Qashqai J11. Fuel system (HRA2DDT, K9K, MR20DD) — part 4
FUEL LEVEL SENSOR UNIT
FL-49
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4.
Open fuel filler lid and filler cap to release the pressure inside fuel tank.
5.
Remove rear seat. Refer to
SE-35, "Removal and Installation"
6.
Remove inspection hole cover.
7.
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.
1
: Harness connector
2
: Quick connector
3
: Fuel level sensor unit, fuel filter and fuel pump assembly
4
: Lock ring
: Vehicle front
E1BIA1129ZZ
A
: Push in tabs
B
: Pull
E1BIA1191ZZ
A
: Connection (cross-section)
B
: Disconnection (cross-section)
C
: Quick connector
D
: Hard tube
E1BIA1190ZZ
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FUEL LEVEL SENSOR UNIT
8.
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.
9.
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
1.
Install new O-ring to fuel tank without any twist.
2.
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.
3.
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
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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 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.
4.
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.
2.
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
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FUEL LEVEL SENSOR UNIT
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
1.
Release the fuel pressure from the fuel lines. Refer to
2.
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
- Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.
3.
Disconnect batterie cable from negative terminal.
4.
Open fuel filler lid and filler cap to release the pressure inside fuel tank.
5.
Remove rear seat. Refer to
SE-35, "Removal and Installation"
6.
Remove inspection hole cover.
• Using a screwdriver, remove it by turning clips clockwise by 90 degrees.
7.
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.
1.
Lock ring
2.
Fuel level sensor unit
3.
O-ring
4.
Sub fuel level sensor unit
A.
To fuel tank
B.
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.
1
: Fuel tube (return side)
2
: Fuel tube (feed side)
JPBIA0852ZZ
FUEL LEVEL SENSOR UNIT
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- 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.
8.
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.
9.
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.
A
: Push in tabs
B
: Pull
E1BIA1191ZZ
A
: Connection (cross-section)
B
: Disconnection (cross-section)
C
: Quick connector
D
: Hard tube
E1BIA1190ZZ
PBIC0240E
FL-54
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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
1.
Remove fuel level sensor unit, fuel filter and fuel pump assembly.
2.
Use lock ring wrench [SST: KV99104700] to remove lock ring.
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 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
1.
Install O-ring to fuel tank without any twist.
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.
JPBIA0851ZZ
PBIC0240E
JPBIA0823ZZ
FUEL LEVEL SENSOR UNIT
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• 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.
3.
Install sub fuel level sensor assembly with its matching mark (A)
aligned with fuel tank matching mark (B) as shown in the figure.
4.
Use lock ring wrench [SST: 99104700] to install lock ring as per
the following steps.
a.
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.
b.
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
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FUEL LEVEL SENSOR UNIT
c.
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
1.
Temporarily install the O-ring to the fuel level sensor unit.
2.
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.
3.
Connect harness connector (A).
4.
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
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FUEL LEVEL SENSOR UNIT
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5.
Install fuel level sensor unit with its matching mark (A) aligned
with fuel tank matching mark (B) as shown in the figure.
6.
Use lock ring wrench [SST: KV99104700] to install lock ring as
per the following steps.
a.
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.
b.
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.
c.
Check that the “ ” mark of the lock ring (1) is between MIN and
MAX [i.e. within (A)].
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.
E1BIA1134ZZ
PBIC0240E
Tightening angle
: Approximately 540
°
E1BIA1130ZZ
E1BIA1133ZZ
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FUEL LEVEL SENSOR UNIT
• 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.
1.
Install inspection hole covers with the front mark (arrow) facing front of vehicle.
2.
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.
1.
Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres-
sure to fuel piping.
2.
Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.
JPBIA0140ZZ
FUEL TANK
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FUEL TANK
2WD
2WD : Exploded View
INFOID:0000000010430545
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
.
1.
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"
.
2.
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.
3.
Remove main muffler. Refer to
.
4.
Remove vent hose from filler tube.
1.
Fuel filler cap
2.
Grommet
3.
Fuel filler tube
4.
Clamp
5.
Fuel filler hose
6.
Clamp
7.
Clamp
8.
Vent hose
9.
Evap hose
10. Fuel tank
11.
Fuel tank band (RH)
12. Fuel tank band (LH)
E1BIA1127GB
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FUEL TANK
5.
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.
6.
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
A
: Connection (cross-section)
B
: Disconnection (cross-section)
C
: Quick connector
D
: Hard tube
E1BIA1190ZZ
FUEL TANK
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7.
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.
8.
Remove fuel tank band (RH and LH).
9.
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
.
• 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
1.
Check connections for damage or foreign material.
2.
Align the matching side connection part with the center of shaft,
and insert connector straight until it clicks.
3.
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
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
.
1.
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"
.
2.
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.
3.
Remove main muffler. Refer to
.
4.
Remove propeller shaft. Refer to
DLN-186, "Removal and Installation"
5.
Remove protector from fuel tank.
6.
Remove vent hose from filler tube.
1.
Fuel filler cap
2.
Grommet
3.
Fuel filler tube
4.
Clamp
5.
Fuel filler hose
6.
Clamp
7.
Fuel tank
8.
Fuel tank band (RH)
9.
Protector
10. Fuel tank band (LH)
11.
Clamp
12. EVAP hose
13. Vent hose
14. Clamp
E1BIA1128GB
FUEL TANK
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7.
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.
8.
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
A
: Connection (cross-section)
B
: Disconnection (cross-section)
C
: Quick connector
D
: Hard tube
E1BIA1190ZZ
FL-64
< REMOVAL AND INSTALLATION >
[R9M]
FUEL TANK
9.
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:
• 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 mountin bolts are correct as pair exploded view. Refer to
.
• 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
1.
Check connections for damage or foreign material.
2.
Align the matching side connection part with the center of shaft,
and insert connector straight until it clicks.
3.
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
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SERVICE DATA AND SPECIFICATIONS (SDS)
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
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