B ENGINE

FL
SECTION
FUEL SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 2 FUEL PUMP ASSEMBLY ........................................... 6 F
Precautions for Supplemental Restraint System Removal and Installation .......................................... 6
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REMOVAL ............................................................. 7
SIONER” .................................................................. 2 INSTALLATION ................................................... 10 G
PREPARATION ........................................................... 3 INSPECTION AFTER INSTALLATION ................ 10
Special Service Tools ............................................... 3 FUEL TANK .............................................................. 11
Commercial Service Tool ......................................... 3 Removal and Installation ........................................ 11
H
FUEL SYSTEM ........................................................... 4 REMOVAL ........................................................... 12
Checking Fuel Lines ................................................. 4 INSTALLATION ................................................... 15
General Precautions ................................................ 4 INSPECTION AFTER INSTALLATION ................ 15
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16 I
Standard and Limit .................................................. 16

Revision: February 2006 FL-1 2005 Xterra

 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EBS00T5D

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Revision: February 2006 FL-2 2005 Xterra

 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools EBS00O3F

The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.
Tool number Description FL
(Kent-Moore No.)
Tool name
— Removing and installing fuel tank lock ring C
(J-45722)
130 mm lock ring tool

LBIA0398E
E
Commercial Service Tool EBS00O3G

Tool name Description

F
Power tool Loosening bolts and nuts

PBIC0190E H

Revision: February 2006 FL-3 2005 Xterra

 FUEL SYSTEM

FUEL SYSTEM PFP:17503

Checking Fuel Lines EBS00O3H

Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.

SMA803A

General Precautions EBS00O3I

WARNING:
When replacing fuel line parts, be sure to observe the following.
● Put a “CAUTION: FLAMMABLE” sign in the workshop.
● Be sure to work in a well ventilated area and furnish the workshop with a CO2 fire extinguisher.
● Do not smoke while servicing the fuel system. Keep open flames and sparks away from the work
area.
CAUTION:
● Use gasoline required by the regulations for the octane rating number. Refer to GI-5, "Precautions
for Fuel (Unleaded Gasoline Recommended)" .
● Before removing fuel line parts, carry out the following procedures:
– Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
– Release fuel pressure from the fuel lines. Refer to EC-92, "FUEL PRESSURE RELEASE" .
– Disconnect the battery negative terminal.
● Always replace O-rings and clamps with new ones.
● Do not kink or twist hoses when they are being installed.
● Do not tighten hose clamps excessively to avoid damaging hoses.
● Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end.
● Ensure that clamp screw does not contact adjacent parts.

Revision: February 2006 FL-4 2005 Xterra

 FUEL SYSTEM

● After connecting the fuel tube quick connectors, make sure

the quick connectors are secure. A
Ensure that the connector and resin tube do not contact
any adjacent parts.
● After installing tubes, make sure there is no fuel leakage at FL
connections in the following steps.
– Apply fuel pressure to fuel lines with turning ignition switch
ON (with engine stopped). Then check for fuel leaks at con-
C
nections.
– Start the engine and rev it up and check for fuel leaks at
connections.
D
● Use only a Genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the MIL may come on.
● For servicing “Evaporative Emission System” parts, refer to
EC-33, "EVAPORATIVE EMISSION SYSTEM" . E
● For servicing “On Board Refueling Vapor Recovery
(ORVR)” parts, refer to EC-40, "ON BOARD REFUELING
VAPOR RECOVERY (ORVR)" . F

G
PBIC1268E

Revision: February 2006 FL-5 2005 Xterra

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY PFP:17042

Removal and Installation EBS00O3J

WBIA0736E

1. Lock ring 2. Fuel level sensor, fuel filter, and fuel 3. Fuel level sensor, fuel filter, and fuel
pump assembly pump assembly O-ring
4. EVAP hose 5. Fuel tank 6. Fuel tank straps
7. Fuel tank shield 8. Lower fuel filler hose 9. Fuel filler pipe and vent pipe
10. Vent hose 11. Upper fuel filler hose 12. Fuel filler pipe and cup

Revision: February 2006 FL-6 2005 Xterra

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

13. Fuel filler hose grommet 14. Fuel filler cap 15. EVAP Canister hose
16. Clip ⇐ Front A

REMOVAL
WARNING: FL
Follow the “General Precautions” before working on the fuel system. Refer to FL-4, "General Precau-
tions" .
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
C
2. Remove the LH rear wheel and tire. Refer to WT-7, "Rotation" .
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 D
from the fuel tank until the fuel gauge indicates the level as
shown, or less.
NOTE:
E
Fuel will be spilled when removing the fuel level sensor, fuel fil-
ter, and fuel pump assembly for the fuel level is above the fuel
level sensor, fuel filter, and fuel pump assembly fuel tank open-
ing. F
● As a guide, the fuel level reaches the fuel gauge position as
shown, or less, when approximately 15 (4 US gal, 3 1/4 Imp WBIA0390E

gal) of fuel are drained from the fuel tank. G

● If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level.

