ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
HR12DE, HR15DE Fuel Tank .................................................................17 F
K9K
PRECAUTION ............................................... 3
PRECAUTION .............................................. 18 G
PRECAUTIONS ................................................... 3
General Precautions ................................................. 3 PRECAUTIONS ................................................. 18
General Precautions ................................................18
PREPARATION ............................................ 4 H
PREPARATION ........................................... 19
PREPARATION ................................................... 4
Special Service Tool ................................................. 4 PREPARATION ................................................. 19
I
Commercial Service Tools ........................................ 4 Special Service Tool ................................................19
Commercial Service Tools .......................................19
PERIODIC MAINTENANCE .......................... 5
PERIODIC MAINTENANCE ........................ 20 J
FUEL SYSTEM .................................................... 5
Inspection .................................................................. 5 FUEL SYSTEM .................................................. 20
Quick Connector ....................................................... 5 Checking Fuel Line ..................................................20
K
REMOVAL AND INSTALLATION ................ 6 FUEL FILTER .................................................... 21
Exploded View .........................................................21
FUEL LEVEL SENSOR UNIT, FUEL FILTER Removal and Installation .........................................21 L
AND FUEL PUMP ASSEMBLY .......................... 6 Water Draining .........................................................21
Exploded View .......................................................... 6 Air Bleeding .............................................................22
Removal and Installation ........................................... 6
REMOVAL AND INSTALLATION ............... 23 M
Disassembly and Assembly ...................................... 9
Inspection ................................................................ 10
FUEL LEVEL SENSOR UNIT ........................... 23
FUEL TANK ........................................................11 Exploded View .........................................................23 N
Exploded View ........................................................ 11 Removal and Installation .........................................23
Removal and Installation ......................................... 11 Disassembly and Assembly .....................................26
Inspection ................................................................ 13 Inspection ................................................................27
O
EVAP CANISTER ...............................................14 FUEL TANK ...................................................... 28
Hydraulic Layout ..................................................... 14 Exploded View .........................................................28
Removal and Installation ......................................... 16 Removal and Installation .........................................28 P
Inspection ................................................................29
SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................ 17 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................ 30
SERVICE DATA AND SPECIFICATIONS
(SDS) ..................................................................17 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 30

Revision: 2012 July FL-1 N17

 Fuel Tank ................................................................ 30

Revision: 2012 July FL-2 N17

 PRECAUTIONS
< PRECAUTION > [HR12DE, HR15DE]

PRECAUTION A
PRECAUTIONS
General Precautions INFOID:0000000006655897
FL

WARNING:
When replacing fuel line parts, be sure to observe the following.
C
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION: D
• Use gasoline required by the regulations for octane number. Refer to GI-27, "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 E
safe area.
- Release fuel pressure from the fuel lines. Refer to EC-540, "Work Procedure".
- Disconnect the battery cable from the negative terminal.
• Always replace O-ring with new ones. F
• 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. G
- 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 H
“MIL” may come on.

Revision: 2012 July FL-3 N17

 PREPARATION
< PREPARATION > [HR12DE, HR15DE]

PREPARATION
PREPARATION
Special Service Tool INFOID:0000000006655898

Tool number
Description
Tool name
KV10119901 Removing and Installing lock ring
Lock ring wrench

JPBIA3555ZZ

Commercial Service Tools INFOID:0000000006655899

Tool name Description

Power tool Loosening bolts and nuts

PBIC0190E

Revision: 2012 July FL-4 N17

 FUEL SYSTEM
< PERIODIC MAINTENANCE > [HR12DE, HR15DE]

PERIODIC MAINTENANCE A
FUEL SYSTEM
Inspection INFOID:0000000006655900
FL
Inspect fuel lines, fuel filler cap, and fuel tank for improper attach-
ment, leakage, cracks, damage, loose connections, chafing or dete-
rioration. C

A : Engine
B : Fuel line D
C : Fuel tank
If necessary, repair or replace damaged parts.
E

JPBIA0129ZZ

Quick Connector INFOID:0000000006655901 F

CAUTION:
• After connecting fuel tube quick connectors, check quick connectors are secure.
G
• Ensure that connector and resin tube never contact any adjacent parts.

