FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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Warning
•  Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•  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 a vehicle.

1.  Level the vehicle.

2.  Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Open the fuel-filler cap.

5.  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.
When the fuel tank is not 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.

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

7.  Remove the service hole cover.

8.  Disconnect the fuel gauge sender unit connector.

9.  Disconnect the quick release connector.

10.  Remove the tunnel member. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

11.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Inspect all parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

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1
Insulator
2
Fuel tank component
(See Fuel Tank Component Removal Note.)
3
Joint hose
(See Joint Hose Installation Note.)
4
Breather hose
(See Breather Hose Installation Note.)
5
Fuel gauge sender unit
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)].)
6
Fuel-filler cap
7
Fuel-filler cap cover
8
O-ring
9
Dust cover
10
Fuel-filler pipe
(See Fuel-Filler Pipe Removal Note.)


Fuel Tank Component Removal Note

1.  Disconnect the joint hose (fuel-filler pipe side).

2.  Disconnect the breather hose (fuel-filler pipe side).

3.  Set the parking cable out of the way.

4.  Remove the fuel tank component.


Fuel-Filler Pipe Removal Note

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

2.  Remove the fuel-filler pipe.


Breather Hose Installation Note

1.  Install the breather hose and clamp 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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