ENGINE
CONTENTS
QR25DE
PRECAUTION ............................................... 3
PRECAUTIONS ................................................... 3
Precautions for Removing Battery Terminal ............. 3
General Precautions ................................................. 3
PREPARATION ............................................ 5
PREPARATION ................................................... 5
Special Service Tools ................................................ 5
SYSTEM DESCRIPTION .............................. 6
SYSTEM .............................................................. 6
INFORMATION DISPLAY (COMBINATION
METER) ....................................................................... 6
INFORMATION DISPLAY (COMBINATION
METER) : Low fuel warning ...................................... 6
WARNING/INDICATOR/CHIME LIST ......................... 6
WARNING/INDICATOR/CHIME LIST : Warning/
Indicator (On Information Display) ............................ 6
WARNING/INDICATOR/CHIME LIST : Warning
lamps/Indicator lamps ............................................... 6
PERIODIC MAINTENANCE .......................... 8
FUEL SYSTEM .................................................... 8
Hydraulic Layout ....................................................... 8
Inspection .................................................................. 8
Quick Connector ....................................................... 8
REMOVAL AND INSTALLATION ............... 10
FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY .........................10
Exploded view ......................................................... 10
Removal and Installation ......................................... 10
Disassembly and Assembly .................................... 12
Inspection ................................................................ 12
FL-1
SECTION
FUEL SYSTEM
FL FL
E
FUEL TANK ...................................................... 14 F
Exploded view .........................................................14
Removal and Installation .........................................14
Inspection ................................................................17 G
EVAP CANISTER .............................................. 18
Hydraulic Layout ......................................................18
Removal and Installation .........................................18 H
Inspection ................................................................19
SERVICE DATA AND SPECIFICATIONS I
(SDS) ............................................................ 20
SERVICE DATA AND SPECIFICATIONS
J
(SDS) ................................................................. 20
Standard and Limit ..................................................20
YS23DDT/YS23DDTT
K
PRECAUTION .............................................. 21
PRECAUTIONS ................................................. 21 L
Precautions for Removing Battery Terminal ............21
General Precautions ................................................21
PREPARATION ........................................... 23 M
PREPARATION ................................................. 23
Special Service Tools ..............................................23 N
SYSTEM DESCRIPTION ............................. 24
COMPONENT PARTS ...................................... 24 O
Water In Fuel Sensor ...............................................24
SYSTEM ............................................................ 25
P
INFORMATION DISPLAY (COMBINATION
METER) ......................................................................25
INFORMATION DISPLAY (COMBINATION
METER) : Low fuel warning .....................................25
WARNING/INDICATOR/CHIME LIST ........................25
 WARNING/INDICATOR/CHIME LIST : Warning/
Indicator (On Information Display) .......................... 25
WARNING/INDICATOR/CHIME LIST : Warning
lamps/Indicator lamps ............................................. 25
PERIODIC MAINTENANCE ........................ 27
FUEL SYSTEM .................................................. 27
Hydraulic Layout ..................................................... 27
Inspection ............................................................... 27
Air Bleeding ............................................................ 27
Quick Connector ..................................................... 28
FUEL FILTER .................................................... 29
Exploded View ........................................................ 29
Removal and Installation ........................................ 29
Draining Water from Fuel Filter .............................. 30
Inspection ............................................................... 30
REMOVAL AND INSTALLATION ............... 31
FUEL LEVEL SENSOR UNIT AND FUEL
PUMP ASSEMBLY ............................................ 31
Exploded View ........................................................ 31
Removal and Installation ........................................ 32
Disassembly and Assembly .................................... 34
Inspection ............................................................... 35
FUEL TANK ....................................................... 36
Exploded View ........................................................ 36
Removal and Installation ........................................ 36
Inspection ............................................................... 39
SERVICE DATA AND SPECIFICATIONS
(SDS) ........................................................... 40
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................. 40
Fuel Tank ................................................................ 40
YD25DDTi
PRECAUTION ............................................. 41
PRECAUTIONS ................................................. 41
Precautions for Removing Battery Terminal ........... 41
General Precautions ............................................... 41
PREPARATION ........................................... 43
PREPARATION ................................................. 43
Special Service Tools ............................................. 43
Commercial Service Tools ...................................... 43
FL-2
SYSTEM DESCRIPTION ........................... 44
COMPONENT PARTS ....................................... 44
Fuel Filter Sensor .................................................... 44
SYSTEM ............................................................ 45
INFORMATION DISPLAY (COMBINATION
METER) ..................................................................... 45
INFORMATION DISPLAY (COMBINATION
METER) : Low fuel warning .................................... 45
WARNING/INDICATOR/CHIME LIST ....................... 45
WARNING/INDICATOR/CHIME LIST : Warning/
Indicator (On Information Display) .......................... 45
WARNING/INDICATOR/CHIME LIST : Warning
lamps/Indicator lamps ............................................. 45
PERIODIC MAINTENANCE ....................... 47
FUEL SYSTEM .................................................. 47
Hydraulic Layout ..................................................... 47
Inspection ................................................................ 48
Air Bleeding ............................................................. 48
Quick Connector ..................................................... 48
FUEL FILTER .................................................... 50
Exploded View ........................................................ 50
Removal and Installation ......................................... 51
Disassembly and Assembly .................................... 52
Draining Water from Fuel Filter ............................... 54
Inspection ................................................................ 54
REMOVAL AND INSTALLATION .............. 55
FUEL LEVEL SENSOR UNIT ............................ 55
Exploded view ......................................................... 55
Removal and Installation ......................................... 55
Disassembly and Assembly .................................... 56
Inspection ................................................................ 57
FUEL TANK ....................................................... 58
Hydraulic Layout ..................................................... 58
Exploded view ......................................................... 59
Removal and Installation ......................................... 59
Inspection ................................................................ 62
SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 63
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 63
Standard and Limit .................................................. 63
 PRECAUTIONS
< PRECAUTION > [QR25DE]

PRECAUTION A
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000013465610
FL
When disconnecting the battery terminal, pay attention to the following.
• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running. C
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi- D
nal after a lapse of the specified time:

D4D engine : 20 minutes YS23DDT : 4 minutes

E
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
F
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
G
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
H
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF. I
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope. J
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon- K
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE: L
The removal of 12V battery may cause a DTC detection error.
General Precautions INFOID:0000000012532380

M
WARNING:
When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
• Use gasoline required by the regulations for octane number. Refer to GI-27, "Fuel". O
• Before removing fuel line parts, perform out the following procedures:
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area. P
- Release fuel pressure from the fuel lines.
- Disconnect the battery cable from the negative terminal.
• Always replace O-ring and clamps with new ones.
• Never kink or twist tubes when they are being installed.
• Never tighten hose clamps excessively to avoid damaging hoses.
• After installing tubes, check there is no fuel leakage at connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check
for fuel leakage at connections.
FL-3
 PRECAUTIONS
< PRECAUTION > [QR25DE]
- Start engine and rev it up and check for fuel leakage at connections.
• Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the
“MI” may come on.

