FUEL SYSTEM

B ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
PRECAUTIONS .......................................................... 2 INSPECTION AFTER INSTALLATION .................. 8 F
Precautions for Battery Service ................................ 2 Disassembly and Assembly ...................................... 9
PREPARATION ........................................................... 3 DISASSEMBLY ..................................................... 9
Commercial Service Tools ........................................ 3 ASSEMBLY ......................................................... 10 G
FUEL SYSTEM ........................................................... 4 FUEL TANK .............................................................. 11
Checking Fuel Lines ................................................. 4 Removal and Installation ........................................ 11
General Precautions ................................................ 4 REMOVAL ........................................................... 11
H
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND INSTALLATION ................................................... 12
FUEL PUMP ASSEMBLY ........................................... 5 INSPECTION AFTER INSTALLATION ................ 12
Removal and Installation .......................................... 5 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
REMOVAL ............................................................. 5 Standard and Limit .................................................. 13 I
INSPECTION AFTER REMOVAL ......................... 7 Tightening Torque ................................................... 13
INSTALLATION ..................................................... 7
J

Revision; 2004 April FL-1 2003 G35 Coupe

 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service ABS00B4A

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.

Revision; 2004 April FL-2 2003 G35 Coupe

 PREPARATION

PREPARATION PFP:00002
A
Commercial Service Tools ABS004WO

Tool name Description

FL
Power tool Loosening bolts and nuts

PBIC0190E D

Revision; 2004 April FL-3 2003 G35 Coupe

 FUEL SYSTEM

FUEL SYSTEM PFP:17503

Checking Fuel Lines ABS002Y6

Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.

SMA803A

General Precautions ABS002Y7

WARNING:
When replacing fuel line parts, be sure to observe the following.
● Put a “CAUTION: INFLAMMABLE” sign in the workshop.
● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
● 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:
– a) Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container
in safe area.
– b) Release fuel pressure from the fuel lines. Refer to EC-48, "FUEL PRESSURE RELEASE" .
– c) Disconnect the battery ground cable.
● Always replace O-rings and clamps with new ones.
● Do not kink or twist tubes when they are being installed.
● After connecting the fuel tube quick connectors, make sure
the quick connectors are secure.
Ensure that the connector and resin tube do not contact
any adjacent parts.
● After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
– a) Apply fuel pressure to fuel lines with turning ignition
switch ON (with engine stopped). Then check for fuel leaks
at connections.
– b) Start the engine and rev it up and check for fuel leaks at
connections.
● Use only a genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the MIL may come on.
● For servicing “Evaporative Emission System” parts, refer to
EC-630, "EVAPORATIVE EMISSION SYSTEM" .
● For servicing “On Board Refueling Vapor Recovery
(ORVR)” parts, refer to EC-637, "ON BOARD REFUELING
VAPOR RECOVERY (ORVR)" .

SBIA0504E

Revision; 2004 April FL-4 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY PFP:17042
A
Removal and Installation ABS004SH

FL

PBIC1061E
G

Main fuel level sensor unit, fuel filter -

1. Retainer 2. 3. O - ring
and fuel pump assembly
H
4. Sub fuel level sensor unit

REMOVAL
I
WARNING:
Read “General Precautions” before working on the fuel system. Refer to FL-4, "General Precautions" .
1. Check fuel level on fuel gauge. If gauge indicates more than the
J
level as shown in the figure (full or almost full), drain fuel from
fuel tank until gauge indicates level as shown in the figure or
below.
NOTE: K
Because fuel will be spilled when removing main and sub fuel
level sensor units for the top of the fuel is above the main and
sub fuel level sensor units installation surface. L
● As a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (4-3/8 Imp gal) of
fuel are drained from fuel tank. PBIC1139E
M
● In a case that fuel pump does not operate, perform the follow-
ing procedure.
a. Insert fuel tube of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to
draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-11, "FUEL TANK" .
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-48, "FUEL PRESSURE RELEASE" .
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove the rear seat cushion, Refer to SE-64, "Removal and Installation" .

