Nissan Frontier. Manual - part 822

FUEL TANK

FL-9

< REMOVAL AND INSTALLATION >

C

D

E

F

G

H

I

J

K

L

M

A

FL

N

P

O

10. Lower the fuel tank using a suitable lift jack and remove it from

the vehicle.

11. Remove the lock ring using Tool as shown.

12. Disconnect the EVAP hose from the molded clip in the top of the

fuel tank.

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

bly. Remove and discard the O-ring.

CAUTION:

• Do not bend the float arm during removal.

• Avoid impacts such as dropping when handling the com-

ponents.

• Discard the O-ring. Do not reuse the O-ring.

INSTALLATION

Installation is in the reverse order of removal.

• For installation, use a new O-ring.

CAUTION:

Do not reuse O-ring.

• 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 pipes and hose connections for

leaks while applying fuel pressure to the system.

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

LBIA0413E

Tool number

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

LBIA0436E

PBIC1653E

FL-10

< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Removal and Installation

INFOID:0000000009478796

1.

Lock ring

2.

Fuel level sensor, fuel filter, and fuel 
pump assembly

3.

EVAP hose

4.

O-ring

5.

Fuel tank

6.

Fuel tank straps

7.

Fuel tank shield

8.

Fuel filler pipe

9.

Fuel filler hose

10. Fuel filler cap

11.

Fuel filler pipe grommet

12. Clamp

13. Evap canister hose

14. Fuel tank protector

A.

Fuel filler hose vent connection

B.

Fuel filler hose connection

Front

AWBIA1152GB

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-11

< REMOVAL AND INSTALLATION >

C

D

E

F

G

H

I

J

K

L

M

A

FL

N

P

O

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

REMOVAL

1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
2. Remove the LH rear wheel and tire using power tool. Refer to 

WT-48, "Adjustment"

.

3. Check the fuel level on level gauge. If the fuel gauge indicates

more than the level as shown (half tank), 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 40   (10 5/8 US gal, 8 3/4

Imp gal) of fuel are 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. Remove the fuel filler pipe shield.
c. Disconnect the fuel filler hose from the fuel filler pipe.
d. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.
4. Release the fuel pressure from the fuel lines. Refer to 

EC-466, "Fuel Pressure Check"

 (QR25DE), 

EC-

959, "Fuel Pressure Check"

 (VQ40DE).

5. Disconnect the negative battery terminal. Refer to 

PG-83, "Removal and Installation"

.

6. Remove the fuel tank shield.
7. Remove the fuel tank strap bolts while supporting the fuel tank

with a suitable lift jack.

8. Lower the fuel tank using a suitable lift jack to access the top of

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

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

assembly harness connector, EVAP hose, and the fuel feed

hose.

• Disconnect the fuel feed hose from the molded clip in the side

of the fuel tank.

AWBIA0161ZZ

LBIA0413E

LBIA0412E

FL-12

< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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 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 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.      

SFE562A

PBIC1268E

PBIC0163E