FUEL PUMP UNIT REMOVAL/INSTALLATION [ZY, Z6]

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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 “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.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [ZY, Z6].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)

4.  Remove the following parts:

(1)  Rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

(2)  Service hole cover.

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(3)  Fuel pump unit connector.

5.  Disconnect the joint hose of fuel tank side.

6.  Disconnect the breather hose of fuel-filler pipe side.

7.  Remove the following parts as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [ZY, Z6].)

•  Fuel tank

•  Breather hose

•  Fuel pump unit

•  Fuel hose

8.  Remove the order indicated in the table.

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1	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZY, Z6].)
2	Fuel pump cap (See Fuel Pump Cap Removal Note.) (See Fuel Pump Cap Installation Note.)
3	Fuel pump unit
4	O-ring

9.  Install in the reverse order of removal.

10.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [ZY, Z6].)

Fuel Pump Cap Removal Note

Caution

•  The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1.  Remove the fuel pump cap using the SST.

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Fuel Pump Cap Installation Note

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there in any gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.

1.  Align the fuel tank and fuel pump unit alignment marks.

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2.  Set the SST as shown in the figure.

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3.  Using the SST, tighten the fuel pump cap within the specified tightening torque without shifting the alignment marks.

•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.

•  If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.