FUEL SYSTEM

B ENGINE

SECTION
FUEL SYSTEM
FL FL

E
CONTENTS
CR FUEL TANK .............................................................. 18 F
Removal and Installation ........................................ 18
PREPARATION ........................................................... 2 REMOVAL ........................................................... 18
Special Service Tools ............................................... 2 INSTALLATION ................................................... 20 G
FUEL SYSTEM ........................................................... 3 INSPECTION AFTER INSTALLATION ................ 20
Checking Fuel Lines ................................................. 3 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 21
General Precautions ................................................ 3 Standard and Limit .................................................. 21
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND H
Tightening Torque ................................................... 21
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
K9K
I
INSTALLATION ..................................................... 6 PREPARATION ......................................................... 22
INSPECTION AFTER INSTALLATION ................. 7 Special Service Tool ............................................... 22
FUEL TANK ................................................................ 8 FUEL SYSTEM ......................................................... 23 J
Removal and Installation .......................................... 8 Checking Fuel Lines ............................................... 23
REMOVAL ............................................................. 8 FUEL FILTER ............................................................ 24
INSTALLATION ................................................... 10 Removal and Installation ........................................ 24
INSPECTION AFTER INSTALLATION ............... 10 K
Water Draining from Fuel Filter .............................. 24
SERVICE DATA AND SPECIFICATIONS (SDS) .......11 DRAINING WATER (RHD) .................................. 24
Standard and Limit ..................................................11 DRAINING WATER (LHD) ................................... 25
Tightening Torque ....................................................11 FUEL FILTER CHECK ......................................... 25 L
Changing Fuel Filter ............................................... 25
HR REMOVAL (RHD) ................................................ 25
REMOVAL (LHD) ................................................. 25 M
PREPARATION ......................................................... 12 INSTALLATION ................................................... 25
Special Service Tools ............................................. 12 Bleeding Fuel Filter ................................................. 26
FUEL SYSTEM ......................................................... 13 FUEL LEVEL SENSOR UNIT ................................... 27
Checking Fuel Lines ............................................... 13 Removal and Installation ........................................ 27
General Precautions .............................................. 13 REMOVAL ........................................................... 27
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND INSTALLATION ................................................... 28
FUEL PUMP ASSEMBLY ......................................... 14 FUEL TANK .............................................................. 29
Removal and Installation ........................................ 14 Removal and Installation ........................................ 29
REMOVAL ........................................................... 14 REMOVAL ........................................................... 29
INSTALLATION ................................................... 16 INSTALLATION ................................................... 30
INSPECTION AFTER INSTALLATION ............... 17 INSPECTION AFTER INSTALLATION ................ 31

FL-1
 PREPARATION
[CR]
PREPARATION
[CR] PFP:00002

Special Service Tools EBS00OJ5

Tool number
(RENAULT tool number) Description
Tool name

KV993G0010 Removing and Installing lock ring

(Mot. 1397)
Lock ring wrench

PBIC1627E

FL-2
 FUEL SYSTEM
[CR]
FUEL SYSTEM PFP:17503
A
Checking Fuel Lines EBS00OJM

Inspect fuel lines, fuel filler cap and tank for improper attachment,
leaks, cracks, damage, loose connections, chafing or deterioration. FL
If necessary, repair or replace faulty parts.

