Removal and Replacement

FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.5]

WARNING:
- Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE PRECAUTION".
- Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation".
- 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.

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

2. Disconnect the negative battery cable. Removal and Replacement

3. Remove the rear seat cushion. Rear Seat Cushion Removal/Installation

4. Remove the service hole cover.






5. Remove in the order indicated in the table.










6. Install in the reverse order of removal.

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

Fuel Pump Cap Removal Note

CAUTION:
- The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1. Remove the fuel pump cap using the SST.






Fuel Pump Cap Installation Note

NOTE:
- The fuel pump unit will rotate and cannot be secured in the specified position if there is any fuel on the gasket. Thoroughly wipe away all fuel from the gasket.
- Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

1. Align the fuel tank mark (No.1) with the fuel pump unit mark as shown in the figure.






2. Align the threading start point of the fuel pump cap with the fuel tank mark (No.2) as shown in the figure.






3. While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 220-260° clockwise.






CAUTION:
- The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.

4. Set the SST as shown in the figure.






5. Using the SST, tighten the fuel pump cap with 360° without shifting the fuel tank mark (No.1) and fuel pump unit alignment marks.
NOTE:
- The total rotation angle is 580-620° if the 220-260° from Step 3 is included.






- If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.
- If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.