Nissan Frontier, Xterra 1998-05

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump module harness connectors
     
    Filler hose shield
     
    Fuel pressure and return lines
     
    Filler hose
     
    Vent hose
     
    Evaporative Emissions (EVAP) hose
     
    Fuel tank skid plate
     
    Fuel tank
     
    Fuel level sender
     
    Fuel pump
     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump
     
    Fuel level sender. Tighten the screws to 17-23 inch lbs. (2.0-2.5 Nm).
     
    Fuel tank. Tighten the bolts to 27-36 ft. lbs. (37-49 Nm).
     
    Fuel tank skid plate. Tighten the bolts to 27-36 ft. lbs. (37-49 Nm).
     
    EVAP hose
     
    Vent hose
     
    Filler hose
     
    Fuel pressure and return lines
     
    Filler hose shield
     
    Fuel pump module harness connectors
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Remove the fuel pump with bracket while lifting the pawl of the pump bracket upward-1998-2004 Frontier and 2000-2001 Xterra

  6.  


NOTE
Be sure to check the fuel gauge indicator. Make sure that it reads less than FULL. If not drain some fuel until the gauge reads less than FULL.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel filler cap. Remove the left rear tire and wheel assembly.
  8.  
  9. Remove the fuel tank shield.
  10.  
  11. Properly support the fuel tank. Remove the fuel tank retaining straps.
  12.  
  13. Lower the fuel tank to gain access to the top of the fuel pump assembly.
  14.  
  15. Disconnect the fuel pump assembly electrical connector, EVAP hose and the fuel feed hose from the molded clip in the side of the fuel tank.
  16.  
  17. Disconnect the quick connector.
  18.  
  19. Lower the fuel tank and remove it from the vehicle. Remove the fuel pump assembly lockring.
  20.  
  21. Disconnect the EVAP hose from the molded clip in the top of the fuel tank.
  22.  
  23. Remove the fuel pump assembly. Discard the O-ring.
  24.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use a new O-ring upon installation.
  4.  
  5. Turn the ignition switch ON, but do not start the engine. Check the fuel lines and hose connections for leaks while applying fuel pressure to the system.
  6.  
  7. Start the engine and check for fuel leaks, correct as required.

    Click image to see an enlarged view

    Fig. Fuel pump and related components-2005 Frontier

  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump module harness connectors
     
    Filler hose shield
     
    Fuel pressure and return lines
     
    Filler hose
     
    Vent hose
     
    Evaporative Emissions (EVAP) hose
     
    Fuel tank skid plate
     
    Fuel tank
     
    Fuel level sender
     
    Fuel pump
     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump
     
    Fuel level sender. Tighten the screws to 17-23 inch lbs. (2.0-2.5 Nm).
     
    Fuel tank. Tighten the bolts to 27-36 ft. lbs. (37-49 Nm).
     
    Fuel tank skid plate. Tighten the bolts to 27-36 ft. lbs. (37-49 Nm).
     
    EVAP hose
     
    Vent hose
     
    Filler hose
     
    Fuel pressure and return lines
     
    Filler hose shield
     
    Fuel pump module harness connectors
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the rear seat cushion and the access panel.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump electrical connectors
     

  8.  
  9. Matchmark the installed position of the fuel line quick connect fittings, then disconnect the fittings by holding the sides of the connector, push in the tabs and pull out the tube inserted in the retainer.
    NOTE
    The tube can be removed when the tabs are completely pushed in. Do NOT use any tools to remove the quick connector.



    Six screws
     
    Fuel level sensor retainer and fuel level sensor
     
    Fuel pump with the bracket, while lifting the pawl of the fuel bracket upward
     
    Fuel level sensor
     

  10.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Fuel pump and related components-2002-2004 Xterra



    Click image to see an enlarged view

    Fig. Fuel pump and related components-2005 Xterra

  4.  


NOTE
Be sure to check the fuel gauge indicator. Make sure that it reads less than FULL. If not drain some fuel until the gauge reads less than FULL.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel filler cap. Remove the left rear tire and wheel assembly.
  8.  
  9. Disconnect the lower fuel filler hose from the fuel tank, the EVAP hose and the vent pipe quick connector.
    NOTE
    Disconnect the fuel feed hose from the molder clip in the side of the fuel tank.

  10.  
  11. Remove the four tank shield retaining bolts. Remove the tank shield.
  12.  
  13. Remove the driveshaft.
  14.  
  15. Properly support the fuel tank. Remove the three fuel tank retaining strap bolts. Remove the fuel tank straps.
  16.  
  17. Lower the fuel tank to gain access to the top of the fuel pump assembly.
    NOTE
    Be careful not to lower the tank too much as you do not want to damage the fuel feed hose and the fuel pump assembly.

  18.  
  19. Disconnect the fuel pump assembly electrical connector, and the fuel feed hose.
  20.  
  21. Disconnect the quick connector.
  22.  
  23. Lower the fuel tank and remove it from the vehicle. Disconnect the EVAP hose from the fuel pump and remove the EVAP hose from the molded clip in the top of the fuel tank.
  24.  
  25. Remove the fuel pump assembly lockring. Remove the fuel pump assembly. Discard the O-ring.
  26.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use a new O-ring upon installation.
  4.  
  5. Turn the ignition switch ON, but do not start the engine. Check the fuel lines and hose connections for leaks while applying fuel pressure to the system.
  6.  
  7. Start the engine and check for fuel leaks, correct as required.
  8.  

 
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