Qashqai J11. Fuel system (HRA2DDT, K9K, MR20DD)

FUEL LEVEL SENSOR UNIT

FL-49

< REMOVAL AND INSTALLATION >

[R9M]

Open fuel filler lid and filler cap to release the pressure inside fuel tank.

Remove rear seat. Refer to

SE-35, "Removal and Installation"

Remove inspection hole cover.

Disconnect harness connector and fuel feed tube.
NOTE:
Make sure that identification between the feed line and return
line is made to enable correct assembly during installation.

• Remove quick connector in the following procedures.
- NOTE:

• The figure show the process of quick connector disconnection. Parts arround quick connector could

have a different shape compare to the figure.

- Hold the sides of quick connector, press tabs and pull out fuel

feed tube.

- If quick connector sticks to tube of main fuel level sensor unit,

push and pull quick connectors several times until they start to
move. Then disconnect them by pulling.

CAUTION:

• Quick connector can be disconnected when the tabs are

depressed completely. Never twist it more than neces-
sary.

• 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 dis-

connection.

• Never insert plug, preventing damage to O–ring in quick

connector.

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

age and foreign materials, cover them completely with
plastic bags or something similar.

: Harness connector

: Quick connector

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

: Lock ring

: Vehicle front

E1BIA1129ZZ

: Push in tabs

: Pull

E1BIA1191ZZ

: Connection (cross-section)

: Disconnection (cross-section)

: Quick connector

: Hard tube

E1BIA1190ZZ

FL-50

< REMOVAL AND INSTALLATION >

[R9M]

FUEL LEVEL SENSOR UNIT

Use lock ring wrench [SST: KV101207S0] (A) to remove lock
ring.

CAUTION:

• To prevent lock ring wrench from being detached,

securely hold down spinner handle (B) by hand.

• To reduce impact caused by removal operation, use long

spinner handle [handle length: 60 cm (23.62 in) or more]
and slowly turn it counterclockwise.

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

CAUTION:

• Never bend float arm (2) during removal.
• Never pollute the residual fuel inside of the tank. Draw out

avoiding 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.

Fuel Level Sensor Unit

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

Install the fuel gauge on the fuel tank with the fuel gauge top sur-
face (A) faced the front of the vehicle.

CAUTION:

• Never allow O-ring to drop.
• Never bend float arm during installing.

Install lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ring wrench [SST:
KV101207S0] by turning clockwise.

CAUTION:

• Install lock ring horizontally.
• Turn the lock ring (A) until it is engaged in the fuel tank

side (B) as shown in the figure.

Quick Connector

• Connect quick connector as follows:
1.

Check the connection for damage or any foreign materials.

JSBIA1633ZZ

JPBIA3557ZZ

: Vehicle front

E1BIA1188ZZ

JPBIA3559ZZ

FUEL LEVEL SENSOR UNIT

FL-51

< REMOVAL AND INSTALLATION >

[R9M]

Align the connector with the tube, then insert the connector straight into the tube until a “click” sound is
heard.

After connecting, check that the connection is secured with following procedures.
• Visually confirm that the two tabs are connected to the connector.
• Pull (A) the tube and the connector to check that they are

securely connected.

Reattach harness connector.

2WD : Inspection

INFOID:0000000010430541

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leaks.
1.

Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres-
sure to fuel piping.

Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.

4WD

4WD : Exploded View

INFOID:0000000010430557

JPBIA0140ZZ

JPBIA3175ZZ

FL-52

< REMOVAL AND INSTALLATION >

[R9M]

FUEL LEVEL SENSOR UNIT

Refer to

GI-4, "Components"

for symbol marks in the figure.

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

4WD : Removal and Installation

INFOID:0000000010430556

REMOVAL

Fuel Level Sensor Unit

WARNING:

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

FL-43, "General

Precautions"

Release the fuel pressure from the fuel lines. Refer to

ECK-153, "Work Procedure"

Check fuel level on a level ground. If the fuel level is at 1/2 or higher, drain enough fuel so that the level on
the fuel gauge is at half or below.
• This is to prevent overflow of fuel from the tank when the fuel level sensor unit, fuel filter and fuel pump

assembly is removed

• In the event of malfunction in fuel pump, insert a hose measuring less than 20mm (0.79 in) in diameter

into fuel filler tube through fuel filler opening to draw fuel from filler tube.

- Disconnect fuel filler hose from fuel filler tube. Refer to

FL-10, "Exploded View"

- Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.

Disconnect batterie cable from negative terminal.

Open fuel filler lid and filler cap to release the pressure inside fuel tank.

Remove rear seat. Refer to

SE-35, "Removal and Installation"

Remove inspection hole cover.
• Using a screwdriver, remove it by turning clips clockwise by 90 degrees.

