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

Electric Fuel Pump Repair Guide

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REMOVAL & INSTALLATION



200SX Model (External Mount Electric Pump)

See Figures 1 and 2

  1. Before disconnecting the fuel lines or any of the fuel system components, refer to "Fuel Pressure Release" procedures and release the fuel pressure.
  2.  

Reducing the fuel pressure to zero is a very important step for correct removal of the electric fuel pump. See Fuel Pressure Release procedures in this section. Disconnect the negative battery cable.

  1. Disconnect the electrical harness connector at the pump. The 200SX pump is located near the center of the car, except on 1984 200SX, on which the pump is located near the fuel tank assembly. Refer to the illustrations.
  2.  
  3. Clamp the hose between the fuel tank and the pump to prevent gas from spewing out from the tank.
  4.  
  5. Remove the inlet and outlet hoses at the pump. Unclamp the inlet hose and allow the fuel lines to drain into a suitable container.
  6.  
  7. Unbolt and remove the pump. The 200SX pump and fuel damper can be removed at the same time.
  8.  

To install:
  1. Install the fuel pump in the correct position. Reconnect all hoses. Use new clamps and be sure all hoses are properly seated on the fuel pump body.
  2.  
  3. Reconnect the electrical harness connector at the pump. Start engine and check for fuel leaks.
  4.  



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Fig. Fig. 1: External mounted fuel pump-200SX



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Fig. Fig. 2: External mounted fuel pump-200SX

200SX and 240SX (In-Tank Electric Pump)

See Figure 3

  1. Before disconnecting the fuel lines or any of the fuel system components, refer to "Fuel Pressure Release" procedures and release the fuel pressure.
  2.  

Reducing the fuel pressure to zero is a very important step for correct removal of the electric fuel pump. SeeFuel Pressure Release proceduresin this section.

  1. Disconnect the negative battery cable. Open the trunk lid, disconnect the fuel gauge electrical connector and remove the fuel tank inspection cover.
  2.  

If vehicle has no fuel tank inspection cover the fuel tank must be lowered or removed to gain access to the in-tank fuel pump. When installing fuel check valve, be careful of its designated direction.

  1. Disconnect the fuel outlet and the return hoses. Remove the fuel tank if necessary. Refer to the Fuel Tank Removal And Installation procedure in this section.
  2.  
  3. Remove the ring retaining bolts and the O-ring, then lift the fuel pump assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system.
  4.  

When removing or installing the fuel pump assembly, be careful not to damage or deform it. Install a new O-ring.

To install:
  1. Install fuel pump assembly in tank with a new O-ring. Install the ring retaining bolts. Install the fuel tank if removed, refer to the Fuel Tank Removal And Installation procedure in this section.
  2.  
  3. Reconnect the fuel lines and the electrical connection.
  4.  
  5. Install the fuel tank inspection cover.
  6.  
  7. Connect battery cable, start engine and check for fuel leaks. On some late models the "Check Engine Light" will stay on after installation is completed. The memory code in the control unit must be erased. To erase the code disconnect the battery cable for 10 seconds then reconnect after installation of fuel pump.
  8.  



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Fig. Fig. 3: In-tank Fuel pump assembly-200SX

Stanza Model (External Mount Electric Pump)

The Stanza (1984-86) fuel pump is located under the vehicle in front of the fuel tank, the (1987 and later) Stanza vehicles use in-tank fuel pump.

Before disconnecting the fuel lines or any of the fuel system components, refer to"Fuel Pressure Release"procedures, in this section and release the fuel pressure.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the rear of the vehicle on jackstands.
  4.  
  5. Disconnect the electrical connector from the fuel pump.
  6.  
  7. Place fuel container under the fuel lines, then disconnect the fuel lines and drain the excess fuel into the container.
  8.  
  9. Remove the mounting braces and the fuel pump from the vehicle.
  10.  

To install:
  1. Install the vehicle fuel lines to the pump.
  2.  
  3. Install the mounting braces and mount pump to vehicle.
  4.  
  5. Connect fuel pump electrical connector.
  6.  
  7. Reconnect battery cable, start engine and check for leaks.
  8.  

Stanza Model (In-Tank Electric Pump)

See Figures 4 through 12



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Fig. Fig. 4: The fuel pump access cover is located under the rear seat. It is secured by four screws (arrows)



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Fig. Fig. 5: Fuel pump components include the locking ring (1), fuel pump assembly (2), electrical harness (3), low pressure fuel return line (4), and high pressure fuel feed line (5)



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Fig. Fig. 6: The locking ring should twist off easily. If it is difficult to remove, it can be tapped around gently with a small hammer and drift



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Fig. Fig. 7: The fuel pump assembly can then be lifted from the fuel tank



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Fig. Fig. 8: The fuel pump assembly consists of the pump cover (1), cover gasket (2), electric fuel pump (3), and strainer (4)

  1. Disconnect the negative battery cable.
  2.  
  3. Open the trunk lid, disconnect the fuel gauge electrical connector and remove the fuel tank inspection cover.
  4.  

If vehicle has no fuel tank inspection cover the fuel tank must be removed. When installing fuel check valve, be careful of its designated direction.

  1. Disconnect the fuel outlet and the return hoses.
  2.  
  3. Using a large brass drift pin and a hammer, drive the fuel tank locking ring in the counterclockwise direction.
  4.  
  5. Remove the locking ring and the O-ring, then lift the fuel pump assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system. When removing the fuel tank gauge unit, be careful not to damage or deform it. Install a new O-ring.
  6.  

To install:
  1. Install fuel pump assembly in tank. With a new O-ring install the fuel tank locking ring in place.
  2.  
  3. Reconnect the fuel lines and the electrical connection.
  4.  
  5. Install the fuel tank inspection cover.
  6.  
  7. Connect battery cable, start engine and check for leaks.
  8.  



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Fig. Fig. 9: External fuel pump-1984-86 Stanza



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Fig. Fig. 10: Installing new O-ring in the fuel tank assembly



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Fig. Fig. 11: Removing the lock ring on the fuel tank assembly



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Fig. Fig. 12: In-tank Fuel pump assembly-Stanza

TESTING



See Figure 13

  1. Release the fuel pressure- refer to the service procedure in this section. Connect a fuel pressure gauge (special tool J2540034 or equivalent) between the fuel filter outlet and fuel feed pipe.
  2.  



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Fig. Fig. 13: Installation of fuel pressure test gauge

  1. Start the engine and read the pressure. All models except the 240SX, it should be 30 psi (207 kpa) at idle, and 37 psi (255 kpa) at the moment the accelerator pedal is fully depressed. On the 240SX model the pressure should be 33 psi (227.5 kpa) at idle.
  2.  

Make sure that the fuel filter is not blocked before replacing any fuel system components.

  1. If pressure is not as specified, replace the pressure regulator and repeat the test. If the pressure is still incorrect, check for clogged or deformed fuel lines, then replace the fuel pump or check valve if so equipped.
  2.  

 
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