Fuel/Instruments - Fuel Gauge Inaccuracy/DTC's Set

Classification: EL07-027D

Reference: NTB07-069D

Date: November 30, 2010

FUEL GAUGE ISSUES AND/OR DTC P0461/2/3

The Parts Information and Service Procedure of this bulletin have been amended.

Please discard previous versions of this bulletin.

APPLIED VEHICLES:
2005-2008* Frontier (D40)
2005-2008* Xterra (N50)
2005-2008* Pathfinder (R51)

APPLIED VINS:
2005-2007* Frontier - ALL
2008 Frontier - Vehicles built before: 1N6(*)D0(***)8 405797
2005-2007* Xterra - ALL
2008 Xterra - Vehicles built before: 5N1AN08(**)8C 504273
2005-2007* Pathfinder - ALL
2008 Pathfinder - Vehicles built before: 5N1(*)R(*)8(**)8C 630614

APPLIED DATES: Vehicles built before: September 19, 2007*

*IMPORTANT:
Some 2006 Frontier, Xterra, and Pathfinder vehicles are not covered by this bulletin; they are covered under Nissan Recall Campaign NTB10-031 (that addresses the separate issue of the fuel gauge reading 1/4 full when the tank is empty). Check Service COMM to see if the vehicle you are working on is instead covered under that Campaign.

IF YOU CONFIRM:

The fuel gauge is erratic, inaccurate, or inoperative.

And/Or

The MIL is "ON" with DTC P0461, P0462, or P0463 stored in Self-Diagnosis.

ACTIONS:

Replace the fuel level sending unit with the one from the Parts Information section of this bulletin.

^ Make sure to use the Clip (Sender Unit Cover) listed in the Parts Information.

NOTE:
Do not replace the entire fuel pump assembly for this incident, if it should occur.





PARTS INFORMATION





CLAIMS INFORMATION

SERVICE PROCEDURE





1. Remove the fuel pump assembly from the vehicle and place it in a clean working area.

^ Refer to section FL in the applicable Service Manual for removal information.

^ Make sure to follow all Service Manual warnings and cautions.





2. At the top of the fuel pump assembly, disconnect the brown connector.

3. Unwind the harness.





4. Remove the fuel gauge sender unit from the fuel pump assembly as follows:

a. Press in on the lock tab.

b. Slide the sender unit off.

C. Unclip the fuel temperature sensor.





5. Install the new fuel level sender unit in reverse order.

Make sure:

^ Sender connector and fuel pump connector are securely connected.

^ Fuel pump harness and sender harness are wrapped / twisted together.

^ Sender and temp sensor wires are inside guide clip.

^ Sender unit is locked in place.

^ Temp sensor is clipped in place.

CAUTION:
Do not bend the float arm when handling the new fuel gauge sender unit.





6. Install the sender unit cover over the sender unit.

^ Slide cover on until it snaps in place.

^ Make sure the 2 clips at the top of the cover are snapped / locked in place.

^ Make sure the lower flange is under the bottom of the fuel pump assembly.

^ Carefully move the float arm through its entire range of motion making sure there is no interference.





7. Carefully reinstall the fuel pump assembly back into the fuel tank.

IMPORTANT:
^ Use a new seal (0-Ring).

^ Make sure the fuel pump assembly is installed straight down into the tank as shown in Figure 6.





8. Install the fuel pump assembly lock ring as follows:

a. Place the fuel pump assembly locating tab between the lock ring holders.

b. Place the lock ring on top of the fuel pump assembly.





c. Insert a pocket screwdriver between the fuel pump assembly plastic locating tab and the lock ring holder as shown in Figure 8.

NOTE:
The pocket screwdriver will hold the plastic locating tab to the left (counterclockwise) while turning the lock ring to the right (clockwise).





d. Hold the pocket screwdriver in place while installing / tightening the lock ring.

NOTE:
^ Use Special Tool J-45722 to install the lock ring.

^ DO NOT use an impact wrench to install the lock ring.

^ The pocket screwdriver will hold the plastic locating tab to the left (counterclockwise) while turning the lock ring to the right (clockwise).





e. Once the lock ring is in the locked position remove the pocket screwdriver.

f. Make sure the locating tab is touching the lock ring holder on the opposite side from where the pocket screwdriver was inserted.

9. Reinstall the fuel tank back into the vehicle in reverse of removal.

^ Refer to the Service Manual as needed.

10. Confirm the Fuel Gauge operates properly.