Juke F15 (2012 year). Service Repair Manual — part 218

FL-22

< REMOVAL AND INSTALLATION >

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FUEL TANK

3.

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

2WD : 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), and check connections for leakage by applying fuel pres-
sure to fuel piping.

2.

Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.

4WD

4WD : Exploded View

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A

: Pull

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1.

Fuel filler cap

2.

Grommet

3.

Fuel filler tube

4.

Clamp

5.

Fuel filler hose

6.

Fuel tank band (RH)

7.

Protector

8.

Fuel tank band (LH)

9.

Fuel tank

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FUEL TANK

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4WD : Removal and Installation

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REMOVAL

WARNING:

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

FL-3, "General Pre-

cautions"

.

CAUTION:

• Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel should be

drained if found the remaining quantity.

• Situate vehicle on a flat and solid surface.

1.

Drain fuel from fuel tank if necessary.

2.

Perform the steps 2 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”. Refer to

FL-11, "4WD : Removal and Installation"

.

3.

Remove center muffler.

4.

Remove propeller shaft. Refer to

DLN-121, "Exploded View"

.

5.

Remove protector from fuel tank.

6.

Remove fuel filler hose (3) at fuel tank side.

7.

Disconnect vent hose connector (1).

8.

Disconnect vent tube and EVAP hose at rear side of fuel tank.
• Instruction for quick connector (A) of EVAP tube and vent

hose. Refer to

FL-11, "4WD : Removal and Installation"

.

9.

Remove parking brake cable mounting bolts. Refer to

PB-4, "Exploded View"

.

10. Disconnect ABS harness connector from fuel tank mounting band.

11. Support left of fuel tank (1) with transmission jack (A), and them

remove fuel tank band (RH) (2).

10. Clamp

11.

Vent hose

A.

To EVAP canister

Vehicile front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

1

: Vent tube

2

: EVAP hose

: Vehicle front

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FL-24

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL TANK

12. Support right of fuel tank(1) with transmission jack (A), and them

remove fuel tank band mounting bolts (LH).

13. Supporting with hands, descend transmission jack carefully, and remove fuel tank.

CAUTION:

Fuel tank may be in an unstable condition because of the shape of fuel tank bottom. Never rely on
jack too much. Be sure to hold tank securely.

INSTALLATION

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

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:0000000006356451

INSPECTION AFTER INSTALLATION

Use the following procedure to check for fuel leakage.

1.

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

2.

Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions.

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: 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)

A

: Pull

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EVAP CANISTER

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EVAP CANISTER

2WD

2WD : Hydraulic Layout

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EVAPORATIVE EMISSION LINE DRAWING

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FL-26

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EVAP CANISTER

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

2WD : Removal and Installation

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REMOVAL

1.

Disconnect EVAP canister hoses.

2.

Remove EVAP canister fixing bolt.

3.

Remove EVAP canister.

INSTALLATION

Install in the reverse order of removal.
NOTE:
Tighten EVAP canister fixing bolt to the specified torque.

4WD

4WD : Hydraulic Layout

INFOID:0000000006357343

EVAPORATIVE EMISSION LINE DRAWING

1.

EVAP canister purge volume control
solenoid valve

2.

EVAP canister

3.

EAVP line

4.

Fuel line

EVAP CANISTER

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NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

1.

EVAP service port

2.

EVAP canister

3.

EVAP line

4.

Fuel line

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FL-28

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EVAP CANISTER

4WD : Removal and Installation

INFOID:0000000006357344

REMOVAL

1.

Remove rear stabilizer (1). Refer to

RSU-34, "Exploded View"

.

2.

Disconnect EVAP canister hoses.

3.

Remove EVAP canister fixing bolt.

4.

Remove EVAP canister (2).

INSTALLATION

Install in the reverse order of removal.
NOTE:
Tighten EVAP canister fixing bolt to the specified torque.

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SERVICE DATA AND SPECIFICATIONS (SDS)

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Fuel Tank

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Standard and Limit

Fuel tank capacity

Approx. 52.0

(11-1/2 Imp gal)

Fuel recommendation

Refer to

GI-35

FL-30

< PRECAUTION >

[HR16DE]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

General Precautions

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WARNING:

When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO

2

fire extinguisher.

• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.

CAUTION:

• Use gasoline required by the regulations for octane number. Refer to

GI-35, "Fuel"

.

• Before removing fuel line parts, perform out the following procedures:
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in

safe area.

- Release fuel pressure from the fuel lines. Refer to

EC-551, "Work Procedure"

.