Revision: 2012 July FL-5 N17

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]

REMOVAL AND INSTALLATION

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Exploded View INFOID:0000000006655902

REMOVAL

JPBIA4501GB

Fuel level sensor unit, fuel filter and

1. Lock ring 2. 3. O-ring
fuel pump assembly
4. Fuel tank
: Always replace after every disassembly.

DISASSEMBLY

JPBIA4166ZZ

1. Fuel level sensor unit 2. Fuel filter and fuel pump assembly

Removal and Installation INFOID:0000000006655903

WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-3, "General Precautions".
REMOVAL
1. Release the fuel pressure from the fuel lines. Refer to following;

Revision: 2012 July FL-6 N17

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
• HR12DE: EC-170, "Work Procedure"
• HR15DE (TYPE 1): EC-540, "Work Procedure" A
• HR15DE (TYPE 2): EC-850, "Work Procedure"
• HR15DE (TYPE 3): EC-1131, "Work Procedure"
2. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri- FL
ate amount of fuel from the fuel tank.

Guideline : Draw approximately 10 liters (2-1/2 imp gal) from a full-tank condition.
C
• In the event of malfunction in fuel pump, insert a hose measuring 20mm (0.79 in) in diameter into the
filler opening to draw approximately 10 liters (2-1/2 Imp gal) fuel.
3. Open fuel filler lid. D
4. Open filler cap and release the pressure inside fuel tank.
5. Remove rear seat. Refer to SE-24, "Exploded View".
6. Remove inspection hole cover. E
7. Disconnect harness connector (1), fuel feed tube (5) and EVAP
tube (4).
F
2 : Fuel level sensor unit, fuel filter and fuel pump assembly
3 : Quick connector
: Vehicle front G

H
JPBIA3422ZZ

• Remove quick connector in the following procedures. I

- Hold the sides of quick connector, press tabs and pull out fuel
feed tube.
J
A : Pull
B : Push in tabs
- If quick connector sticks to tube of main fuel level sensor unit, K
push and pull quick connectors several times until they start to
move. Then disconnect them by pulling.
L
JPBIA0134ZZ

CAUTION: M

Revision: 2012 July FL-7 N17

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
• Quick connector (1) can be disconnected when the tabs
(F) are depressed completely. Never twist it more than
necessary.

B : Connection (cross-section)
D : To under floor fuel line
E : To fuel tank
G : Disconnection
• Never use any tools to disconnected quick connector.
• Keep resin tube (C) 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 remove the remaining retainer (2) on hard tube (or
the equivalent) (A) except when resin tube or retainer is
replaced.
• When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with new one.

Retainer color : Blue JPBIA0130ZZ

• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely with
plastic bags (B) or something similar.

A : Fuel feel hose

C : Fuel tube

JSBIA1295ZZ

8. Use lock ring wrench [SST: KV10119901] (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: 60cm (23.62in) or more]
and slowly turn it counterclockwise.

JSBIA1633ZZ

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.

JPBIA3557ZZ

Revision: 2012 July FL-8 N17

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
INSTALLATION
Note to the following, and install in the reverse order of removal. A
CAUTION:
Do not reuse O-rings.
Fuel Level Sensor Unit FL
1. Install new O-ring to fuel tank without any twist.
CAUTION:
Do not reuse O-ring. C
2. Install the fuel fuel level sensor unit, fuel filter and fuel pump
assembly on the fuel tank with the fuel level sensor unit, fuel fil-
ter and fuel pump assembly top surfase (A) fased the rear of the D
vehicle.

: Vehicle front
E
CAUTION:
• Never allow O-ring to drop.
• Never bend float arm during installing. F
JPBIA3558ZZ

3. Install lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with lock ring wrench [SST: G
KV10119901] by turning clockwise.
CAUTION:
• Install lock ring horizontally.
• Turn the lock ring (A) until it is engaged in the fuel tank H
side (B) as shown in the figure.

K
JPBIA3559ZZ

Quick Connector
• Connect quick connector as follows: L
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. M
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
N
securely connected.

JPBIA0140ZZ

Disassembly and Assembly INFOID:0000000006655904

DISASSEMBLY

Revision: 2012 July FL-9 N17

 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
1. Disconnect harness connector (A).

JPBIA4167ZZ

2. Press (A) with a suitable tool to release the lock and push out
the fuel level sensor unit (1).

JSBIA1085ZZ

3. To remove the fuel level sensor unit (1), slide it in the direction
(A) of the arrow with the lock released.

JPBIA4169ZZ

ASSEMBLY
CAUTION:
Fuel level sensor unit cannot be disassembled and should be replaced as a unit.
1. Check for damage of fuel level sensor unit installation position on the side of fuel filter and fuel pump
assembly.
2. 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.
3. Connect harness connector.
Inspection INFOID:0000000006655905

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.

