Juke F15 (2012 year). Service Repair Manual — part 219

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< REMOVAL AND INSTALLATION >

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FUEL TANK

FUEL TANK

Exploded View

INFOID:0000000006500715

Removal and Installation

INFOID:0000000006500716

WARNING:

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

FL-30, "General Pre-

cautions"

.

REMOVAL

• Drain fuel from fuel tank if necessary. Refer to

FL-33, "Removal and Installation"

.

• Perform work on level place.
1.

Remove RH rear wheel.

2.

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-33, "Removal and

Installation"

.

3.

Remove sub muffler. Refer to

EM-166, "Removal and Installation"

.

4.

Remove insulator on vehicle side located above center and sub muffler.

1.

Fuel filler cap

2.

Grommet

3.

Fuel filler tube

4.

Vent hose

5.

Clamp

6.

Fuel filler hose

7.

Clamp

8.

Fuel tank

9.

Fuel tank mounting band (RH)

10. Fuel tank mounting band (LH)

11.

EVAP canister

12. EVAP canister hose

A.

To fuel tube

: Vehicle front

: N·m (kg-m, ft-lb)

JPBIA4109GB

FUEL TANK

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5.

Remove floor under covers (RH, LH) Refer to

EXT-25, "Exploded View"

.

6.

Move parking brake cable (1) from the lower face of fuel tank. Then remove clips for parking brake cable.

7.

Disconnect fuel filler hose at fuel tank side.

8.

Remove vent hose at RH rear wheel well side

9.

Remove EVAP canister 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 damage and foreign materials, cover them

completely with plastic bags or something similar.

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

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

1

: Filler tube

2

: Filler hose

JPBIA4217ZZ

3.

: Centralized under-floor piping

A.

: quick connector

: Vehicle front

PBIC3789E

PBIC3790E

: Vehicle front

PBIC5221J

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< REMOVAL AND INSTALLATION >

[HR16DE]

FUEL TANK

11. Remove quick connectors (A) from the EVAP canister (1).

12. 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 hose
• 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 damage and foreign materials, cover them

completely with plastic bags or something similar.

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

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

(B).

CAUTION:

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

14. Remove fuel tank mounting bands (RH and LH).

15. 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

2.

: EVAP canister hose

JPBIA4218ZZ

JPBIA4219ZZ

JPBIA4220ZZ

FUEL TANK

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1.

Temporarily tighten bolts [except (4)] in numerical order as
shown in the figure.

2.

Tighten bolt (4) to specified torque, pressing fuel tank in the
direction (

) shown in the figure.

3.

Tighten bolts [except (4)] 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 canister 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. Check connections are secure.

Inspection

INFOID:0000000006500717

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.

A

: 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)

A

: Pull

JPBIA4216ZZ

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EVAP CANISTER

EVAP CANISTER

Hydraulic Layout

INFOID:0000000006635457

EVAPORATIVE EMISSION LINE DRAWING

1.

EVAP canister purge volume control
solenoid valve

2.

Resonator

3.

EVAP canister

JSBIA0595ZZ

EVAP CANISTER

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

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< SERVICE DATA AND SPECIFICATIONS (SDS)

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Fuel Tank

INFOID:0000000006500718

Standard and Limit

Fuel tank capacity

Approx. 52.0 (11-1/2 Imp gal)

Fuel recommendation

Refer to

GI-35, "Fuel"

PRECAUTIONS

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< PRECAUTION >

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PRECAUTION

PRECAUTIONS

General Precautions

INFOID:0000000006500719

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 diesel fuel required by the regulations for cetane number. Refer to

GI-35, "Fuel"

.

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

safe area.

- 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 that there is no fuel leakage at connections in the following steps.
- 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.

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< PREPARATION >

[K9K]

PREPARATION

PREPARATION

PREPARATION

Special Service Tool

INFOID:0000000006500720

Commercial Service Tools

INFOID:0000000006500721

NISSAN tool number
(RENAULT tool number)
Tool name

Description

KV99104700
(Mot. 1397)
Lock ring wrench

Removing and Installing lock ring

ZZA0122D

Tool name

Description

Power tool

Loosening bolts and nuts

PBIC0190E

FUEL SYSTEM

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PERIODIC MAINTENANCE

FUEL SYSTEM

Checking Fuel Line

INFOID:0000000006500722

Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.If necessary, repair or replace.

SMA803A

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< PERIODIC MAINTENANCE >

[K9K]

FUEL FILTER

FUEL FILTER

Exploded View

INFOID:0000000006500723

Removal and Installation

INFOID:0000000006500724

REMOVAL (RHD)

1.