FL-4
 PREPARATION
< PREPARATION > [QR25DE]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000012532381
FL

Tool number
Description C
Tool name
KV99104700 Removing and Installing lock ring
Lock ring wrench
D

E
ZZA0122D

FL-5
 SYSTEM
< SYSTEM DESCRIPTION > [QR25DE]

SYSTEM DESCRIPTION
SYSTEM
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : Low fuel warning INFOID:0000000012532382

DESIGN/PURPOSE
This warns the driver that the fuel level is low.

Design Message

Low Fuel

JPNIA1905ZZ

SYSTEM DIAGRAM

JPBIA6242GB

SIGNAL PATH
The combination meter receives fuel level sensor signal (resistance value) from the fuel level sensor unit and
indicates low fuel level warning lamp and low fuel level warning on the vehicle information display when fuel
level sensor signal (resistance value) is less than the specified value.
For more details, refer to MWI-47, "WARNING LAMPS/INDICATOR LAMPS : Low Fuel Warning Lamp".
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)
INFOID:0000000012532383

Name Design Arrangement/Function

Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low fuel warning
Regarding the function. Refer to FL-6, "INFORMATION DISPLAY
(COMBINATION METER) : Low fuel warning".

WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps INFOID:0000000012532384

FL-6
 SYSTEM
< SYSTEM DESCRIPTION > [QR25DE]
Name Design Arrangement/Function
A
Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low Fuel Warning Lamp
Regarding the function. Refer to MWI-47, "WARNING LAMPS/INDI-
CATOR LAMPS : Low Fuel Warning Lamp". FL

FL-7
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [QR25DE]

PERIODIC MAINTENANCE
FUEL SYSTEM
Hydraulic Layout INFOID:0000000012532385

JPBIA7005ZZ

EVAP canister purge volume control

EVAP purge port EVAP line
solenoid valve
Fuel level sensor unit, fuel filter and
Fuel line Fuel tank
fuel pump assembly
EVAP canister Fuel filler tube

Inspection INFOID:0000000012532386

• Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leakage, cracks, damage, loose connections, chafing or
deterioration.

: Engine
: Fuel line
: Fuel tank

• If necessary, repair or replace damaged parts.

JPBIA0129ZZ

Quick Connector INFOID:0000000012532387

CAUTION:

FL-8
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [QR25DE]
• After connecting fuel tube quick connectors, check quick con-
nectors are secure. A

: Quick connector
: Retainer FL
: Hard tube (or the equivalent)
: Connection (cross-section)
C
: Resin tube
: To under floor fuel line
: To fuel tank D
: Tab
: Disconnection
E
• Ensure that connector and resin tube never contact any adja-
cent parts.
F

G
JPBIA0130ZZ

FL-9
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]

REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Exploded view INFOID:0000000012532388

REMOVAL

JPBIA7002GB

Fuel level sensor unit, fuel filter and

Lock ring Seal packing
fuel pump assembly
Fuel tank

: Always replce afetr every disassembly

: Vehicle front

: N·m (kg-m, ft-lb)

DISASSEMBLY

JPBIA7003ZZ

Fuel level sensor unit Fuel filter and fuel pump assembly

Removal and Installation INFOID:0000000012532389

REMOVAL

FL-10
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "General Precau- A
tions".
1. Remove fuel tank from the vehicle. Refer to FL-14, "Removal and Installation".
2. Remove lock ring for fuel level sensor unit, fuel filter and fuel FL
pump assembly with lock ring wrench [SST: KV99104700] by
turning counterclockwise
C

PBIC0240E E

3. Remove fuel level sensor unit, fuel filter and fuel pump assembly.
CAUTION:
F
• Never bend the float arm during removal.
• Never cause impacts such by dropping when handling components.
4. Preform inspection after removal. Refer to FL-12, "Inspection".
G
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION: H
Do not reuse seal packing.
1. Temporarily install the seal packing to the fuel level sensor unit, fuel filter and fuel pump assembly.
2. Insert the fuel level sensor unit, fuel filter and fuel pump assembly to the fuel tank, and then install the I
temporarily installed seal packing (Step 1) to the opening of the fuel tank.
CAUTION:
• Never bend float arm during installation.
J
3. Install fuel level sensor unit, fuel filter and fuel pump assembly
with aligning mating marks on fuel tank and fuel level sen-
sor unit, fuel filter and fuel pump assembly as shown in the fig-
ure. K

: Vehicle front
L

M
JPBIA7062ZZ

4. Tighten lock ring for fuel level sensor unit, fuel filter and fuel
pump assembly with lock ring wrench [SST:KV99104700] by N
turning clockwise.

PBIC0240E

5. Perform inspection after installation. Refer to FL-12, "Inspection".

FL-11
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
Disassembly and Assembly INFOID:0000000012532390

DISASSEMBLY
1. Disconnect fuel level sensor harness connector .

JPBIA7006ZZ

2. Press (A) with a flat-blade screwdriver or an equivalent to

release the lock and push out the fuel level sensor unit .

JSBIA5646ZZ

3. To remove the fuel level sensor unit , slide it in the direction

shown by the arrow ( ).
CAUTION:
• Be careful not to damage the fuel level sensor.
• Never disassemble fuel level sensor unit.

JPBIA7007ZZ

ASSEMBLY
1. Check for damage of fuel level sensor unit installation position on the side of fuel filter and fuel pump
assembly.
2. Slide fuel level sensor unit until it aligns to installation groove, then insert it until stops.
• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.
3. Connect harness connector.
Inspection INFOID:0000000012532391

INSPECTION AFTER REMOVAL

Check fuel level sensor unit is free from foreign materials. If any are found, remove them.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leakage by applying fuel pres-
sure to fuel piping.
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.

FL-12
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
3. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description".
A

FL

FL-13
 FUEL TANK
< REMOVAL AND INSTALLATION > [QR25DE]
FUEL TANK
Exploded view INFOID:0000000012532392

JPBIA7004GB

EVAP tube Fuel tank Fuel tank protector

Clip Fuel tank band Fuel tank band
Fuel filler tube Grommet Fuel filler cap
Clamp Fuel filler hose Clamp
Vent hose
To centralized under-floor piping

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

, : Indicates that the part is connected at points with same symbol in actual vehicle.

