FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6]

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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.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6].)

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

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.

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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].)

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

12.  Remove the insulator No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

13.  Remove in the order indicated in the table.

14.  Install in the reverse order of removal.

15.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6].)

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1
Fuel tank component
(See Fuel Tank Component Removal Note.)
2
Joint hose
(See Joint Hose Installation Note.)
3
Breather hose
(See Breather Hose Installation Note.)
4
Fuel gauge sender unit
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)
5
Fuel-filler cap
6
Fuel-filler cap cover
7
O-ring
8
Dust cover
9
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.


Joint Hose Installation Note

1.  Connect the joint hose as shown in the figure.

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Fuel tank side
1.  Marking of joint hose is matched to the rib of fuel tank.
Fuel-filler pipe side
1.  Marking of joint hose is matched and marking of fuel-filler pipe is matched.

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

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Breather Hose Installation Note

1.  Connect the breather hose as shown in the figure.

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Fuel tank side
1.  Marking of breather hose is matched to the rib of fuel tank.
Fuel-filler pipe side
1.  Marking of breather hose is matched and marking of fuel-filler pipe is matched.

2.  Install the breather hose and clamp as shown in the figure.

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