NISSAN NAVARA 2005 Repair Workshop Manual

FUEL COOLER
FL-7
C
D
E
F
G
H
I
J
K
L
MA
FL
FUEL COOLERPFP:17511
Components (4WD Models Only)EBS01FEY
Removal and Installation (4WD Models Only)EBS01FEZ
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove protector (fuel tube).
2. Remove protector (fuel cooler) mounting bolts (3 pieces) then disconnect fuel tubes from fuel cooler
assembly.
CAUTION:
lPlug fuel tubes and fuel cooler assembly to prevent fuel from draining.
lDo not splash fuel during removal. If fuel is splashed, immediately wipe it off.
3. Remove fuel cooler assembly from protector (fuel cooler)
CAUTION:
lDo not bend fuel tubes during removal.
lAvoid impacts such as falling when handling components.
1. Fuel tube (return) (to fuel tank) 2. Fuel tube (return) (to engine) 3. Bracket
4. Protector (fuel cooler) 5. Protector (fuel tube) 6. Fuel cooler assembly
7. Bracket
PBIC4059E

FL-8
FUEL COOLER
INSTALLATION
Note the following, and install in the reverse order of removal.
lInsert hose to the length below when there is no spool on the fuel tube and surely clamp fuel hoses.
lBe sure hose clamp is not positioned on swelled area of fuel tube.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart engine and rev it up and make sure there is no fuel leakage at connections.Fuel hose : 25 mm (0.98 in)

FUEL TANK
FL-9
C
D
E
F
G
H
I
J
K
L
MA
FL
FUEL TANKPFP:17202
ComponentsEBS01F6O
Removal and InstallationEBS01E77
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank.
1. Fuel filler cap 2. Grommet 3. Fuel filler tube (Double cab models)
4. EVAP tube 5. Fuel tank 6. Fuel tank band
7. Fuel tank band 8. Fuel feed tube 9. Fuel return tube
10. Vent hose 11. Fuel filler hose (Double cab models) 12. Fuel filler hose (King cab models)
13. Fuel filler tube (King cab models)
A. To fuel filter B.To fuel cooler (under floor) (4WD
models)
To fuel return tube (2WD models)
PBIC4094E

FL-10
FUEL TANK
3. Check fuel level on level place. If fuel gauge indicates more than
the level shown in figure (full or almost full), drain fuel from fuel
tank until gauge indicates level as shown in the figure or below.
NOTE:
Because fuel will be spilled when removing fuel level sensor unit
for the top of the fuel is above fuel level sensor unit installation
surface.
lAs a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (4-3/8 lmp gal) of
fuel are drained from fuel tank.
lRefer to the following for draining fuel.
a. Insert fuel tube of less than 15 mm (0.59 in) in diameter into fuel filler tube through fuel filler opening to
draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
4. Disconnect the battery cable from the negative terminal.
5. Disconnect fuel feed tube (C) and fuel return tube (D).
Disconnect quick connector of fuel feed tube and fuel return tube as
follows.
NOTE:
lHold the sides of the connector, push in tubs and pull out the
tube.
lIf the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them by
pulling.
A : Harness connector
B : EVAP tube
E : Fuel filler hose
F : Vent hose
PBIC3631E
PBIC3375E
SFE562A

FUEL TANK
FL-11
C
D
E
F
G
H
I
J
K
L
MA
FL
CAUTION:
lQuick connector can be disconnected when the tabs are
completely depressed. Do not twist it more than necessary.
lDo not use any tools to disconnect quick connector.
lKeep resin tube away from heat. Be especially careful when
welding near the resin tube.
lPrevent acid liquid such as battery electrolyte etc. from get-
ting on resin tube.
lDo not bend or twist resin tube during installation and
removal.
lDo not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is replaced.
lWhen resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one. Replace same color
retainer as before replacing.
lTo keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
6. Using a transmission jack (A), support the bottom of fuel tank
(1).
CAUTION:
Support the position that fuel tank bands do not engage.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC3377E

FL-12
FUEL TANK
7. Remove fuel tank bands, and lower the transmission jack care-
fully until harness connector (A), EVAP tube (B), fuel filler hose
(E) and vent hose (F) can be disconnected.
8. Disconnect harness connector (A), EVAP tube (B), fuel filler
hose (E) and vent hose (F).
9. Supporting with hands, lower transmission jack carefully, and remove fuel tank.
CAUTION:
lPay attention not to fall fuel tank.
lMake sure that all connection points have been disconnected.
lConfirm there is no interference with vehicle.
10. Remove fuel filler tubes, fuel filler hoses and vent hoses if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal.
lSurely clamp fuel hoses and insert hose to the length below.
lBe sure hose clamp is not positioned on swelled area of fuel tube.
lTighten fuel hose clamp so that the flange (A) of bolt head is on
the paint mark (B) on the band.
lFit mounting band pin to the vehicle side securely.
lBefore fixing the fuel tank, temporarily install the fuel filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.
lConnect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
lVisually confirm that the two tabs are connected to connector.
C : Fuel feed tube
D : Fuel return tube
PBIC3375E
Fuel filler hose : 35 mm (1.38 in)
The other hose : 25 mm (0.98 in)
PBIC4058E

FUEL TANK
FL-13
C
D
E
F
G
H
I
J
K
L
MA
FL
lPull the tube and connector to make sure they are securely
connected.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following step.
lStart engine and rev it up and make sure there is no fuel leakage at connections.
PBIC1653E

FL-14
FUEL LEVEL SENSOR UNIT
FUEL LEVEL SENSOR UNIT
PFP:17042
ComponentsEBS01F6N
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E76
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer toFL-9, "
FUEL TANK".
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
3. Remove fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit is free from foreign materials. If any are found, remove them.
1. Lock ring 2. Fuel level sensor unit 3. Seal packing
4. Fuel tank
A. Refer to text.
PBIC3374E
PBIC0240E

FUEL LEVEL SENSOR UNIT
FL-15
C
D
E
F
G
H
I
J
K
L
MA
FL
INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall fuel level sensor unit (1) with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown in the figure.
lInstall lock ring (1), and tighten lock ring by hand. Then tighten
lock ring with a fuel tank lock ring wrench (commercial service
tool), aligning mating marks (A) on fuel tank and lock ring as
showninthefigure.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart engine and rev it up and make sure there is no fuel leakage at connections.
: Vehicle front
PBIC3506E
: Vehicle front
PBIC3632E

FL-16
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS01E78
Fuel tank capacity
Approx. 80 (17-5/8 Imp gal)
Fuel recommendation Refer toGI-6
.