CAUTION:
Fuel filler tube and grommet are integral parts.
Removal and Installation INFOID:0000000012532393

WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "General Pre-
cautions".
REMOVAL
WARNING:
Be careful of the following when replacing fuel system parts:

FL-14
 FUEL TANK
< REMOVAL AND INSTALLATION > [QR25DE]
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area. A
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place.
CAUTION:
FL
• Perform the operation with vehicle on level ground.
• Do not bend and twist hose and tube.
1. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-
ate amount of fuel from the fuel tank. C

Guideline : Draw approximately 15 liters (3-2/8 Imp gal) from a full-tank condition.
D
• In the event of malfunction in fuel pump, insert a hose measuring 20 mm (0.79 in) in diameter into the
filler opening to draw approximately 15 liters (3-2/8 Imp gal) fuel.
2. Release the fuel pressure from the fuel lines.
E
3. Open fuel filler lid.
4. Open the fuel filler cap and release the pressure inside the fuel tank.
5. Disconnect EVAP tube , vent hose and fuel filler hose F
from the rear of fuel tank.

: Vehicle front
G
NOTE:
Fuel filler hose disconnect fuel filler tube side.
H

JPBIA7064ZZ
I
6. Using transmission jack (A), support bottom of fuel tank
securely. Then remove fuel tank mounting bands (front and rear)
from tank. J

JSBIA4942ZZ

7. Little down the fuel tank and disconnect the harness connector M
and quick connector .

: Vehicle front N

JPBIA7065ZZ
P

Disconnect quick connectors of each tube as follows:

FL-15
 FUEL TANK
< REMOVAL AND INSTALLATION > [QR25DE]
• Hold the sides of connector, push in tabs and pull out fuel
feed tube.

: Pull

• If quick connector sticks to tube of main fuel level sensor unit,

push and pull quick connector several times until they start to
move. Then disconnect them by pulling.

JPBIA0134ZZ

CAUTION:
• Quick connector can be disconnected when the tabs
are completely depressed. Never twist it more than neces-
sary.

: Connection (cross-section)
: Resin tube
: To under floor fuel line
: To fuel tank
: Disconnection

• Never use any tools to disconnected 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.
• Never bend or twist resin tube during installation and dis-
connection.
• Never 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 new one. JPBIA0130ZZ

• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely with
plastic bags or something similar.

JPBIA0135ZZ

8. While supporting fuel tank by hand, lower transmission jack carefully, and remove fuel tank.
CAUTION:
While removing tank, check all connections are disconnected. Also make certain that components
never come in contact with other components.
9. Remove following parts if necessary.
• Fuel filler hose
• Vent hose
• EVAP tube
• Fuel level sensor unit, fuel filter and fuel pump assembly

FL-16
 FUEL TANK
< REMOVAL AND INSTALLATION > [QR25DE]
INSTALLATION
Install in the reverse order of removal, paying attention to followings. A
Hose and Tube
• Insert each hose to the dimensions shown below, and secure them with clamps.
FL
Fuel filler hose : 35 mm (1.38 in)
Others : 25 mm (0.98 in)
C
• When installing clamps, do not allow clamps to contact bulge (bump) of tube.
• Tighten each clamp (both ends) of filler hose, as follows:
Fuel tank side D
- Tighten until flange of bolt head is on the paint mark on the
band.
E

G
JPBIA0146ZZ

Filler tube side H

- Tighten the clamp with specified torque.

Specified torque : 3.2 N·m (0.33 kg-m, 28 in-lb) I

Quick Connector
Connect quick connector as follows:
1. Check the connection for damage or any foreign materials. J
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is
heard.
3. After connecting, check that the connection is secure by following method. K
• Pull the tube and the connector to check they are securely
connected.
• Visually confirm that the two retainer tabs are connected to the L
connector.

N
JPBIA0140ZZ

Inspection INFOID:0000000012532394
O

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.
P
1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres-
sure to fuel piping.
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.
3. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description".

FL-17
 EVAP CANISTER
< REMOVAL AND INSTALLATION > [QR25DE]
EVAP CANISTER
Hydraulic Layout INFOID:0000000012532395

JPBIA7005ZZ

EVAP canister purge volume control

EVAP purge port EVAP line
solenoid valve
Fuel level sensor unit, fuel filter and
Fuel line Fuel tank
fuel pump assembly
EVAP canister Fuel filler tube

Removal and Installation INFOID:0000000012532396

REMOVAL
1. Remove hoses .

: Vehicle front

JPBIA7066ZZ

2. Remove EVAP canister by sliding it to the left side of vehicle.

INSTALLATION

FL-18
 EVAP CANISTER
< REMOVAL AND INSTALLATION > [QR25DE]
Install in the reverse order of removal.
A
Inspection INFOID:0000000012532397

INSPECTION AFTER REMOVAL

FL
Check EVAP canister.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage. C
1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres-
sure to fuel piping.
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec- D
tions.

FL-19
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000012532398

Fuel tank capacity Approx. 80 (17-5/8 Imp gal)

Fuel recommendation Refer to GI-27, "Fuel"

FL-20
 PRECAUTIONS
< PRECAUTION > [YS23DDT/YS23DDTT]

PRECAUTION A
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000013465611
FL
When disconnecting the battery terminal, pay attention to the following.
• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running. C
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi- D
nal after a lapse of the specified time:

D4D engine : 20 minutes YS23DDT : 4 minutes

E
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
F
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
G
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
H
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF. I
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope. J
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon- K
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE: L
The removal of 12V battery may cause a DTC detection error.
General Precautions INFOID:0000000012532400

M
WARNING:
When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
• Use diesel fuel required by the regulations for cetane number. Refer to GI-27, "Fuel". O
• Before removing fuel line parts, perform out the following procedures:
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area. P
- Disconnect the battery cable from the negative terminal.
• Always replace O-ring and clamps with new ones.
• Never kink or twist tubes when they are being installed.
• Never tighten hose clamps excessively to avoid damaging hoses.
• After installing tubes, check there is no fuel leakage at connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check
for fuel leakage at connections.
- Start engine and rev it up and check for fuel leakage at connections.
FL-21
 PRECAUTIONS
< PRECAUTION > [YS23DDT/YS23DDTT]
• Drain water from fuel filter, when the water-in-fuel-filter warn-
ing lamp turns ON (with fuel filter warning). Refer to FL-30,
"Draining Water from Fuel Filter".

