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Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION [MZI-3.5]

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.

2WD
1. Level the vehicle.
2. Complete the "BEFORE REPAIR PROCEDURE". (See BEFORE REPAIR PROCEDURE [MZI-3.5].) Before Repair Procedure
3. Disconnect the negative battery cable.




4. Remove the engine cover.
5. Remove the fuel line schrader valve cap.
6. Connect a long hose to the disconnected schrader valve cap and drain the fuel into a container used for collecting gasoline.
7. Start the fuel pump using the following procedure.

Using M-MDS
1. Connect the negative battery cable.




2. Connect the M-MDS to the DLC-2.
3. Using the simulation function FP, start the fuel pump.

Without using M-MDS
1. Remove the fuel pump relay.

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




2. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.
3. Connect the negative battery cable and operate the fuel pump.

CAUTION: The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

8. When essentially no fuel is being discharged, stop the fuel pump.
9. Disconnect the negative battery cable.
10. Remove the presilencer.
11. To remove the fuel pump unit, remove the following parts:
1. Second-row seat (LH)
2. Edge cover
3. Long slider cover
4. Rear heat duct No.3
5. Fuel pump unit

12. Siphon the fuel from the fuel tank.
13. Remove in the order indicated in the table.
14. Install in the reverse order of removal.




15. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE [MZI-3.5].) After Repair Procedure

Fuel-filler pipe protector removal note
1. Remove the rear tire (LH).
2. Remove the splash shield (LH).
3. Remove the fuel-filler pipe protector.

Fuel-filler pipe removal note
1. Remove the rear tire (RH).
2. Remove the spare tire.
3. Remove the main silencer (LH).
4. Remove the main silencer insulator (LH).
5. To lower the rear crossmember, perform the following procedure:
1. Set the rear ABS wheel-speed sensor out of the way.
2. Rear coil spring
3. Lowered the rear crossmember.

6. Remove the fuel-filler pipe.

AWD
1. Level the vehicle.
2. Complete the "BEFORE REPAIR PROCEDURE". (See BEFORE REPAIR PROCEDURE [MZI-3.5].) Before Repair Procedure
3. Disconnect the negative battery cable.




4. Remove the engine cover.
5. Remove the fuel line schrader valve cap.
6. Connect a long hose to the disconnected schrader valve cap and drain the fuel into a container used for collecting gasoline.
7. Start the fuel pump using the following procedure.

Using M-MDS




1. Connect the negative battery cable.
2. Connect the M-MDS to the DLC-2.
3. Using the simulation function FP, start the fuel pump.

Without using M-MDS
1. Remove the fuel pump relay.

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




2. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.
3. Connect the negative battery cable and operate the fuel pump.

CAUTION: The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

8. When essentially no fuel is being discharged, stop the fuel pump.
9. Disconnect the negative battery cable.




10. To remove the propeller shaft, remove the following parts:
1. Presilencer
2. Presilencer insulator
3. Propeller shaft

11. To remove the fuel pump unit, remove the following parts:
1. Second-row seat (LH)
2. Edge cover
3. Long slider cover
4. Rear heat duct No.3
5. Fuel pump unit

12. Siphon the fuel from the fuel tank.
13. Remove in the order indicated in the table.
14. Install in the reverse order of removal.




15. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE [MZI-3.5].) After Repair Procedure

Fuel-filler pipe protector removal note
1. Remove the rear tire (LH).
2. Remove the splash shield (LH).
3. Remove the fuel-filler pipe protector.

Fuel-filler pipe removal note
1. Remove the rear tire (RH).
2. Remove the spare tire.
3. Remove the main silencer (LH).
4. Remove the main silencer insulator (LH).
5. To lower the rear crossmember, perform the following procedure:
1. Set the rear ABS wheel-speed sensor out of the way.
2. Rear coil spring
3. Lowered the rear crossmember.

6. Remove the fuel-filler pipe.
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