FUEL TANK REMOVAL/INSTALLATION [MZR 2.3 DISI 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 the “BEFORE SERVICE PRECAUTION”.
•  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
•  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.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 2.3 DISI Turbo].)

3.  Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

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4.  Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

5.  Drain the fuel from the fuel tank using the following procedure:

Using M-MDS
1.  Connect the M-MDS to the DLC-2.
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2.  Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)
Without using M-MDS
1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
3.  Remove the fuel pump relay.
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Caution
•  Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
4.  Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
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5.  Connect the negative battery cable and operate the fuel pump. (See (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].).)
Caution
•  The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

6.  Stop the fuel pump using the following procedure.

Using M-MDS
1.  Using the simulation function “FP”, stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)
2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
Without using M-MDS
1.  Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

7.  To remove the fuel pump unit, 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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

9.  Remove the under cover. (See REAR TRAILING LINK REMOVAL/INSTALLATION.)

10.  Remove the insulator (middle No.1). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

11.  Remove in the order indicated in the table.

12.  Install in the reverse order of removal.

13.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 2.3 DISI Turbo].)

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1
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
2
Quick release connector
(See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
3
Quick release connector
(See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
4
Fuel tank strap
5
Joint hose
(See Joint Hose Installation Note.)
6
Breather hose
(See Breather Hose Removal Note.)
(See Breather Hose Installation Note.)
7
Fuel hose
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
8
Set plate
9
Fuel pump unit
10
O-ring
11
Fuel tank
12
Fuel-filler cap
13
Protector
14
Dust cover
15
Fuel-filler pipe protector (Vehicle with fuel-filler pipe protector)
16
Fuel-filler pipe
(See Fuel-Filler Pipe Removal Note.)


Breather Hose Removal Note

1.  Disconnect the breather hose of fuel tank side.

2.  Remove the following parts as a single unit.

•  Fuel tank
•  Breather hose
•  Fuel pump unit
•  Fuel hose

3.  Remove the breather hose.


Fuel-Filler Pipe Removal Note

1.  Remove the rear tire (LH). (See GENERAL PROCEDURES (SUSPENSION).)

2.  Remove the mudguard (RH) (Vehicles without fuel-filler pipe protector).

3.  Remove the fuel-filler pipe.


Breather Hose Installation Note

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

Fuel tank side

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Fuel-filler pipe side

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Joint Hose Installation Note

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

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