JPNIA1924ZZ

FL-22
 PREPARATION
< PREPARATION > [YS23DDT/YS23DDTT]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000012532401
FL

Tool number
Description C
Tool name
KV101207S0 Removing and installing lock ring
Unified fuel lock ring wrench
D

E
JPBIA6384ZZ

FL-23
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [YS23DDT/YS23DDTT]

SYSTEM DESCRIPTION
COMPONENT PARTS
Water In Fuel Sensor INFOID:0000000012532402

• Water in fuel sensor is integrated in the drain plug and detects

the water in the fuel filter.

JSBIA6155ZZ

• When the fuel filter warning lamp turns ON, drain water from fuel
filter. Refer to FL-30, "Draining Water from Fuel Filter".

PBIC2664E

NOTE:
If the fuel filter warning lamp turns ON after draining water from fuel filter, perform the following.
• Disconnect water in fuel sensor connector.
• Check condition of the fuel filter warning lamp.
- If the warning lamp is ON, check the harness between combination meter and water in fuel sensor. Refer to
MWI-175, "Wiring Diagram".
- If the warning lamp is OFF, replace the water in fuel sensor.

FL-24
 SYSTEM
< SYSTEM DESCRIPTION > [YS23DDT/YS23DDTT]
SYSTEM
A
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : Low fuel warning INFOID:0000000012532403
FL
DESIGN/PURPOSE
This warns the driver that the fuel level is low.
C
Design Message

E
Low Fuel

JPNIA1905ZZ
G
SYSTEM DIAGRAM

J
JPBIA6242GB

SIGNAL PATH
K
The combination meter receives fuel level sensor signal (resistance value) from the fuel level sensor unit and
indicates low fuel level warning lamp and low fuel level warning on the vehicle information display when fuel
level sensor signal (resistance value) is less than the specified value.
For more details, refer to MWI-47, "WARNING LAMPS/INDICATOR LAMPS : Low Fuel Warning Lamp". L
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display) M
INFOID:0000000012532404

Name Design Arrangement/Function N

Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low fuel warning O
Regarding the function. Refer to FL-25, "INFORMATION DISPLAY
(COMBINATION METER) : Low fuel warning".

WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps INFOID:0000000012532405

P

FL-25
 SYSTEM
< SYSTEM DESCRIPTION > [YS23DDT/YS23DDTT]
Name Design Arrangement/Function
Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low Fuel Warning Lamp
Regarding the function. Refer to MWI-47, "WARNING LAMPS/INDI-
CATOR LAMPS : Low Fuel Warning Lamp".
Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Fuel filter warning lamp
Regarding the function. Refer to MWI-41, "WARNING LAMPS/INDI-
CATOR LAMPS : Fuel filter warning lamp".

FL-26
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [YS23DDT/YS23DDTT]

PERIODIC MAINTENANCE A
FUEL SYSTEM
Hydraulic Layout INFOID:0000000012532406
FL

JPBIA7111ZZ J

Fuel pump Fuel filter Fuel return tube

Fuel feed tube Fuel return tube Fuel cooling tube K
Fuel level sensor unit and fuel pump
Fuel tank EVAP tube
assembly
Vent hose Fuel filler tube L

Inspection INFOID:0000000012532407

• Inspect fuel lines, fuel filler cap and fuel tank for improper attach- M
ment, leakage, cracks, damage, loose connections, chafing or
deterioration.
N
: Engine
: Fuel line
: Fuel tank O

• If necessary, repair or replace damaged parts.

P
JPBIA0129ZZ

Air Bleeding INFOID:0000000012532408

NOTE:
Degassing from the diesel circuit is automatic.

FL-27
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [YS23DDT/YS23DDTT]
Quick Connector INFOID:0000000012532409

CAUTION:
• After connecting fuel tube quick connectors, check quick con-
nectors are secure.

: Quick connector
: Retainer
: Hard tube (or the equivalent)
: Connection (cross-section)
: Resin tube
: To under floor fuel line
: To fuel tank
: Tab
: Disconnection

• Ensure that connector and resin tube never contact any adja-
cent parts.

JPBIA0130ZZ

FL-28
 FUEL FILTER
< PERIODIC MAINTENANCE > [YS23DDT/YS23DDTT]
FUEL FILTER
A
Exploded View INFOID:0000000012532410

FL

I
JPBIA7127GB

Fuel feed hose Fuel filter Water in fuel sensor J

Fuel filter bracket
Clamp
To under floor piping
Fuel feed tube Fuel return hose
Fuel temperature sensor
(with fuel return hose) K

: N·m (kg-m, in-lb)

L
: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000012532411 M

REMOVAL
WARNING: N
Be careful of the following when replacing fuel system parts:
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area. O
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place.
CAUTION:
• Perform the operation with vehicle on level ground. P
• Do not bend and twist hose and tube.
1. Disconnect fuel feed tube and fuel hose from fuel filter.
CAUTION:
Plug the pipe to prevent fuel from draining.
2. Disconnect fuel filter harness connector.
3. Disconnect water in fuel sensor harness connector.

FL-29
 FUEL FILTER
< PERIODIC MAINTENANCE > [YS23DDT/YS23DDTT]
4. Loosen fuel filter bracket bolt.
5. Remove fuel filter.
CAUTION:
Never splash fuel during removal. If fuel is splashed, immediately wipe it off.
6. Remove water in fuel sensor.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Securely tighten water in fuel sensor by hand.
• After installing fuel filter, turn ignition switch ON and check for fuel leakage.
Draining Water from Fuel Filter INFOID:0000000012532412

1. Disconnect the water in fuel sensor harness connector.

2. Connect drain hose (suitable hose) to the end of water in fuel
sensor .
3. Prepare a tray at the drain hose open end.
4. Disconnect fuel hose and fuel feed tube connectors from fuel fil-
ter.
CAUTION:
• Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
• Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
JSBIA6155ZZ
5. Loosen water in fuel sensor with 3 - 4 turns.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak. Never use tools to
tighten drain plug.
6. Tighten the water in fuel sensor.
7. Start engine and check there is no fuel leakage.
Inspection INFOID:0000000012532413

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.
1. Check fuel leakage at the fuel system tube and hose connections.
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.

FL-30
 FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]

REMOVAL AND INSTALLATION A

FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
Exploded View INFOID:0000000012532414
FL

REMOVAL
C

J
JPBIA7108GB

Fuel level sensor unit and fuel pump K

Lock ring O-ring
assembly
Fuel tank
: Vehicle front L
: Always replace after every disassembly.

DISASSEMBLY M

JPBIA7110ZZ

FL-31
 FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]

Fuel level sensor unit Fuel pump assembly

Removal and Installation INFOID:0000000012532415

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-21, "General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer to FL-36, "Removal and Installation".
2. Remove lock ring according to the following instructions:
a. Install pawl (B) of unified fuel lock ring wrench [SST:
KV101207S0] (A) to the position shown in the figure.