Revision; 2004 April FL-5 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

6. Peel off floor carpet, then remove inspection hole cover for main
and sub fuel level sensor unit.

PBIC1278E

7. Disconnect the harness connector and fuel feed tube.

PBIC1063E

Disconnect the quick connector as follows:

● Hold the sides of the connector, push in tubs and pull out the
tube.
● If the connector and the tubs are stuck together, push and pull
several times until they start to move.Then disconnect them
by pulling.

SFE562A

Revision; 2004 April FL-6 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:
● The quick connector can be disconnected when the tabs A
are completely depressed. Do not twist it more than nec-
essary.
● Do not use any tools to disconnect the quick connector. FL
● Keep the resin tube away from heat. Be especially careful
when welding near the tube.
● Prevent acid liquid such as battery electrolyte, etc. From C
getting on the resin tube.
● Do not bend or twist the resin tube during installation and
disconnection. D
● Do not remove the remaining retainer on the hard tube (or
the equivalent) except when the resin tube or the retainer
is replaced.
E
● When the resin tube or hard tube (or the equivalent) is
replaced, also replace the retainer with a new one (White
colored retainer).
F

G
SBIA0504E

● To keep the connecting portion clean and to avoid dam- H

age and foreign materials, cover them completely with
plastic bags or something similar.
I

PBIC0163E
K

8. Remove main fuel level sensor unit, fuel filter, fuel pump assembly, and sub fuel level sensor unit.
L
CAUTION:
● Do not bend the float arm during removal.

● Avoid impacts such as falling when handling components.

M
Removal of main fuel level sensor unit, fuel filter, fuel pump
assembly:
● Raise the sender unit, and using a snap ring pliers, remove
the fuel hose connector.
CAUTION:
● Be careful not to damage fuel hose connector by expand-
ing them excessively.
Removal of sub fuel level sensor unit:
● Raise and release the sub fuel level sensor unit to remove.

PBIC1279E

INSPECTION AFTER REMOVAL

Make sure the fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Install in the reverse order of removal paying attention to the following.

Revision; 2004 April FL-7 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

● When installing fuel hose connector, insert them fully until a click
sound of full stopper engagement is heard.

PBIC1281E

● Face fuel gauge as shown in figure, and install it with knock pin
on back aligned with pinhole on fuel tank.

PBIC1065E

● Install retainer so that its notch becomes parallel with notch on

fuel tank.
● Tighten retainer mounting bolts evenly.

PBIC1066E

● Connect the quick connector as follows.

1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector
straight into the tube until a click is heard.
3. After connecting, make sure that the connection is secure by fol-
lowing method.
4. Pull the tube and the connector to make sure they are securely
connected.
● Visually confirm that the two retainer tabs are connected to the
connector. PBIC1653E

INSPECTION AFTER INSTALLATION

● Use the following procedure to check for fuel leaks.
1. Turn ignition key ON (do not start engine), then check connections for leaks by applying fuel pressure to
fuel piping.
2. Start the engine and let it idle and make sure there are no fuel leaks at the fuel system connections.

Revision; 2004 April FL-8 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Disassembly and Assembly ABS004SI

FL

PBIC1081E D

Main fuel filter and fuel pump assem-

1. Fuel level sensor unit 2.
bly
E
NOTE:
● Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY F
Remove fuel level sensor unit with the following procedure.
1. Disconnect harness connector.
● Hold connector by fingers and pull it out, because there is no
G
stopper release tab.

PBIC1078E
J
2. Using a suitable tool, pull up tubs points shown in the figure (two
points) to release the tabs, and disconnect them.
CAUTION: K
● Be careful not to damage it.

M
PBIC1079E

3. After fixing tab is disengaged, slide fuel level sensor unit out in
direction shown by the arrow.
CAUTION:
● Do not disassemble fuel filter and fuel pump assembly.