SMA803A

E
General Precautions EBS00OJN

WARNING:
when replacing fuel line parts, be sure to observe the following.
F
● Put a “CAUTION: IN FLAMMABLE” sign in workshop.
● Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
● Do not smoke while servicing fuel system, keep open flames and spark away from work area. G
CAUTION:
● Use gasoline required by the regulation for octane number. Refer to GI-5, "Precautions for Fuel"
● Before removing fuel line parts, carry out the following procedures. H
– Put drained fuel in an explosion-proof container and put the lid on securely, keep the container in
safe area.
– Release fuel pressure from fuel line. Refer to EC-51, "FUEL PRESSURE RELEASE" (with EURO- I
OBD), refer to EC-482, "FUEL PRESSURE RELEASE" (without EURO-OBD).
– Disconnect battery negtive cable.
● Always replace O-ring and clamps with new ones. J
● Do not tighten hose clamps excessively to avoid damaging hoses.
● Do not kink or twist tubes when they are being installed.
● Perform work on level place. K
● Do not tighten hose clamps excessively to avoid damaging hoses.
Tighten high-pressure rubber hose clamp so that clamp
end is 3 mm (0.12 in) from hose end. L
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts. M
● After installing tubes, run engine and check for fuel leaks at
connections.
● For servicing “Evaporative Emission System” parts, refer to
EC-444, "EVAPORATIVE EMISSION SYSTEM" (with EURO-
OBD), EC-796, "EVAPORATIVE EMISSION SYSTEM" (with-
out EURO-OBD). MMA104A

FL-3
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY PFP:17042

Removal and Installation EBS00OJH

MBIB1354E

1. Lock ring 2. Fuel filter and fuel pump assembly 3. Fuel level sensor unit
4. O-ring 5. Fuel tank

REMOVAL
WARNING:
Read “General Precautions” before working on the fuel system.
Refer to FL-3, "General Precautions" .
1. Check fuel level. If gauge indicates more than the level shown in
figure (full or almost full), drain fuel from fuel tank until gauge
indicates the level in figure or below.
When fuel pump malfunctions, insert hose with outer diameter of
25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler
tube. Disconnect connections of fuel filler tube and fuel filler
hose to drain fuel from fuel filler hose.
● As guide, fuel amount becomes the level shown in figure or
below when approximately 7 liter (1-1/2 lmp gal) of fuel are
drained from full.
NOTE: PBIC1495E

Adjusting fuel level is to prevent fuel from spilling, when fuel

level sensor unit, fuel filter and fuel pump assembly are removed.
2. Release fuel pressure. Refer to EC-51, "Fuel Pressure Check" (with EURO-OBD), EC-482, "Fuel Pres-
sure Check" (without EURO-OBD).
a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump
assembly.
b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line.
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove rear seat. Refer to SE-15, "REAR SEAT" .
6. Remove inspection hole cover.
● Using a screwdriver, remove it by turning clips clockwise by 90°.

FL-4
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
7. Remove harness connector and fuel feed hose from sender unit.
NOTE: A
● Connections of harness connector and fuel feed hose are
called sender unit.
FL

PBIC1496E

D
● Remove quick connector in the following procedures.
– Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand. E
– If quick connector and tube on sender unit are stuck, push
and pull several times until they move, and pull out.
CAUTION: F
● 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. G
● Keep the resin tube away from heat. Be especially PBIC1497E
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. H
● 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 I
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick J
connector.

PBIC0713E
L
8. Using lock ring wrench [SST: KV993G0010], remove lock ring.
CAUTION:
M
Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reac-
tion force is applied from fuel tank inside to upward.
9. Remove fuel level sensor unit, fuel filter and fuel pump assem-
bly.
CAUTION:
● Be careful not to bend the float arm when removing.

● Handle them carefully without subjecting them to impacts

such as dropping.

PBIC1498E

FL-5
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
10. Install lock ring temporally by hand tightening until it stops with
maximum force.
● Direct arrow mark on lock ring to vehicle rear. Then turn clock-
wise to tighten lock ring.
CAUTION:
Do not remove lock ring until fuel level sensor unit, fuel fil-
ter and fuel pump assembly is installed.
11. Remove fuel level sensor unit in the following procedures.
a. Remove harness connector (brown).
● Hold connector with your fingers, because there is no tab for PBIC1573E
releasing stopper. Pull it out straight downward.
b. Insert a screwdriver into the gap between fuel level sensor unit
left side and mounting part. Pry the screwdriver in the direction
shown by arrow.
CAUTION:
Be careful not to damage anything.
c. When fixing tab comes off, slide fuel level sensor unit in the
direction indicated by arrow to remove.
CAUTION:
● Do not reuse removed fuel level sensor unit.

