Nissan Pathfinder (2005 year). Manual - part 262

Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.

General Precautions

EBS00KAV

WARNING:

When replacing fuel line parts, be sure to observe the following.

●

Put a “CAUTION: FLAMMABLE” sign in the workshop.

●

Be sure to work in a well ventilated area and furnish the workshop with a CO

fire extinguisher.

●

Do not smoke while servicing the fuel system. Keep open flames and sparks away from the work
area.

CAUTION:

●

Use gasoline required by the regulations for the octane rating number. Refer to

GI-5, "Precautions

for Fuel (Unleaded Regular Gasoline Recommended)"

●

Before removing fuel line parts, carry out the following procedures:

–

Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.

–

Release fuel pressure from the fuel lines. Refer to

EC-91, "FUEL PRESSURE RELEASE"

–

Disconnect the battery negative terminal.

●

Always replace O-rings and clamps with new ones.

●

Do not kink or twist hoses when they are being installed.

●

Do not tighten hose clamps excessively to avoid damaging hoses.

●

Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end.

●

Ensure that clamp screw does not contact adjacent parts.

SMA803A

FL-4

FUEL SYSTEM

2005 Pathfinder

●

After connecting the fuel tube quick connectors, make sure
the quick connectors are secure.
Ensure that the connector and resin tube do not contact
any adjacent parts.

●

After installing tubes, make sure 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 leaks at con-
nections.

–

Start the engine and rev it up and check for fuel leaks at
connections.

●

Use only a Genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the MIL may come on.

●

For servicing “Evaporative Emission System” parts, refer to

EC-33, "EVAPORATIVE EMISSION SYSTEM"

●

For

servicing

“On

Board

Refueling

Vapor

Recovery

(ORVR)” parts, refer to

EC-40, "ON BOARD REFUELING

VAPOR RECOVERY (ORVR)"

PBIC1268E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-5

2005 Pathfinder

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

PFP:17042

Removal and Installation

EBS00M47

Lock ring

Fuel level sensor, fuel filter, and fuel
pump assembly

Fuel level sensor, fuel filter, and fuel
pump assembly O-ring

EVAP hose

Fuel tank

Fuel tank straps

Fuel tank shield

Lower fuel filler hose

Fuel filler pipe and vent pipe

WBIA0631E

FL-6

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2005 Pathfinder

REMOVAL

WARNING:

Follow the “General Precautions” before working on the fuel system. Refer to

FL-3, "General Precau-

tions"

Remove the fuel filler cap to release the pressure from inside the fuel tank.

Remove the LH rear wheel and tire. Refer to

WT-6, "Rotation"

Check the fuel level on level gauge. If the fuel gauge indicates
more than the level as shown (full or almost full), drain the fuel
from the fuel tank until the fuel gauge indicates the level as
shown, or less.

NOTE:
Fuel will be spilled when removing the fuel level sensor, fuel fil-
ter, and fuel pump assembly for the fuel level is above the fuel
level sensor, fuel filter, and fuel pump assembly fuel tank open-
ing.

●

As a guide, the fuel level reaches the fuel gauge position as
shown, or less, when approximately 15

(4 US gal, 3 1/4 Imp

gal) of fuel are drained from the fuel tank.

●

If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level.

Insert a suitable hose of less than 15 mm (0.59 in) diameter into the fuel filler pipe through the fuel filler
opening to drain the fuel from fuel filler pipe.

Remove the fuel filler pipe shield.

Disconnect the fuel filler hose from the fuel filler pipe.

Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.

Release the fuel pressure from the fuel lines. Refer to

EC-91, "FUEL PRESSURE RELEASE"

Disconnect the battery negative terminal.

Disconnect the lower fuel filler hose from the fuel tank, the EVAP hose, and the vent pipe quick connector.

●

Disconnect the fuel feed hose from the molded clip in the side of the fuel tank.

Disconnect the quick connector as follows:

●

Hold the sides of the connector, push in the 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.

10. Vent hose

11.

Upper fuel filler hose

12. Fuel filler pipe and cup

13. Fuel filler hose grommet

14.

Fuel filler cap

WBIA0390E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-7

2005 Pathfinder

CAUTION:

●

The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor more than necessary.

●

Do not use any tools to disconnect the quick connector.

●

Keep the resin tube away from heat. Be especially careful
when welding near the tube.

●

Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube.

●

Do not bend or twist the resin tube during connection.

●

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

●

When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (semi-
transparent colored retainer).

●

To keep the quick connector clean and to avoid damage
and contamination from foreign materials, cover the
quick connector with plastic bags or suitable material as
shown.

Remove the four bolts and remove the fuel tank shield.

Remove the propeller shaft. Refer to

PR-9, "REAR PROPELLER SHAFT"

Support the fuel tank using a suitable lift jack.

10. Remove the three fuel tank strap bolts while supporting the fuel

tank with a suitable lift jack.

11. Remove the fuel tank straps and slowly lower the fuel tank to access the top of the fuel level sensor, fuel

filter and fuel pump assembly.

CAUTION:

Do not lower the fuel tank too far to prevent damage to the fuel feed hose and the fuel level sensor,
fuel filter and fuel pump assembly connector

PBIC1268E

PBIC0163E

LBIA0413E

FL-8

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2005 Pathfinder

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

assembly electrical connector, and the fuel feed hose.

Disconnect the quick connector as follows:

●

Hold the sides of the connector, push in the 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 quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor more than necessary.

●

Do not use any tools to disconnect the quick connector.

●

Keep the resin tube away from heat. Be especially careful
when welding near the tube.

●

Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube.

●

Do not bend or twist the resin tube during connection.

●

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

●

When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (semi-
transparent colored retainer).

LBIA0412E

SFE562A

PBIC1268E

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