Nissan Cube. Manual - part 499

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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< REMOVAL AND INSTALLATION >

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REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Exploded View

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Removal and Installation

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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-478, "Inspection"

.

2.

Check fuel level on fuel gauge. If fuel gauge indicates more than
the level as shown in the figure (full or almost full), drain fuel
from fuel tank until fuel gauge indicates level as shown in the fig-
ure or below.
NOTE:
The above instructions must be followed since fuel spills when
removing the fuel level sensor unit if the fuel level exceeds the
mounting surface. 
• As a guide, fuel level becomes the position as shown in the

figure or below when approximately 10   (2-5/8 US gal, 2-1/4
Imp gal) of fuel are drained from fuel tank. 

• In a case that fuel pump does not operate, perform the follow-

ing procedure.

1.

Lock 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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< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

a.

Insert hose of less than 20 mm (0.79 in) in diameter into fuel filler tube through fuel filler opening to draw
fuel from fuel filler tube.

b.

Disconnect fuel filler hose from fuel filler tube. Refer to 

FL-9, "Exploded View"

.

c.

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

3.

Open fuel filler lid.

4.

Open filler cap and release the pressure inside fuel tank.

5.

Remove rear seat. Refer to 

SE-17, "Exploded View"

.

6.

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

7.

Disconnect harness connector (1) and quick connector (3).

• 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.

8.

Remove lock ring for fuel level sensor unit, fuel filter and fuel
pump assembly with fuel tank lock ring wrench [SST:
KV991J0090 (J-46214)] (A) by turning counterclockwise.

2

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

: Vehicle front

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PBIC5102J

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: Vehicle front

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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9.

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

CAUTION:

• Never bend float arm (2) 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.

Fuel Level Sensor Unit

1.

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

CAUTION:

Do not reuse O-ring.

2.

Align (A) with (B) as shown in the figure. Install fuel level sensor
unit, fuel filter and fuel pump assembly (1) to fuel tank.

CAUTION:

• Never allow O-ring to drop.
• 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 [SST: KV991J0090 (J-46214)]
(A) by turning clockwise.

CAUTION:

Install lock ring horizontally.

Quick Connector

Connect quick connector as follows:

1.

Check the connection for damage or any foreign materials.

2.

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

3.

After connecting, check that the connection is secure by following method.
• Visually confirm that the two tabs are connected to the connector.

PBIC5103J

: Vehicle front

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: Vehicle front

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< REMOVAL AND INSTALLATION >

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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

connected.

Inspection

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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.

1

: Quick connector

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