JSBIA6357ZZ

b. Temporarily tighten mounting bolt (B) of the pawl according to

the measurement (R) from the center of unified fuel lock ring
wrench [SST: KV101207S0] (A) to the end of pawl (C).

R : 82 mm (3.23 in)

JPBIA6871ZZ

c. Set unified fuel lock ring wrench [SST: KV101207S0] to lock ring and tighten the mounting bolt of the pawl.
d. Remove lock ring.
CAUTION:
• To prevent lock ring wrench from being detached,
securely hold down spinner handle by hand.
• To reduce impact caused by removal operation, use long
spinner handle [handle length: 60 cm (23.62 in) or more]
and slowly turn it counterclockwise.

JSBIA4247ZZ

3. Remove fuel level sensor unit and fuel pump assembly.

CAUTION:
• Never bend the float arm during removal.
• Avoid impacts such as falling when handling components.
4. Preform inspection after removal. Refer to FL-35, "Inspection".
INSTALLATION
Note to the following, and install in the reverse order of removal.
1. Install new O-ring to fuel tank without any twist.
CAUTION:

FL-32
 FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
Do not reuse O-rings.
2. Install fuel level sensor unit and fuel pump assembly on the A
fuel tank with the fuel level sensor unit and fuel pump assembly
top surface as shown in the figure.
FL
: Vehicle front

CAUTION:
Never bend float arm during installing. C

JSBIA6356ZZ
D

3. Install lock ring for fuel level sensor unit, fuel filter and fuel pump
assembly with unified fuel lock ring wrench [SST:KV101207S0] E
by turning clockwise.

JSBIA4247ZZ

H
CAUTION:
• Install lock ring horizontally.
• Turn the lock ring until it is engaged in the fuel tank I
side as shown in the figure.

JPBIA6861ZZ L

4. Connect quick connector of fuel feed tube as per following procedures.

a. Check the connection for damage or any foreign materials. M
b. Align the connector with the tube, then insert the connector straight into the tube until a “click” sound is
heard.
c. After connecting, check that the connection is secured with following procedures. N
• Visually confirm that the two tabs are connected to the connector.
• Pull the tube and the connector to check that they are
securely connected.
O
5. Preform inspection after installation. Refer to FL-35, "Inspec-
tion".

JPBIA0140ZZ

CAUTION:

FL-33
 FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
Perform “FUEL PUMP FIRST PRIMING PROCEDURE” when replacing fuel level sensor unit and fuel
pump assembly. Refer to EC-926, "Description".
Disassembly and Assembly INFOID:0000000012532416

DISASSEMBLY
1. Disconnect fuel level sensor harness connector .

JSBIA6358ZZ

2. Remove fuel level sensor from fuel pump assembly, according to the following steps.
a. Remove fuel level sensor harness from fuel pump assembly.
b. Press into pawl of fuel level sensor mounting area.

JSBIA6359ZZ

c. With the fuel level sensor unlocked, slide it in the direction .

CAUTION:
• Be careful not to damage the fuel level sensor.
• Never disassemble fuel pump assembly.

JSBIA6360ZZ

ASSEMBLY
1. Install fuel level sensor all the way. Tactually and aurally check the fit.
2. Connect fuel level sensor harness connector .
3. Install fuel level sensor harness to fuel pump assembly.

JSBIA6358ZZ

FL-34
 FUEL LEVEL SENSOR UNIT AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
Inspection INFOID:0000000012532417

A
INSPECTION AFTER REMOVAL
Check fuel level sensor unit is free from foreign materials. If any are found, remove them.
FL
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leakage by applying fuel pres-
C
sure to fuel piping.
2. Start engine and let it idle and check there are no fuel leakage at the fuel system connections.
3. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description". D

FL-35
 FUEL TANK
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
FUEL TANK
Exploded View INFOID:0000000012532418

JPBIA7109GB

EVAP tube Fuel tank Fuel tank protector

Clip Fuel tank band Fuel tank band
Fuel filler tube Fuel filler cap Clamp
Fuel filler hose Clamp Vent hose
To fuel cooler To fuel filter

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

, : Indicates that the part is connected at points with same symbol in actual vehicle.

Removal and Installation INFOID:0000000012532419

WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-21, "General Pre-
cautions".
REMOVAL
WARNING:
Be careful of the following when replacing fuel system parts:
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area.
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place.
CAUTION:
• Perform the operation with vehicle on level ground.
• Do not bend and twist hose and tube.

FL-36
 FUEL TANK
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
1. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-
ate amount of fuel from the fuel tank. A

Guideline : Draw approximately 15 liters (3-2/8 Imp gal) from a full-tank condition.
• In the event of malfunction in fuel pump, insert a hose measuring 20 mm (0.79 in) in diameter into the FL
filler opening to draw approximately 15 liters (3-2/8 Imp gal) fuel.
2. Open fuel filler lid.
3. Open the fuel filler cap and release the pressure inside the fuel tank. C
4. Disconnect vent hose and fuel filler hose from the rear of
fuel tank.
D
: Vehicle front

NOTE:
Fuel filler hose disconnect fuel filler tube side. E

F
JSBIA4940ZZ

5. Using transmission jack (A), support bottom of fuel tank G

securely. Then remove fuel tank mounting bands (front and rear)
from tank.
H

JSBIA4942ZZ J

6. Little down the fuel tank and disconnect the harness connec-
tor . K

: Vehicle front

JSBIA6361ZZ

7. Disconnect EVAP tube , fuel feed tube , and fuel return tube N
.

: Quick connector O
: Vehicle front

NOTE: P
The followings are also applied to quick connector of each tube.

JSBIA6363ZZ

Disconnect quick connectors of each tube as follows:

FL-37
 FUEL TANK
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
• Hold the sides of connector, push in tabs and pull out fuel
feed tube.

: Pull

• If quick connector sticks to tube of main fuel level sensor unit,

push and pull quick connector several times until they start to
move. Then disconnect them by pulling.

JPBIA0134ZZ

CAUTION:
• Quick connector can be disconnected when the tabs
are completely depressed. Never twist it more than neces-
sary.

: Connection (cross-section)
: Resin tube
: To under floor fuel line
: To fuel tank
: Disconnection

• Never use any tools to disconnected 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.
• Never bend or twist resin tube during installation and dis-
connection.
• Never 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 new one. JPBIA0130ZZ

• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely with
plastic bags or something similar.

