Nissan Juke (2014 year). Service Repair Manual - part 136

 

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Nissan Juke (2014 year). Service Repair Manual - part 136

 

 

FL-4

< PERIODIC MAINTENANCE >

[MR16DDT ]

FUEL SYSTEM

PERIODIC MAINTENANCE

FUEL SYSTEM

Inspection

INFOID:0000000009750156

Inspect fuel lines, fuel filler cap, and fuel tank for improper attach-
ment, leakage, cracks, damage, loose connections, chafing or dete-
rioration.

If necessary, repair or replace damaged parts.

Quick Connector

INFOID:0000000009750157

CAUTION:

• After connecting fuel tube quick connectors, check quick connectors are secure.
• Ensure that connector and resin tube never contact any adjacent parts.

A

: Engine

B

: Fuel line

C

:  Fuel  tank

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REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2WD

2WD : Exploded View

INFOID:0000000009750158

REMOVAL

DISASSEMBLY

1.

Rock ring

2.

Fuel level sensor unit, fuel filter and 
fuel pump assembly

3.

O-ring

4.

Fuel tank

Vehicle front

 : Always replace after every disassembly.

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1.

Fuel filter and fuel pump assembly

2.

Fuel level sensor unit

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< REMOVAL AND INSTALLATION >

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2WD : Removal and Installation

INFOID:0000000009750159

WARNING:

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

FL-2, "General Precautions"

.

REMOVAL

1.

Release the fuel pressure from the fuel lines. Refer to 

EC-149, "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. Refer to 

SE-25, "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. 
• 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.

Guideline

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

3

: Fuel feed hose

4

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

: Vehicle front

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8.

Remove lock ring for fuel level sensor unit, fuel filter and fuel
pump assembly with lock ring wrench (A) [SST: KV99110600 (J-
46214)] turning counterclockwise.
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) [SST: KV99110600 (J-
46214)] 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.

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FL-8

< REMOVAL AND INSTALLATION >

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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:0000000009750160

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.

1

: Quick connector

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2WD : Inspection

INFOID:0000000009750161

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:0000000009750162

REMOVAL

DISASSEMBLY

1.

Lock ring

2.

Fuel level sensor unit, fuel filter and fuel pump 
assembly

3.

O-ring

4.

Sub fuel level sensor assembly

A.

Right side

B.

Left side

 : Always replace after every disassembly.

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< REMOVAL AND INSTALLATION >

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

CAUTION:

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

AWD : Removal and Installation

INFOID:0000000009750163

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-149, "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-25, "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. 

1.

Fuel filter and fuel pump assembly

2.

Fuel level sensor unit

Guideline

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

3

: Fuel feed hose

4

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

: Vehicle front

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• 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) [SST: KV99110600 (J-
46214)] by turning counterclockwise.
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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FL-12

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2.

Remove lock ring for sub fuel level sensor assembly with lock
ling wrench (A) [SST: KV99110600 (J-46214)] by turning coun-
terclockwise.

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.

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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) [SST: KV99110600 (J-46214)] 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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< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

• 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 fuel level sensor unit, fuel filter and fuel pump
assembly with lock ling wrench (A) [SST: KV99110600 (J-
46214)] 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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• Pull (A) the tube and the connector to check that they are

securely connected.

8.

Connect harness connector.

Inspection Hole Cover

• Before installing inspection hole cover, check that the connecting part has no fuel leakage. Refer to 

FL-9,

"2WD : Inspection"

.

1.

Install inspection hole covers with the front mark (arrow) facing front of vehicle. 

AWD : Disassembly and Assembly

INFOID:0000000009750164

DISASSEMBLY

CAUTION:

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

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 senor unit (1).

3.

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

) of the arrow with the lock release.

ASSEMBLY

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FL-16

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP 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.

AWD : Inspection

INFOID:0000000009750165

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.

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FUEL TANK

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< REMOVAL AND INSTALLATION >

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FUEL TANK

2WD

2WD : Exploded View

INFOID:0000000009750166

2WD : Removal and Installation

INFOID:0000000009750167

WARNING:

Be sure to read “General Precautions” when working on the fuel system. Refer to 

FL-2, "General Pre-

cautions"

.

REMOVAL

• Drain fuel from fuel tank if necessary. Refer to 

FL-6, "2WD : Removal and Installation"

.

• Perform work on level place.
1.

Perform steps 2 to 7 of “REMOVAL” in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP
ASSEMBLY” on fuel level sensor unit, fuel filter and fuel pump assembly. Refer to 

FL-6, "2WD : Removal

and Installation"

.

2.

Remove center muffler. Refer to 

EX-5, "Exploded View"

.

3.

Remove insulator on vehicle side located above center and main mufflers.

1.

Fuel filler cap

2.

Grommet

3.

Fuel filler tube

4.

Cover

5.

Clamp

6.

Fuel filler hose

7.

Clamp

8.

EVAP canister protector

9.

Fuel tank

10. Fuel tank mounting band (RH)

11.

Fuel tank mounting band (LH)

12. Vent tube

A.

To EVAP canister

 : N·m (kg-m, ft-lb)

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[MR16DDT ]

FUEL TANK

4.

Move parking brake cable (1) from the lower face of fuel tank.
Then remove clips for parking brake cable.

5.

Disconnect fuel filler hose (4) at fuel tank side.

6.

Disconnect EVAP hose and vent tube at the position shown in
the figure.
• Instruction for quick connector of EVAP hose and vent tube,

refer to the following:

EVAP hose

CAUTION:

• Quick connector (1) can be disconnected when the tabs

(F) are depressed completely. Never twist it more than
necessary.

• Never use any tools to disconnected quick connector.
• Keep resin tube (C) 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 dis-

connection.

• Never remove the remaining retainer (2) on hard tube (or

the equivalent) (A) except when resin tube or retainer is
replaced.

• When resin tube or hard tube (or the equivalent) is

replaced, also replace retainer with new one.

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1

: Vent tube

2

: Fuel tank mounting band (RH)

3

: EVAP hose

A

: Quick connector

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B

: Connection (cross-section)

D

: To fuel tank

E

: To fuel filler tube

G : Disconnection

Retainer color

: Green

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FUEL TANK

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• 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.

Vent tube
• 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 vehicle are stuck, push and pull

several times until they move, and pull out.

CAUTION:

• The tube can be removed when the tabs are completely

depressed. Never twist it more than necessary.

• Never use any tools to disconnect quick connector.
• Keep the resin tube away from heat. Be especially care-

ful when welding near the tube.

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

getting on the resin tube.

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

7.

Support the center part of fuel tank (1) with transmission jack
(A).

CAUTION:

Securely support the fuel tank with a piece of wood (B).

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