ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
PRECAUTION ............................................... 2 REMOVAL AND INSTALLATION ................ 6 F

PRECAUTIONS ................................................... 2 FUEL TANK ....................................................... 6

Precaution for Supplemental Restraint System Removal and Installation .......................................... 6 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 2 FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY ........................ 12
FUEL SYSTEM .................................................... 3 Removal and Installation .........................................12 H
General Precaution ................................................... 3
DISASSEMBLY AND ASSEMBLY .............. 18
PREPARATION ............................................ 4 I
FUEL LEVEL SENSOR UNIT, FUEL FILTER
PREPARATION ................................................... 4 AND FUEL PUMP ASSEMBLY ........................ 18
Special Service Tool ................................................. 4 Disassembly and Assembly .....................................18
Commercial Service Tool .......................................... 4 J
SERVICE DATA AND SPECIFICATIONS
BASIC INSPECTION .................................... 5 (SDS) ............................................................ 19
FUEL SYSTEM .................................................... 5 K
SERVICE DATA AND SPECIFICATIONS
Checking Fuel Line ................................................... 5 (SDS) ................................................................. 19
Standard and Limit ..................................................19
L

Revision: October 2007 FL-1 2008 Titan

 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000001338008

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 SR 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 performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR 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 har-
ness connectors.

Revision: October 2007 FL-2 2008 Titan

 FUEL SYSTEM
< PRECAUTION >
FUEL SYSTEM
A
General Precaution INFOID:0000000001338012

WARNING: FL
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 workshop with a CO2 fire extinguisher.
C
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
• 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 D
safe area.
- Release fuel pressure from the fuel lines. Refer to EC-481, "Fuel Pressure Check" .
- Disconnect the battery negative terminal. E
• Always replace O-rings and clamps with new ones.
• Do not kink or twist hoses when they are being installed.
• After connecting the fuel tube quick connectors, make sure
the quick connectors are secure. F
Ensure that the connector and resin tube do not contact any
adjacent parts.
• After installing tubes, make sure there is no fuel leakage at G
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-
nections. H
- Start the engine and rev it up and check for fuel leaks at con-
nections.
• Use only a Genuine NISSAN fuel filler cap as a replacement. If I
an incorrect fuel filler cap is used, the MIL may come on.
• For servicing “Evaporative Emission System” parts, refer to
EC-485, "Removal and Installation" .
• For servicing “On Board Refueling Vapor Recovery (ORVR)” J
parts, refer to EC-483, "How to Detect Fuel Vapor Leakage" .

L
PBIC1268E

Revision: October 2007 FL-3 2008 Titan

 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000001338009

The actual shapes of the Kent-Moore tools may differ from those of the special tools illustrated here.

Tool number Description

(Kent-Moore No.)
Tool name
— Removing and installing fuel tank lock ring
(J-46536)
Fuel tank lock ring tool

LBIA0398E

Commercial Service Tool INFOID:0000000001338010

Tool name Description

Power tool Loosening bolts and nuts

PBIC0190E

Revision: October 2007 FL-4 2008 Titan

 FUEL SYSTEM
< BASIC INSPECTION >
BASIC INSPECTION A
FUEL SYSTEM
Checking Fuel Line INFOID:0000000001338013
FL
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration. C
If necessary, repair or replace damaged parts.

SMA803A

Revision: October 2007 FL-5 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
FUEL TANK
Removal and Installation INFOID:0000000001338019

Short Wheel Base

AWBIA0523GB

1. Fuel line pump protector 2. Lock ring 3. Fuel level sensor, fuel filter, and fuel
pump assembly
4. Fuel tank 5. Fuel tank protector 6. Fuel tank protector clips
7. Fuel tank straps 8. Fuel level sensor, fuel filter, and fuel 9. Fuel filler hose
pump assembly O-ring
10. Fuel filler pipe 11. Fuel filler hose grommet 12. Fuel filler cap
13. Fuel tank shield

Revision: October 2007 FL-6 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
Long Wheel Base
A

FL

L
AWBIA0524GB

1. Fuel line pump protector 2. Lock ring 3. Fuel level sensor, fuel filter, and fuel M
pump assembly
4. Fuel tank 5. Fuel tank protector 6. Fuel tank protector clips
7. Fuel tank straps 8. Fuel level sensor, fuel filter, and fuel 9. Fuel filler hose N
pump assembly O-ring
10. Fuel filler pipe 11. Fuel filler hose grommet 12. Fuel filler cap
13. Fuel tank shield O
REMOVAL
WARNING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "General Precau- P
tion" .
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.

Revision: October 2007 FL-7 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
2. 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.
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. Remove the LH rear wheel and tire. Refer to WT-38, "Rotation" .
WBIA0390E

c. Remove the fuel filler pipe shield.

LBIA0437E

d. Disconnect the fuel filler hose from the fuel filler pipe and dis-
connect the vent hose quick connector.
e. Insert a suitable hose into the fuel tank through the fuel filler
hose to drain the fuel from the fuel tank.

LBIA0386E

3. Release the fuel pressure from the fuel lines. Refer to EC-481, "Fuel Pressure Check" .
4. Disconnect the battery negative terminal.
5. Remove the three nuts and remove fuel line pump protector.
6. Disconnect the EVAP hose at the EVAP canister.

LBIA0405E

Revision: October 2007 FL-8 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
7. Disconnect the fuel level sensor, fuel filter, and fuel pump
assembly electrical connector, and the fuel feed hose. A

FL

LBIA0406E

D
Disconnect the quick connector as follows:
• Hold the sides of the connector, push in 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.
• Do not remove the remaining retainer on the hard tube (or K
the equivalent) except when the resin tube or the retainer
is replaced.
• When the resin tube or hard tube, or the equivalent, is L
replaced, also replace the retainer with a new one (white
colored retainer).

