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Removal And Installation: Removal

WARNING: This page is about a different car, the 2004 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Follow the General Precautions before working on the fuel system. Refer to GENERAL PRECAUTIONS .
  1. Drain the fuel from the fuel tank, if necessary.
    • Position the vehicle so it is level.
  2. Remove the fuel filler cap to release the pressure from inside the fuel tank.
  3. Check the fuel level on level gauge. If the fuel gauge indicates more than the level as shown (full or almost full), drain the fuel from the fuel tank until the fuel gauge indicates the level as shown, or less.
    • If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level after disconnecting the fuel filler hose from the fuel filler pipe.
      1. Insert a suitable hose of less than 15 mm (0.59 in) diameter into the fuel filler pipe through the fuel filler opening to drain the fuel from fuel filler pipe.
      2. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.
    • As a guide, the fuel level reaches the fuel gauge position as shown, or less, when approximately 14 liters (3 3/4 US gal, 3 1/8 lmp gal) of fuel are drained from the fuel tank.
    Fig 1: Checking The Fuel Level
    G00728342Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Remove the LH rear wheel and tire. Refer to WT-6, "Rotation"  .
  5. Disconnect the fuel filler hose from the fuel filler pipe and disconnect the vent hose quick connector.
    Fig 2: Disconnecting The Fuel Filler Hose
    G00728343Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Release the fuel pressure from the fuel lines. See FUEL PRESSURE RELEASE in BASIC DIAGNOSTIC PROCEDURES - TITAN article in ENGINE PERFORMANCE..
  7. Remove the three nuts and remove fuel line pump protector.
  8. Disconnect the EVAP hose at the EVAP canister.
    Fig 3: Disconnecting The EVAP Hose
    G00728344Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Disconnect the fuel level sensor, fuel filter, and fuel pump assembly electrical connector, and the fuel feed hose.
    Fig 4: Disconnecting The Connector And The Hose
    G00728345Courtesy of NISSAN MOTOR CO., U.S.A.

    Disconnect the quick connector as follows:

    • Hold the sides of the connector, push in tabs and pull out the tube.
    • If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.
    Fig 5: Disconnecting The Quick Connector
    G00728346Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • The quick connector can be disconnected when the tabs are completely depressed. Do not twist the quick connector more than necessary.
    • Do not use any tools to disconnect the quick connector.
    • Keep the resin tube away from heat. Be especially careful when welding near the tube.
    • Prevent any acid liquids such as battery electrolyte, from getting on the resin tube.
    • Do not bend or twist the resin tube during connection.
    • Do not remove the remaining retainer on the hard tube (or the equivalent) except when the resin tube or the retainer is replaced.
    • When the resin tube or hard tube, or the equivalent, is replaced, also replace the retainer with a new one (white colored retainer).
      Fig 6: Identifying The Quick Connector
      G00728347Courtesy of NISSAN MOTOR CO., U.S.A.
    • To keep the quick connector clean and to avoid damage and contamination from foreign materials, cover the quick connector with plastic bags or suitable material as shown.
    Fig 7: Covering The Quick Connector With Plastic Bags
    G00728348Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Remove the four bolts and remove the fuel tank shield using power tool.
  11. Remove the three clips and remove the fuel tank protector at the front of the fuel tank as necessary to transfer to the new fuel tank.
    Fig 8: Removing The Fuel Tank Protector
    G00728349Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Disconnect fuel filler hose at the fuel tank side.
  13. Remove the fuel tank strap bolts while supporting the fuel tank with a suitable lift jack.
  14. Lower the fuel tank using a suitable lift jack and remove it from the vehicle.
    Fig 9: Supporting The Fuel Tank
    G00728350Courtesy of NISSAN MOTOR CO., U.S.A.
  15. If necessary, remove the lock ring using Tool as shown.

    Tool number : - (J-46214) 

  16. If necessary, remove the fuel level sensor, fuel filter, and fuel pump assembly. Discard the fuel level sensor, fuel filter, and fuel pump assembly O-ring.
    CAUTION:
    • Do not bend the float arm during removal.
    • Avoid impacts such as dropping when handling the components.
Fig 10: Removing The Lock Ring
G00728351Courtesy of NISSAN MOTOR CO., U.S.A.
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