- Disconnect the battery cable from the negative terminal.
• Always replace O-ring and clamps with new ones.
• Never kink or twist tubes when they are being installed.
• Never tighten hose clamps excessively to avoid damaging hoses.
• After installing tubes, check there is no fuel leakage at connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check

for fuel leakage at connections.

- Start engine and rev it up and check for fuel leakage at connections.
• Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the

“MI” may come on.

• For servicing “EVAPORATIVE EMISSION SYSTEM” parts, refer to

EC-480, "EVAPORATIVE EMISSION

SYSTEM : System Diagram"

.

PREPARATION

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PREPARATION

PREPARATION

Special Service Tool

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Commercial Service Tools

INFOID:0000000006500709

Tool number
Tool name

Description

KV99104700
Lock ring wrench

Removing and Installing lock ring

ZZA0122D

Tool name

Description

Power tool

Loosening bolts and nuts

PBIC0190E

FL-32

< PERIODIC MAINTENANCE >

[HR16DE]

FUEL SYSTEM

PERIODIC MAINTENANCE

FUEL SYSTEM

Inspection

INFOID:0000000006500710

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:0000000006500711

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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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

Exploded View

INFOID:0000000006500712

Removal and Installation

INFOID:0000000006500713

WARNING:

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

FL-30, "General Precautions"

.

REMOVAL

1.

Release the fuel pressure from the fuel lines. Refer to

EC-551, "Work Procedure"

.

1.

Fuel tank

2.

Rock ring

3.

Fuel level sensor unit, fuel filter and
fuel pump assembly

4.

O-ring

: Vehicle front

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

1.

Fuel filter and fuel pump assembly

2.

Fuel gauge

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< REMOVAL AND INSTALLATION >

[HR16DE]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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:
Because fuel will be spilled when removing fuel level sensor
units for the top of the fuel is above the fuel level sensor units
installation surface.
• As a guide, fuel level becomes the position as shown in the

figure or below when approximately 25 (6-5/8 US gal, 5-4/8
Imp gal) of fuel are drained from fuel tank.

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

ing procedure.

a.

Insert hose of less than 25 mm (0.98 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-38, "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-32, "Exploded View"

.

6.

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

7.

Disconnect harness connector (1), fuel feed hose (4) 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.

2

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

: Vehicle front

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PBIC5102J

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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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 fuel tank lock ring wrench [SST:
KV99104700] (A) by turning counterclockwise.

INSTALLATION

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

Fuel Level Sensor Unit

1.

Temporarily install seal packing to the fuel gauge fuel filter fuel pump assembly.

2.

Insert the fuel gauge fuel filter fuel pump assembly into fuel tank and install the above temporarily installed
seal packing to the opening of fuel tank.

CAUTION:

Never bend float arm during removal.

3.

Install fuel level sensor unit to fuel tank with alignment mark (B)
on the upper surface facing the tree inscribed lines (A) on the
tank side.

CAUTION:

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

4.

Install lock ring for fuel level sensor unit, fuel filter and fuel pump
assembly with lock ring wrench [SST: KV993G0010 or
KV99104700] by turning clockwise.

CAUTION:

Install lock ring horizontally.

Quick Connector

Connect quick connector as follows:

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PBIC0240E

: Vehicle front

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PBIC0240E

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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

connected.

Disassembly and Assembly

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DISASSEMBLY

CAUTION:

Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
Remove main fuel level sensor unit as follows:
1.

Disconnect harness connector (A).

a.

Hold connector by fingers and push stopper release tab.

b.

Pull it out connector.

2.

Remove main fuel level sensor unit (1) from fuel filter and fuel
pump assembly (2) as follows:

a.

Push in tab (A) to release the lock.

b.

After fixing tabs are disengaged, slide main fuel level sensor unit
out in direction shown by the arrow (B).

CAUTION:

• Be careful not to damage the main fuel level sensor unit.
• Never disassemble fuel filter and fuel pump assembly.

ASSEMBLY

CAUTION:

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

1.

Check for damage of main fuel level sensor unit installation position on the side of fuel filter and fuel pump
assembly.

2.

Slide main fuel level sensor unit until it aligns to installation groove, then insert it until it stops.
• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.

1

: Quick connector

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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3.

Connect the white (A), black (B), and red (C) harnesses so that
they are in the positions shown in the figure.
• Securely insert harness connector until it stops.

Inspection

INFOID:0000000006500714

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.

JPBIA2588ZZ