● Do not disassemble fuel filter and fuel tank pump assem-

PBIC1500E
bly.
INSTALLATION
Install in the reverse order of removal which being careful of the following.
Installation of Fuel Level Sensor Unit
Install it in the following procedures.
1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage.
2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts
the face.
● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit
does not come off.
3. Connect harness connector.
● Insert harness connector securely until it contacts the face.

Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
Install it in the following procedures.
1. Remove lock ring.
2. Install O-ring to fuel tank without any twist.

PBIC1501E

FL-6
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
3. Install fuel level sensor unit, fuel filter and fuel pump assembly,
aligning the sender unit rear side protrusion with the fuel tank A
opening rear side cutout.
CAUTION:
● Do not allow O-ring to drop. FL
● Maintain closely jointed status by pressing fuel level sen-
sor unit, fuel filter and fuel pump assembly at an opening
of the tank until the end of step 5, in order to prevent the
C
fallout of O-ring (To maintain the O-ring installed status of
view A in the figure at step 2).
PBIC1502E

D
4. Direct arrow mark on lock ring to vehicle rear. Then turn lock ring
clockwise by hand until it steps with maximum force.
CAUTION: E
Install lock ring horizontally.
5. Tighten lock ring to the specification with lock ring wrench [SST:
KV993G0010]. F

G
PBIC1573E

Fuel Feed Hose Installation H

● Connect quick connector in the following procedures.
1. Check connections for damage or foreign material.
2. Align the mating side connection part with the center of shaft on I
the sender unit, and insert quick connector straight until it clicks.
3. After connecting, pull out quick connector by hand. Make sure
connections are secure. J

K
PBIC1503E

INSPECTION AFTER INSTALLATION

● Check for fuel leak in the following procedures. L
1. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
2. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. M

FL-7
 FUEL TANK
[CR]
FUEL TANK PFP:17202

Removal and Installation EBS00OJ9

MBIB1355E

1. Fuel tank 2. Vent hose 3. EVAP tube

4. Fuel filler cap 5. Grommet 6. Fuel filler tube
7. Vent hose 8. Clamp 9. Fuel filler hose
10. Mounting band 11. EVAP hose

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system.
Refer to FL-3, "General Precautions" .
1. Remove RH rear wheel.
2. Perform steps 1 to 7 of FL-4, "REMOVAL" in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unsta-
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 underfloor support. Refer to RSU-10, "UNDERFLOOR SUPPORT" (C+C Models).
4. Remove center muffler and main muffler. Refer to EX-4, "EXHAUST SYSTEM" .
5. Remove vehicle side insulator on upper center muffler and main muffler.
6. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.

FL-8
 FUEL TANK
[CR]
7. Disconnect fuel filler hose on fuel tank side.
CAUTION: A
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- FL
essarily, put mating marks, and remove.
8. Remove vent hose at RH rear wheelwell side.
C

PBIC1505E

D
9. Remove EVAP hose at front side of fuel tank.

G
PBIC1507E

● Remove quick connector in the following procedures. H

– Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
I
– 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 J
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

K
PBIC1509E
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
L
● 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. M
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC0713E

FL-9
 FUEL TANK
[CR]
10. Support center of fuel tank with suitable transmission jack.
CAUTION:
Securely support the fuel tank with a piece of wood.
11. Remove RH/LH mounting band.
12. Lower suitable transmission jack carefully to remove fuel tank
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.

● Avoid interference with tank by pulling parking brake cable by

hand. PBIC1508E

CAUTION:
Tank may be in an unstable condition because of the shape 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.
Installation of Fuel Tank Mounting Band
● Install it by referring to the identification stamp mark “R” and “L” on the end.
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.
● Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tighten-
ing torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb].
Installation of EVAP Hose
● Connect quick connector in the following procedures.
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.
3. After connecting, pull out quick connector by hand. Make sure
connections are secure.

