ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
HR16DE, MR20DE 4WD : Exploded View ..............................................17 F
4WD : Removal and Installation ..............................17
PRECAUTION ............................................... 3 4WD : Inspection .....................................................19
G
PRECAUTIONS ................................................... 3 SERVICE DATA AND SPECIFICATIONS
General Precautions ................................................. 3 (SDS) ............................................................ 20
PREPARATION ............................................ 4 SERVICE DATA AND SPECIFICATIONS H
(SDS) ................................................................. 20
PREPARATION ................................................... 4
Fuel Tank .................................................................20
Commercial Service Tools ........................................ 4
K9K I
ON-VEHICLE MAINTENANCE ..................... 5
PREPARATION ........................................... 21
FUEL SYSTEM .................................................... 5 J
Inspection .................................................................. 5 PREPARATION ................................................. 21
Quick Connector ....................................................... 5 Special Service Tools ..............................................21

ON-VEHICLE REPAIR .................................. 6 ON-VEHICLE MAINTENANCE .................... 22 K

FUEL LEVEL SENSOR UNIT, FUEL FILTER FUEL SYSTEM .................................................. 22

AND FUEL PUMP ASSEMBLY .......................... 6 Inspection ................................................................22
L
2WD ............................................................................. 6 FUEL FILTER .................................................... 23
2WD : Exploded View ............................................... 6 Exploded View .........................................................23
2WD : Removal and Installation ................................ 7 Replacement ...........................................................23 M
2WD : Disassembly and Assembly ........................... 9 Water Draining .........................................................23
2WD : Inspection ..................................................... 10 Air Bleeding .............................................................23
Inspection ................................................................24
N
4WD ........................................................................... 10
4WD : Exploded View ............................................. 10 ON-VEHICLE REPAIR ................................. 25
4WD : Removal and Installation .............................. 11
4WD : Disassembly and Assembly ......................... 14
FUEL LEVEL SENSOR UNIT ........................... 25 O
Exploded View .........................................................25
4WD : Inspection ..................................................... 14
Removal and Installation .........................................25
FUEL TANK ........................................................15 P
FUEL TANK ...................................................... 27
2WD ........................................................................... 15 Exploded View .........................................................27
2WD : Exploded View ............................................. 15 Removal and Installation .........................................27
2WD : Removal and Installation .............................. 15 Inspection ................................................................29
2WD : Inspection ..................................................... 16
SERVICE DATA AND SPECIFICATIONS
4WD ........................................................................... 17 (SDS) ............................................................ 30

FL-1
SERVICE DATA AND SPECIFICATIONS Fuel Tank ................................................................ 30
(SDS) .................................................................. 30

FL-2
 PRECAUTIONS
< PRECAUTION > [HR16DE, MR20DE]

PRECAUTION A
PRECAUTIONS
General Precautions INFOID:0000000000905647
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-32, "FUEL : Unleaded Pre-
mium Gasoline".
• Before removing fuel line parts, perform out the following procedures: E
- 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-357, "Inspection" (HR16DE) or EC-978,
"Inspection" (MR20DE). F
- 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. G
• Never tighten hose clamps excessively to avoid damaging hoses.
• After installing tubes, make sure 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 leaks at connections. H
- Start engine and rev it up and check for fuel leaks 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. I
• For servicing “Evaporative Emission System” parts. Refer to EC-74, "System Diagram" (HR16DE) or
EC-692, "System Diagram" (MR20DE).
• For servicing “On Board Refueling Vapor Recovery (ORVR)” parts. Refer to EC-87, "Diagnosis
Description" (HR16DE) or EC-706, "Diagnosis Description" (MR20DE). J

FL-3
 PREPARATION
< PREPARATION > [HR16DE, MR20DE]

PREPARATION
PREPARATION
Commercial Service Tools INFOID:0000000000905648

Tool name Description

Lock ring wrench Removing and Installing lock ring

ZZA0122D

FL-4
 FUEL SYSTEM
< ON-VEHICLE MAINTENANCE > [HR16DE, MR20DE]

ON-VEHICLE MAINTENANCE A
FUEL SYSTEM
Inspection INFOID:0000000000905649
FL
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration. C
If necessary, repair or replace damaged parts.

