Juke F15 (2012 year). Service Repair Manual — part 217

FL-6

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

2WD

2WD : Exploded View

INFOID:0000000006356439

2WD : Removal and Installation

INFOID:0000000006356440

WARNING:

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

FL-3, "General Precautions"

REMOVAL

Release the fuel pressure from the fuel lines. Refer to

EC-551, "Work Procedure"

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, 5-1/4
Imp gal) of fuel are drained from fuel tank.

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

ing procedure.

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.

Disconnect fuel filler hose from fuel filler tube. Refer to

FL-18, "2WD : Exploded View"

Fuel tank

Lock ring

Fuel level sensor unit, fuel filter and
fuel pump assembly

Rock ring

Vehicle front

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA4108GB

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-7

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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

Open fuel filler lid.

Open filler cap and release the pressure inside fuel tank.

Remove rear seat. Refer to

SE-32, "Exploded View"

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

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.
• 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.

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.

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

: Vehicle front

JPBIA2923ZZ

PBIC5102J

JPBIA2889ZZ

PBIC0240E

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< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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.

Fuel Level Sensor Unit

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

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.

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.

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:

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 secure by following method.

PBIC5103J

JPBIA3100ZZ

: Vehicle front

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PBIC0240E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-9

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• 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:0000000006707468

Unit Disassembly and Assembly

Disassembly

Disconnect harness connector(A).

Press (A) with a flat-blade screwdriver or an equivalent to
release lock and push out the fuel gauge(1).

: Quick connector

JPBIA2893ZZ

Fuel level sensor unit, fuel filter and
fuel pump assembly

Fuel gauge

JPBIA4226ZZ

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< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

To remove the fuel gauge(1), side it in the direction (A) of the
arrow with the lock release.

Assembly

CAUTION:

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

Check for damage of fuel level sensor unit installation position on the side of fuel filter and pump assem-
bly.

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.

Connect harness connector.

2WD : Inspection

INFOID:0000000006356441

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.

Start engine and let it idle and check there are no fuel leakage at the fuel system connections.

4WD

4WD : Exploded View

INFOID:0000000006356561

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-11

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CAUTION:

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

4WD : Removal and Installation

INFOID:0000000006356562

REMOVAL

Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly

WARNING:

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

FL-3, "General Pre-

cautions"

Release the fuel pressure from the fuel lines. Refer to XX-XX, "*****".

figure or below when approximately 25 (6-5/8 US gal, 5-1/4
Imp gal) of fuel are drained from fuel tank.

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

ing procedure.

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.

Disconnect fuel filler hose from fuel filler tube. Refer to XX-XX, "*****".

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

Open fuel filler lid.

Open filler cap and release the pressure inside fuel tank.

Remove rear seat cushion. Refer to

SE-41, "Exploded View"

Remove inspection hole cover.

Disconnect harness connector (1) and quick connector (2).

• Remove quick connector in the following procedures.

Lock ring

Fuel level sensor unit, fuel filter and fuel pump
assembly

O-ring

Sub fuel level sensor assembly

Right side

Left side

: Always replace after every disassembly.

: Fuel feed hose

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

: Vehicle front

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FL-12

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

- 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.

Using lock ring wrench (A) (commercial service tool), remove
lock ring.
NOTE:
For reference when installing, put a matching mark on lock ring,
fuel pump assembly and fuel tank.

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.

JPBIA4462ZZ

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JPBIA4463ZZ

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-13

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• 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

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

Use lock ring wrench (A) (commercial service tool) 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 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.

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.

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< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

• 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 (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 front side.

Use lock ring wrench (A) (commercial service tool) to remove
lock ring as per the following steps.

Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly

Temporarily install the O-ring to the fuel level sensor unit, fuel filter and fuel pump assembly.

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.

Connect harness connector (B).

: Vehicle front

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-15

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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.

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.
NOTE:

Use lock ring wrench (A) (commercial service tool) to remove
lock ring as per the following steps.