PBIC1509E

INSPECTION AFTER INSTALLATION

● Check for fuel leak in the following procedures.
1. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
2. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

FL-10
 SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Standard and Limit EBS00OJO

Fuel tank capacity Approx. 46 (10-1/8 Imp gal)

FL
Tightening Torque EBS00OJP

Unit: N·m (kg-m, ft-lb)

Fuel tank mounting band 21.0 - 29.0 (2.1 - 3.0, 15 - 21) C
Fuel filler tube 15.8 - 24.2 (1.7 - 2.4, 12 - 17)
Lock ring 65.0 - 75.0 (6. - 7.7, 48 - 55)
D

FL-11
 PREPARATION
[HR]
PREPARATION
[HR] PFP:00002

Special Service Tools EBS01J8A

Tool number
(RENAULT tool number) Description
Tool name

KV993G0010 Removing and Installing lock ring

(Mot. 1397)
Lock ring wrench

PBIC1627E

FL-12
 FUEL SYSTEM
[HR]
FUEL SYSTEM PFP:17503
A
Checking Fuel Lines EBS01J8B

Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio- FL
ration.
If necessary, repair or replace damaged parts.
C

SMA803A

E
General Precautions EBS01J8C

WARNING:
When replacing fuel line parts, be sure to observe the following. F
● Put a “CAUTION: INFLAMMABLE” sign in the workshop.
● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. G
● Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
CAUTION: H
● Use gasoline required by the regulations for octane number.
Refer to GI-5, "Precautions for Fuel" .
● Before removing fuel line parts, perform the following procedures: I
– Release fuel pressure from the fuel lines. Refer to EC-861, "FUEL PRESSURE RELEASE" (with
EURO-OBD) or EC-1286, "FUEL PRESSURE RELEASE" (without EURO-OBD).
– Disconnect the battery cable from the negative cable. J
● Always replace O-rings and clamps with new ones.
● Do not kink or twist tubes when they are being installed.
● Perform work on level place. K
● Do not tighten hose clamps excessively to avoid damaging hoses.
● After connecting fuel tube quick connectors, make sure quick connectors are secure.
Ensure that connector and resin tube do not contact any adjacent parts. L
● 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. M
– 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 “MIL” may come on.
● For servicing “Evaporative Emission System” parts, refer to EC-825, "EVAPORATIVE EMISSION
SYSTEM" (with EURO-OBD) or EC-1262, "EVAPORATIVE EMISSION SYSTEM" (without EURO-
OBD).

FL-13
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY PFP:17042

Removal and Installation EBS01J8D

MBIB1354E

1. Lock ring 2. Fuel filter and fuel pump assembly 3. Fuel level sensor unit
4. O-ring 5. Fuel tank

REMOVAL
WARNING:
Read “General Precautions” before working on the fuel system.
Refer to FL-13, "General Precautions" .
1. Check fuel level. If gauge indicates more than the level shown in
figure (full or almost full), drain fuel from fuel tank until gauge
indicates the level in figure or below.
When fuel pump malfunctions, insert hose with outer diameter of
25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler
tube. Disconnect connections of fuel filler tube and fuel filler
hose to drain fuel from fuel filler hose.
● As guide, fuel amount becomes the level shown in figure or
below when approximately 7 liter (1-1/2 lmp gal) of fuel are
drained from full.
NOTE: PBIC1495E

Adjusting fuel level is to prevent fuel from spilling, when fuel

level sensor unit, fuel filter and fuel pump assembly are removed.
2. Release fuel pressure. Refer to EC-861, "Fuel Pressure Check" (with EURO-OBD), EC-1286, "Fuel Pres-
sure Check" (without EURO-OBD).
a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump
assembly.
b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line.
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove rear seat. Refer to SE-15, "REAR SEAT" .
6. Remove inspection hole cover.
● Using a screwdriver, remove it by turning clips clockwise by 90°.

