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Nissan Juke (2016 year). Service Repair Manual - part 397

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

8. Remove lock ring for fuel level sensor unit, fuel filter and fuel

pump assembly with lock ring wrench (A) by turning counter-

clockwise.

NOTE:

For reference when installing, put a matching mark on lock ring,

fuel pump assembly and fuel tank.

9. Raise fuel level sensor unit, fuel filter and fuel pump assembly

(1).

CAUTION:

• Never bend float arm during removal.

• Never pollute the inside by residue fuel. Draw out avoid-

ing inclination by supporting with a cloth.

• Never cause impacts such by dropping when handling

components.

INSTALLATION

Note to the following, and install in the reverse order of removal.

CAUTION:

Do not reuse O-rings.

1. Install O-ring to fuel tank without twist.

CAUTION:

Do not reuse O-ring.

2. Install fuel level sensor unit, fuel filter and fuel pump assembly

(1) with its matching mark (A) aligned with fuel tank matching

mark (B) as shown in the figure.

CAUTION:

Never bend float arm during installing.

3. Install lock ring for fuel level sensor unit, fuel filter and fuel pump

assembly with lock ring wrench (A) by turning clockwise.

4. Connect quick connector of fuel feed tube as per following procedures.
a. Check the connection for damage or any foreign materials.
b. Align the connector with the tube, then insert the connector straight into the tube until a click sound is

heard.

Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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: Vehicle front

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Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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c. After connecting, check that the connection is secure by following method.

• Visually confirm that the two tabs are connected to the connector.

• Pull (A) the tube and the connector to check they are securely

connected.

2WD : Disassembly and Assembly

INFOID:0000000012197585

DISASSEMBLY

1. Disconnect harness connector (A).

2. Press (A) with a flat-blade screwdriver or an equivalent to

release lock and push out the fuel level sensor unit (1).

3. To remove the fuel level sensor unit (1), side it in the direction

(

) of the arrow with the lock release.

ASSEMBLY

1. Check for damage of fuel level sensor unit installation position on the side of fuel filter and pump assem-

bly.

2. Slide fuel level sensor unit until it aligns to installation groove, then insert it until stops.

• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.

3. Connect harness connector.

: Quick connector

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2WD : Inspection

INFOID:0000000012197586

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leakage by applying fuel pres-

sure to fuel piping.

2. Start engine and let it idle and check there are no fuel leakage at the fuel system connections.

AWD
AWD : Exploded View

INFOID:0000000012197587

REMOVAL

DISASSEMBLY

Lock ring

Fuel level sensor unit, fuel filter and fuel pump
assembly

O-ring

Sub fuel level sensor assembly

A. Right side

B. Left side

: Always replace after every disassembly.

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CAUTION:

Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.

AWD : Removal and Installation

INFOID:0000000012197588

REMOVAL

Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly

WARNING:

Read “General Precautions” before working on the fuel system. Refer to

FL-2, "General Precautions"

1. Release the fuel pressure from the fuel lines. Refer to

EC-166, "Work Procedure"

2. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-

ate amount of fuel from the fuel tank.

• In the event of malfunction in fuel pump, insert a hose measuring 25 mm (0.98 in) in diameter into the

filler opening to draw approximately 25 liters fuel.

3. Open fuel filler lid.
4. Open filler cap and release the pressure inside fuel tank.
5. Remove rear seat cushion. Refer to

SE-29, "Exploded View"

6. Remove inspection hole cover.
7. Disconnect harness connector (1) and quick connector (2).

• Remove quick connector in the following procedures.

- Pinch quick connector square-part (A) with your fingers, and

pull out the quick connector (1) by hand.

- If quick connector and tube on sender unit are stuck, push and

pull several times until they move, and pull out.

CAUTION:

• Quick connector can be removed when the tabs are com-

pletely depressed. Never twist it more than necessary.

• Never use any tools to disconnected quick connector.

• Keep resin tube away from heat. Be especially careful

when welding near the resin tube.

• Prevent acid liquid such as battery electrolyte, etc. from

getting on resin tube.

• Never bend or twist resin tube during installation and disconnection.

Fuel filter and fuel pump assembly

Fuel level sensor unit

Guideline

Draw approximately 25 liters (6-5/8 US gal, 5-1/4 Imp gal) from a full-tank
condition.

: Fuel feed hose

: Fuel level sensor unit, fuel filter and fuel pump.

: Vehicle front

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely with

plastic bags (A) or something similar.

• Never insert plug, preventing damage on O-ring in quick

connector.