Revision: 2012 July FL-10 N17

 FUEL TANK
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
FUEL TANK
A
Exploded View INFOID:0000000006655906

FL

I
JPBIA3365GB

1. Fuel tank 2. Fuel tank mounting band (RH) 3. Fuel tank mounting band (LH) J
4. Clamp 5. Fuel filler hose 6. Fuel filler tube
7. Grommet 8. Fuel filler cap 9. Clamp
10. Vent hose K
: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000006655907 L

WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "General Pre- M
cautions".
REMOVAL
• Drain fuel from fuel tank if necessary. Refer to FL-6, "Removal and Installation". N
• Perform work on level place.
1. 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, "Removal and O
Installation".
2. Remove center muffler. Refer to EX-5, "Exploded View".
3. Remove insulator on vehicle side located above center and main mufflers. P

Revision: 2012 July FL-11 N17

 FUEL TANK
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
4. Disconnect fuel filler hose at fuel filler tube side.

1 : Filler tube
2 : Filler hose
3 : Vent hose
5. Remove vent hose from fuel tank side.

JPBIA3423ZZ

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

JPBIA3424ZZ

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

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

Fuel filler hose : 35 mm (1.38 in)

The other hose : 25 mm (0.98 in)
• 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.
• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.

Fuel tank side hose clamp : 7 - 11 mm (0.28 - 0.43 in)

Fuel filler tube side hose clamp : 8 - 12mm (0.31 - 0.47 in)
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.

Revision: 2012 July FL-12 N17

 FUEL TANK
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
3. After connecting, pull out quick connector and centralized under
floor piping by hand. Check connections are secure. A

A : Pull
FL

JPBIA0140ZZ

D
Inspection INFOID:0000000006655908

INSPECTION AFTER INSTALLATION E

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

Revision: 2012 July FL-13 N17

 EVAP CANISTER
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]
EVAP CANISTER
Hydraulic Layout INFOID:0000000007806310

EVAPORATIVE EMISSION LINE DRAWING

HR12DE

JPBIA5736ZZ

Revision: 2012 July FL-14 N17

 EVAP CANISTER
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]

EVAP canister purge volume control A

1. 2. EVAP canister 3. EVAP line
solenoid valve
4. Fuel line

NOTE: FL
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
HR15DE
C

JPBIA5607ZZ

Revision: 2012 July FL-15 N17

 EVAP CANISTER
< REMOVAL AND INSTALLATION > [HR12DE, HR15DE]

EVAP canister purge volume control

1. 2. EVAP canister 3. EVAP line
solenoid valve
4. Fuel line

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
Removal and Installation INFOID:0000000007806311

REMOVAL
1. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Exploded
View".
2. Remove IPDM E/R bracket and IPDM E/R. Refer to PCS-39, "Exploded View" (WITH I-KEY models) or
PCS-73, "Exploded View" (WITHOUT I-KEY models).
3. Remove EVAP canister.
INSTALLATION
Install in the reverse order of removal.

Revision: 2012 July FL-16 N17

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR12DE, HR15DE]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank INFOID:0000000006655909
FL

Standard and Limit

C
Fuel tank capacity Approx. 41.0 (9.0 Imp gal)
Fuel recommendation Refer to GI-27, "Fuel"
D

Revision: 2012 July FL-17 N17

 PRECAUTIONS
< PRECAUTION > [K9K]

PRECAUTION
PRECAUTIONS
General Precautions INFOID:0000000007838713

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 CO2 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-27, "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.
- 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
“MIL” may come on.
• Drain water from fuel filter, when the fuel filter warning lamp
turns ON (with fuel filter warning). Refer to FL-21, "Water
Draining".