A : Engine D
B : Fuel line
C : Fuel tank
E

JPBIA0129ZZ

Quick Connector INFOID:0000000000905650 F

CAUTION:
• After connecting fuel tube quick connectors, make sure quick connectors are secure. G
• Ensure that connector and resin tube do not contact any adjacent parts.

FL-5
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]

ON-VEHICLE REPAIR
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
2WD
2WD : Exploded View INFOID:0000000000905651

Removal and Installation

JPBIA0300GB

Fuel level sensor unit, fuel filter and fuel pump

1. Lock ring 2. 3. O-ring
assembly
4. Fuel tank
: Vehicle front
Refer to GI-4, "Components" for symbols in the figure.

Disassembly and Assembly

FL-6
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]

FL

JPBIA0299GB F

1. Fuel filter and fuel pump assembly 2. Fuel level sensor unit
:Vehicle front
G
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
H
2WD : Removal and Installation INFOID:0000000000905652

REMOVAL I
WARNING:
Be sure to read “General Precautions” before working on the fuel system. Refer to FL-3, "General Pre-
cautions".
J
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. K
NOTE:
Because fuel will be spilled when removing fuel level sensor
unit, fuel filter and fuel pump assembly for the top of the fuel is L
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 15 (3- 1/4 Imp gal) of
fuel are drained from fuel tank. M
JPBIA0459ZZ
• In case fuel pump does not operate, perform the following pro-
cedure.
a. Insert hose of less than 20 mm (0.79 in) in diameter into fuel filler tube through fuel filler opening to draw N
fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-15, "2WD : Exploded View".
c. Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank. O
2. Release the fuel pressure from the fuel lines. Refer to EC-357, "Inspection" (HR16DE) or EC-978,
"Inspection" (MR20DE).
3. Open fuel filler lid. P
4. Open fuel filler cap and release the pressure inside the fuel tank.
5. Remove rear seat cushion. Refer to SE-30, "Exploded View".
6. Remove inspection hole cover.
• Using a screwdriver, remove it by turning clips clockwise by 90 degrees.

FL-7
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
7. Disconnect harness connector (A) and quick connector (B).

: Vehicle front

JPBIA0457ZZ

• Remove quick connector in the following procedures.

- Pinch quick connector square-part (A) with your fingers, and
pull out the quick connector 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
completely depressed. Never twist it more than neces-
sary.
• Never use any tools to disconnect quick connector.
• Keep resin tube away from heat. Be especially careful
when welding near the resin tube.
PBIC3779E
• 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 or something similar.
• Never insert plug, preventing damage on o-ring in quick
connector.

PBIC0713E

8. Using lock ring wrench (commercial service tool), remove lock

ring.
NOTE:
For reference when installing, put a matching mark on lock ring,
fuel pump assembly and fuel tank.

PBIC0240E

9. Remove fuel level sensor unit, fuel filter and fuel pump assembly.
CAUTION:
• Never bend float arm during removal.
• Avoid polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with
a cloth.
• Avoid impacts such as falling when handling components.
INSTALLATION
Note the following, and install in the reverse order of removal.

FL-8
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Install O-ring to fuel tank without any twist. A
2. Install fuel level sensor unit with aligning matching mark (A) on
fuel level sensor unit and (B) on fuel tank as shown in the figure.
FL
: Vehicle front

D
JPBIA0555ZZ

Quick Connector E
Connect quick connector of fuel feed tube in the following procedures.
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 F
heard.
3. After connecting, make sure that the connection is secure by following procedures.
• Visually confirm that the two tabs are connected to the connector. G
• Pull the tube and the connector to make sure they are securely
connected.
H

J
PBIC1653E

4. Connect harness connector.

K
Inspection Hole Cover
• Before installing inspection hole cover, check that the connecting part has no fuel leaks. Refer to FL-10,
"2WD : Inspection".
L
1. Install inspection hole covers with the front mark (arrow) facing front of vehicle.
2. Lock clips by turning counterclockwise.
2WD : Disassembly and Assembly INFOID:0000000000905664 M

DISASSEMBLY
1. Disconnect harness connector. N
2. Remove fuel level sensor unit (1) in the following procedures.
a. Push the pawl of fuel level sensor unit mounting area with an L-
shaped iron rod or an equivalent to unlock. O
CAUTION:
Be careful not to damage fuel level sensor unit.
b. With the fuel level sensor unit unlocked, slide it in the direction P
shown by the arrow ( ).