FL-14
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
7. Remove harness connector and fuel feed hose from sender unit.
NOTE: A
● Connections of harness connector and fuel feed hose are
called sender unit.
FL

PBIC1496E

D
● Remove quick connector in the following procedures.
– Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand. E
– If quick connector and tube on sender unit are stuck, push
and pull several times until they move, and pull out.
CAUTION: F
● 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. G
● Keep the resin tube away from heat. Be especially PBIC1497E
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. H
● 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 I
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick J
connector.

PBIC0713E
L
8. Using lock ring wrench [SST: KV993G0010], remove lock ring.
CAUTION:
M
Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reac-
tion force is applied from fuel tank inside to upward.
9. Remove fuel level sensor unit, fuel filter and fuel pump assem-
bly.
CAUTION:
● Be careful not to bend the float arm when removing.

● Handle them carefully without subjecting them to impacts

such as dropping.

PBIC1498E

FL-15
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
10. Install lock ring temporally by hand tightening until it stops with
maximum force.
● Direct arrow mark on lock ring to vehicle rear. Then turn clock-
wise to tighten lock ring.
CAUTION:
Do not remove lock ring until fuel level sensor unit, fuel fil-
ter and fuel pump assembly is installed.
11. Remove fuel level sensor unit in the following procedures.
a. Remove harness connector (brown).
● Hold connector with your fingers, because there is no tab for PBIC1573E
releasing stopper. Pull it out straight downward.
b. Insert a screwdriver into the gap between fuel level sensor unit
left side and mounting part. Pry the screwdriver in the direction
shown by arrow.
CAUTION:
Be careful not to damage anything.
c. When fixing tab comes off, slide fuel level sensor unit in the
direction indicated by arrow to remove.
CAUTION:
● Do not reuse removed fuel level sensor unit.

● Do not disassemble fuel filter and fuel tank pump assem-

PBIC1500E
bly.
INSTALLATION
Install in the reverse order of removal which being careful of the following.
Installation of Fuel Level Sensor Unit
Install it in the following procedures.
1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage.
2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts
the face.
● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit
does not come off.
3. Connect harness connector.
● Insert harness connector securely until it contacts the face.

Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
Install it in the following procedures.
1. Remove lock ring.
2. Install O-ring to fuel tank without any twist.

PBIC1501E

FL-16
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
3. Install fuel level sensor unit, fuel filter and fuel pump assembly,
aligning the sender unit rear side protrusion with the fuel tank A
opening rear side cutout.
CAUTION:
● Do not allow O-ring to drop. FL
● Maintain closely jointed status by pressing fuel level sen-
sor unit, fuel filter and fuel pump assembly at an opening
of the tank until the end of step 5, in order to prevent the
C
fallout of O-ring (To maintain the O-ring installed status of
view A in the figure at step 2).
PBIC1502E

D
4. Direct arrow mark on lock ring to vehicle rear. Then turn lock ring
clockwise by hand until it steps with maximum force.
CAUTION: E
Install lock ring horizontally.
5. Tighten lock ring to the specification with lock ring wrench [SST:
KV993G0010]. F

G
PBIC1573E

Fuel Feed Hose Installation H

● Connect quick connector in the following procedures.
1. Check connections for damage or foreign material.
2. Align the mating side connection part with the center of shaft on I
the sender unit, and insert quick connector straight until it clicks.
3. After connecting, pull out quick connector by hand. Make sure
connections are secure. J

K
PBIC1503E

INSPECTION AFTER INSTALLATION

● Check for fuel leak in the following procedures. L
1. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
2. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. M

FL-17
 FUEL TANK
[HR]
FUEL TANK PFP:17202

Removal and Installation EBS01J8E

MBIB1355E

1. Fuel tank 2. Vent hose 3. EVAP tube

4. Fuel filler cap 5. Grommet 6. Fuel filler tube
7. Vent hose 8. Clamp 9. Fuel filler hose
10. Mounting band 11. EVAP hose