PBIC2664E

Revision: 2012 July FL-18 N17

 PREPARATION
< PREPARATION > [K9K]

PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000007838714
FL

Tool number
Description C
Tool name
KV10119901 Removing and Installing lock ring
Lock ring wrench
D

E
JPBIA3555ZZ

Commercial Service Tools INFOID:0000000007838715 F

Tool name Description

G
Power tool Loosening bolts and nuts

I
PBIC0190E

Revision: 2012 July FL-19 N17

 FUEL SYSTEM
< PERIODIC MAINTENANCE > [K9K]

PERIODIC MAINTENANCE
FUEL SYSTEM
Checking Fuel Line INFOID:0000000007838716

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

SMA803A

Revision: 2012 July FL-20 N17

 FUEL FILTER
< PERIODIC MAINTENANCE > [K9K]
FUEL FILTER
A
Exploded View INFOID:0000000007838717

FL

G
JSBIA1013GB

1. Priming bulb 2. Fuel filter

H
Removal and Installation INFOID:0000000007838718

REMOVAL I
1. Remove quick connectors in the following procedures.
• Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand. J
• If quick connector and tube on vehicle are stuck, push and pull
several times until they move, and pull out.
K

L
JSBIA1014ZZ

2. Remove fuel filter from fuel filter bracket. M

CAUTION:
Never spill the fuel during removal. If the fuel is spill, immediately wipe it off. Be especially careful
to prevent the fuel from adhering to the insulators of the engine mounts.
N
Water Draining INFOID:0000000007838719

DRAINING WATER O
CAUTION:
Before carrying out any work, wait for the fuel temperature is dropped.
P

Revision: 2012 July FL-21 N17

 FUEL FILTER
< PERIODIC MAINTENANCE > [K9K]
Open water in fuel sensor (1) at the bottom of fuel filter.

JSBIA1015ZZ

Air Bleeding INFOID:0000000007838720

1. Prime the circuit using the priming bulb (1).

2. Perform engine cranking with repeating several times until
engine starting.

JSBIA1016ZZ

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

a. Remove quick connector (1).

JSBIA1017ZZ

b. Connect drain hose (suitable hose) (1).

c. Place a tray at the drain hose open end.
d. 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.

JSBIA1018ZZ

Revision: 2012 July FL-22 N17

 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [K9K]

REMOVAL AND INSTALLATION A

FUEL LEVEL SENSOR UNIT
Exploded View INFOID:0000000007838721
FL

REMOVAL
C

H
JPBIA4501GB

1. Lock ring 2. Fuel level sensor unit 3. O-ring

4. Fuel tank I

: Always replace after every disassembly.

DISASSEMBLY J

JSBIA0989ZZ O

1. Fuel gauge 2. Fuel level sensor unit

Removal and Installation INFOID:0000000007838722

P

WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-18, "General Precautions".
REMOVAL
1. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-
ate amount of fuel from the fuel tank.

Revision: 2012 July FL-23 N17

 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [K9K]

Guideline : Draw approximately 10 liters (2-2/8 Imp gal) from a full-tank

condition.
• In the event of malfunction in fuel pump, insert a hose measuring 20mm (0.79 in) in diameter into the
filler opening to draw approximately 10 liters (2-2/8 Imp gal) fuel.
2. Open fuel filler lid.
3. Open filler cap and release the pressure inside fuel tank.
4. Remove rear seat. Refer to SE-24, "Exploded View".
5. Remove inspection hole cover.
6. Disconnect harness connector (1), fuel feed tube (4).

2 : Fuel level sensor unit

3 : Quick connector
: Vehicle front

JSBIA0990ZZ

• Remove quick connector in the following procedures.

- Hold the sides of quick connector, press tabs and pull out fuel
feed tube.

A : Pull
B : Push in tabs
- 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.

JPBIA0134ZZ

CAUTION:

Revision: 2012 July FL-24 N17

 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [K9K]
• Quick connector (1) can be disconnected when the tabs
(F) are depressed completely. Never twist it more than A
necessary.

B : Connection (cross-section)
FL
D : To under floor fuel line
E : To fuel tank
G : Disconnection
C
• Never use any tools to disconnected quick connector.
• Keep resin tube (C) away from heat. Be especially careful
when welding near the resin tube.
D
• Prevent acid liquid such as battery electrolyte, etc. from
getting on resin tube.
• Never bend or twist resin tube during installation and dis-
connection. E
• Never remove the remaining retainer (2) on hard tube (or
the equivalent) (A) except when resin tube or retainer is
replaced. F
• When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with new one.

Retainer color : Blue G

JPBIA0130ZZ

• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely with H
plastic bags (A) or something similar.