PBIC4900J

ASSEMBLY

FL-9
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
Install fuel level sensor unit according to the following procedure.
• Insert until you hear a “click” sound and actually feel the engagement.
• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.
2WD : Inspection INFOID:0000000000905653

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:0000000001078679

Removal and Installation

JPBIA0297GB

Fuel level sensor unit, fuel filter and fuel pump

1. Lock ring 2. 3. O-ring
assembly
4. Sub fuel level sensor assembly
:Vehicle front
Refer to GI-4, "Components" for symbols in the figure.

Disassembly and Assembly

FL-10
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]

FL

JPBIA0301GB F

1. Fuel filter and fuel pump assembly 2. Fuel level sensor unit 3. Sub fuel level sensor base
4. Sub fuel level sensor unit
G
: Vehicle front

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

4WD : Removal and Installation INFOID:0000000001078680

I
REMOVAL
WARNING:
Be sure to read “General Precautions” before working on the fuel system. Refer to FL-3, "General Pre- J
cautions".
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
K
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 L
unit, fuel filter and fuel pump assembly 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 M
figure or below when approximately 15 (3- 1/4 Imp gal) of
fuel are drained from fuel tank. JPBIA0459ZZ
• In case fuel pump does not operate, perform the following pro-
cedure. N
a. Insert hose of less than 20 mm (0.79 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-17, "4WD : Exploded View". O
c. Insert hose into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-978, "Inspection".
P
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside the fuel tank.
5. Remove rear seat cushion. Refer to SE-30, "Exploded View".
6. Remove inspection hole cover.
• Using a screwdriver, remove it by turning clips clockwise by 90 degrees.

FL-11
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
7. Disconnect harness connector (A) and quick connector (B).

: Vehicle front

JPBIA0457ZZ

• Remove quick connector in the following procedures.

- Pinch quick connector square-part (A) with your fingers, and
pull out the quick connector 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
completely depressed. Never twist it more than neces-
sary.
• Never use any tools to disconnect quick connector.
• Keep resin tube away from heat. Be especially careful
when welding near the resin tube.
PBIC3779E
• 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 or something similar.
• Never insert plug, preventing damage on o-ring in quick
connector.

PBIC0713E

8. Using lock ring wrench (commercial service tool), remove lock

ring.
NOTE:
For reference when installing, put a matching mark on lock ring,
fuel pump assembly and fuel tank.

PBIC0240E

FL-12
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
9. Raise fuel level sensor unit, fuel filter and fuel pump assembly
(1), and disconnect fuel tube and harness connector. A
CAUTION:
• Never bend float arm during removal.
• Avoid polluting the inside by residue fuel. Draw out with
FL
avoiding inclination by supporting with a cloth.
• Avoid impacts such as falling when handling compo-
nents.
C

PBIC3780E

D
10. Raise sub fuel level sensor assembly.
CAUTION:
• Never disassembly a fuel tube from sub fuel sensor assembly.
E
• Never bend float arm during removal.
• Avoid polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with
a cloth.
• Avoid impacts such as falling when handling components. F
INSTALLATION
Note the following, and install in the reverse order of removal.
G
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly and Sub Fuel Level Sensor Assembly
1. Install O-ring to fuel tank without any twist.
2. Install fuel level sensor unit with aligning mating marks (A) on H
fuel level sensor unit and (B) on fuel tank as shown in the figure.

: Vehicle front
I
NOTE:
Figure shows fuel level sensor unit, fuel filter and fuel pump
assembly side of fuel tank. J

JPBIA0555ZZ K
Quick Connector
Connect quick connector of fuel feed tube in the following procedures.
1. Check the connection for damage or any foreign materials. L
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, make sure that the connection is secure by following procedures.
• Visually confirm that the two tabs are connected to the connector.
• Pull the tube and the connector to make sure they are securely
connected. N

PBIC1653E

4. Connect harness connector.

Inspection Hole Cover

FL-13
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
• Before installing inspection hole cover, check that the connecting part has no fuel leaks. Refer to FL-14,
"4WD : Inspection".
1. Install inspection hole covers with the front mark (arrow) facing front of vehicle.
2. Lock clips by turning counterclockwise.
4WD : Disassembly and Assembly INFOID:0000000001078681

DISASSEMBLY
Fuel level sensor unit, fuel filter and fuel pump assembly side
1. Disconnect harness connector.
2. Remove fuel level sensor unit (1) in the following procedures.
a. Push the pawl of fuel level sensor unit mounting area with an L-
shaped iron rod or an equivalent to unlock.
CAUTION:
Be careful not to damage fuel level sensor unit.
b. With the fuel level sensor unit unlocked, slide it in the direction
shown by the arrow ( ).

