Nissan Pathfinder. Manual - part 638

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< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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

age and foreign materials, cover them completely with

plastic bags or something similar.      

11. Remove the lock ring from the fuel level sensor, fuel filter, and fuel pump assembly.

• Remove the lock ring using Tool (A).

• Prior to removal, observe the alignment between the fuel level

sensor, fuel filter, and fuel pump assembly tabs (A) and the

matching marks (C) on the fuel tank as shown. This alignment

is necessary for proper installation.

12. Raise the fuel level sensor, fuel filter, and fuel pump assembly

high enough to gain access and disconnect the transfer tube

connector (A).

CAUTION:

Do not pull on the transfer tube or damage to the fuel tank

can occur.

13. Remove the fuel level sensor, fuel filter, and fuel pump assembly

and O-ring. Discard the O-ring.

CAUTION:

Do not bend the float arm during removal. 

INSPECTION AFTER REMOVAL

Inspect the fuel level sensor, fuel filter, and fuel pump for any defects and foreign materials. Replace as neces-

sary.

INSTALLATION

1. Install the fuel level sensor, fuel filter, and fuel pump assembly with the following procedure.

CAUTION:

• It is important that the fuel level sensor, fuel filter, and fuel pump assembly be installed carefully,

according to the method in this step to prevent the transfer hose from being pinched under the

fuel pump and to ensure it is routed correctly inside the tank.

• Do not reuse O-ring.

PBIC0163E

Tool number

: ( — ) J-45747

: Front

ALBIA0784ZZ

(B)

: Retainer mounting pawl

JPBIA4665ZZ

ALBIA0785ZZ

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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< REMOVAL AND INSTALLATION >

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NOTE:

Transfer hose (1) should be routed as shown.

a. Obtain a piece of plastic or nylon packing strap approximately 91cm (35.8 in)

• Packing strap is commonly used to reinforce boxes for shipping.

b. Loop the packing strap (2) around the transfer hose as shown.

• Position the strap ends toward the passenger side.

• Use your fingers to put a bend (1) in the strap near the transfer hose (3). This will help keep the strap in

place.

c. Lower the transfer hose and fuel level sensor unit, fuel filter and

fuel pump assembly into the tank keeping the strap looped

around the transfer hose.

: Front

ALBIA1011ZZ

: Front

ALBIA1012ZZ

ALBIA1013ZZ

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< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

d. With the fuel level sensor unit, fuel filter and fuel pump assembly

in the tank, turn 1/4 turn clockwise so the fuel feed tube (1) is

pointing toward the driver side.

• The fuel level sensor unit, fuel filter and fuel pump assembly

should now be oriented to the installed position.

e. Tilt the top of the fuel pump toward the driver side.
f.

Pull up on the packing strap (2) (pull the transfer hose up) just enough to see the transfer hose (1).

NOTE:

If you are unable to pull the transfer hose so it can be seen as shown, remove the fuel level sensor, fuel fil-

ter and fuel pump assembly from the tank and restart from the beginning of INSTALLATION.

g. Hold the fuel pump down so the bottom of the pump stays against the bottom of the tank.
h. While holding the pump down, pull out the packing strap, pull towards the passenger side (

).

• Make sure the O-ring is still in place.

: Front

(2) : Packing strap

ALBIA1014ZZ

: Front

ALBIA1015ZZ

ALBIA1016ZZ

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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< REMOVAL AND INSTALLATION >

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i.

Continue to hold down the fuel pump while installing the fuel

pump lock ring (turn clockwise) using Tool.

NOTE:

• If the fuel level sensor, fuel filter and fuel pump assembly is

allowed to lift off of the bottom of the fuel tank the transfer

hose may slide under it.

• If the fuel level sensor, fuel filter and fuel pump assembly lifts

off the bottom of the tank before the lock ring is installed,

remove the fuel level sensor, fuel filter and fuel pump assem-

bly and restart from the beginning of INSTALLATION.

j.

Align the tabs (A) of the fuel level sensor, fuel filter, and fuel

pump assembly to the matching marks (C) of the fuel tank for

proper installation.

2. Reconnect the EVAP hose (2) and the fuel feed hose (1).

: Front

ALBIA1017ZZ

Tool number

: ( — ) J-45747

: Front

ALBIA0784ZZ

(B)

: Retainer mounting pawl

JPBIA4665ZZ

ALBIA1018ZZ