Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



1983-90 Pulsar

See Figures 1, 2 and 3



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Fig. Fig. 1: Exploded view of the fuel tank components-1983-86 Pulsar



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Fig. Fig. 2: Exploded view of the fuel tank components-1987-90 Pulsar



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Fig. Fig. 3: Remove the inspection cover, then disconnect the fuel lines and wiring harness from the fuel tank

  1. Following proper procedures, relieve fuel system residual pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Remove the rear seat cushion.
  6.  
  7. Remove the inspection cover.
  8.  
  9. Disconnect the fuel gauge electrical harness connector.
  10.  
  11. Disconnect the fuel filler and the ventilation hoses. Disconnect the fuel outlet, return and evaporation hoses, at the front of the tank. Plug open fuel lines.
  12.  

Remove the tank protector, if so equipped.

  1. Remove the fuel tank mounting bolts and the tank from the vehicle.
  2.  

To install:
  1. Install the fuel tank to vehicle and torque the mounting bolts to 20-27 ft. lbs. (27-37 Nm).
  2.  
  3. Reconnect all fuel lines, ventilation hoses and the electrical connection.
  4.  
  5. Install the inspection cover and rear seat cushion.
  6.  
  7. Start engine and check for fuel leaks.
  8.  

1982-90 Sentra
2WD MODELS

See Figure 4



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Fig. Fig. 4: Exploded view of the fuel tank components-1984-90 2WD Sentra


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Also observe all safety practices outlined earlier in the Fuel System Safety Precautions. Failure to do so may result in fire or personal injury.

  1. Following proper procedures, relieve fuel system residual pressure.
  2.  
  3. Disconnect the negative battery cable. Drain fuel into a safe, enclosed, metal container.
  4.  
  5. Remove inspection cover and disconnect fuel tank gauge unit harness connector.
  6.  
  7. Disconnect fuel filler and ventilation tubes.
  8.  

Plug hose and pipe openings to prevent entry of dust and dirt.

  1. Disconnect fuel outlet, return and evaporation hoses.
  2.  
  3. Place a suitable jack under the tank to support. Remove 6 bolts attaching fuel tank flange to the body and then lower the fuel tank.
  4.  

To install:
  1. Raise the tank and install the 6 bolts attaching fuel tank flange to the body. Torque the bolts to 20-27 ft. lbs. (27-34 Nm).
  2.  
  3. Connect fuel outlet, return and evaporation hoses.
  4.  
  5. Connect fuel filler and ventilation tubes.
  6.  
  7. Connect the fuel gauge and pump harness connectors. Install inspection cover.
  8.  
  9. Refill the fuel tank and check for leaks. Connect the negative battery cable, start the engine and check for leaks.
  10.  

4WD MODELS

See Figure 5


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Also observe all safety practices outlined earlier in the Fuel System Safety Precautions. Failure to do so may result in fire or personal injury.

  1. Following proper procedures, relieve fuel system residual pressure.
  2.  
  3. Disconnect the negative battery cable. Drain fuel into a safe, enclosed, metal container.
  4.  
  5. Remove inspection cover and disconnect fuel tank gauge unit harness connector.
  6.  
  7. Disconnect fuel filler and ventilation tubes.
  8.  

Plug hose and pipe openings to prevent entry of dust and dirt.

  1. Disconnect the fuel outlet, return and evaporation hoses.
  2.  
  3. Raise the car and support it securely. Support the tank securely from underneath. Remove the bolt from the rear end of the support strap on either side (the bolts screw in upward). You may twist the strap 90° an pull it out of the fitting in the body where it connects, if necessary for clearance or to replace it if damaged.
  4.  
  5. Lower the tank and remove it.
  6.  

To install:
  1. If the tank is being replaced, remove the fuel pump mounting bolts and remove the pump. Install it with a new O-ring, torquing the bolts to 17-23 inch lbs. (1.9-2.6 Nm).
  2.  
  3. Inspect the straps and, if they are bent or show cracks anywhere along their length, replace them. They can be installed by inserting the inner end into the body fitting with the outer end turned outboard and then turning them 90° so they run from front to rear.
  4.  
  5. Raise the tank into position. Then, raise the rear ends of the straps into position so the bolt holes in the straps line up with those in the body. Install the attaching bolts and torque them to 20-27 ft. lbs. (27-34 Nm).
  6.  
  7. Reconnect the fuel lines, evaporative emissions system, tank filler and electrical connectors in reverse of the removal procedure.
  8.  

1991-96 Sentra

See Figures 6 and 7


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Also observe all safety practices outlined earlier in the Fuel System Safety Precautions. Failure to do so may result in fire or personal injury.

  1. Following proper procedures, relieve fuel system residual pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove the rear seat cushion.
  8.  
  9. Remove the inspection cover.
  10.  
  11. Disconnect the fuel gauge and the fuel pump electrical harness connector.
  12.  
  13. At the fuel filler door, disconnect the fuel filler tube from the body.
  14.  
  15. Raise and support the vehicle safely.
  16.  
  17. Disconnect the ventilation hoses.
  18.  
  19. Disconnect the fuel outlet, return and evaporation hoses, at the front of the tank and plug the open fuel lines.
  20.  

If equipped, remove the tank protector.

  1. Support the tank, remove the fuel tank mounting bolts, and lower the tank from the vehicle.
  2.  

To install:

If the sending unit or the fuel pump are removed, a new O-ring must be installed.

  1. Install the fuel tank to vehicle and torque the mounting bolts to 20-26 ft. lbs. (27-37 Nm). If removed, install the fuel tank protector.
  2.  
  3. Connect all the fuel lines and ventilation hoses.
  4.  
  5. Lower the vehicle and connect the filler tube to the vehicle body.
  6.  
  7. Connect the fuel gauge and fuel pump electrical connections.
  8.  
  9. Install the inspection cover and rear seat cushion.
  10.  
  11. Pour fuel back into fuel tank.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start engine and check for fuel leaks.
  16.  



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Fig. Fig. 5: Exploded view of the fuel tank components-1988-90 4WD Sentra



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Fig. Fig. 6: Exploded view of the fuel tank components-1991-94 Sentra/NX Coupe



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Fig. Fig. 7: Exploded view of the fuel tank components-1995-96 Sentra

 
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