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Home >> Nissan-Datsun >> 2021 >> NV2500 HD S >> Repair and Diagnosis >> External Pages >> Different car >> Section 191 (Fuel System (CUMMINS 5.0L)) >> Removal And Installation >> Fuel Tank >> Removal and Installation >> Removal

Removal and Installation: Removal

WARNING: This page is about a different car, the 2018 Nissan Titan XD. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Follow the "General Precautions" before working on the fuel system. Refer to General Precaution .
WARNING: The fuel system (fuel pump, high pressure fuel lines, fuel rail, injectors) contains very high pressure fuel. To avoid the risk of personal injury or fire:
  • Do not loosen any fittings while the engine is running.
  • Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.
  • Wear appropriate eye protection and protective equipment as high-pressure fuel spray can penetrate skin.
  • Never smoke or allow sparks or flames (such as pilot lights, electrical switches, or welding equipment) in the work area. Never allow diesel fuel to spill onto a hot exhaust manifold which can cause a fire.
WARNING: To avoid the risk of personal injury or fire, drain diesel fuel into an approved container and safely dispose of in accordance with local environmental regulations.
NOTE: When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
  1. Remove the fuel filler cap to release the pressure from inside the fuel tank.
  2. Check the fuel level on level gauge. If the fuel gauge indicates more than the level as shown (half tank), drain the fuel from the fuel tank until the fuel gauge indicates the level as shown, or less.
    GNSDB123486Courtesy of NISSAN NORTH AMERICA, INC.
    • As a guide, the fuel level reaches the fuel gauge position as shown, or less, when approximately 49.2 SYMBOL (12 US gal, 10-7/8 Imp gal) of fuel is drained from a full tank.
    • If the fuel pump does not operate, use the following procedure to drain the fuel to the specified level.
      • Insert a suitable hose of less than 15 mm (0.59 in) in diameter into the fuel filler pipe through the fuel filler opening to drain the fuel from fuel filler pipe.
  3. Disconnect the battery or batteries. Refer to Battery Disconnect .
  4. Remove fender protector. Refer to Removal and Installation - Rear Fender Protector .
  5. Disconnect fuel supply line at the fuel filter housing (Stage 1).
  6. Disconnect the fuel filler hose from fuel filler tube and fuel tank using the following steps:
    1. Directions for service of a one-button quick-disconnect connector (1):
      1. Disconnect the one-button quick-disconnect connector by pressing in the raised section of the clip on the connector.
        GNSALBIA2719Z-719Courtesy of NISSAN NORTH AMERICA, INC.
      2. With the clip fully depressed, the fuel line can be removed from the female mating port.
      3. Connect the one-button quick-disconnect connector by pushing the connector into the female mating port until it clicks.
    2. Directions for service of a two-button quick-disconnect connector (2):
      1. Disconnect the two-button quick-disconnect connector by pressing in the locking tangs on both sides of the connector.
      2. After pressing the opposing locking tangs, the quick-disconnect connector can be removed from the male fuel fitting.
      3. Connect the two-button quick-disconnect connector by pushing the quick-disconnect connector onto the male fuel fitting until it clicks.
    CAUTION:
    • To avoid damage, do not kink or bend tubing lines. Ensure all tubes and lines are routed and installed properly and care is given during the diassembly and assembly process. Failure to do so can result in damage to the tubes, lines, or surrounding components.
    • The quick connector can be disconnected when the tabs are completely depressed. Do not twist the quick connector more than necessary.
    • 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.
    • 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 the equivalent) except when the resin tube or the retainer is replaced.
    • When the resin tube or hard tube, or the equivalent, is

      replaced, also replace the retainer with a new one (white colored retainer).

    • To keep the connecting portions clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
  7. Remove fuel filler tube.
  8. Disconnect the fuel tube return line.
  9. Remove front fuel tank protector.
  10. Release fuel lines from frame.
  11. Position a suitable jack under the fuel tank.
  12. Remove rear fuel tank mounting strap.
  13. Remove side fuel tank protector.
  14. Remove front fuel tank mounting strap.
  15. While using a suitable jack, lower tank approximately 4 in.
    CAUTION: Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to secure fuel tank at all times.
  16. Disconnect the fuel level sensor and the breather hose.
  17. Lower the fuel tank using a suitable lift jack and remove it from the vehicle.
    CAUTION: Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to secure fuel tank at all times.
  18. If replacing the fuel tank, remove the fuel level sensor unit to transfer to the new fuel tank. Refer to Removal and Installation .
    CAUTION:
    • Do not reuse the O-ring.
    • Do not bend float arm during removal and installation.
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