Service Procedure

IMPORTANT:
The Service Procedures for the Frontier and Xterra are different. Make sure you use the correct procedure for the vehicle you are working on.

2001 Frontier

WARNING:
Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area. Make sure the appropriate rated fire extinguisher is available for immediate use.

1. Release the fuel pressure from the fuel system using CONSULT-II (or other suitable method). Follow the procedure in the "EC" section of the ESM.

2. Use a suitable device to remove the fuel from the fuel tank.

3. Remove the fuel tank:

^ For detailed instructions on fuel tank removal and installation, refer to the vehicle specific Service Manual, Section FE (Fuel And Exhaust)/Fuel System/Removal and Installation/Fuel Tank.

WARNING:
Follow all warnings and cautions provided in the Service Manual.





^ Use duct tape and an "indelible" marker (permanent marker), to mark the matching pipes and hoses (attached to the fuel filler neck) before disassembly. See Figure 1.

^ The hoses and pipes must be marked for correct re-assembly.

^ The hoses MUST be re-connected to the same pipes they were removed from. If the hoses are re-connected incorrectly, refueling difficulties may occur.

4. Remove the fuel level sensor. Refer to the "FE" section of the Service Manual for the fuel level sensor removal procedure. Cut and discard the old fuel level sensor 0-ring. You will be installing a new 0-ring later.

NOTE:
To disconnect the fuel return hose from the fuel level sensor, do the following





^ Push UP on the fuel return hose connector 1 to 2 mm (see Figure 2A).

^ With the hose connector pushed UP hold the two plastic tabs (see Figure 2B).

^ While holding the plastic tabs pry down on the hose connector with hose removal pliers (such as #47900, Lisle Corporation or equivalent). See Figure 2C.

NOTE:
The hose removal pliers (noted above) are available from TECH-MATE at 1-800-662-2001 (option # 4).

5. You'll be working inside the fuel tank. To prevent injury, place a split piece of rubber vacuum hose or other suitable covering onto the edge of the fuel level sensor opening.

WARNING:
The fuel level sensor opening edge is sharp.





6. Remove the fuel shutter valve from inside the fuel tank (see Figure 3) as follows:

^ For tanks with a black rubber hose connecting the white plastic fuel shutter valve inside the tank (type 1, see Figure 4);

a. Loosen the screw-type hose clamp on the rubber hose next to the inside wall of the fuel tank.

b. Remove the complete hose and shutter valve.





^ For tanks with only a white plastic shutter valve, NO black rubber hose (type 2, see Figure 4);

a. Remove the shutter valve with a twisting motion while pulling it straight off.





7. Install the replacement shutter valve (see Figure 5) as follows:

a. Lube the 0-ring inside the replacement shutter valve with Texaco Canopus 13 Mineral Oil (see Figure 4).

b. Push the new shutter valve onto the tube where the old shutter valve was removed.

c. Make sure the new shutter valve is pushed all the way onto the tube and it "snaps" into position.

NOTE:
The opening (the Shutter "door") should be pointing straight down toward the fuel tank bottom when installation is complete (see right side of Figure 5 below).





8. Install the new fuel level sensor 0-ring in the groove on the fuel tank.

9. Re-install the fuel level sensor on the fuel tank. Refer to the"FE" section in the applicable Service Manual.

10. Re-install the fuel tank. Refer to the FE" section in the applicable Service Manual

IMPORTANT:
Make sure the hoses removed from the fuel tank are correctly reconnected to the pipes they were removed from.

2001 Xterra

WARNING:
Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area. Make sure the appropriate rated fire extinguisher is available for immediate use.

1. Release the fuel pressure from the fuel system using CONSULT-II (or other suitable method). Follow the procedure in the "EC" section of the ESM.

2. Use a suitable device to remove the fuel from the fuel tank.

3. Remove the fuel level sensor as follows:

a. Remove the right rear passenger seat bottom cushion and fuel level sensor access cover.

b. Refer to the "FE" section of the Service Manual for the fuel level sensor removal procedure. Cut and discard the old fuel level sensor O-ring. You will be instating a new 0-ring later.

NOTE:
To disconnect the fuel return hose from the fuel level sensor, do the following:

^ Push UP on the fuel return hose connector 1 to 2 mm (see Figure 6A)

^ With the hose connector pushed UP. hold the two plastic tabs (see Figure 6B).

^ While holding the plastic tabs, pry down on the hose connector with hose removal pliers (such as # 47900, Lisle Corporation or equivalent). See Figure 6C

NOTE:
The hose removal pliers (noted above) are available from TECH-MATE a 1-800-662-2001 (option # 4).

4. You'll be working inside the fuel tank. To prevent injury, place a split piece of rubber vacuum hose or other suitable covering onto the edge of the fuel level sensor opening.

WARNING:
The fuel level sensor opening edge is sharp.





5. Remove the fuel shutter valve from inside the fuel tank (see Figure 7) as follows:





^ For tanks with a black rubber hose connecting the white plastic fuel shutter valve inside the tank (type 1, see Figure 8);

a. Loosen the screw-type hose clamp on the rubber hose next to the inside wall of the fuel tank.

b. Remove the complete hose and shutter valve.

^ For tanks with only a white plastic shutter valve, NO black rubber hose (type 2, see Figure 8);

a. Remove the shutter valve with a twisting motion while pulling it straight off.





6. Install the replacement shutter valve (see Figure 9) as follows:

a. Lube the 0-ring inside the replacement shutter valve with Texaco Canopus 13 Mineral Oil (see Figure 8).

b. Push the new shutter valve onto the tube where the old shutter valve was removed.

c. Make sure the new shutter valve is pushed all the way onto the tube and it "naps" into position.

NOTE:
The opening (the Shutter "door") should be pointing straight down toward the fuel tank bottom when installation is complete (see right side of Figure 9 above).

7. Install the new fuel level sensor 0-ring in the groove on the fuel tank.

8. Re-install the fuel level sensor on the fuel tank. Refer to the "FE" section of the applicable Service Manual.