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Fuel Sending Unit *help requested*

7K views 9 replies 5 participants last post by  crunchradio  
#1 ·
I am waiting for autozone to finally send my $7 lock ring and o ring so that I can replace my fuel sending unit. Does anybody have a diagram or other type of pictures of how you replace the fuel sending unit on a fuel pump. I am going to attempt the "bed tilt" method on my '00 xe 2.4L. That is why I am not going to just replace the fuel pump while I'm in there. It "should" be easy enough to access the top of the gas tank.

Anybody have any tips? Does anybody know a replacement part number for the "cab to pickup bed" rubber gasket/bumper, or the "biscuits" that are between the bed and the frame that pad the 4 mounting bolts that hold the bed to the chassis?

My gas tank has been on half forever. It never changes, so I'm assuming it is the fuel sending unit. Is there anything else I can try in the mean time. I basically commute 8 miles a day round trip, so this is not a high priority. I can just fill up weekly and I should not run out of gas.
 
#2 ·
Have you downloaded a copy of the Nissan Factory Service Manual, (FSM)? You can download a copy from any of the attached weblinks:

It should have a diagram showing the fuel pump assembly & fuel sending unit in the FSM. Have you checked YouTube??

Not sure about the "cab to bed" rubber gasket / bumper / biscuit.... Check this website...they might have a diagram showing the part / part number....
Just be prepared to click thru all the filters you need to go thru first to get the results you are looking for....

If that part is no longer available then you might want to try your local Ace Hardware store or McMaster-Carr to see if you can create you own rubber gasket / biscuit.

And before you go thru the hassle of lifting the bed / dropping the tank, check the wiring harness between the fuel gauge and the gas tank to make sure the wiring is okay. Use the wiring harness diagram in the FSM for the fuel sender unit to trace the line. Oh...also check the gas gauge on the dash / instrument cluster to make sure it is working too!!

Anyhow, hope this helps... Good Luck!!

CC:
@butterman2473
@Cusser
 
#3 ·
Okay, that's some good advise. I don't know how often sending gauge units go bad, but I'll check some wiring first and if I can get it working I can just return the parts to AutoZone. Even if I couldn't I'm out about $40. Not a big deal either way. I could find much on YouTube. Just the overall fuel pump replacement. And I don't remember seeing much in the way of the truck bed in the service manuals so that's why I was asking. Some people have different resources than the common service manuals. Also I "got" access to alldata and it is just the service manuals with outdated prices and labor times, so not much there either.
 
#4 · (Edited)
I've replaced my pump twice in recent memory on my 98 2wd. Once with the bed off last January, and then again earlier this year using the bed tilt method. I don't drive it often and left the fuel level low enough for the pump to seize. Replaced the pump anyway, but a soft shock to the pump freed it up.

My replies to your post...

1. No lock ring; just six small screws and an o-ring.

2. I didn't remove the FSU, but did clean up the contacts. I want to say it just snaps or clips on to the plastic piece that holds the fuel pump. Not sure if the pump blocks access to the clips, though...

3. Bed tilt method is...interesting. I didn't enjoy doing it. I tilted it sideways, and not to the rear like dumptruck. I used some 4x4 blocks to prop it up between the bed support beams and the frame, and also kept the two driver's side bed bolts loosely in the frame (rear-most bolt removed because it's not inline with the side bolts) mainly as a pivot point, but also out of fear of the whole bed sliding off or something dumb. Also:
  • get a friend or a cherry picker to help; I definitely don't recommended doing it solo with a floor jack or anything like that. It's heavy and awkward to grip, not to mention the only decent place to lift by hand is the wheel well...which means you'll most likely be blocking the space where your helper needs to shove blocks into.
  • tuck a towel or blanket between the bed and cab to not scratch things.
  • disconnect the license plate and tail light harnesses
  • I think the bumper needs to be removed...mine was already off but I presume it would be in the way (i.e., scraping the tail of the bedside)
  • remove the 3 screws holding the filler neck to the bed, and push the filler neck away so it doesn't snag anything when tilting.
  • There's a fuel temp sensor inside the tank, and its wire runs to the assembly. Don't try to pull the assembly out before disconnecting, of course. On my truck, that wire also had some extremely brittle plastic wire loom on it. I removed what I could and fished out the pieces.
4. When I had the bed off to do an axle swap, I wanted to replace the "biscuits" and the bed bolts. I think all those parts were ridiculously overpriced for what they were, so I found some salvageable hardware off a junkyard truck, and bought a pack of Energy Suspension 9.9533G polyurethane pads to replace the biscuits. The pads are 2"x2"x1/4" thick with a 7/16" hole (I think the OE pads were about 2" diameter and also about 1/4" thick). The bed bolts have a 12mm shoulder if I recall, so I just drilled out the holes a little to fit the shoulders. They come as an 8-pack, available on Amazon in black (the "G" in part number) or red ("R") and worked great for my needs.