Remove quick connectors in the following procedures.
• Pinch quick connector square-parts with your fingers, and pull

out the quick connector by hand.

• If quick connector and tube on vehicle are stuck, push and pull

several times until they move, and pull out.

MBIB1064E

MBIB1065E

MBIB1048E

FUEL FILTER

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2.

Remove fuel filter from fuel filter bracket.

CAUTION:

Never spill the fuel during removal. If the fuel is spill, imme-
diately wipe it off. Be especially careful to prevent the fuel
from adhering to the insulators of the engine mounts.

REMOVAL (LHD)

1.

Remove priming bulb from priming bulb bracket.

2.

Remove fuel filter from fuel filter bracket.

3.

Remove quick connectors as above.

CAUTION:

Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator. Be espe-
cially careful to prevent any damage.

INSTALLATION

Install in the reverse order of removal, paying attention to the following points:
• To install fuel filter connectors, respect paint marks on fuel filter as

shown.

• After installation, operate the priming bulb vertically, if it is possible,

to perform air bleeding.
Refer to

FL-50, "Air Bleeding"

.

CAUTION:

Never bend or twist the tube during installation and removal.

Water Draining

INFOID:0000000006500725

DRAINING WATER (RHD)

CAUTION:

Before carrying out any work, wait for the fuel temperature is dropped.
Open drain valve at the bottom of fuel filter.

DRAINING WATER (LHD)

1.

Remove fender protector RH. Refer to

EXT-22, "Exploded View"

.

2.

Remove foam insulator.

3.

Open drain valve at the bottom of fuel filter.

CAUTION:

Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator.

FUEL FILTER CHECK

MBIB1049E

MBIA0095E

MBIB0530E

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< PERIODIC MAINTENANCE >

[K9K]

FUEL FILTER

Check fuel filter for fuel leakage, damage and other abnormal signs.

Air Bleeding

INFOID:0000000006500726

1.

Prime the circuit using the priming bulb.

2.

Perform engine cranking with repeating several times until
engine starting.

3.

If the engine does not start, perform the following procedure.

a.

Remove high pressure pump protector. Refer to

EM-298,

"Exploded View"

.

b.

Remove quick connector (black tab).

c.

Connect drain hose (suitable hose) (1) to the end of quick con-
nector (supply pipe side) (3).

d.

Place a tray (4) at the drain hose open end.

e.

Operate the priming bulb to completely bleed air from the circuit.

4.

When air bleeding is completed, install quick connector, and check absence of leakage.

MBIB9045E

2

: High pressure supply pump

JPBIA3096ZZ

FUEL LEVEL SENSOR UNIT

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REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT

Exploded View

INFOID:0000000006500727

Removal and Installation

INFOID:0000000006500728

WARNING:

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

FL-45, "General Precautions"

.

REMOVAL

1.

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 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.

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-55, "Exploded View"

.

c.

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

2.

Open fuel filler lid.

3.

Open filler cap and release the pressure inside fuel tank.

4.

Remove rear seat. Refer to

SE-32, "Exploded View"

.

5.

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

E1BIA0015GB

1.

Lock ring

2.

Fuel level sensor unit

3.

Seal packing

A.

To fuel tank

: Always replace after every disassembly

JPBIA2797ZZ

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FUEL LEVEL SENSOR UNIT

6.

Disconnect harness connector (1), fuel feed tube (4) and quick
connector (3).

• Hold the connector while pushing in tabs, and pull out the

tube.

CAUTION:

• Quick connector can be removed when the tabs are completely 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.

7.

Using lock ring wrench [SST: KV99104700 (Mot.1397)], remove lock ring.

CAUTION:

Rotate SST while pressing fuel level sensor unit as spring reaction force is applied from fuel tank
inside to up ward.

2

: Fuel level sensor unit

: Vehicle front

JPBIA3052ZZ

MBIB1052E

JFE628A

JPBIA2889ZZ

FUEL LEVEL SENSOR UNIT

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8.

Remove fuel level sensor unit.

CAUTION:

• Be careful not to bend the float arm (3) when removing.
• Handle them carefully without subjecting them to impacts

such as dropping.

INSTALLATION

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

Fuel Level Sensor Unit

1.

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

2.

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.

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 (Mot. 1397)]
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.

2

: O-ring

JPBIA3099ZZ

JPBIA3100ZZ

: Vehicle front

JPBIA3101ZZ

PBIC0240E