B ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
PREPARATION ........................................................... 2 FUEL TANK ................................................................ 9 F
Special Service Tools ............................................... 2 Removal and Installation .......................................... 9
Commercial Service Tool ......................................... 2 REMOVAL ........................................................... 10
FUEL SYSTEM ........................................................... 3 INSTALLATION ................................................... 12 G
Checking Fuel Lines ................................................. 3 INSPECTION AFTER INSTALLATION ................ 12
General Precautions ................................................ 3 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND Standard and Limit .................................................. 13
H
FUEL PUMP ASSEMBLY ........................................... 5
Removal and Installation .......................................... 5
REMOVAL ............................................................. 6
INSTALLATION ..................................................... 8 I
INSPECTION AFTER INSTALLATION ................. 8

Revision: November 2005 FL-1 2005 Frontier

 PREPARATION

PREPARATION PFP:00002

Special Service Tools EBS00M8N

The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
— Removing and installing fuel tank lock ring
(J-45722)
130 mm Lock ring tool

LBIA0398E

Commercial Service Tool EBS00M8O

Tool name Description

Power tool Loosening bolts and nuts

PBIC0190E

Revision: November 2005 FL-2 2005 Frontier

 FUEL SYSTEM

FUEL SYSTEM PFP:17503

A
Checking Fuel Lines EBS00M8P

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

SMA803A

E
General Precautions EBS00M8Q

WARNING:
When replacing fuel line parts, be sure to observe the following. F
● Put a “CAUTION: INFLAMMABLE” sign in the workshop.
● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. G
CAUTION:
● Use gasoline required by the regulations for octane number. Refer to GI-5, "Precautions for Fuel" .
● Before removing fuel line parts, carry out the following procedures: H
– 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-98, "FUEL PRESSURE RELEASE" (QR), EC- I
723, "FUEL PRESSURE RELEASE" (VQ).
– Disconnect the battery negative terminal.
● Always replace O-rings and clamps with new ones. J
● Do not kink or twist hoses when they are being installed.
● Do not tighten hose clamps excessively to avoid damaging
hoses. K
Tighten high-pressure rubber hose clamp so that clamp
end is 3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber L
hose clamps.
Ensure that screw does not contact adjacent parts.
M

MMA104A

Revision: November 2005 FL-3 2005 Frontier

 FUEL SYSTEM

● 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-38, "EVAPORATIVE EMISSION SYSTEM" (QR), EC-664,
"EVAPORATIVE EMISSION SYSTEM" (VQ).
● For servicing “On Board Refueling Vapor Recovery
(ORVR)” parts, refer to EC-45, "ON BOARD REFUELING
VAPOR RECOVERY (ORVR)" (QR), EC-671, "ON BOARD
REFUELING VAPOR RECOVERY (ORVR)" (VQ).

PBIC1268E

Revision: November 2005 FL-4 2005 Frontier

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY PFP:17042
A
Removal and Installation EBS00M8R

FL

WBIA0635E

1. Lock ring 2. Fuel level sensor, fuel filter, and fuel 3. Fuel level sensor, fuel filter, and fuel
pump assembly pump assembly O-ring
4. EVAP hose 5. Fuel tank 6. Fuel tank straps
7. Fuel tank shield 8. Clip 9. Fuel filler pipe shield

Revision: November 2005 FL-5 2005 Frontier

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

10. Fuel filler pipe 11. Fuel filler hose 12. Fuel filler pipe grommet
13. Fuel filler cap

REMOVAL
WARNING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "General Precau-
tions" .
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-6, "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 WBIA0390E

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-98, "FUEL PRESSURE RELEASE" (QR), EC-
723, "FUEL PRESSURE RELEASE" (VQ).
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.

LBIA0413E

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.

LBIA0412E

Revision: November 2005 FL-6 2005 Frontier

 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 A
tube.
● If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them FL
by pulling.

SFE562A

D
CAUTION:
● The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec- E
tor more than necessary.
● Do not use any tools to disconnect the quick connector.

● Keep the resin tube away from heat. Be especially careful F

when welding near the tube.
● Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube. G
● 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 H
is replaced.
● When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (semi- I
transparent retainer).

K
PBIC1268E

● To keep the quick connector clean and to avoid damage

and contamination from foreign materials, cover the L
quick connector with plastic bags or suitable material as
shown.
M

PBIC0163E

Revision: November 2005 FL-7 2005 Frontier

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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.

LBIA0413E

11. Remove the lock ring using Tool as shown.

Tool number : — (J-45722)
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.
LBIA0436E
● 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 con-
nection 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.

PBIC1653E

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.

Revision: November 2005 FL-8 2005 Frontier

 FUEL TANK

FUEL TANK PFP:17202

A
Removal and Installation EBS00NGB

FL

WBIA0635E

1. Lock ring 2. Fuel level sensor, fuel filter, and fuel 3. Fuel level sensor, fuel filter, and fuel
pump assembly pump assembly O-ring
4. EVAP hose 5. Fuel tank 6. Fuel tank straps
7. Fuel tank shield 8. Clip 9. Fuel filler pipe shield

Revision: November 2005 FL-9 2005 Frontier

 FUEL TANK

10. Fuel filler pipe 11. Fuel filler hose 12. Fuel filler pipe grommet
13. Fuel filler cap

REMOVAL
WARNING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "General Precau-
tions" .
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-6, "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 WBIA0390E

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-98, "FUEL PRESSURE RELEASE" (QR), EC-
723, "FUEL PRESSURE RELEASE" (VQ).
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.

LBIA0413E

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.

LBIA0412E

Revision: November 2005 FL-10 2005 Frontier

 FUEL TANK

Disconnect the quick connector as follows:

● Hold the sides of the connector, push in tabs and pull out the A
tube.
● If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them FL
by pulling.

SFE562A

D
CAUTION:
● The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec- E
tor more than necessary.
● Do not use any tools to disconnect the quick connector.

● Keep the resin tube away from heat. Be especially careful F

when welding near the tube.
● Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube. G
● 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 H
is replaced.
● When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (semi- I
transparent retainer).

K
PBIC1268E

● To keep the quick connector clean and to avoid damage

and contamination from foreign materials, cover the L
quick connector with plastic bags or suitable material as
shown.
M

PBIC0163E

Revision: November 2005 FL-11 2005 Frontier

 FUEL TANK

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

LBIA0413E

11. Remove the lock ring using Tool as shown.

Tool number : — (J-45722)
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.
LBIA0436E
● 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 con-
nection 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.

PBIC1653E

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.

Revision: November 2005 FL-12 2005 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Standard and Limit EBS00M8T

Fuel tank capacity 80 (21 1/8 US gal, 17 5/8 Imp gal)

FL

Revision: November 2005 FL-13 2005 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: November 2005 FL-14 2005 Frontier