FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2]SM2444762
FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2]

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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 the “BEFORE SERVICE PRECAUTION”.
Caution
• Disconnecting/connecting the quick release connector without cleaning it may 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”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

3.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.Drain the fuel using the following procedure.

When the fuel tank is full
1. Disconnect the breather hose from the fuel-filler pipe.
2. Drain the fuel by tilting the breather hose.
3. Siphon the fuel from the fuel tank using a fuel drawing pump.
Except when the fuel tank is full
1. Disconnect the joint hose from the fuel-filler pipe.
2. Drain the fuel by tilting the joint hose.
3. Siphon the fuel from the fuel tank using a fuel drawing pump.

5.Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION.)

6.Remove the fuel gauge sender unit (main) and fuel gauge sender unit (sub). (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.Remove the SCR converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.Remove the propeller shaft (4WD). (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

9.Remove the floor under cover.

10.Remove the rear parking brake cable installation bolts, then move the rear parking brake cable out of the way.

11.Remove in the order indicated in the table.

12.Install in the reverse order of removal.

13.Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)
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1
Fuel tank strap
2
Fuel tank
3
Joint hose
(See Joint Hose Installation Note.)
4
Breather hose
(See Breather Hose Installation Note.)
5
Evaporative hose
6
Fuel tank insulator
(See Fuel Tank Insulator Removal Note.)
7
Fuel-filler cap
8
Protector
9
O-ring
10
Dust cover
11
Fuel-filler pipe protector
12
Fuel-filler pipe
(See Fuel-filler Pipe Removal Note.)


Fuel Tank Insulator Removal Note

Caution
• Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.
Note
• The fuel tank insulator is installed using rivets.
• When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1.Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).
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2.Remove the flange using a drill (5 mm {0.20 in} drill bit).
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Fuel-filler Pipe Removal Note

1.Remove the rear tire (LH). (See GENERAL PROCEDURES (STEERING).)

2.Remove the fuel-filler pipe.


Breather Hose Installation Note

1.Install the breather hose as shown in the figure.
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Joint Hose Installation Note

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