PBIC4900J

Sub fuel level sensor unit assembly side

• Remove fuel level sensor unit (1) in the following procedures.
- Push the pawl of sub fuel level sensor unit mounting area with an
L-shaped iron rod or an equivalent to unlock.
CAUTION:
Be careful not to damage sub fuel level sensor unit.
- With the sub fuel level sensor unit unlocked, slide it in the direction
shown by the arrow ( ).

JPBIA0458ZZ

ASSEMBLY
Install fuel level sensor unit according to the following procedure.
• Insert until you hear a “click” sound and actually feel the engagement.
• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.
4WD : Inspection INFOID:0000000001078682

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.

FL-14
 FUEL TANK
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
FUEL TANK
A
2WD
2WD : Exploded View INFOID:0000000000905654
FL
2WD
C

K
JPBIA0298GB

1. Fuel filler cap 2. Grommet 3. Fuel filler tube L

4. Cover 5. Clamp 6. Fuel filler hose
7. Clamp 8. Fuel tank band (RH) 9. Fuel tank band (LH)
10. Protector 11. Fuel tank 12. Vent hose M
Refer to GI-4, "Components" for to symbols in the figure.

2WD : Removal and Installation INFOID:0000000000905655

N
REMOVAL
WARNING:
O
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "General Pre-
cautions".
1. Perform the steps 2 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”. Refer to FL-7, "2WD : Removal and Installation". P
2. Drain fuel from fuel tank if necessary. Refer to FL-7, "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.
3. Remove main muffler. Refer to EX-5, "Exploded View" (HR16DE) or EX-10, "Exploded View" (MR20DE).

FL-15
 FUEL TANK
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
4. Remove protector from fuel tank.
5. Remove vent hose (1) at rear side of fuel tank.

: Vehicle front

6. Disconnect EVAP tube (2) at rear side of fuel tank.

• Instruction for quick connector (A) of EVAP tube. Refer to FL-
6, "2WD : Exploded View"
7. Remove fuel filler hose (3) at fuel filler tube side.

JPBIA0456ZZ

8. Support center of fuel tank (1) with transmission jack (A).

CAUTION:
Securely support the fuel tank with a piece of wood (B).

PBIC3792E

9. Remove fuel tank band (RH and LH).

10. 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
• Insert fuel filler hose to the length below.

: 35 mm (1.38 in)
• 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.

Fuel filler tube side : 7 - 11 mm (0.28 - 0.43 in)

Fuel tank side : 5 - 9 mm (0.20 - 0.35 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.
3. After connecting, pull out quick connector and centralized under-
floor piping by hand. Make sure connections are secure.

PBIC1653E

2WD : Inspection INFOID:0000000000905656

FL-16
 FUEL TANK
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks. A
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 make sure there are no fuel leaks at the fuel system tube and hose connec- FL
tions.
4WD
C
4WD : Exploded View INFOID:0000000001078683

4WD D

JPBIA0302GB
M
1. Fuel filler cap 2. Grommet 3. Fuel filler tube
4. Cover 5. Clamp 6. Fuel filler hose
7. Clamp 8. Fuel tank band (RH) 9. Fuel tank band (LH)
N
10. Protector 11. Fuel tank 12. Vent hose
Refer to GI-4, "Components" for to symbols in the figure.
O
4WD : Removal and Installation INFOID:0000000001078684

REMOVAL P
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "General Pre-
cautions".
1. 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".
2. Drain fuel from fuel tank if necessary. Refer to FL-11, "4WD : Removal and Installation".

FL-17
 FUEL TANK
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
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.
3. Remove propeller shaft. Refer to DLN-110, "Exploded View".
4. Remove main muffler. Refer to EX-10, "Exploded View".
5. Remove protector from fuel tank.
6. Remove vent hose (1) at rear side of fuel tank.

: Vehicle front

7. Disconnect EVAP tube (2) at rear side of fuel tank.

• Instruction for quick connector (A) of EVAP tube. Refer to FL-
10, "4WD : Exploded View"
8. Remove fuel filler hose (3) at fuel filler tube side.