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system.
Refer to FL-13, "General Precautions" .
1. Remove RH rear wheel.
2. Perform steps 1 to 7 of FL-14, "REMOVAL" in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unsta-
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 underfloor support. Refer to RSU-10, "UNDERFLOOR SUPPORT" (C+C models).
4. Remove center muffler and main muffler. Refer to EX-4, "EXHAUST SYSTEM" .
5. Remove vehicle side insulator on upper center muffler and main muffler.
6. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.

FL-18
 FUEL TANK
[HR]
7. Disconnect fuel filler hose on fuel tank side.
CAUTION: A
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- FL
essarily, put mating marks, and remove.
8. Remove vent hose at RH rear wheelwell side.
C

PBIC1505E

D
9. Remove EVAP hose at front side of fuel tank.

G
PBIC1507E

● Remove quick connector in the following procedures. H

– Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
I
– 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 J
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

K
PBIC1509E
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
L
● 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. M
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC0713E

FL-19
 FUEL TANK
[HR]
10. Support center of fuel tank with suitable transmission jack.
CAUTION:
Securely support the fuel tank with a piece of wood.
11. Remove RH/LH mounting band.
12. Lower suitable transmission jack carefully to remove fuel tank
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.

● Avoid interference with tank by pulling parking brake cable by

hand. PBIC1508E

CAUTION:
Tank may be in an unstable condition because of the shape 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.
Installation of Fuel Tank Mounting Band
● Install it by referring to the identification stamp mark “R” and “L” on the end.
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.
● Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tighten-
ing torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb].
Installation of EVAP Hose
● Connect quick connector in the following procedures.
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.
3. After connecting, pull out quick connector by hand. Make sure
connections are secure.

PBIC1509E

INSPECTION AFTER INSTALLATION

● Check for fuel leak in the following procedures.
1. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
2. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

FL-20
 SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Standard and Limit EBS01JAT

Fuel tank capacity Approx. 46 (10-1/8 Imp gal)

FL
Tightening Torque EBS01JAU

Unit: N·m (kg-m, ft-lb)

Fuel tank mounting band 21.0 - 29.0 (2.1 - 3.0, 15 - 21) C
Fuel filler tube 15.8 - 24.2 (1.7 - 2.4, 12 - 17)
Lock ring 65.0 - 75.0 (6.6 - 7.7, 48 - 55)
D

FL-21
 PREPARATION
[K9K]
PREPARATION
[K9K] PFP:00002

Special Service Tool EBS01C7Y

Tool number
(RENAULT tool number) Description
Tool name

KV993G0010 Removing and Installing lock ring

(Mot. 1397)
Lock ring wrench

PBIC1627E

FL-22
 FUEL SYSTEM
[K9K]
FUEL SYSTEM PFP:17503
A
Checking Fuel Lines EBS01C7Z

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

SMA803A

FL-23
 FUEL FILTER
[K9K]
FUEL FILTER PFP:16400

Removal and Installation EBS01C80

MBIB1064E

MBIB1065E

Water Draining from Fuel Filter EBS01C81

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.

MBIB0530E

FL-24
 FUEL FILTER
[K9K]
DRAINING WATER (LHD)
Refer to EM-227, "PRECAUTIONS" , EC-K9K-23, “DIESEL EQUIPMENT”. A
1. Remove right fender protector. Refer to EI-14, "FENDER PROTECTOR" .
2. Remove foam insulator.
FL
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.
C
FUEL FILTER CHECK
Check fuel filter for fuel leakage, damage and other abnormal signs.
D
Changing Fuel Filter EBS01C82

REMOVAL (RHD)
1. Remove quick connectors in the following procedures.
E
● 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. F

MBIB1048E
H
2. Remove fuel filter from fuel filter bracket.
CAUTION:
Do not spill the fuel during removal. If the fuel is spill, I
immediately wipe it off. Be especially careful to prevent the
fuel from adhering to the insulators of the engine mounts.
J

K
MBIB1049E

REMOVAL (LHD)
L
1. Remove Cowl Top. Refer to EI-13, "COWL TOP" .
2. Remove priming bulb from priming bulb bracket.
3. Remove fuel filter from fuel filter bracket. M
4. Remove quick connectors as shown.
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.