JPBIA0135ZZ
K
7. Use lock ring wrench [SST: KV10119901] (A) to remove lock
ring.
CAUTION: L
• 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
M
spinner handle [handle length: 60cm (23.62in) or more]
and slowly turn it counterclockwise.
NOTE:
For reference when installing, put a matching mark on lock ring, N
fuel pump assembly and fuel tank.
JSBIA1633ZZ

8. Remove fuel level sensor unit (1). O

CAUTION:
• Never bend float arm (2) during removal.
• Never pollute the inside by residue fuel. Draw out avoid-
P
ing inclination by supporting with a cloth.
• Never cause impacts such by dropping when handling
components.

JSBIA0991ZZ

Revision: 2012 July FL-25 N17

 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [K9K]
INSTALLATION
Note to the following, and install in the reverse order of removal.
CAUTION:
Do not reuse O-ring
Fuel Level Sensor Unit
1. Install O-ring to fuel tank without any twist.
CAUTION:
Do not reuse O-ring
2. Install the fuel gauge on the fuel tank with the fuel gauge top sur-
fase (A) fased the rear of the vehicle.

: Vehicle front

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

JSBIA0992ZZ

3. Install lock ring for fuel level sensor unit with lock ring wrench [SST: KV10119901] 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.

JPBIA3559ZZ

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 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.

JPBIA0140ZZ

Disassembly and Assembly INFOID:0000000007838723

DISASSEMBLY

Revision: 2012 July FL-26 N17

 FUEL LEVEL SENSOR UNIT
< REMOVAL AND INSTALLATION > [K9K]
1. Disconnect harness connector (A).
A

FL

JSBIA0993ZZ

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

G
JSBIA0994ZZ

3. To remove the fuel gauge (1) , slide it in the direction (A) of the
H
arrow with the lock released.

JSBIA0995ZZ
K

ASSEMBLY
1. Check for damage of fuel level sensor unit installation position on the side of fuel filter and fuel level sen- L
sor unit assembly.
2. 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. M
3. Connect harness connector.
Inspection INFOID:0000000007838724

N
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- O
sure to fuel piping.
2. Start engine and let it idle and check there are no fuel leakage at the fuel system connections.
P

Revision: 2012 July FL-27 N17

 FUEL TANK
< REMOVAL AND INSTALLATION > [K9K]
FUEL TANK
Exploded View INFOID:0000000007838725

JPBIA3365GB

1. Fuel tank 2. Fuel tank mounting band (RH) 3. Fuel tank mounting band (LH)
4. Clamp 5. Fuel filler hose 6. Fuel filler tube
7. Grommet 8. Fuel filler cap 9. Clamp
10. Vent hose

: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000007838726

WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-18, "General Pre-
cautions".
REMOVAL
• Drain fuel from fuel tank if necessary. Refer to FL-23, "Removal and Installation".
• Perform work on level place.
1. Perform steps 2 to 7 of “REMOVAL” in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP
ASSEMBLY” on fuel level sensor unit. Refer to FL-23, "Removal and Installation".
2. Remove center tube. Refer to EX-11, "Exploded View".
3. Remove insulator on vehicle side located above center tube and main mufflers.

Revision: 2012 July FL-28 N17

 FUEL TANK
< REMOVAL AND INSTALLATION > [K9K]
4. Disconnect fuel filler hose at fuel filler tube side.
A
1 : Filler tube
2 : Filler hose
3 : Vent hose FL
5. Remove vent hose from fuel tank side.

JPBIA3423ZZ

D
6. Support the center part of fuel tank (1) with transmission jack
(A).
E

G
JPBIA3424ZZ

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

H
8. 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. I

INSTALLATION
Note the following, and install in the reverse order of removal. J
Fuel Filler Hose
• Surely clamp fuel hose insert fuel filler hose to the length below.
K
Fuel filler hose : 35 mm (1.38 in)
The other hose : 25 mm (0.98 in)
• Be sure hose clamp is not placed on swelled area of fuel filler tube. L
• Install fuel filler hose to fuel tank, paying attention to install mark.
• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.
M
Fuel tank side hose clamp : 7 - 11 mm (0.28 - 0.43 in)
Fuel filler tube side hose clamp : 8 - 12mm (0.31 - 0.47 in)
N
Inspection INFOID:0000000007838727

INSPECTION AFTER INSTALLATION O

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

Revision: 2012 July FL-29 N17

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank INFOID:0000000007838728

Standard and Limit

Fuel tank capacity Approx. 41.0 (9.0 Imp gal)

Fuel recommendation Refer to GI-27, "Fuel"

Revision: 2012 July FL-30 N17