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.

: Vehicle front

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< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

• 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. Refer to

FL-10,

"2WD : Inspection"

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

4WD : Disassembly and Assembly

INFOID:0000000006707467

Unit Disassembly and Assembly

Disassembly

Disconnect harness connector(A).

Press (A) with a flat-blade screwdriver or an equivalent to
release lock and push out the fuel gauge(1).

JPBIA0140ZZ

Fuel level sensor unit, fuel filter and
fuel pump assembly

Fuel gauge

JPBIA4470ZZ

JPBIA4471ZZ

JPBIA4472ZZ

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FL-17

< REMOVAL AND INSTALLATION >

[MR16DDT ]

To remove the fuel gauge(1), side it in the direction (A) of the
arrow with the lock release.

Assembly

CAUTION:

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

Check for damage of fuel level sensor unit installation position on the side of fuel filter and pump assem-
bly.

Connect harness connector.

4WD : Inspection

INFOID:0000000006356448

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.

Start engine and let it idle and check there are no fuel leakage at the fuel system connections.

JPBIA4473ZZ

FL-18

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL TANK

FUEL TANK

2WD

2WD : Exploded View

INFOID:0000000006356442

2WD : Removal and Installation

INFOID:0000000006356443

WARNING:

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

FL-3, "General Pre-

cautions"

REMOVAL

Drain fuel from fuel tank if necessary. Refer to

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

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.

Remove RH rear wheel.

Fuel filler cap

Grommet

Fuel filler tube

EVAP canister hose

Fuel tank mounting band (RH)

Fuel tank mounting band (LH)

Fuel tank

Clamp

Fuel filler hose

10. Vent hose

Vehicle front

: N·m (kg-m, ft-lb)

JPBIA4327GB

FUEL TANK

FL-19

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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"

Remove center muffler. Refer to

DLN-121, "Exploded View"

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

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

Remove brake tube protector.

Disconnect fuel filler hose at fuel tank side.

Remove vent hose at RH rear wheel well side

10. Remove EVAP hose (1) at front side of fuel tank (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 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 or something similar.

• Never insert plug, preventing damage on O-ring in quick

connector.

: Filler tube

: Vent hose

: Filler hose

JPBIA4217ZZ

: Vehicle front

JPBIA3028ZZ

JPBIA4219ZZ

PBIC0713E

FL-20

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL TANK

11. Remove EVAP hose (1) in the back for fuel tank side.

12. If necessary, remove mounting screw and quick connectors and

slide the EVAP canister rearward to remove it from the fuel tank.

13. 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:

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.

: Vehicle front

JPBIA4330ZZ

JPBIA4331ZZ

JPBIA4219ZZ

JPBIA2898ZZ

FUEL TANK

FL-21

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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

(B).

CAUTION:

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

15. Remove fuel tank mounting bands (RH and LH).
16. Lower transmission jack carefully to remove fuel tank while holding it by hand.

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 Tank

Temporarily tighten bolts [except (2)] in numerical order as
shown in the figure.

Tighten bolt (2) to specified torque, pressing fuel tank in the
direction (

) shown in the figure.

Tighten bolts [except (2)] to specified torque in the reverse order
as shown in the figure.

Fuel Filler Hose

• Surely clamp fuel hose insert fuel filler hose to the length below.

• Be sure hose clamp is not placed on swelled area of fuel filler tube.
• Install fuel filler hose to fuel tank, paying attention to install mark. Marking faces downward.
• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.

EVAP Hose and Vent Tube

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.

JPBIA4220ZZ

: Under view

: Vehicle front

JPBIA2856ZZ

Fuel filler hose

: 35 mm (1.38 in)

The other hose

: 25 mm (0.98 in)

Fuel filler tube side

: 8 - 12 mm (0.28 - 0.43 in)

Fuel tank side

: 5 - 9 mm (0.25 - 0.35 in)

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Juke F15 (2012 year). Service Repair Manual — part 217

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