Disconnect harness connector and quick connectors (A).
NOTE:
Make sure that identification between the feed line and return
line is made to enable correct assembly during installation.

• Remove quick connector in the following procedures.
- NOTE:

• The figure show the process of quick connector disconnection. Parts arround quick connector could

have a different shape compare to the figure.

Lock ring

Fuel level sensor unit

O-ring

Sub fuel level sensor unit

To fuel tank

Tightening must be done following the Installation procedure. Refer to

FL-52, "4WD : Removal and Installation"

: Vehicle front

Guideline

: Draw approximately 32 liters (7 Imp gal) from a full-tank con-
dition.

: Fuel tube (return side)

: Fuel tube (feed side)

JPBIA0852ZZ

FUEL LEVEL SENSOR UNIT

FL-53

< REMOVAL AND INSTALLATION >

[R9M]

- Hold the sides of quick connector, press tabs and pull out fuel

feed tube.

- If quick connector sticks to tube of main fuel level sensor unit,

push and pull quick connectors several times until they start to
move. Then disconnect them by pulling.

CAUTION:

• Quick connector can be disconnected when the tabs are

depressed completely. Never twist it more than neces-
sary.

• 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 dis-

connection.

• Never insert plug, preventing damage to O–ring in quick

connector.

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

age and foreign materials, cover them completely with
plastic bags or something similar.

Using lock ring wrench [SST: KV99104700], remove lock ring.
NOTE:
For reference when installing, put a matching mark on lock ring,
fuel level sensor unit and fuel tank.

Raise fuel level sensor unit.

CAUTION:

• Never bend float arm during removal.
• Never pollute the residual fuel inside of the tank. Draw out avoiding 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.

: Push in tabs

: Pull

E1BIA1191ZZ

: Connection (cross-section)

: Disconnection (cross-section)

: Quick connector

: Hard tube

E1BIA1190ZZ

PBIC0240E

FL-54

< REMOVAL AND INSTALLATION >

[R9M]

FUEL LEVEL SENSOR UNIT

• Pinch quick connector (B) 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 diesel-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 (A).

Sub Fuel Level Sensor Assembly

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

Use lock ring wrench [SST: KV99104700] to remove lock ring.

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 residual fuel inside of the tank. Draw out

avoiding 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.

Sub Fuel Level Sensor Assembly

Install O-ring to fuel tank without any twist.

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.

JPBIA0851ZZ

PBIC0240E

JPBIA0823ZZ

FUEL LEVEL SENSOR UNIT

FL-55

< REMOVAL AND INSTALLATION >

[R9M]

• 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.

Install sub fuel level sensor assembly with its matching mark (A)
aligned with fuel tank matching mark (B) as shown in the figure.

Use lock ring wrench [SST: 99104700] to install lock ring as per
the following steps.

Align the “ ” mark located on the rim of the lock ring (1) with the
“MAX” position of the fuel tank. Press the locking ring horizon-
tally to prevent the lock ring from tilting.
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 front side.

After aligning the “ ” mark with “MAX” turn the lock ring counter-
clockwise until the lock ring thread engages with the tank.
Turn the lock ring roughly 540

until the “ ” mark is between

"MIN" and "MAX" position.

E1BIA1189ZZ

E1BIA1135ZZ

PBIC0240E

Tightening angle

: Approximately 540

E1BIA1136ZZ

FL-56

< REMOVAL AND INSTALLATION >

[R9M]

FUEL LEVEL SENSOR UNIT

Check that the “ ” mark of the lock ring (1) is between MIN and
MAX [i.e. within (A)].
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 front side.

Fuel Level Sensor Unit

Temporarily install the O-ring to the fuel level sensor unit.

Connect the fuel tube as per the following steps.
• Insert the quick connector (B) straight to the fuel level sensor

unit.

• Judge a good fit from connecting sound and tactile feedback.
• Pull the fuel tube by hand to check a secure fit.

Connect harness connector (A).

Insert the fuel level sensor unit to the fuel tank, and then install the temporarily installed O-ring (Step 1) to
the opening of 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.

E1BIA1138ZZ

JPBIA0851ZZ

E1BIA1189ZZ

FUEL LEVEL SENSOR UNIT

FL-57

< REMOVAL AND INSTALLATION >

[R9M]

Install fuel level sensor unit with its matching mark (A) aligned
with fuel tank matching mark (B) as shown in the figure.

Use lock ring wrench [SST: KV99104700] to install lock ring as
per the following steps.

Align the “ ” mark located on the rim of the lock ring (1) with the
“MAX” position of the fuel tank. Press the locking ring horizon-
tally to prevent the lock ring from tilting.

