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Originally Posted by GeorgiaTechFrontier
I have not verified this myself, but have been told that the fuel pump sits at the bottom of the fuel tank and is required to be immersed in fuel to keep it cool. When your gas tank gets too low, the fuel pump could overheat and eventually wear out. I may be completely wrong, but it makes sense to me. In addition to giving you enough warning to find a gas station, I think this is a reason why the fuel light turns on with 3-4 gallons left.
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This is probably not correct. If the Nissan fuel pump motor is a "wet" design it is lubricated and cooled by fuel flowing through the motor. This is not a fire or explosion hazard because there is insufficient oxygen to allow combustion. As long as the motor has fuel flowing through it it is fine (and if fuel is not flowing through it you are probably out of gas). It has been my experience that fuel pump failures occur realtively soon after running out of gas. I routinely run my Nissan 20 to 30 miles after the light has come on with no fuel pump issues to date (103,000 miles).
If the motor is a "dry" design (no fuel through the pump motor) then the cooling logic still does not hold. If the motor is a permanent magnet motor with the magnets attached to the case, there is no good thermal path for fuel to cool the heat generating armature. I would be surprised if the motor was anything other than a permanent magnet design.
In short, the light may turn on as a warning to avoid running out of gas but a reduced fuel level is not critical to fuel pump cooling.
Steve