Inspect Fuel Sending Unit

Xterra: Inspect Fuel Sending Unit

CAUTION:
Use suitable covers to protect carpet, upholstery, paint, etc. when performing this procedure.

1. Remove the rear, passenger-side, bottom Seat Cushion as follows:





a. Pull on the Seat Cushion Release Straps while lifting UP on the front edge of the Seat Cushion (see Figure 23).

b. Remove the Cushion and place it in a clean, safe location.





2. Remove four Bolts and remove the Body Cover Plate (see Figure 24).





3. Remove three Bolts and lift the Fuel Sending Unit Inspection Cover UP (see Figure 25).





4. Disconnect the Fuel Sending Unit Connectors (see Figure 26).





5. Install the Connector Cover onto the Fuel Sending Unit Connectors until it is fully seated. See Figure 27.





6. Use the Nylon Brush #J-47239 to loosen/remove dirt and debris on the vertical surface of the Fuel Sending Unit Connectors (see Figure 28).

NOTE:
If needed, you can bend the Brush to better reach the vertical surfaces.

7. Remove the Connector Cover once you're done with the above step.





8. Install the Cleaning Adapter (white color adapter) onto the Fuel Sending Unit Connectors until it clicks (locks) in place. See Figure 29.

CAUTION:
When performing the following steps:

^ Use suitable protective gloves, safety glasses, or face shield.

^ Use suitable covers to protect carpet, upholstery, etc.





9. Spray Brake Cleaner #999MP-AH001P through each Adapter Tube for about two seconds (see Figure 30).

^ You will need to insert the Adapter Tube into the Brake Cleaner spray can nozzle.

10. Remove and discard the Cleaning Adapter.

NOTE:
^ When you remove the Cleaning Adapter, one or both of the connector inserts may come out of the Adapter.

^ Make sure you remove the insert(s) from the Fuel Sending Unit connector(s).





11. Install the Connector Cover onto the Fuel Sending Unit Connectors until it is fully seated. See Figure 31.





12. Use shop air to thoroughly dry the vertical surface of the Fuel Sending Unit connectors, then remove the Connector Cover. See Figure 32.

13. Inspect the Fuel Pump Connector for green corrosion.

^ Inspection is NOT required for the Fuel Level Sensor Connector.

^ Use a mirror to look at the connector.





^ See illustrations below for examples of green corrosion.

a. If OK, go to "Xterra: Add Protective Coating To Fuel Sending Unit".

b. If NG, go to "Xterra: Replace Fuel Sending Unit".