After aligning the “ ” mark with “MAX” turn the lock ring counter-
clockwise until the lock ring thread engages with the tank.
Turn the lock ring roughly 540

until the “ ” mark is between

"MIN" and "MAX" position.

Check that the “ ” mark of the lock ring (1) is between MIN and
MAX [i.e. within (A)].

Connect quick connector of fuel feed tube as per following procedures.

Check the connection for damage or any foreign materials.

Align the connector with the tube, then insert the connector straight into the tube until a “click” sound is
heard.

After connecting, check that the connection is secured with following procedures.
• Visually confirm that the two tabs are connected to the connector.

E1BIA1134ZZ

PBIC0240E

Tightening angle

: Approximately 540

E1BIA1130ZZ

E1BIA1133ZZ

FL-58

< REMOVAL AND INSTALLATION >

[R9M]

FUEL LEVEL SENSOR UNIT

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

securely connected.

Connect harness connector.

Inspection Hole Cover

• Before installing inspection hole cover, check that the connecting part has no fuel leakage.
1.

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

Lock clips by turning counterclockwise.

INSPECTION AFTER INSTALLATION

Check that there is no fuel leakage at connections in the following steps.
• Start engine and rev it up and check that there is no fuel leakage at connections.

4WD : Inspection

INFOID:0000000010430544

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leaks.

Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres-
sure to fuel piping.

Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.

JPBIA0140ZZ

FUEL TANK

FL-59

< REMOVAL AND INSTALLATION >

[R9M]

FUEL TANK

2WD

2WD : Exploded View

INFOID:0000000010430545

Refer to

GI-4, "Components"

for symbol marks in the figure.

2WD : Removal and Installation

INFOID:0000000010763740

REMOVAL

WARNING:

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

FL-30, "General Pre-

cautions"

Perform the steps 1 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”. Refer to

FL-6, "Removal and Installation"

Drain fuel from fuel tank if necessary. Refer to

FL-6, "Removal and Installation"

CAUTION:

• Fuel tank will become unstable whilst removing. Fuel should be drained from tank prior to

removal to reduce this effect.

• Situate vehicle on a flat and solid surface.

Remove main muffler. Refer to

EX-6, "Exploded View"

Remove vent hose from filler tube.

Fuel filler cap

Grommet

Fuel filler tube

Clamp

Fuel filler hose

Clamp

Vent hose

Evap hose

10. Fuel tank

11.

Fuel tank band (RH)

12. Fuel tank band (LH)

E1BIA1127GB

FL-60

< REMOVAL AND INSTALLATION >

[R9M]

FUEL TANK

Remove fuel filler hose from fuel tank.

CAUTION:

• Do not remove fuel filler hose from fuel filler tube to prevent interference with suspension when

installing.

• If removal of fuel filler hose from fuel filler tube is necessary use mating marks to ensure correct

orientation.

Disconnect EVAP hose.
• Remove quick connector in the following procedures.
- Hold the sides of quick connector, press tabs and disconnect EVAP hose.
- If quick connector sticks to tube, push and pull quick connectors several times until they start to move.

Then disconnect them by pulling.

CAUTION:

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

are depressed completely. Never twist it more than neces-
sary.

• 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 dis-

connection.

• Never insert plug, preventing damage to O–ring in quick

connector.

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

age and foreign materials, cover them completely with
plastic bags or something similar.

E1BIA1192ZZ

: Connection (cross-section)

: Disconnection (cross-section)

: Quick connector

: Hard tube

E1BIA1190ZZ

FUEL TANK

FL-61

< REMOVAL AND INSTALLATION >

[R9M]

Support center of fuel tank (1) with transmission jack (A) and
piece of wood (B).

CAUTION:

• Make sure the tank bottom surface is supported well

enough to prevent an unstable condition when lowering
the tank.

• Make sure to hold it securely as tank surface may not be

flat.

Remove fuel tank band (RH and LH).

Lower transmission jack carefully to remove fuel tank while holding it by hand.

CAUTION:

Make sure to avoid any interference with surrounding component that may cause damage.

INSTALLATION

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

CAUTION:

• Make sure hose clamps and hoses clips are not secured on top of the filler tube bulges.
• Make sure all quick connectors and their mating part are free of foreign matter, check for damage.
• Ensure the tank bands are correctly assembled as per their identification marks "L" and "R".
• Make sure that the torques of the mounting bolts are correct as per exploded view. Refer to

FL-59,

"2WD : Exploded View"

• Make sure that when installing the connectors, the confirmation click sound is heard. Pull back on

the connector to ensure proper engagement.

Fuel Filler Hose

• Insert fuel filler hose to the length below.

• Be sure hose clamp is not placed on swelled area of fuel filler tube.
• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.

EVAP Hose

Check connections for damage or foreign material.