FL-25
 FUEL FILTER
[K9K]
● To install fuel filter connectors, respect paint marks on fuel filter
as shown.
● After installation, operate the priming bulb vertically, if it is possi-
ble, to perform air bleeding.
Refer to FL-26, "Bleeding Fuel Filter" .
CAUTION:
Do not bend or twist the tube during installation and
removal.

MBIA0095E

Bleeding Fuel Filter EBS01C83

1. Prime the circuit using the priming bulb.

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

MBIB1050E

FL-26
 FUEL LEVEL SENSOR UNIT
[K9K]
FUEL LEVEL SENSOR UNIT PFP:17042
A
Removal and Installation EBS01C84

FL

MBIB1047E
G

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

4. Float arm H

REMOVAL
1. Disconnect battery ground cable. I
2. Open fuel filler lid and filler cap to release the pressure inside the fuel tank.
3. Remove rear seat cushion. Refer to SE-15, "REAR SEAT" .
4. Remove inspection hole cover under the rear seat. J
5. Disconnect electrical connector.
6. Disconnect the quick connectors.
K

MBIB1051E

● Hold the connector while pushing in tabs, and pull out the
tube.

MBIB1052E

FL-27
 FUEL LEVEL SENSOR UNIT
[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.

Retainer color:
Red (Feed hose side)
White (Return hose side)
7. Using lock ring wrench [SST: KV993G0010], 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.
8. Remove fuel level sensor unit.
CAUTION:
● Be careful not to bend the float arm when removing.

● Handle them carefully without subjecting them to impacts

such as dropping.

MBIB1231E

INSTALLATION
Install in the reverse order of removal.

FL-28
 FUEL TANK
[K9K]
FUEL TANK PFP:17202
A
Removal and Installation EBS01C85

FL

PBIC1504E

1. Fuel tank 2. Vent hose 3. EVAP tube J

4. Fuel filler cap 5. Grommet 6. Fuel filler tube
7. Vent hose 8. Clamp 9. Fuel filler hose
10. Mounting band 11. EVAP hose K

REMOVAL
1. Remove RH rear wheel. L
2. Perform steps 1 to 7 of FL-27, "REMOVAL" in “FUEL LEVEL SENSOR UNIT”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unsta- M
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 center muffler and main muffler. Refer to EX-4, "EXHAUST SYSTEM" .
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.
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

FL-29
 FUEL TANK
[K9K]
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 PBIC1509E

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.

● 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
9. Support center of fuel tank with suitable transmission jack.
CAUTION:
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
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.

● Avoid interference with tank by pulling parking brake cable by

hand. PBIC1508E

CAUTION:
Tank may be in an unstable condition because of the shape 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.
Installation of Fuel Tank Mounting Band
● Install it by referring to the identification stamp mark “R” and “L” on the end.

FL-30
 FUEL TANK
[K9K]
Installation of fuel Filler Hose
● Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp. A
● When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube.
● Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tighten-
ing torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb]. FL

Installation of EVAP Hose

● Connect quick connector in the following procedures. C
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. D
3. After connecting, pull out quick connector by hand. Make sure
connections are secure.
E

PBIC1509E
F
Installation of Vent Hose
● Push vent hose into through hole of vehicle.
● Insert vent hose into vent rubber hose, and secure it with clamp. G

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections in the following procedure. H
● Start engine, rev it up and make sure there is no fuel leakage at connections.

FL-31
FUEL TANK
[K9K]

FL-32