Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



1982-83 200SX Models

See Figure 1

Always replace O-rings and gas hose retaining clamps. Do not kink or twist any hose or fuel lines when they are installed. Do not tighten hose clamps excessively to avoid damaging hoses.

Release the Fuel Pressure- refer to the necessary service procedure.

When installing fuel check valve, be careful of its designated direction.

  1. Remove the battery ground cable.
  2.  
  3. Drain the fuel from the fuel tank.
  4.  



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Fig. Fig. 1: Fuel tank and lines 1982-83 200SX

  1. Remove the protector from the luggage compartment, and then remove the following parts:
    1. Harness connector for the fuel tank gauge unit.
    2.  
    3. Ventilation hose.
    4.  
    5. Evaporation hoses
    6.  
    7. Fuel filler hose (Hatchback)
    8.  

  2.  
  3. Remove the following parts from beneath the floor:
    1. Fuel outlet hose
    2.  
    3. Fuel return hose
    4.  
    5. Evaporation hose
    6.  
    7. Fuel filler hose (Hardtop)
    8.  

  4.  
  5. Remove the bolts which secure the fuel tank and remove the tank.
  6.  

To remove the Reservoir tank from the Hatchback:
  1. Remove the battery cable.
  2.  
  3. Remove the protector from the luggage compartment. Also remove the right hand speaker and side lower finisher.
  4.  
  5. Remove the evaporation hoses and then remove the reservoir tank.
  6.  

To install:
  1. Install the reservoir tank in place and fuel tank assembly in the correct position. While supporting the tank in place torque the gas tank strap retaining bolts EVENLY.
  2.  
  3. Reconnect all lines, hoses and the electrical connection.
  4.  
  5. Install the protector in the luggage compartment. Connect the battery ground cable.
  6.  

1984-88 200sxand 240SX Models

See Figures 2 and 3

Always replace O-rings and gas hose retaining clamps. Do not kink or twist any hose or fuel lines when they are installed. Do not tighten hose clamps excessively to avoid damaging hoses.

Release the Fuel Pressure- refer to the necessary service procedure.

When installing fuel check valve, be careful of its designated direction.

The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc. but the basic procedure should cover all years and models.

  1. Remove the battery ground cable.
  2.  
  3. Drain the fuel from the fuel tank.
  4.  



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Fig. Fig. 2: Access plate location-1984-88 200SX



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Fig. Fig. 3: Fuel tank assembly-1984-88 200SX

  1. Remove the access plate if so equipped from the trunk area. Disconnect the hoses, evaporative (vent) tube line if so equipped and fuel pump electrical connection.
  2.  
  3. Raise the rear of vehicle and safely support it with the proper jackstands.
  4.  
  5. Remove the fuel tank protector assembly.
  6.  
  7. Disconnect the fuel filler hose at the gas tank.
  8.  
  9. Remove the gas tank strap retaining bolts and slowly lower the tank assembly down from the vehicle.
  10.  

To install:
  1. Install the tank in the correct position.
  2.  
  3. While supporting the tank in place torque the gas tank strap retaining bolts EVENLY to 2027 ft. lbs.
  4.  
  5. Reconnect the fuel filler hose at the gas tank using a new clamp.
  6.  
  7. Install the fuel tank protector assembly and connect the evaporative (vent) tube line if so equipped.
  8.  
  9. Lower the vehicle, connect all hoses with new clamps and the electrical connection. Install the access plate if so equipped.
  10.  

13.Refill the gas tank. Reconnect the battery ground cable.

Stanza And Stanza 2WD And 4WD Wagons

See Figures 4, 5, 6 and 7



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Fig. Fig. 4: Fuel tank assembly-1992 Stanza



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Fig. Fig. 5: Fuel tank assembly and lines-1985 Stanza



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Fig. Fig. 6: Fuel tank assembly-Stanza 2WD wagon



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Fig. Fig. 7: Fuel tank assembly-Stanza 4WD wagon

Always replace O-rings and gas hose retaining clamps. Do not kink or twist any hose or fuel lines when they are installed. Do not tighten hose clamps excessively to avoid damaging hoses.

Release the Fuel Pressure (EFI vehicles)- refer to all necessary service procedures and illustrations.

When installing fuel check valve, be careful of its designated direction.

The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc. but the basic procedure should cover all years and models.

  1. Drain the fuel tank. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat cushion.
  4.  
  5. Remove the inspection cover.
  6.  
  7. Disconnect the fuel gauge electrical harness connector.
  8.  
  9. Disconnect the fuel filler (if so equipped) and the ventilation hoses. Disconnect the fuel outlet, return and evaporation hoses, at the front of the tank. Plug open fuel lines. Remove the tank protector.
  10.  
  11. Remove the fuel tank mounting bolts and the tank from the vehicle.
  12.  

To install:
  1. Install the fuel tank to vehicle and torque the mounting bolts EVENLY to 2027 ft. lbs.
  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.  

SENDING UNIT REPLACEMENT



See Figures 8, 9, 10 and 11



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Fig. Fig. 8: Access plate location-Stanza



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Fig. Fig. 9: Removing the electrical connection fuel gauge assembly



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Fig. Fig. 10: Removing the lock-ring in the fuel tank assembly



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Fig. Fig. 11: Replacing the O-ring in the fuel tank assembly

Always replace O-rings and gas hose retaining clamps. Do not kink or twist any hose or fuel lines when they are installed. Do not tighten hose clamps excessively to avoid damaging hoses.

Release the Fuel Pressure (EFI vehicles)- refer to all necessary service procedures and illustrations.

When installing fuel check valve, be careful of its designated direction.

The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc. but the basic procedure should cover all years and models.

  1. Release the Fuel Pressure. Disconnect the negative battery cable.
  2.  
  3. On Stanza models, remove the rear seat cushion-remove the inspection cover. On later model 200SX vehicles the inspection cover or access plate must be removed -which is in the trunk area.
  4.  
  5. If vehicle has no inspection cover or access plate (1982-83 200SX and 240SX models) to fuel sending unit assembly the "Fuel Tank" must be removed from the vehicle. Refer to the necessary service procedures in this section.
  6.  
  7. Disconnect fuel tank gauge harness connector and all fuel/vapor line connections.
  8.  
  9. Remove the lock plate and remove the fuel tank gauge unit -Refer to "Electric Fuel Pump In-Tank" service procedures in this section.
  10.  
  11. Installation is the reverse of the removal procedure. When taking out fuel gauge/fuel pump assembly if so equipped be careful not to damage the assembly. Install a new O-ring in the fuel tank before installing lock ring and new gas hose clamps on all connections.
  12.  

 
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