Align the matching side connection part with the center of shaft,
and insert connector straight until it clicks.

After connecting, pull out quick connector and centralized under-
floor piping by hand. Make sure connections are secure.

2WD : Inspection

INFOID:0000000010430547

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections in the following procedure.
• Start engine, rev it up and make sure there is no fuel leakage at connections.

4WD

PBIC3792E

: 35 mm (1.38 in)

Fuel filler tube side

: 7 - 11 mm (0.28 - 0.43 in)

Fuel tank side

: 5 - 9 mm (0.20 - 0.35 in)

PBIC1653E

FL-62

< REMOVAL AND INSTALLATION >

[R9M]

FUEL TANK

4WD : Exploded View

INFOID:0000000010430548

Refer to

GI-4, "Components"

for symbol marks in the figure.

4WD : Removal and Installation

INFOID:0000000010430549

REMOVAL

WARNING:

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

FL-43, "General Pre-

cautions"

Perform the steps 1 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”. Refer to

FL-6, "Removal and Installation"

Drain fuel from fuel tank if necessary. Refer to

FL-6, "Removal and Installation"

CAUTION:

• Fuel tank will become unstable whilst removing. Fuel should be drained from tank prior to

removal to reduce this effect.

• Situate vehicle on a flat and solid surface.

Remove main muffler. Refer to

EX-6, "Exploded View"

Remove propeller shaft. Refer to

DLN-186, "Removal and Installation"

Remove protector from fuel tank.

Remove vent hose from filler tube.

Fuel filler cap

Grommet

Fuel filler tube

Clamp

Fuel filler hose

Clamp

Fuel tank

Fuel tank band (RH)

Protector

10. Fuel tank band (LH)

11.

Clamp

12. EVAP hose

13. Vent hose

14. Clamp

E1BIA1128GB

FUEL TANK

FL-63

< REMOVAL AND INSTALLATION >

[R9M]

Remove fuel filler hose from fuel tank.

CAUTION:

• Do not remove fuel filler hose from fuel filler tube to prevent interference with suspension when

installing.

• If removal of fuel filler hose from fuel filler tube is necessary use mating marks to ensure correct

orientation.

Then disconnect them by pulling.

CAUTION:

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

are depressed completely. Never twist it more than neces-
sary.

• 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 dis-

connection.

• Never insert plug, preventing damage to O–ring in quick

connector.

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

age and foreign materials, cover them completely with
plastic bags or something similar.

E1BIA1192ZZ

: Connection (cross-section)

: Disconnection (cross-section)

: Quick connector

: Hard tube

E1BIA1190ZZ

FL-64

< REMOVAL AND INSTALLATION >

[R9M]

FUEL TANK

Support center of fuel tank (1) with transmission jack (A) and
piece of wood (B).

CAUTION:

• Make sure the tank bottom surface is supported well

enough to prevent an unstable condition when lowering
the tank.

• Make sure to hold it securely as tank surface may not be

flat.

10. Remove fuel tank band (RH and LH).

11. Lower transmission jack carefully to remove fuel tank while holding it by hand.

CAUTION:

Make sure to avoid any interference with surrounding component that may cause damage.

INSTALLATION

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

CAUTION:

FL-62,

"4WD : Exploded View"

• Make sure that when installing the connectors, the confirmation click sound is heard. Pull back on

the connector to ensure proper engagement.

Fuel Filler Hose

• Insert fuel filler hose to the length below.

• Be sure hose clamp is not placed on swelled area of fuel filler tube.
• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.

EVAP Hose

Check connections for damage or foreign material.

Align the matching side connection part with the center of shaft,
and insert connector straight until it clicks.

After connecting, pull out quick connector and centralized under-
floor piping by hand. Make sure connections are secure.

4WD : Inspection

INFOID:0000000010430550

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections in the following procedure.
• Start engine, rev it up and make sure there is no fuel leakage at connections.

PBIC3792E

: 35 mm (1.38 in)

Fuel filler tube side

: 7 - 11 mm (0.28 - 0.43 in)

Fuel tank side

: 5 - 9 mm (0.20 - 0.35 in)

PBIC1653E

SERVICE DATA AND SPECIFICATIONS (SDS)

FL-65

< SERVICE DATA AND SPECIFICATIONS (SDS)

[R9M]

SERVICE DATA AND SPECIFICATIONS (SDS)

Fuel Tank

INFOID:0000000010419032

Standard and Limit

Fuel tank capacity 2WD

Approx. 55 (12-1/8 Imp gal)

Fuel tank capacity 4WD

Approx. 65 (14-1/4 Imp gal)

Fuel recommendation

Refer to

GI-35, "Fuel"

Qashqai J11. Fuel system (HRA2DDT, K9K, MR20DD) - part 4