JPBIA0135ZZ

8. While supporting fuel tank by hand, lower transmission jack carefully, and remove fuel tank.
CAUTION:
While removing tank, check all connections are disconnected. Also make certain that components
never come in contact with other components.
9. Remove following parts if necessary.
• Fuel filler hose
• EVAP tube
• Fuel level sensor unit and fuel pump assembly
INSTALLATION
FL-38
 FUEL TANK
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
Install in the reverse order of removal, paying attention to followings.
Hose and Tube A
• Insert each hose to the dimensions shown below, and secure them with clamps.

Fuel filler hose : 35 mm (1.38 in) FL

Others : 25 mm (0.98 in)
• When installing clamps, do not allow clamps to contact bulge (bump) of tube. C
• Tighten each clamp (both ends) of filler hose, as follows:
Fuel tank side
- Tighten until flange of bolt head is on the paint mark on the D
band.

JPBIA0146ZZ G

Filler tube side

- Tighten the clamp with specified torque. H

Specified torque : 3.2 N·m (0.33 kg-m, 28 in-lb)

Quick Connector I
Connect quick connector as follows:
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is J
heard.
3. After connecting, check that the connection is secure by following method.
• Pull the tube and the connector to check they are securely K
connected.
• Visually confirm that the two retainer tabs are connected to the
connector. L

JPBIA0140ZZ
N

Inspection INFOID:0000000012532420

O
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage.
1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres- P
sure to fuel piping.
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.
3. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description".

FL-39
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [YS23DDT/YS23DDTT]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank INFOID:0000000012532421

Standard and Limit

Fuel tank capacity Approx. 80 (17-5/8 Imp gal)

Fuel recommendation Refer to GI-27, "Fuel"

FL-40
 PRECAUTIONS
< PRECAUTION > [YD25DDTi]

PRECAUTION A
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000013465614
FL
When disconnecting the battery terminal, pay attention to the following.
• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running. C
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi- D
nal after a lapse of the specified time:

D4D engine : 20 minutes YS23DDT : 4 minutes

E
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
F
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
G
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
H
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF. I
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope. J
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon- K
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE: L
The removal of 12V battery may cause a DTC detection error.
General Precautions INFOID:0000000012532423

M
WARNING:
When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
• Use diesel fuel required by the regulations for cetane number. Refer to GI-27, "Fuel". O
• Before removing fuel line parts, perform out the following procedures:
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area. P
- Disconnect the battery cable from the negative terminal.
• Always replace O-ring and clamps with new ones.
• Never kink or twist tubes when they are being installed.
• Never tighten hose clamps excessively to avoid damaging hoses.
• After installing tubes, check that there is no fuel leakage at connections in the following steps.
- Start engine and rev it up and check for fuel leakage at connections.

FL-41
 PRECAUTIONS
< PRECAUTION > [YD25DDTi]
• Drain water from fuel filter, when the fuel filter warning lamp
turns ON (with fuel filter warning). Refer to FL-54, "Draining
Water from Fuel Filter".

PBIC2664E

FL-42
 PREPARATION
< PREPARATION > [YD25DDTi]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000012532424
FL

Tool number
Description C
Tool name
KV99104700 Removing and Installing lock ring
Lock ring wrench
D

E
ZZA0122D

Commercial Service Tools INFOID:0000000012532425 F

Tool name Description G

Power tool Loosening bolts and nuts

I
PBIC0190E

FL-43
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [YD25DDTi]

SYSTEM DESCRIPTION
COMPONENT PARTS
Fuel Filter Sensor INFOID:0000000012532426

• Fuel filter sensor is integrated in the drain plug and detects the
water in the fuel filter.

JSBIA4953ZZ

• When the fuel filter warning lamp turns ON, drain water from drain
plug. Refer to FL-54, "Draining Water from Fuel Filter".

PBIC2664E

NOTE:
If the fuel filter warning lamp turns ON after draining water from fuel filter, perform the following.
• Disconnect fuel filter sensor connector.
• Check condition of the fuel filter warning lamp.
- If the warning lamp is ON, check the harness between combination meter and fuel filter sensor. Refer to
MWI-175, "Wiring Diagram".
- If the warning lamp is OFF, replace the fuel filter sensor.

FL-44
 SYSTEM
< SYSTEM DESCRIPTION > [YD25DDTi]
SYSTEM
A
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : Low fuel warning INFOID:0000000012532427
FL
DESIGN/PURPOSE
This warns the driver that the fuel level is low.
C
Design Message

E
Low Fuel

JPNIA1905ZZ
G
SYSTEM DIAGRAM

J
JPBIA6242GB

SIGNAL PATH
K
The combination meter receives fuel level sensor signal (resistance value) from the fuel level sensor unit and
indicates low fuel level warning lamp and low fuel level warning on the vehicle information display when fuel
level sensor signal (resistance value) is less than the specified value.
For more details, refer to MWI-47, "WARNING LAMPS/INDICATOR LAMPS : Low Fuel Warning Lamp". L
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display) M
INFOID:0000000012532428

Name Design Arrangement/Function N

Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low fuel warning O
Regarding the function. Refer to FL-45, "INFORMATION DISPLAY
(COMBINATION METER) : Low fuel warning".

WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps INFOID:0000000012532429

P

FL-45
 SYSTEM
< SYSTEM DESCRIPTION > [YD25DDTi]
Name Design Arrangement/Function
Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Low Fuel Warning Lamp
Regarding the function. Refer to MWI-47, "WARNING LAMPS/INDI-
CATOR LAMPS : Low Fuel Warning Lamp".
Regarding the arrangement. Refer to MWI-11, "METER SYSTEM : De-
sign".
Fuel filter warning lamp
Regarding the function. Refer to MWI-41, "WARNING LAMPS/INDI-
CATOR LAMPS : Fuel filter warning lamp".

FL-46
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [YD25DDTi]

PERIODIC MAINTENANCE A
FUEL SYSTEM
Hydraulic Layout INFOID:0000000012532430
FL

JSBIA5648ZZ

FL-47
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [YD25DDTi]

Fuel pump Fuel feed tube Fuel filler hose

Vent hose EVAP tube Fuel level sensor unit
Fuel tank Fuel return tube Fuel cooling tube
Fuel fillter Priming pump

Inspection INFOID:0000000012532431

• Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leakage, cracks, damage, loose connections, chafing or
deterioration.

: Engine
: Fuel line
: Fuel tank

• If necessary, repair or replace damaged parts.