PBIC1080E

Revision; 2004 April FL-9 2003 G35 Coupe

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

ASSEMBLY
Install in the reverse order of removal paying attention to the following.
1. Check for damage at the fuel filter and fuel pump assembly side fuel gauge installation position.
2. Slide fuel level sensor unit until it aligns to installation groove, then insert it until stop.
● After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.

3. Connect harness connector.

● Securely insert harness connector until it stops.

Revision; 2004 April FL-10 2003 G35 Coupe

 FUEL TANK

FUEL TANK PFP:17202

A
Removal and Installation ABS004SJ

FL

PBIC1977E

1. Grommet 2. Fuel filler cap 3. Clip J

4. Fuel filler tube protector 5. Fuel tank mounting band 6. Fuel tank protector
7. Fuel tank 8. Vent tube 9. Vent hose
10. EVAP hose 11. Vent hose 12. Fuel filler hose K
13. Fuel filler tube

REMOVAL L
WARNING:
Read “General Precautions” before working on the fuel system. Refer to FL-4, "General Precautions" .
● Drain fuel from fuel tank if necessary.
M
● Perform work on level place.
1. Carry out steps 2 to 7 of “REMOVAL” in“ FUEL LEVEL SENSOR UNIT, FUEL FILTER, AND FUEL PUMP
ASSEMBLY”on main and sub fuel level sensor units. Refer to FL-5, "REMOVAL" .
2. Remove the exhaust front tube, center muffler. Refer to EX-3, "Removal and Installation" .
3. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
4. Remove parking brake cables. Refer to PB-6, "PARKING BRAKE CONTROL" .
5. Remove rear suspension assembly. Refer to RSU-7, "Components" .
6. Remove fuel tank protector.

Revision; 2004 April FL-11 2003 G35 Coupe

 FUEL TANK

7. Disconnect fuel filler hose, vent hose and EVAP hoses at fuel
tank side.

PBIC1674E

8. Remove fuel tank mounting band bolts while supporting fuel

tank.
9. Remove the fuel tank.

PBIC0878E

INSTALLATION
Install in the reverse order of removal paying attention to the following.
● Surely clamp fuel hoses and insert hose to the length below.
Fuel filler hose : 35 mm (1.38 in)
The other hoses : 25 mm (0.98 in)
● Be sure hose clamp is not placed on swelled area of fuel tube.
● Tighten each clamp of the filler hose so that the remaining length for tightening becomes 8 to12 mm (0.31
to 0.47 in) fuel tank side and 5.7 to 9.7mm (0.224 to 0.382in) fuel filler tube side.
● To connect the quick connector, refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY" .
INSPECTION AFTER INSTALLATION
● Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure
to fuel piping.
2. Run the engine and check for fuel leaks at the fuel system tube and hose connections.

Revision; 2004 April FL-12 2003 G35 Coupe

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Standard and Limit ABS002YB

Fuel tank capacity Approx. 76 (20 US gal,16-5/8 Imp gal)

FL
Tightening Torque ABS002YC

Unit: N·m (kg-m, ft. - lb)

Unit: N·m (kg-m, in - lb)*
C
Fuel tank mounting band 37.0 - 49.0 (3.8 - 5.0, 28 - 36)
Fuel filler tube 10.9 - 14.7 (1.1 - 1.5, 8 - 10)
Fuel tank protector 10.9 - 14.7 (1.1- 1.5, 8 - 10) D
Main fuel level sensor unit, fuel filter and fuel pump assembly 2.0 - 2.5 (0.20 - 0.26, 18 - 22)*
Sub fuel level sensor unit 2.0 - 2.5 (0.20 - 0.26, 18 - 22)*
E

Revision; 2004 April FL-13 2003 G35 Coupe

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision; 2004 April FL-14 2003 G35 Coupe