JPBIA0456ZZ

9. Support center of fuel tank (1) with transmission jack (A).

CAUTION:
Securely support the fuel tank with a piece of wood (B).

PBIC3792E

10. Remove fuel tank band (RH and LH).

11. 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
• Insert fuel filler hose to the length below.

: 35 mm (1.38 in)
• 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.

Fuel filler tube side : 7 - 11 mm (0.28 - 0.43 in)

Fuel tank side : 5 - 9 mm (0.20 - 0.35 in)
EVAP Hose

FL-18
 FUEL TANK
< ON-VEHICLE REPAIR > [HR16DE, MR20DE]
1. Check connections for damage or foreign material.
2. Align the matching side connection part with the center of shaft, A
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. FL

PBIC1653E

D
4WD : Inspection INFOID:0000000001078685

INSPECTION AFTER INSTALLATION E

Use the following procedure to check for fuel leaks.
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 make sure there are no fuel leaks at the fuel system tube and hose connec-
tions.
G

FL-19
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE, MR20DE]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank INFOID:0000000000905660

Standard and Limit

Fuel tank capacity Approximate 65 (14-1/2 Imp gal)

Fuel recommendation Refer to GI-32

FL-20
 PREPARATION
< PREPARATION > [K9K]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001062547
FL

Tool number
(RENAULT tool number) Description C
Tool name
KV993G0010 Removing and Installing lock ring
(Mot. 1397) D
Lock ring wrench

PBIC1627E

FL-21
 FUEL SYSTEM
< ON-VEHICLE MAINTENANCE > [K9K]

ON-VEHICLE MAINTENANCE
FUEL SYSTEM
Inspection INFOID:0000000001062535

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

SMA803A

FL-22
 FUEL FILTER
< ON-VEHICLE MAINTENANCE > [K9K]
FUEL FILTER
A
Exploded View INFOID:0000000001062549

FL

G
E1BIA0030ZZ

1. Fuel filter 2. Fuel filter bracket 3. Fuel filter protector

H
Replacement INFOID:0000000001062550

1. Remove priming bulb from priming bulb bracket. I

2. Remove fuel filter from fuel filter bracket.
3. Remove quick connectors as above.
CAUTION: J
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.
4. Install in the reverse order of removal. K
• After installation, operate the priming bulb vertically, if it is possible, to perform air bleeding.
Refer to FL-23, "Air Bleeding".
CAUTION:
Do not bend or twist the tube during installation and removal. L

Water Draining INFOID:0000000001062551

M
Open drain valve (1) 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. N

P
E1BIA0032ZZ

Air Bleeding INFOID:0000000001062552

FL-23
 FUEL FILTER
< ON-VEHICLE MAINTENANCE > [K9K]
1. Prime the circuit using the priming bulb (1).
2. Perform engine cranking with repeating several times until
engine starting.

E1BIA0031ZZ

3. If the engine does not start, use a flat bladed screwdriver to lift
up the button on the fuel return pipe and perform engine crank-
ing.
4. When the bleeding is completed, push the button, and check
absence of leakage.
: Bleeding position
: Normal position

MBIB9038E

Inspection INFOID:0000000001062561

INSPECTION AFTER REPLACEMENT

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

FL-24
 FUEL LEVEL SENSOR UNIT
< ON-VEHICLE REPAIR > [K9K]

ON-VEHICLE REPAIR A
FUEL LEVEL SENSOR UNIT
Exploded View INFOID:0000000001062537
FL

E1BIA0015GB
H
1. Rock ring 2. Fuel level sensor unit 3. Seal packing
A. To fuel tank
Refer to GI-4, "Components" for symbols not described on the above. I

Removal and Installation INFOID:0000000001062569

J
REMOVAL
1. Disconnect battery ground cable.
2. Open fuel filler lid and filler cap to release the pressure inside the fuel tank. K
3. Remove rear seat cushion. Refer to SE-31, "Removal and Installation".
4. Remove inspection hole cover under the rear seat.
5. Disconnect electrical connector. L
6. Disconnect the quick connectors.
• Hold the connector while pushing in tabs, and pull out the
tube. M

O
MBIB1052E

FL-25
 FUEL LEVEL SENSOR UNIT
< ON-VEHICLE REPAIR > [K9K]

