Nissan Xterra. Manual - part 433

FUEL TANK

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< REMOVAL AND INSTALLATION >

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REMOVAL

WARNING:

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

FL-2, "General Precau-

tion"

.

NOTE:

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

ing.
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
2. Check the fuel level on level gauge. If the fuel gauge indicates

more than the level as shown (half "1/2"), drain the fuel from the

fuel tank until the fuel gauge indicates the level as shown, or

less.

NOTE:

Fuel may be spilled through the lower fuel tank filler hose fitting

when lowering the fuel tank if the level is above "1/2".

• As a guide, the fuel level reaches the fuel gauge position as

shown, or less, when approximately 40   (10 5/8 US gal, 8 3/4

Imp gal) of fuel is drained from a full fuel tank. 

• If the fuel pump does not operate, use the following procedure

to drain the fuel to the specified level.

a. 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.

b. Disconnect the fuel filler hose from the fuel filler pipe.
c. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to 

EC-494, "Fuel Pressure Check"

.

4. Disconnect the negative battery terminal. Refer to 

PG-72, "Removal and Installation"

.

5. 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.

CAUTION:

13. Fuel filler pipe cup grommet

14. Fuel filler cap

15. EVAP Canister hose

16. Clip

17. Fuel tank protector

Front

AWBIA0161ZZ

FL-8

< REMOVAL AND INSTALLATION >

FUEL TANK

• 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.      

6. Remove the four bolts and remove the fuel tank shield.
7. Remove the propeller shaft. Refer to  

DLN-140, "Removal and Installation"

 (2S1330).

8. Support the fuel tank using a suitable lift jack.
9. Remove the three fuel tank strap bolts while supporting the fuel

tank with a suitable lift jack.

10. 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

LBIA0387E

FUEL TANK

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< REMOVAL AND INSTALLATION >

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11. Disconnect the harness connector (A) from the fuel level sensor,

fuel filter, and fuel pump assembly.

• Disconnect the fuel feed hose from the fuel feed hose connec-

tor (B).

• (C): EVAP hose
•

: Front

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).

AWBIA1516ZZ

SFE562A

PBIC1268E

FL-10

< REMOVAL AND INSTALLATION >

FUEL TANK

• 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.      

12. Lower the fuel tank using a suitable lift jack and remove the fuel tank.
13. Disconnect the EVAP hose from the fuel pump and remove the EVAP hose from the molded clip in the top

of the fuel tank.

14. Remove the lock ring using Tool.

15. Remove the fuel level sensor, fuel filter, and fuel pump assem-

bly. Remove and discard O-ring.

CAUTION:

• Do not bend the float arm during removal.

• Avoid impacts such as dropping when handling the com-

ponents.

• Do not reuse O-ring.

INSTALLATION

Installation is in the reverse order of removal.

CAUTION:

• Do not reuse O-ring.

• Do not bend the float arm during installation.

• Connect the quick connector as follows:

- Check the connection for any damage or foreign materials.

- Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.

- After connecting the quick connector, make sure that the connec-

tion is secure by checking as follows:

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

connected.

- Visually inspect the connector to make sure the two retainer tabs

are securely connected.

INSPECTION AFTER INSTALLATION

1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for

leaks while applying fuel pressure.

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

PBIC0163E

Tool number

:  — (J-45722) (shown)
: KV101207S0 ( — )

LBIA0445E

PBIC1653E