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.

2WD

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. Engine Cover Removal/Installation

5. Perform the work using the following procedure.

- Set the air cleaner cover aside.
- 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. Start the fuel pump using the following procedure.

Using M-MDS
- Connect the negative battery cable. Removal and Replacement
- Connect the M-MDS to the DLC-2.

- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test

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

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

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

- 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.

7. Stop the fuel pump using the following procedure.

Using M-MDS
- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test
- Disconnect the negative battery cable. Removal and Replacement

Without M-MDS
- Disconnect the negative battery cable to stop the fuel pump. Removal and Replacement

8. Remove the presilencer. Service and Repair

9. To remove the fuel pump unit, remove the following parts:
a. Second-row seat (LH) Rear - Second-Row Seat Removal/Installation

b. Edge cover Long Slider Removal/Installation

c. Long slider cover Long Slider Removal/Installation

d. Rear heat duct No.3 Rear Heat Duct Component Removal/Installation

e. Fuel pump unit Removal and Replacement

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

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

Fuel-filler pipe protector removal note

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

2. Remove the splash shield (LH). Service and Repair

3. Remove the fuel-filler pipe protector.

Fuel-filler pipe removal note

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

2. Remove the spare tire. Handling Spare Tire

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

4. Remove the main silencer insulator (LH). Service and Repair

5. To lower the rear crossmember, perform the following procedure:
a. Set the rear ABS wheel-speed sensor out of the way. Rear

b. Rear coil spring Rear Suspension - Coil Spring Removal/Installation

c. Lowered the rear crossmember. Service and Repair

6. Remove the fuel-filler pipe.

AWD

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. Engine Cover Removal/Installation

5. Perform the work using the following procedure.

- Set the air cleaner cover aside.
- 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.

- Using the simulation function "FP", start the fuel pump.

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

c. Propeller shaft

9. To remove the fuel pump unit, remove the following parts:
a. Second-row seat (LH) Rear - Second-Row Seat Removal/Installation

b. Edge cover Long Slider Removal/Installation

c. Long slider cover Long Slider Removal/Installation

d. Rear heat duct No.3 Rear Heat Duct Component Removal/Installation

e. Fuel pump unit Removal and Replacement

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

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