JFE628A

CAUTION:
• The tube can be removed when the tabs are completely depressed. Do not twist it more than
necessary.
• Do not use any tools to remove the quick connector.
• Keep the resin tube away from heat. Be especially careful when welding near the tube.
• Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
• Do not bend or twist the tube during installation and removal.
• Only when the tube is replaced, remove the remaining retainer.
• When the tube is replaced, also replace the retainer with a new one.
7. Using lock ring wrench [SST: KV993G0010], remove lock ring
(2).
CAUTION:
Rotate SST while pressing fuel level sensor unit as spring
reaction force is applied from fuel tank inside to up ward.
8. Remove fuel level sensor unit(1).
CAUTION:
• Be careful not to bend the float arm when removing.
• Handle them carefully without subjecting them to impacts
such as dropping.
E1BIA0033ZZ

INSTALLATION
Install in the reverse order of removal.

FL-26
 FUEL TANK
< ON-VEHICLE REPAIR > [K9K]
FUEL TANK
A
Exploded View INFOID:0000000001062540

FL

I
E1BIA0014GB

1. Fuel filler tube protector 2. Fuel filler cap 3. Fuel filler cap protector J
4. Fuel filler tube 5. Clamp 6. Fuel filler hose
7. Clamp 8. Fuel tank 9. Fuel tank mounting band
10. Fuel tank protector 11. Vent hose K
Refer to GI-4, "Components" for symbols not described on the above.

Removal and Installation INFOID:0000000001062571

L

REMOVAL
1. Remove RH rear wheel. M
2. Remove fuel level sensor unit. Refer to FL-25, "Removal and Installation".
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unsta-
N
ble, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank
can be held by hand even if the balance is lost.
3. Remove muffler. Refer to EX-15, "Removal and Installation".
O
4. Remove vehicle side insulator on upper center muffler and main muffler.
5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.
P

FL-27
 FUEL TANK
< ON-VEHICLE REPAIR > [K9K]
6. Disconnect fuel filler hose on fuel tank side.
CAUTION:
Do not remove fuel filler hose at fuel filler tube side, pre-
venting to interfere with suspension due to dislocation
when installing. When removing at fuel filler tube side nec-
essarily, put mating marks, and remove.

PBIC1505E

7. Remove vent hose at RH rear wheelwell side.

8. Remove EVAP hose at front side of fuel tank.

PBIC1507E

• Remove quick connector 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.
CAUTION:
• The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
• Do not use any tools to remove the quick connector.
• Keep the resin tube away from heat. Be especially care-
ful when welding near the tube.
PBIC1509E
• Prevent acid liquid such as battery electrolyte etc. from
getting on the resin tube.
• Do not bend or twist the tube during installation and removal.
• To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic bags
or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC0713E

FL-28
 FUEL TANK
< ON-VEHICLE REPAIR > [K9K]
9. Support center of fuel tank with suitable transmission jack.
CAUTION: A
Securely support the fuel tank with a piece of wood.
10. Remove RH/LH mounting band.
11. Lower suitable transmission jack carefully to remove fuel tank FL
while holding it by hand. Perform the following works at the
same time.
• Pull out vent hose from through hole of vehicle.
C
• Avoid interference with tank by pulling parking brake cable by
hand.
CAUTION: PBIC1508E

Tank may be in an unstable condition because of the shape D

of fuel tank bottom. Do not rely on jack too much. Be sure to hold tank securely.
INSTALLATION
Install in the reverse order of removal which being careful of the following. E

Installation of Fuel Tank Mounting Band

• Install it by referring to the identification stamp mark “R” and “L” on the end.
F
Installation of fuel Filler Hose
• Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp.
• When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube.
G
• Tighten the clamp of filler hose to a torque of 2.5 N·m (0.26 kg-m, 22 in-lb).
Installation of EVAP Hose
• Connect quick connector in the following procedures. H
1. Check connections for damage or foreign material.
2. Align the mating side connection part with the center of shaft,
and insert connector straight until it clicks. I
3. After connecting, pull out quick connector by hand. Make sure
connections are secure.
J

PBIC1509E K
Installation of Vent Hose
• Push vent hose into through hole of vehicle.
• Insert vent hose into vent rubber hose, and secure it with clamp. L
Inspection INFOID:0000000001062542

INSPECTION AFTER INSTALLATION M

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.
N

FL-29
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank INFOID:0000000001062546

Fuel tank capacity Approx. 65 (14-1/4 Imp gal)

FL-30