FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [MZR-CD (RF-Turbo)]

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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”.

•  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, before performing the fuel gauge sender unit removal/installation, always complete the “Fuel Leak Inspection After Fuel Gauge Sender Unit Installation”.

1.  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)].)

2.  Disconnect the negative battery cable.

3.  Remove the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Remove in the order indicated in the table.

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1	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY, Z6].) (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF, L3] (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3 Turbo]
2	Cap (See Cap Removal Note.) (See Cap Installation Note.)
3	Fuel gauge sender unit

5.  Install in the reverse order of removal.

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

Cap Removal Note

Caution

•  The 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 cap using the SST.

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Cap Installation Note

Note

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

1.  Align the fuel tank and fuel gauge sender unit alignment marks as shown in the figure.

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2.  Set the SST as shown in the figure.

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

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

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