Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION [MZI-3.7]

WARNING:
- Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Level the vehicle.

2. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

3. Disconnect the negative battery cable. Removal and Replacement

4. Remove the engine cover. Service and Repair

5. Perform the work using the following procedure.

- Remove the air hose. Service and Repair
- Disconnect the quick release connector from the fuel distributor. Quick Release Connector Removal/Installation
- Connect the thick end of SST (49 T013 102) to the quick release connector until a click sound is heard.





- Connect a long hose to the SST (49 T013 102) and drain the fuel into a container used for collecting gasoline.

6. Remove the fuel pump relay.

CAUTION:
- Short the specified terminals because shorting the wrong terminal of the main fuse block may cause malfunctions.

7. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.






8. Connect the negative battery cable and operate the fuel pump. Removal and Replacement

CAUTION:
- The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when the fuel discharge amount becomes unstable.

9. Disconnect the negative battery cable to stop the fuel pump.

10. To remove the fuel pump unit, remove the following parts:
a. Rear seat cushion Rear Seat Cushion Removal/Installation

b. Service hole cover

c. Fuel pump unit Removal and Replacement

11. Remove the presilencer. Service and Repair

12. Remove the insulator (middle). Service and Repair

13. Remove the under cover.

14. Remove the insulator (rear). Service and Repair

15. Remove in the order indicated in the table.

16. Install in the reverse order of removal.

17. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution










Fuel-Filler Pipe Removal Note

1. Remove the rear tire (LH). Service and Repair

2. Remove the main silencer (LH). Service and Repair

3. Remove the splash shield. Splash Shield Removal/Installation

4. Remove the fuel-filler pipe.

Joint Hose Installation Note

1. Install the joint hose as shown in the figure.