Nissan Frontier D40. Manual - part 684

 

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Nissan Frontier D40. Manual - part 684

 

 

FL-10

< ON-VEHICLE REPAIR >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Removal and Installation

INFOID:0000000005275654

1.

Lock ring

2.

Fuel level sensor, fuel filter, and fuel 
pump assembly

3.

EVAP hose

4.

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

5.

Fuel tank

6.

Fuel tank straps

7.

Fuel tank shield (If equipped)

8.

Clip

9.

Fuel filler pipe shield

10. Fuel filler pipe (crew cab)

11.

Fuel filler hose

12. Fuel filler hose

13. Fuel filler pipe (king cab)

14.

Fuel filler cap

15. Fuel filler pipe grommet

AWBIA0866GB

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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REMOVAL

WARNING:

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

FL-2, "General Precau-

tion"

.

1.

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

2.

Remove the LH rear wheel and tire. Refer to 

WT-46, "Rotation"

.

3.

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.

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-454, "Fuel Pressure Check"

 (QR25DE), 

EC-

954, "Fuel Pressure Check"

 (VQ40DE).

5.

Disconnect the battery negative terminal.

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 electrical connector, EVAP hose, and the fuel feed
hose.
• Disconnect the fuel feed hose from the molded clip in the side

of the fuel tank.

16. Clamp

17.

EVAP canister hose

B.

Fuel filler hose connection

A.

Fuel filler hose vent connection

Front

WBIA0390E

LBIA0413E

LBIA0412E

FL-12

< ON-VEHICLE REPAIR >

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

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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

the vehicle to access the fuel level sensor, fuel filter, and fuel
pump assembly.

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

CAUTION:

• Do not bend the float arm during removal.
• Avoid impacts such as dropping when handling the com-

ponents.

INSTALLATION

Installation is in the reverse order of removal.
• For installation, use a new fuel level sensor, fuel filter, and fuel pump assembly 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 the engine and rev it above idle speed, then check that there are no fuel leaks at any of the fuel pipe
and hose connections.

LBIA0413E

Tool number

(J-45722)

LBIA0436E

PBIC1653E

 

 

 

 

 

 

 

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