuel
tank.
CAUTION:
Sustain the bottom of the tank by using plate or anything
same.
11. Remove fuel tank.
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.

After lifting down the front portion of fuel tank, remove the fuel tank by pulling it from the upper front of
final drive assembly, so that the fuel tank can move forwardly.
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 positioned on swelled area of fuel tube.

Tighten fuel hose clamp so that the distance between its lugs becomes to the following.

Fit mounting band pin to the vehicle side securely.

Before fixing the fuel tank, temporarily install the fuel filler tube.
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-19, "FUEL LEVEL SENSOR UNIT" .
KBIA0285E
PBIC2035E
KBIA0290E
Fuel filler hose : 35 mm (1.38 in)
The other hose : 25 mm (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)

MA-26
ENGINE MAINTENANCE (QR20DE·QR25DE)

Checking and Changing Spark PlugsELS000ZK
REMOVAL
1. Remove ignition coil. Refer to EM-29, "IGNITION COIL" .
2. Remove spark plug with spark plug wrench (commercial service
tool).
CAUTION:
Do not drop or shock it.
INSPECTION AFTER REMOVAL
Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:

Frequent engine starts

Low ambient temperatures
Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:

Extended highway driving

Frequent high engine revolution

Check plug gap of each spark plug.

If out of standard, adjust or replace spark plug.

Use a wire brush for cleaning, if necessary.
INSTALLATION
Install in the reverse order of removal.
Checking EVAP Vapor LinesELS000ZL
1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections,
chafing and deterioration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.
Refer to EC-474, "
EVAPORATIVE EMISSION LINE DRAWING" .
SEM294A
MakeNGK
Standard typeLFR5A-11
Hot typeLFR4A-11
Cold typeLFR6A-11
Standard :1.0 - 1.1 mm (0.039 - 0.043 in)
SMA476
Spark plug:
: 24.5 N·m (2.5 kg-m, 18 ft-lb)