8. Remove lock ring for fuel level sensor unit, fuel filter and fuel

pump assembly with lock ling wrench (A) by turning counter-

clockwise.

NOTE:

For reference when installing, put a matching mark on lock ring,

fuel pump assembly and fuel tank.

9. Raise fuel level sensor unit, fuel filter and fuel pump assembly

(1).

CAUTION:

• Never bend float arm during removal.

• Never pollute the inside by residue fuel. Draw out avoid-

ing inclination by supporting with a cloth.

• Never cause impacts such by dropping when handling

components.

10. Separate fuel tube as per the following steps to remove fuel level sensor unit, fuel filter and fuel pump

assembly.

• Pinch quick connector (A) square-part with your fingers, and

pull out the quick connector by hand.

• If quick connector and tube on sender unit are stuck, push

several times until they move, and pull out.

NOTE:

When separating the fuel tube, tie a gasoline-resistance rope

to the tip of the fuel tube and leave the rope on the fuel tank

side to easily pull the fuel tube for installation.

• Disconnect harness connector (B).

Sub Fuel Level Sensor Assembly

1. Remove fuel level sensor unit, fuel filter and fuel pump assembly.

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Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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2. Remove lock ring for fuel level sensor unit, fuel filter and fuel

pump assembly with lock ling wrench (A) by turning counter-

clockwise.

NOTE:

For reference when installing, put a matching mark on lock ring,

fuel pump assembly and fuel tank.

3. Remove sub fuel level sensor assembly (1).

CAUTION:

• Never disassemble a fuel tube (2) from sub fuel sensor

assembly.

• Never bend float arm during removal.

• Never pollute the inside by residue fuel. Draw out avoid-

ing inclination by supporting with a cloth.

• Never cause impacts such by dropping when handling

components.

NOTE:

Tie a gasoline-resistance rope to a tip of the tube. Draw and

leave the rope to the fuel tank side so that the rope can be the

guide for installation.

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:

Do not reuse O-rings.

Sub Fuel Level Sensor Assembly

1. Install O-ring to fuel tank without any twist.

CAUTION:

Do not reuse O-ring.

2. Using the rope left on the fuel tank side at removal, run the fuel tube inside the fuel tank to install the sub

fuel level sensor assembly to the fuel tank.

CAUTION:

• Never bend float arm during installation.
• To install, fuel tube (1) must run to the front (

) of the vehicle to avoid the interference with the

float arm (2), as shown in the figure.

Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

3. Install sub fuel level sensor assembly (1) with its matching mark

(A) aligned with fuel tank matching mark (B) as shown in the fig-

ure.

NOTE:

• Figure shows fuel level sensor unit, fuel filter and fuel pump

assembly side of fuel tank.

• For sub fuel level sensor assembly matching mark is located

on the fuel tank of the vehicle rear side.

4. Install lock ring for sub fuel level sensor assembly with lock ling

wrench (A) by turning clockwise.

Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly

1. Temporarily install the O-ring to the fuel level sensor unit, fuel filter and fuel pump assembly.
2. Connect the fuel tube as per the following steps.

• Insert the quick connector (A) straight to the fuel level sensor

unit, fuel filter and fuel pump assembly.

• Judge a good fit from connecting sound and tactile feedback.

• Pull the fuel tube by hand to check a secure fit.

3. Connect harness connector (B).

4. Insert the fuel level sensor unit, fuel filter and fuel pump assembly to the fuel tank.

CAUTION:

• Never bend float arm during installation.
• To install, fuel tube (1) must run to the front (

) of the vehicle to avoid the interference with the

float arm (2), as shown in the figure.

: Vehicle front

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Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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Revision: November 2015

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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• Through the clearance of the mounting part of the fuel level sensor unit and the fuel filter and

fuel pump assembly, visually check that the fuel tube is placed on the vehicle front side of them.

5. Install fuel level sensor unit, fuel filter and fuel pump assembly

(1) with its matching mark (A) aligned with fuel tank matching

mark (B) as shown in the figure.

6. Install lock ring for sub fuel level sensor assembly with lock ling

wrench (A) by turning clockwise.

7. Connect quick connector of fuel feed tube as per following procedures.
a. Check the connection for damage or any foreign materials.
b. Align the connector with the tube, then insert the connector straight into the tube until a “click” sound is

heard.

c. After connecting, check that the connection is secured with following procedures.

• Visually confirm that the two tabs are connected to the connector.

: Vehicle front

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Tool number (A)

: KV991J0090 (J-46214) (shown)
: KV101207S0 ( — )

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Revision: November 2015

2016 JUKE

Content .. 395 396 397 398 ..