JPBIA0129ZZ

Air Bleeding INFOID:0000000012532432

After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
1. Prime the circuit using the priming pump .
2. Perform engine cranking with repeating several times until
engine starting.
NOTE:
• If engine does not start, stop cranking and repeat “step 1”
above.
• If engine does not operate smoothly after it has started, race it
two or three times.
CAUTION:
Crank engine until it starts. Never crank engine for more
than 30 seconds. JSBIA5650ZZ

Quick Connector INFOID:0000000012532433

CAUTION:

FL-48
 FUEL SYSTEM
< PERIODIC MAINTENANCE > [YD25DDTi]
• After connecting fuel tube quick connectors, check quick con-
nectors are secure. A

: Quick connector
: Retainer FL
: Hard tube (or the equivalent)
: Connection (cross-section)
C
: Resin tube
: To under floor fuel line
: To fuel tank D
: Tab
: Disconnection
E
• Ensure that connector and resin tube never contact any adja-
cent parts.
F

G
JPBIA0130ZZ

FL-49
 FUEL FILTER
< PERIODIC MAINTENANCE > [YD25DDTi]
FUEL FILTER
Exploded View INFOID:0000000012532434

REMOVAL

JSBIA5606GB

Fuel filter Priming pump Clamp

Fuel hose Clamp Fuel hose
Clamp Fuel hose Fuel hose
Clamp Bracket Clamp
Fuel hose Bracket Clip
From fuel tank From fuel gallery To fuel gallery
To fuel tank

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

DISASSEMBLY

FL-50
 FUEL FILTER
< PERIODIC MAINTENANCE > [YD25DDTi]

FL

I
JSBIA5649GB

Fuel filter sensor Gasket O-ring

J
Valve Clamp Clamp
Valve O-ring Top lid
O-ring Filter element Filter housing K
: Always replace after every disassembly·

: N·m (kg-m, in-lb) L

Removal and Installation INFOID:0000000012532435

M
REMOVAL
WARNING:
Be careful of the following when replacing fuel system parts: N
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area.
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place. O
CAUTION:
• Perform the operation with vehicle on level ground.
• Do not bend and twist hose and tube. P
1. Remove engine cover. Refer to EM-289, "Removal and Installation".
2. Disconnect the fuel filter sensor harness connector.
3. Drain the fuel inside the filter housing. Refer to FL-54, "Draining Water from Fuel Filter"

FL-51
 FUEL FILTER
< PERIODIC MAINTENANCE > [YD25DDTi]
4. Disconnect all fuel hoses on top of fuel filter.

: Vehicle front

CAUTION:
Plug the pipe to prevent fuel from draining.
5. Remove the priming pump from clip.
6. Remove fuel filter bracket nuts .

JSBIA5602ZZ

7. Remove fuel filter with bracket.

CAUTION:
Never splash fuel during removal. If fuel is splashed, immediately wipe it off.
INSTALLATION
Note the following, and install in the reverse order of removal.
Fuel hose between priming pump and fuel tank
To install fuel hose, set rectangular paint mark on the priming
pump side .

: To fuel tank

JPBIA7096ZZ

Air bleed
After installation, bleed air from fuel path. Refer to FL-48, "Air Bleeding".
Disassembly and Assembly INFOID:0000000012532436

WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-41, "General Precautions".
Disassembly
WARNING:
Be careful of the following when replacing fuel system parts:
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area.
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place.
CAUTION:
• Perform the operation with vehicle on level ground.
• Do not bend and twist hose and tube.
1. Remove fuel filter from vehicle. Refer to FL-51, "Removal and Installation".

FL-52
 FUEL FILTER
< PERIODIC MAINTENANCE > [YD25DDTi]
2. Remove fuel filter bracket nuts and remove bracket .
A

FL

JSBIA5603ZZ

D
At the bench work
1. Prepare for empty bucket or pan for remaining fuel collect.
2. Remove fuel filter sensor carefully, remaining fuel might splash. E
CAUTION:
Refrain from damaging or scratch on the sealing surface of water level sensor gasket.
3. Remove the screws in the order 5→1 as shown in figure. F

JSBIA4950ZZ
I
4. Remove top lid by inserting suitable tool (A).
CAUTION:
Be careful not to force drastically to avoid scratch and J
deformation of the top lid.
5. Remove filter element. Refer to FL-50, "Exploded View".
6. Remove valves and O-rings as necessary. K

JSBIA5604ZZ

Assembly M
1. Install valves and O-rings, if removed.
2. Insert top lid together with filter element and adjust the position.
3. Press the top lid using two hands while holding housing neck, press sequentially on several times until top N
lid interfere with filter housing.
4. Tighten the screws in the order 1 →5 as shown in figure.
NOTE: O
Use priming pump to fill the fuel filter completely.

JSBIA4950ZZ

FL-53
 FUEL FILTER
< PERIODIC MAINTENANCE > [YD25DDTi]
Draining Water from Fuel Filter INFOID:0000000012532437

1. Disconnect the fuel filter sensor harness connector.

2. Connect drain hose (suitable hose) to the end of drain .
3. Prepare a tray at the drain hose open end.
4. Loosen fuel filter sensor, and operate priming pump to drain
water from fuel filter.
CAUTION:
• Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
• Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
5. After draining, close drain plug by hand.
JSBIA4951ZZ
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak. Never use tools to
tighten drain plug.
6. Bleed air in fuel piping. Refer to FL-48, "Air Bleeding".
7. Start engine and check there is no fuel leakage.
Inspection INFOID:0000000012532438

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.
1. Bleed air in fuel piping. Refer to FL-48, "Air Bleeding".
2. Check fuel leakage at the fuel system tube and hose connections.
3. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.

FL-54
 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [YD25DDTi]

REMOVAL AND INSTALLATION A

FUEL LEVEL SENSOR UNIT
Exploded view INFOID:0000000012532439
FL

REMOVAL
C

H
JPBIA2220GB

Lock ring Fuel level sensor unit Seal packing

I
Fuel tank

: Always replce afetr every disassembly·

J
: N·m (kg-m, ft-lb)

DISASSEMBLY
K

JSBIA5644ZZ

P
Fuel level sensor Fuel level sensor unit

Removal and Installation INFOID:0000000012532440

REMOVAL
WARNING:

FL-55
 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [YD25DDTi]
Be sure to read “General Precautions” when working on fuel system. Refer to FL-41, "General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer to FL-59, "Removal and Installation".
2. Using a lock ring wrench [SST: KV99104700] to remove the lock
ring by turning counterclockwise

PBIC0240E

3. Remove fuel level sensor unit.

CAUTION:
• Never bend the float arm during removal.
• Avoid impacts such as falling when handling components.
4. Preform inspection after removal. Refer to FL-57, "Inspection".
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Do not reuse seal packing.
1. Install fuel level sensor unit with aligning mating marks on
fuel tank and fuel level sensor unit as shown in the figure.

: Vehicle front

PBIC3506E

2. Tighten lock ring for fuel level sensor unit, fuel filter and fuel
pump assembly with lock ring wrench [SST: KV99104700] by
turning clockwise.

