FUEL TANK REMOVAL/INSTALLATION [MZI-3.7]

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  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”. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

4. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)

5. Perform the work using the following procedure.

  1. Set the air cleaner cover aside.
  2. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
  3. Connect the thick end of SST (49 T013 102) to the quick release connector until a click sound is heard.

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  4. 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

  1. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)
  2. Connect the M-MDS to the DLC-2.

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  3. Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZI-3.7].)

  Without using M-MDS

  1. Remove the fuel pump relay.

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    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.

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  3. Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)
    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

  1. Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZI-3.7].)
  2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

  Without using M-MDS

  1. Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

8. Remove the presilencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

9. To remove the fuel pump unit, remove the following parts:

  (1) Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)

  (2) Edge cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (3) Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (4) Rear heat duct No.3 (See REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

  (5) Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZI-3.7].)

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1 | Joint hose
2 | Evaporative hose component
3 | Breather hose
4 | Fuel tank
5 | Fuel tank bracket
6 | Fuel tank insulator
7 | Fuel-filler cap
8 | Fuel-filler pipe protector (See Fuel-filler pipe protector removal note.)
9 | Fuel-filler pipe (See Fuel-filler pipe removal note.)

Fuel-filler pipe protector removal note

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

2. Remove the splash shield (LH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

3. Remove the fuel-filler pipe protector.

Fuel-filler pipe removal note

1. Remove the rear tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

2. Remove the spare tire. (See HANDLING SPARE TIRE.)

3. Remove the main silencer (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

4. Remove the main silencer insulator (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

5. To lower the rear crossmember, perform the following procedure:

  (1) Set the rear ABS wheel-speed sensor out of the way. (See REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [2WD].)

  (2) Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)

  (3) Lowered the rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION [2WD].)

6. Remove the fuel-filler pipe.

4WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

4. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)

5. Perform the work using the following procedure.

  1. Set the air cleaner cover aside.
  2. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
  3. Connect the thick end of SST (49 T013 102) to the quick release connector until a click sound is heard.

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  4. 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

  1. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)
  2. Connect the M-MDS to the DLC-2.

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  3. Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZI-3.7].)

  Without using M-MDS

  1. Remove the fuel pump relay.

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    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.

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  3. Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)
    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

  1. Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZI-3.7].)
  2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

  Without using M-MDS

  1. Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

8. To remove the propeller shaft, remove the following parts:

  (1) Presilencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

  (2) Presilencer insulator

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  (3) Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

9. To remove the fuel pump unit, remove the following parts:

  (1) Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)

  (2) Edge cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (3) Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (4) Rear heat duct No.3 (See REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

  (5) Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZI-3.7].)

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1 | Joint hose
2 | Evaporative hose
3 | Breather hose
4 | Protector
5 | Fuel tank
6 | Fuel tank bracket
7 | Fuel tank insulator No.1
8 | Fuel tank insulator No.2
9 | Fuel-filler cap
10 | Fuel-filler pipe protector (See Fuel-filler pipe protector removal note.)
11 | Fuel-filler pipe (See Fuel-filler pipe removal note.)

Fuel-filler pipe protector removal note

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

2. Remove the splash shield (LH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

3. Remove the fuel-filler pipe protector.

Fuel-filler pipe removal note

1. Remove the rear tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

2. Remove the spare tire. (See HANDLING SPARE TIRE.)

3. Remove the main silencer (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

4. Remove the main silencer insulator (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

5. To lower the rear crossmember, perform the following procedure:

  (1) Set the rear ABS wheel-speed sensor out of the way. (See REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4WD].)

  (2) Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)

  (3) Lowered the rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION [4WD].)

6. Remove the fuel-filler pipe.