Nissan Pathfinder. Manual - part 639

FL-12

< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

• Connect the quick connector as follows:

- Check the connection for damage or any foreign materials.

- Align the connector with the tube, then insert the connector straight

into the tube until a click is heard.

• After the tube is connected, make sure the connection is secure by

performing the following checks:

- Pull the tube and the connector to make sure they are securely

connected.

- Visually confirm that the two retainer tabs are connected to the

quick connector. 

• Installation of the remaining components in the reverse order of

removal.

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leaks.
1. Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then

check the connections for fuel leaks.

2. Start engine, raise idle, and verify there are no fuel leaks at the fuel system connections.

PBIC1653E

PBIC0199E

FUEL TANK

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< REMOVAL AND INSTALLATION >

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FUEL TANK

Exploded View

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Removal and Installation

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NOTE:

When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-

ing.

REMOVAL

WARNING:

Read “General Precautions” before working on the fuel system. 

1.

Fuel tank protector 3

2.

Fuel tank protector 2

3.

Fuel tank mounting strap 1

4.

Fuel tank mounting strap 2

5.

Fuel tank mounting strap 3

6.

Fuel tank protector 1

7.

Fuel tank

8.

Clamp

9.

Fuel filler hose

10. Fuel filler tube

11. Fuel filler cap

Front

ALBIA0786GB

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< REMOVAL AND INSTALLATION >

FUEL TANK

Refer to 

FL-2, "General Precaution"

.

1. Open the fuel filler cap to release the pressure inside the fuel tank.
2. Check the fuel level with the vehicle on a level surface. If the fuel

gauge indicates more than the level as shown (1/2 full), drain

the fuel from the fuel tank until the fuel gauge indicates a level at

or below as shown (1/2 full). 

• In case the fuel pump does not operate, use the following pro-

cedure.

a. Insert fuel tubing of less than 25mm (0.98in) diameter into the

fuel filler tube through the fuel filler opening to drain fuel from the

fuel filler tube.

b. Disconnect the fuel filler hose from the fuel filler tube.
c.

Insert fuel tubing into the fuel tank through the fuel filler hose to

drain fuel from the fuel tank.

• As a guide, the fuel level reaches or is less than the level on the fuel gauge as shown, when approxi-

mately 37   (9-3/4 US gal, 8-1/8 Imp gal) of fuel is drained from a full fuel tank.

3. Release fuel pressure from fuel line. Refer to 

EC-151, "Work Procedure"

.

4. Disconnect the battery negative terminal. Refer to 

PG-90, "Removal and Installation"

.

5. Remove both second row (LH) bench seat front slide covers. Refer to 

SE-91, "Exploded View"

.

6. Position the second row (LH) bench seat to full forward position.
7. Remove both second row (LH) bench seat rear slide covers. Refer to 

SE-91, "Exploded View"

.

8. Position and secure the carpet to gain access to the fuel pump inspection hole cover.

CAUTION:

Cover the immediate area surrounding the fuel pump inspection hole cover with plastic to avoid

gasoline damage to the carpet.

9. Remove the center floor duct (LH). Refer to 

VTL-13, "CENTER FLOOR DUCT : Removal and Installation

- Center Floor Duct"

.

10. Turn the four retainers (A) 90 degrees to disengage the clips

and remove the fuel pump inspection hole cover.

11. Disconnect the fuel level sensor, fuel filter, and fuel pump

assembly harness connector (A), EVAP hose connector (C), and

the fuel feed hose connector (B) from the fuel level sensor unit,

fuel filter, and fuel pump assembly.

: Front

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: Front

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FUEL TANK

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< REMOVAL AND INSTALLATION >

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Disconnect the quick connector as follows:

• Hold the sides of the connector, push in tabs and pull out the

tube.

• If the connector and the tube are stuck together, push and pull

several times until they start to move. Then disconnect them

by pulling.

CAUTION:

• The tube can be removed when the tabs are completely

depressed. Do not twist it more than necessary.

• Do not use any tools to remove the 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 the resin tube.

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

• Only when the tube is replaced, remove the remaining retainer on the tube or fuel level sensor,

fuel filter, and fuel pump assembly.

• When the tube or fuel level sensor, fuel filter, and fuel pump assembly is replaced, also replace

the retainer with a new one (green colored retainer).

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

age and foreign materials, cover them completely with

plastic bags or something similar.      

12. Remove fuel tank protector 1 from the front side of the fuel tank.
13. Remove the nut (A) and separate the (LH) rear park brake cable

(1) from fuel tank protector 3.

14. Remove the bolts and the outer reinforcement bar (if equipped).
15. Disconnect the fuel filler hose (A), the recirculation hose (B) and

the EVAP tube (C).

16. Support the center part of the fuel tank using a suitable jack.
17. Remove the fuel tank mounting strap bolts and mounting straps

while supporting the fuel tank with a suitable jack.

NOTE:

The fuel tank, fuel tank mounting straps, fuel tank protector 2

and fuel tank protector 3 will be removed from the vehicle as an

assembly.

18. Lower suitable jack carefully to remove the fuel tank.

CAUTION:

Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to

secure tank at all times.

SFE562A

PBIC0163E

: Front

ALBIA0788ZZ

: Front

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