Nissan 240SX/Altima 1993-1998 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Exploded view of a fuel tank assembly-Altima



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Fig. Fig. 2: Exploded view of a fuel tank assembly-240SX



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Fig. Fig. 3: A special tool is usually available to remove or install the fuel pump locking cam



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Fig. Fig. 4: A brass drift and hammer can also be used to loosen the fuel pump locking cam



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Fig. Fig. 5: Once the locking cam is released, it can be removed to free the fuel pump

  1. Drain the fuel from the fuel tank.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the fuel pump access plate beneath the rear seat.
  6.  
  7. Label and disconnect the fuel hoses and electrical harness.
  8.  
  9. Raise and safely support the rear of the vehicle.
  10.  
  11. Label all fuel lines for installation reference.
  12.  
  13. On 240SX models, remove the exhaust center tube, driveshaft, differential carrier and rear suspension member.
  14.  
  15. Disconnect the fuel filler hose and vent hose.
  16.  
  17. Remove the fuel tank protector assembly.
  18.  
  19. Remove the fuel tank band retaining bolts while supporting the fuel tank with a transmission jack.
  20.  
  21. Slowly lower the tank assembly from the vehicle.
  22.  

To install:
  1. Position the tank assembly on the vehicle.
  2.  
  3. Install the fuel tank retaining bands and tighten the bolts to 20-27 ft. lbs. (26-36 Nm).
  4.  
  5. Install the fuel tank protector assembly.
  6.  
  7. Connect the fuel filler hose and vent hose. Tighten the hose clamps securely.
  8.  
  9. On 240SX models, install the exhaust center tube, driveshaft, differential carrier and rear suspension member.
  10.  
  11. Lower the rear of the vehicle.
  12.  
  13. Connect the fuel hoses and electrical harness.
  14.  
  15. Install the fuel pump access plate beneath the rear seat.
  16.  
  17. Fill the fuel tank with a few gallons of fresh fuel.
  18.  
  19. Pressurize the fuel system and check for leaks.
  20.  

 
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