PBIC0240E

3. Perform inspection after installation. Refer to FL-57, "Inspection".

Disassembly and Assembly INFOID:0000000012532441

DISASSEMBLY

FL-56
 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [YD25DDTi]
1. Disconnect fuel level sensor harness connector .
A

FL

JSBIA5645ZZ

D
2. Press (A) with a flat-blade screwdriver or an equivalent to
release the lock and push out the fuel level sensor .
E

G
JSBIA5646ZZ

3. To remove the fuel level sensor , slide it in the direction shown H

by the arrow ( ).
CAUTION:
• Be careful not to damage the fuel level sensor.
• Never disassemble fuel level sensor unit. I

JSBIA5647ZZ
K

ASSEMBLY
1. Check for damage of fuel level sensor unit installation position on the side of fuel level sensor unit. L
2. Slide fuel level sensor unit until it aligns to installation groove, then insert it until stops.
• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.
3. Connect harness connector. M
Inspection INFOID:0000000012532442

INSPECTION AFTER REMOVAL N

Check fuel level sensor unit is free from foreign materials. If any are found, remove them.
INSPECTION AFTER INSTALLATION O
Use the following procedure to check for fuel leakage.
1. Bleed air in fuel piping. Refer to FL-48, "Air Bleeding".
2. Check fuel leakage at the fuel system tube and hose connections. P
3. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.
4. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description".

FL-57
 FUEL TANK
< REMOVAL AND INSTALLATION > [YD25DDTi]
FUEL TANK
Hydraulic Layout INFOID:0000000012532443

JSBIA5648ZZ

Fuel pump Fuel feed tube Fuel filler hose

Vent hose EVAP tube Fuel level sensor unit

FL-58
 FUEL TANK
< REMOVAL AND INSTALLATION > [YD25DDTi]
Fuel tank Fuel return tube Fuel cooling tube
Fuel filter Priming pump
A

Exploded view INFOID:0000000012532444

FL

JSBIA5598GB
K
Fuel filler cap Grommet Fuel filler tube
EVAP tube Fuel tank Fuel tank band
L
Fuel tank band Vent hose Fuel filler hose
To fuel filter To fuel cooler tube
M
: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

N
Removal and Installation INFOID:0000000012532445

WARNING: O
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-41, "General Pre-
cautions".
REMOVAL P
WARNING:
Be careful of the following when replacing fuel system parts:
• Display “CAUTION: flammable material”.
• Keep away from flames, and work in a well-ventilated area.
• Keep a fire extinguisher handy.
• Keep drained fuel in a safe place.
CAUTION:

FL-59
 FUEL TANK
< REMOVAL AND INSTALLATION > [YD25DDTi]
• Perform the operation with vehicle on level ground.
• Do not bend and twist hose and tube.
1. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-
ate amount of fuel from the fuel tank.

Guideline : Draw approximately 15 liters (3-2/8 Imp gal) from a full-tank condition.
• In the event of malfunction in fuel pump, insert a hose measuring 20 mm (0.79 in) in diameter into the
filler opening to draw approximately 15 liters (3-2/8 Imp gal) fuel.
2. Open fuel filler lid.
3. Open the fuel filler cap and release the pressure inside the fuel tank.
4. Disconnect vent hose and fuel filler hose from the rear of
fuel tank.

: Vehicle front

NOTE:
Fuel filler hose disconnect fuel filler tube side.

JSBIA4940ZZ

5. Using transmission jack (A), support bottom of fuel tank

securely. Then remove fuel tank mounting bands (front and rear)
from tank.

JSBIA4942ZZ

6. Little down the fuel tank and disconnect the harness connector
from the front-left of fuel tank.

: Fuel tank
: Vehicle front

JSBIA4939ZZ

7. Disconnect EVAP tube fuel feed tube and fuel return tube
from front-right of fuel tank.

: Quick connector

NOTE:
The followings are also applied to quick connector of each tube.

JSBIA4938ZZ

FL-60
 FUEL TANK
< REMOVAL AND INSTALLATION > [YD25DDTi]
Disconnect quick connectors of each tube as follows:
• Hold the sides of connector, push in tabs and pull out fuel A
feed tube.

: Pull
FL
• If quick connector sticks to tube of fuel level sensor unit, push
and pull quick connector several times until they start to move.
Then disconnect them by pulling.
C

JPBIA0134ZZ D

CAUTION:
• Quick connector can be disconnected when the tabs E
are completely depressed. Never twist it more than neces-
sary.

: Connection (cross-section) F
: Resin tube
: To under floor fuel line
G
: To fuel tank
: Disconnection
H
• Never use any tools to disconnected 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 I
getting on resin tube.
• Never bend or twist resin tube during installation and dis-
connection. J
• Never 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 K
replaced, also replace retainer with new one. JPBIA0130ZZ

L
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
M

O
JPBIA0135ZZ

8. While supporting fuel tank by hand, lower transmission jack carefully, and remove fuel tank. P
CAUTION:
While removing tank, check all connections are disconnected. Also make certain that components
never come in contact with other components.
9. Remove following parts if necessary.
• Fuel filler hose
• EVAP tube
• Fuel level sensor unit

FL-61
 FUEL TANK
< REMOVAL AND INSTALLATION > [YD25DDTi]
INSTALLATION
Install in the reverse order of removal, paying attention to followings.
Hose and Tube
• Insert each hose to the dimensions shown below, and secure them with clamps.

Fuel filler hose : 35 mm (1.38 in)

Others : 25 mm (0.98 in)
• When installing clamps, do not allow clamps to contact bulge (bump) of tube.
• Tighten each clamp (both ends) of filler hose, as follows:
Fuel tank side
- Tighten until flange of bolt head is on the paint mark on the
band.

JPBIA0146ZZ

Filler tube side

- Tighten the clamp with specified torque.

Specified torque : 3.2 N·m (0.33 kg-m, 28 in-lb)

Quick Connector
Connect quick connector as follows:
1. Check the connection for damage or any 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, check that the connection is secure by following method.
• Pull the tube and the connector to check they are securely
connected.
• Visually confirm that the two retainer tabs are connected to the
connector.

JPBIA0140ZZ

Inspection INFOID:0000000012532446

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.
1. Bleed air in fuel piping. Refer to FL-48, "Air Bleeding".
2. Check fuel leakage at the fuel system tube and hose connections.
3. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.
4. Check condition of fuel gauge. Refer to MWI-29, "FUEL GAUGE : System Description".

FL-62
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000012532447
FL

Fuel tank capacity Approx. 80 (17-5/8 Imp gal)

C
Fuel recommendation Refer to GI-27, "Fuel"

FL-63