The 2005 Murano fuel tank fails repeatedly in two distinct ways. First, the tank ruptures or punctures when struck by road debris during normal highway driving—owners report impacts at 35 mph, 65 mph, and highway speeds causing cracks, holes, or catastrophic splits that spill gasoline. The plastic tank hangs down from the frame with minimal protection, and its smooth undersurface is exposed to the road. Nissan issued recalls 06V003000 (tank assembly) and 06V054000 (vapor recirculation fitting) to address this, installing tank protectors and replacing defective welds. However, multiple owners report the recall repair either failed to prevent subsequent punctures or that the defect recurred within thousands of miles.
Second, independent of impact, brand-new 2005 Muranos develop tank leaks within weeks of delivery—gas odor and warning lights appearing the day after purchase. Dealers replaced these defective tanks under warranty.
Beyond impact and manufacturing defects, owners also report fuel level sensors that malfunction at higher mileage, alternating between showing empty and showing fuel present, with repair costs around $500. One owner documented rust at the fuel filler opening that Nissan excluded from warranty coverage. Tank replacement costs exceed $750, with lead times stretching a month or longer for parts shipment.
Failure modes owners describe
Fuel tank puncture/rupture from road debris
Gas tank sustains punctures or catastrophic ruptures when struck by road debris during normal highway driving. The tank's plastic construction and lower-frame mounting position expose it to impact. Multiple owners report sudden detection of gas odor, visible leaks, and loss of fuel. Some ruptures involve multiple holes or gaps 2-3 inches wide.
When: Various speeds including 35 mph, 65 mph, and highway speeds; typically within first year of ownership (2005 purchase date)
Symptoms owners cite: Strong gasoline odor; Visible fuel leaking from tank; Rapid fuel level drop; Fuel pooling under vehicle
Repairs/costs cited: Tank replacement required. One owner cited cost exceeding $750; another paid for replacement out of pocket after Nissan refused to compensate. Lead times reported as long as one month for parts shipment.
Recalls/TSBs owners mention: Recall 06V003000 and 06V054000 issued addressing fuel tank assembly and tank protector design. However, multiple owners report recall repairs failed to prevent subsequent tank punctures or that the defect recurred post-repair.
Fuel tank protector detachment/inadequate protection
Tank protector shields partially detach from the frame or fail to prevent debris from puncturing the tank. Owners report the protective guard installed under recall 06V003000 did not stop tank ruptures. The tank design itself—hanging down with smooth unprotected surface—remains vulnerable despite the protector.
When: First occurrence around 52,000–90,000 miles; some defects emerged shortly after recall repair
Symptoms owners cite: Visible protector separation from frame; Subsequent tank puncture despite installed guard; Fuel leak following impact
Repairs/costs cited: Recall repair performed but defect recurred. Some owners advised to take vehicle back to dealer for inspection but repair not completed at time of complaint.
Recalls/TSBs owners mention: Recalls 06V003000 (Tank Assembly) and 06V054000 (Vapor Recirculation Fitting) were issued. Per narrative #13, the vapor recirculation fitting may separate because incorrect material was used in welding to the tank. Dealers experienced parts shortages.
Fuel tank leak—early manufacturing defect
Gas tanks leak or have cracks within days of vehicle delivery, independent of road debris impact. Owner #1 experienced a leak with SERVICE ENGINE SOON indicator on the day after purchase, requiring tank replacement at dealership within one month.
When: Within one day to one month of new vehicle delivery (July–August 2005)
Symptoms owners cite: Gasoline odor; SERVICE ENGINE SOON warning light
Repairs/costs cited: Tank replaced under warranty. Owner #1 also required exhaust valve and computer replacement to resolve related emission codes.
Recalls/TSBs owners mention: Dealership replaced defective tank and related emission components. Nissan Consumer Affairs opened a case to expedite part shipment.
Fuel level sensor malfunction
Fuel gauge displays inaccurate readings, alternating between showing fuel present and showing empty tank despite actual fuel in tank. Occurs at higher mileage and outside warranty period.
When: At 160,000 miles; current mileage 170,000
Symptoms owners cite: Fuel gauge reading empty while fuel is present; Fuel gauge fluctuation
Repairs/costs cited: Repair cost cited at $500; not completed at time of complaint due to warranty expiration.
Recalls/TSBs owners mention: Dealer stated no recalls applied and owner responsible for repair cost.
Rust at fuel filler opening
Unusual rust accumulation appears around the fuel tank opening/filler ring. Nissan does not cover this corrosion under the 5-year rust warranty.
When: Timing not specified
Symptoms owners cite: Rust visible around fuel filler area
Repairs/costs cited: Not covered under warranty.
Recalls/TSBs owners mention: Nissan denied warranty coverage.
Synthesized from 21 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.