a. 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. H
b. Disconnect the fuel filler hose from the fuel filler pipe.
c. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.
I
4. Release the fuel pressure from the fuel lines. Refer to EC-92, "FUEL PRESSURE RELEASE" .
5. Disconnect the battery negative terminal.
6. Disconnect the lower fuel filler hose from the fuel tank, the EVAP hose, and the vent pipe quick connector. J
● Disconnect the fuel feed hose from the molded clip in the side of the fuel tank.

Disconnect the quick connector as follows:

● Hold the sides of the connector, push in the tabs and pull out the tube.
K
● If the connector and the tube are stuck together, push and pull several times until they start to move.
Then disconnect them by pulling.
L

Revision: February 2006 FL-7 2005 Xterra

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:
● The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor 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 (semi-
transparent colored retainer).

PBIC1268E

● 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.

PBIC0163E

7. Remove the four bolts and remove the fuel tank shield.
8. Remove the propeller shaft. Refer to PR-9, "REAR PROPELLER SHAFT" .
9. Support the fuel tank using a suitable lift jack.
10. Remove the three fuel tank strap bolts while supporting the fuel
tank with a suitable lift jack.

LBIA0387E

11. Remove the fuel tank straps and slowly lower the fuel tank to access the top of the fuel level sensor, fuel
filter and fuel pump assembly.
CAUTION:
Do not lower the fuel tank too far to prevent damage to the fuel feed hose and the fuel level sensor,
fuel filter and fuel pump assembly connector

Revision: February 2006 FL-8 2005 Xterra

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

12. Disconnect the fuel level sensor, fuel filter, and fuel pump
assembly electrical connector, and the fuel feed hose. A

FL

LBIA0412E

D
Disconnect the quick connector as follows:
● Hold the sides of the connector, push in the tabs and pull out
the tube. E
● If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them
by pulling. F

G
SFE562A

CAUTION: H
● The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor more than necessary. I
● 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. J
● Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube.
● Do not bend or twist the resin tube during connection. K
● Do not remove the remaining retainer on the hard tube (or
the equivalent) except when the resin tube or the retainer
is replaced. L
● When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (semi-
transparent colored retainer). M

PBIC1268E

Revision: February 2006 FL-9 2005 Xterra

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

● 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.

PBIC0163E

13. Lower the fuel tank using a suitable lift jack and remove the fuel tank.

14. Disconnect the EVAP hose from the fuel pump and remove the EVAP hose from the molded clip in the top
of the fuel tank.
15. Remove the lock ring using Tool.
Tool number : — (J-45722)
16. Remove the fuel level sensor, fuel filter, and fuel pump assem-
bly.
CAUTION:
● Do not bend the float arm during removal.

● Avoid impacts such as dropping when handling the com-

ponents.
LBIA0445E

INSTALLATION
Installation is in the reverse order of removal.
● Connect the quick connector as follows:
– Check the connection for any damage or foreign materials.
– Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.
– After connecting the quick connector, make sure that the con-
nection is secure by checking as follows:
– Pull the tube and the connector to make sure they are securely
connected.
– Visually inspect the connector to make sure the two retainer tabs
are securely connected.
CAUTION:
● Do not bend the float arm during installation.
● Avoid impacts such as dropping when handling the compo-
nents. PBIC1653E

INSPECTION AFTER INSTALLATION

1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for
leaks while applying fuel pressure.
2. Start the engine and rev it above idle, then check that there are no fuel leaks at any of the fuel pipe and
hose connections.

Revision: February 2006 FL-10 2005 Xterra

 FUEL TANK

FUEL TANK PFP:17202

A
Removal and Installation EBS00O3K

FL

WBIA0736E

1. Lock ring 2. Fuel level sensor, fuel filter, and fuel 3. Fuel level sensor, fuel filter, and fuel
pump assembly pump assembly O-ring
4. EVAP hose 5. Fuel tank 6. Fuel tank straps
7. Fuel tank shield 8. Lower fuel filler hose 9. Fuel filler pipe and vent pipe
10. Vent hose 11. Upper fuel filler hose 12. Fuel filler pipe and cup

Revision: February 2006 FL-11 2005 Xterra

 FUEL TANK

13. Fuel filler pipe cup grommet 14. Fuel filler cap 15. EVAP Canister hose
16. Clip ⇐ Front

REMOVAL
WARNING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-4, "General Precau-
tions" .
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
2. Remove the LH rear wheel and tire. Refer to WT-7, "Rotation" .
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.
NOTE:
Fuel will be spilled when removing the fuel level sensor, fuel fil-
ter, and fuel pump assembly for the fuel level is above the fuel
level sensor, fuel filter, and fuel pump assembly fuel tank open-
ing.
● As a guide, the fuel level reaches the fuel gauge position as
shown, or less, when approximately 15 (4 US gal, 3 1/4 Imp WBIA0390E

gal) of fuel are drained from the fuel tank.

