asnu battleship mk2 fitting instructions - .asnu battleship mk2 fitting instructions ... remove the

Download ASNU Battleship MK2 Fitting Instructions - .ASNU Battleship MK2 Fitting Instructions ... Remove the

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  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    ASNU Battleship MK2 Fitting Instructions

    You will be required to disassemble certain parts from the stock fuel system and then integrate them

    into the battleship before reinstalling the system into the tank. If you are unsure of your ability to fit

    this kit, we advise that you consult your supplier or a trained mechanic before you start.

    Before you commence any work, log any security or access codes that are battery dependant before

    disconnecting the battery.

    Please ensure that this work is carried out in a well ventilated area away from any possible point of

    ignition as fuel or fuel vapour will be present and could present a fire hazard.

    We advise the use of appropriate clothing and safety glasses

    Also ensure that a fire extinguisher of the appropriate type is available.

    When working with fuel we advise that the correct protective equipment is worn including glasses

    and gloves where appropriate.

    Kit Contents:

    Battleship main assembly

    Stainless steel fuel module lid complete with quick connect scavenge connectors

    Fuel return pipe with quick connect connector

    Fuel pickup pipes with filters

    Appropriate flange mounting bolts

    Male 4-way connector and terminals

    Cable ties

    Hose clamps

    mailto:enquiries@asnu.comhttp://www.asnu.com/

  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    Section 1: System removal

    Prepare car by running it until the fuel warning lamp is illuminated leaving only 15 /

    20 litres of fuel in the tank

    Open vehicle windows fully to allow fumes to vent

    Disconnect vehicle battery and remove any sources of ignition from the work area

    Remove rear seat squab in line with Nissan workshop manual

    Remove tank cover plate from floor plan

    Disconnect fuel module electrical harnesses

    Remove OE fuel module in line with Nissan workshop manual

    Refit tank cover plate temporarily to prevent excess fuel vapour entering the car

    whilst the fuel system is being prepared.

    You now have a fuel module out of the tank - we would advise that this is drained of any residual

    fuel, and if possible left in a well ventilated area for 30 to 60 minutes before work is commenced to

    minimise the contact with liquid fuel.

    Section 2: Module Disassembly

    1. Unclip and unfasten from its port, the blue siphon jet feed located at the nose of the

    surge tank.

    2. Using a pair of pliers and a screw driver release the fuel return pipe and the siphon jet

    flow regulator from the lid of the surge tank

    3. Remove the fuel return hose from the siphon jet feed by cutting along the axis of the

    pipe carefully with a scalpel or similar; several light cuts in the same place are more

    effective than one heavy cut. Take care not to damage the spigot underneath, as the

    siphon jet feed fitting is required in the new system

    4. Unclip the fuel temp sensor from the clip in the fuel filter (if fitted)

    5. Unclip the anti static earth connection from the top of the filter assembly

    mailto:enquiries@asnu.comhttp://www.asnu.com/

  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    6. The surge tank can now be disassembled.

    7. Around the side of the surge tank are 4 locking tags. Starting at the front of the tank

    unclip with a small flat blade screw driver each of the lock tabs in turn. It may be

    nessecery to wedge the lock tab up to prevent it relocking when you move onto the next

    tab. We advise the use of a wooden coffee stirrer cut into short lengths for this.

    8. Remove the tank level sensor from the OE top plate by depressing the locking leg and

    sliding upwards towards the top plate

    9. Disconnect the wiring for the sensors from the underside of the top plate

    10. You will require the module base, the level and fuel temp sensors with their wiring, and

    the siphon feed jet. Separate these parts for reuse

    11. Safely store the remaining parts of the OE module (top plate, pump & filter assembly).

    These will still have residual fuel in so should be stored in a well ventilated area free

    from sources of ignition

    Section 3: Reassembly of Fuel Module & return fuel line.

