FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7]

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  Warning
  • 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, always complete the “Fuel Line Safety Procedure”.
  • 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, 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.

  Caution
  • Because the fuel tank is constructed such that the fuel level is higher than the installation surface of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of 3/4 or more, perform the following Steps 3—7 to drain 10—15 L {2.7—3.9 US gal, 2.2—3.2 lmp gal} of fuel.
  • 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.

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. When essentially no fuel is being discharged, stop operation of the fuel pump.

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

9. To remove the rear heat duct No.3, 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) Remove the rear heat duct No.3. (See REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

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].)

2WD

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1 | Service hole cover
2 | Connector
3 | Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
4 | Set plate
5 | Fuel pump unit
6 | Packing

4WD

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1 | Service hole cover
2 | Connector
3 | Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
4 | Set plate
5 | Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
6 | Fuel pump unit
7 | Packing