PBIC1268E
O

Revision: October 2007 FL-9 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
• 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

8. Remove the four bolts and remove the fuel tank shield using power tool.
9. Disconnect fuel filler hose at the fuel tank side.
10. Remove the fuel tank strap bolts while supporting the fuel tank
with a suitable lift jack.
11. Lower the fuel tank using a suitable lift jack and remove it from
the vehicle.

LBIA0387E

12. If necessary, remove the lock ring using Tool as shown.

Tool number : — (J-46536)

13. 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 com-
ponents.
LBIA0407E

INSTALLATION
Installation is in the reverse order of removal.
• For installation, use a new fuel level sensor, fuel filter, and fuel pump assembly O-ring.
• 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 connec-
tion 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.

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 to the system.

Revision: October 2007 FL-10 2008 Titan

 FUEL TANK
< REMOVAL AND INSTALLATION >
2. Start the engine and rev it above idle speed, then check that there are no fuel leaks at any of the fuel pipe
and hose connections. A

FL

Revision: October 2007 FL-11 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Removal and Installation INFOID:0000000001338015

Short Wheel Base

AWBIA0523GB

1. Fuel line pump protector 2. Lock ring 3. Fuel level sensor, fuel filter, and fuel
pump assembly
4. Fuel tank 5. Fuel tank protector 6. Fuel tank protector clips
7. Fuel tank straps 8. Fuel level sensor, fuel filter, and fuel 9. Fuel filler hose
pump assembly O-ring
10. Fuel filler pipe 11. Fuel filler hose grommet 12. Fuel filler cap
13. Fuel tank shield

Revision: October 2007 FL-12 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
Long Wheel Base
A

FL

L
AWBIA0524GB

1. Fuel line pump protector 2. Lock ring 3. Fuel level sensor, fuel filter, and fuel M
pump assembly
4. Fuel tank 5. Fuel tank protector 6. Fuel tank protector clips
7. Fuel tank straps 8. Fuel level sensor, fuel filter, and fuel 9. Fuel filler hose N
pump assembly O-ring
10. Fuel filler pipe 11. Fuel filler hose grommet 12. Fuel filler cap
13. Fuel tank shield O
REMOVAL
WARNING:
Follow the “General Precautions” before working on the fuel system. Refer to FL-3, "General Precau- P
tion" .
1. Remove the fuel filler cap to release the pressure from inside the fuel tank.

Revision: October 2007 FL-13 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
2. 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.
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. Remove the LH rear wheel and tire. Refer to WT-38, "Rotation" .
WBIA0390E

c. Remove the fuel filler pipe shield.

LBIA0437E

d. Disconnect the fuel filler hose from the fuel filler pipe and dis-
connect the vent hose quick connector.
e. Insert a suitable hose into the fuel tank through the fuel filler
hose to drain the fuel from the fuel tank.

LBIA0386E

3. Release the fuel pressure from the fuel lines. Refer to EC-481, "Fuel Pressure Check" .
4. Disconnect the battery negative terminal.
5. Remove the three nuts and remove fuel line pump protector.
6. Disconnect the EVAP hose at the EVAP canister.

LBIA0405E

Revision: October 2007 FL-14 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
7. Disconnect the fuel level sensor, fuel filter, and fuel pump
assembly electrical connector and the fuel feed hose. A

FL

LBIA0406E

D
Disconnect the quick connector as follows:
• Hold the sides of the connector, push in 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.
• Do not remove the remaining retainer on the hard tube (or K
the equivalent) except when the resin tube or the retainer
is replaced.
• When the resin tube or hard tube, or the equivalent, is L
replaced, also replace the retainer with a new one (white
colored retainer).

PBIC1268E
O

Revision: October 2007 FL-15 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
• 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

8. Remove the four bolts and remove the fuel tank shield using power tool.
9. Remove the fuel tank strap bolts while supporting the fuel tank
with a suitable lift jack.
10. Lower the fuel tank using a suitable lift jack and remove it from
the vehicle to access the fuel level sensor, fuel filter, and fuel
pump assembly.

LBIA0387E

11. Remove the lock ring using Tool as shown.

Tool number : — (J-46536)

12. Remove the fuel level sensor, fuel filter, and fuel pump assem-
bly. Remove and 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 com-
ponents.
LBIA0407E

INSTALLATION
Installation is in the reverse order of removal.
• For installation, use a new fuel level sensor, fuel filter, and fuel pump assembly O-ring.
• 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 connec-
tion 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.

PBIC1653E

INSPECTION AFTER INSTALLATION

1. Turn the ignition switch ON but do not start engine, then check the fuel pipes and hose connections for
leaks while applying fuel pressure to the system.

Revision: October 2007 FL-16 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
2. Start the engine and rev it above idle speed, then check that there are no fuel leaks at any of the fuel pipe
and hose connections. A

FL

Revision: October 2007 FL-17 2008 Titan

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< DISASSEMBLY AND ASSEMBLY >
DISASSEMBLY AND ASSEMBLY
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Disassembly and Assembly INFOID:0000000001338018

Fuel Level Sender Unit

WAIA0111E

1. Harness connector 2. Sending unit module 3. Fuel sensor

4. Floater arm assembly

Disassembly
1. Disconnect the harness connectors.
2. Remove the fuel sensor from the pump assembly.
3. Remove the sending unit module and floater arm assembly.
Assembly
Assembly is the reverse order of disassembly.

Revision: October 2007 FL-18 2008 Titan

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000001338020
FL

Standard 105.8 (28 US gal, 23 1/4 Imp gal)

Fuel tank capacity C
Large 140 (37 US gal, 30 3/4 Imp gal)

Revision: October 2007 FL-19 2008 Titan