● If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level.

a. 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.
b. Disconnect the fuel filler hose from the fuel filler pipe.
c. Insert a suitable hose into the fuel tank through the fuel filler hose to drain the fuel from the fuel tank.

4. Release the fuel pressure from the fuel lines. Refer to EC-92, "FUEL PRESSURE RELEASE" .
5. Disconnect the battery negative terminal.
6. Disconnect the lower fuel filler hose from the fuel tank, the EVAP hose, and the vent pipe quick connector.
● Disconnect the fuel feed hose from the molded clip in the side of the fuel tank.

Disconnect the quick connector as follows:

● Hold the sides of the connector, push in the 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.

Revision: February 2006 FL-12 2005 Xterra

 FUEL TANK

CAUTION:
● The quick connector can be disconnected when the tabs A
are completely depressed. Do not twist the quick connec-
tor more than necessary.
● Do not use any tools to disconnect the quick connector. FL
● Keep the resin tube away from heat. Be especially careful
when welding near the tube.
● Prevent any acid liquids such as battery electrolyte, from C
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 D

the equivalent) except when the resin tube or the retainer
is replaced.
● When the resin tube or hard tube, or the equivalent, is
E
replaced, also replace the retainer with a new one (semi-
transparent colored retainer).

PBIC1268E

● To keep the quick connector clean and to avoid damage H

and contamination from foreign materials, cover the
quick connector with plastic bags or suitable material as
shown. I

PBIC0163E
K

7. Remove the four bolts and remove the fuel tank shield.
8. Remove the propeller shaft. Refer to PR-9, "REAR PROPELLER SHAFT" . L
9. Support the fuel tank using a suitable lift jack.
10. Remove the three fuel tank strap bolts while supporting the fuel
tank with a suitable lift jack. M

LBIA0387E

11. Remove the fuel tank straps and slowly lower the fuel tank to access the top of the fuel level sensor, fuel
filter and fuel pump assembly.
CAUTION:
Do not lower the fuel tank too far to prevent damage to the fuel feed hose and the fuel level sensor,
fuel filter and fuel pump assembly connector.

Revision: February 2006 FL-13 2005 Xterra

 FUEL TANK

12. Disconnect the fuel level sensor, fuel filter, and fuel pump
assembly electrical connector, and the fuel feed hose.

LBIA0412E

Disconnect the quick connector as follows:

● Hold the sides of the connector, push in the 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.

SFE562A

CAUTION:
● The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor 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 (semi-
transparent colored retainer).

PBIC1268E

Revision: February 2006 FL-14 2005 Xterra

 FUEL TANK

● To keep the quick connector clean and to avoid damage

and contamination from foreign materials, cover the A
quick connector with plastic bags or suitable material as
shown.
FL

PBIC0163E

D
13. Lower the fuel tank using a suitable lift jack and remove the fuel tank.

14. Disconnect the EVAP hose from the fuel pump and remove the EVAP hose from the molded clip in the top
E
of the fuel tank.
15. Remove the lock ring using Tool.
Tool number : — (J-45722) F
16. Remove the fuel level sensor, fuel filter, and fuel pump assem-
bly.
CAUTION: G
● Do not bend the float arm during removal.

● Avoid impacts such as dropping when handling the com-

ponents. H

LBIA0445E

INSTALLATION I
Installation is in the reverse order of removal.
● Connect the quick connector as follows:
– Check the connection for any damage or foreign materials. J
– Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.
– After connecting the quick connector, make sure that the con-
nection is secure by checking as follows: K
– Pull the tube and the connector to make sure they are securely
connected.
– Visually inspect the connector to make sure the two retainer tabs L
are securely connected.
CAUTION:
● Do not bend the float arm during installation. M
● Avoid impacts such as dropping when handling the compo-
nents. PBIC1653E

INSPECTION AFTER INSTALLATION

1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for
leaks while applying fuel pressure.
2. Start the engine and rev it above idle, then check that there are no fuel leaks at any of the fuel pipe and
hose connections.

Revision: February 2006 FL-15 2005 Xterra

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Standard and Limit EBS00O3L

Fuel tank capacity 80 (21 1/8 US gal, 17 5/8 Imp gal)

Revision: February 2006 FL-16 2005 Xterra