    1. Insert end of the return hose (without quick connect fitting) into a cup of boiling water

    and leave to soften for 5 mins - it may need to be stretched slightly which can be

    performed by inserting a pair of long nose pliers and gently opening them to stretch the

    hose

    2. Insert siphon feed fitting into the return hose ensuring it goes fully home to the shoulder

    on the fitting as shown below:

    3. Wipe any residual dirt or debris from the inside of the module base and prepare for

    refitting

    4. Install module lid with quick connect scavenge fitting onto the module base

    5. Refit fuel return line and siphon feed fitting to the module

    6. Tighten cable tie on top deck of module around fuel return line and trim excess back

    7. Fit stainless top plate to module base ensuring all locking tabs are engaged

    8. Refit module as per OE instructions, and reconnect the siphon and scavenge fittings

    leaving siphon jet quick connect out of the tank

    9. Ensure the siphon pickup fittings are correctly positioned on the floor of the tank. If

    incorrectly positioned they will impede the operation of the tank level sensor when the

    pump unit is fitted.

    mailto:enquiries@asnu.comhttp://www.asnu.com/

  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    Section 4: Electrical connection of sensors

    Supplied with the kit is an un-terminated 4-way male connector and the appropriate spade

    terminals. You will require this before progressing further.

    1. Remove the OE connector from the level sensor approx 3cm below the plug

    2. Strip the wires on the level sensor back leaving 1.5cm of wire exposed, fold the exposed

    wire in half and then fold back again parallel to the insulated wire.

    3. Crimp terminals on to the sensor wires.

    4. Take the standard factory fuel level sensor and connect to the level sensor arm on the

    pump module

    5. Cut the factory connector from the OE fuel temp sensor approx 3 cm below the plug

    6. Take the female electrical plug housing and connect to the male plug already connected

    to the pump module

    7. The male wiring is numbered 1 to 3 with a link wire duplicating the 3rd connection. This

    connects to a male 4-way connector. The female connector is supplied un-terminated.

    Each wire is numbered on a white tag on the underside of the top plate

    8. Insert the red wire on the fuel level sensor into the connector housing so that it mates

    with wire 2

    9. Insert the black wire on the fuel level sensor into the connector housing so that it mates

    with wire 3

    10. The fuel temp sensor is not polarity sensitive so can be wired either way round

    11. Take one of the black wires on the fuel level sensor into the connector housing so that it

    mates with the link wire coming from wire 3

    12. Take the other black wire on the fuel level sensor into the connector housing so that it

    mates with link 3

    In case of further modifications the in tank wiring is as follows:

    Wire 1 = Fuel temperature sensor signal supply/high side.

    Wire 2 = Fuel level sensor signal supply/high side.

    Wire 3 = Sensor earth for fuel temperature sensor.

    Link 3 = Sensor earth for fuel level sensor.

    mailto:enquiries@asnu.comhttp://www.asnu.com/

  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    Fuel pickup pipe installation

    1. The fuel pickup pipe has a 90 degree -8orb fitting at one end and the filter at the

    other

    2. Lubricate the o-rings on the -8orb fitting with clean non silicone engine oil

    3. Remove red transit cap from the base of the pump

    4. Blow through the pickup hose from the filter end to ensure nothing has entered the

    hose during transit

    5. The pre filter thimble can be removed should it become crushed or damaged. By

    removing the filter you can gently press the unit back into shape from the inside

    mailto:enquiries@asnu.comhttp://www.asnu.com/

  • ASNU Corporation Europe Ltd 65-67 Glencoe Road, Bushey, Herts, WD23 3DP, UK

    Tel: +44 (0) 208 4204494 Email: enquiries@asnu.com Web: www.asnu.com

    6. To fit the hose to the base of the pump, use a spanner to hold the base of the pump

    and tighten the hose nut with another spanner against the spanner on the pump

    base to prevent any rotational load being placed on the pump assembly.

    Failure to follow this instruction may cause the pump internals to become out of

    alignment and reduce the pump flow or prevent it from operating.

    System installation

    The Fuel module and the fuel pickup pipes should now have been fitted to the system. Re-fit the OE

    fuel tank