Fuel System - MIL ON/DTC P1491 Stored in Memory

Classification:
EC03-021

Reference:
NTB03-079

Date:
August 13, 2003

2003 FRONTIER AND XTERRA; MIL "ON" WITH DTC P1491

APPLIED VEHICLES:
2003 Frontier (D22) 2003 Xterra (WD22)

IF YOU CONFIRM:

An Applied Vehicle has the MIL "ON" with DIG P1491 (Vacuum Cut Valve Bypass Valve - VC CUT/V BYPASS/V) stored in the ECM,

ACTION:

Remove fuel from the fuel tank "Signal Line".

NOTE:
Fuel that may be in the Signal Line got there during the first filling of the fuel tank at the factory. This will not reoccur with later filling of the fuel tank.

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line claim using the claims coding shown.

NOTE:
The purpose of "ACTION" (above) is to give you a quick idea of the work you will be performing. You must closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair.

SERVICE PROCEDURE

WARNING:
Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e. open flames, sparks, etc.) in or around the vehicle/work area. Make sure the appropriate rated fire extinguisher is available for immediate use.





1. For Xterra: Remove the fuel line protective cover in the right rear wheel well (see Figure 1).





2. Remove any fuel that may be in the Signal Line (see Figure 2)

a. Remove rubber "signal" hose from the metal signal line tube. It's right next to the fuel fill hose.

b. Attach one end of a clear rubber hose to the signal hose.

c. Attach the other end of the clear rubber hose to a hand vacuum pump.

NOTE:
J-42909 EVAP Pressure Test Kit is an Essential Tool. It contains a hand-operated vacuum pump and is kept in drawer 6 of the STSS (Special Tool Storage System).

d. Apply vacuum to remove any fuel that may be trapped in the signal line. You should see fuel collecting at the bottom of the clear hose.

IMPORTANT:

^ Put a U-bend in the rubber hose between the signal hose and the vacuum pump to "hold" any fuel removed from the signal line.

^ If fuel gets into the hand vacuum pump, it may damage the pump.

e. Continue applying vacuum until there is no more fuel in the signal hose.

3. Re-install any removed items.

4. Check for proper operation, and that there are no fuel leaks.

5. Erase the DTC using CONSULT-II.