5. Not exactly sure what the "cab to pickup bed" rubber gasket/bumpers are...unless you're talking about the rectangular rubber pads that are between the frame and the bed support beams and each held on by a pair of hex screws. For those, I pulled them off, degreased them, sprayed them black, and re-installed them upside down. Good as new.

Here's a bed-off reference pic from my axle swap project below. Note the harness location on the top of the frame. The pads from item #5 are visible in the pic, too, if those are what you're referring to.

Image
 
#5 ·
Consider using your trip odometer to determine when it's time to get gas.....

My own 1998 Frontier (270K) and 2004 Frontier (110K) are still on their factory fuel pumps and sending units (both 4-cylinder, 5-speed, Arizona).
 
#8 ·
I had some time today to mess with this. I measured the resistance at the fuel pump electrical harness and got about 27 ohm. Had my wife jiggle the truck a little and the reading bounced 27-28 ohm for a couple minutes until the fuel settled. So that rules out the sending unit. Then I took the instrument cluster out and changed a bunch of burned out bulbs. I poked around a lot trying to read the fuel sensor but was unable to trace anything. When I went back to reinstall the cluster the fuel gauge needle was just laying at the bottom of the cluster. I took the front off and put a very small dab of gel loctite on the small hole on the needle and held it on the guage for a few seconds. When I turned the truck on the needle when way past the full mark so I took it apart and carefully loosened the needle and repositioned it. So now the remaining glue is acting as a little bit of friction. I'll have to see what happens when I fill up tomorrow. Also the 7.5A fuse #7 in the j/b block was reading continuity across the front but the fuse terminals looked pretty toasted so I replaced it with a 10A cuz that's the smallest I had.
 
#9 ·
Could be a pump issue. test with a malet to the tank. Most likely burnt fuse on gauge cluster since those are notorious. There a specific procedure to test the gauge cluster which basically moves all needles to the top to see if they are working correctly(it involves the odometer reset pin). although fuel sending units are notorious for going bad I would suggest taking a look at the dash first since its free. usually frontier owners either get a bottomed out needle or eratic needle movement but not stationary in the middle when its the fuel sending unit.
 
#10 ·
I never bothered to pull the fuel tank electrical plug after the fill up and check the ohm reading again. If the ohm reading was in the 4-7 ohm range on a known full tank I was going to just add an external fuel gauge, but just for a daily commute and an occasional hauling trip here and there I'm just going to fill up around the 100 mile range on the trip and call it good.

I tried to get the front grill off to replace the washer fluid pump and all kinds of hold downs started breaking as well as the corner of the grill assembly. And a corner of the front clear lens for the instrument cluster broke due to being old and brittle. So I really don't care that much about fixing it. Certain things just aren't worth it. The fuel pump is still sending fuel and the emissions passed just fine. I took most of June off of work and had the free time, but now I'm working and don't feel like messing around with it unless it doesn't drive.

Additionally the junk yard that I like to use doesn't get many frontiers in and there actually weren't that many pickups even, so the only thing I would even be willing to do is try swapping the fuel gauge as a one last final thing if I were able to find one. I don't really suspect the fuel pump or sender anymore and wasn't able to get the same ohm reading in the cluster as what was on the fuel pump connections. So it could be a ground issue somewhere, but since the needle fell off on me the second time I reinstalled the cluster, I probably would have an issue there, it just isn't worth it to me that much. My plan is just to have a mechanic trace the fuel pump electrical connections when/if I get suspension work done as it will be lifted already and easy to see.