FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2]

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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-CD 2.2].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  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.

Except when the fuel tank is 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.

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

6.  Remove the service hole cover.

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7.  Disconnect the fuel gauge sender unit connector.

8.  Set the presilencer out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the insulator (middle No.1). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

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1	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
2	Fuel tank strap
3	Joint hose (See Joint Hose Installation Note.)
4	Breather hose (See Breather Hose Removal Note.) (See Breather Hose Installation Note.)
5	Fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
6	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)
7	Fuel tank
8	Fuel-filler cap
9	Protector
10	Dust cover
11	Fuel-filler pipe (See Fuel-filler Pipe Removal Note.)
12	Non-return valve

Breather Hose Removal Note

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

2.  Remove the following parts as a single unit.

•  Fuel tank

•  Breather hose

•  Fuel gauge sender unit

•  Fuel hose

3.  Remove the breather hose.

Fuel-filler Pipe Removal Note

1.  Remove the rear mudguard.

2.  To remove the rear crossmember, remove the following parts:

1.  Rear auto leveling sensor (Vehicles with AFS) (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

2.  Rear stabilizer (See REAR STABILIZER REMOVAL/INSTALLATION.)

3.  Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)

4.  Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)

5.  Rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

3.  Remove the fuel-filler pipe.

Breather Hose Installation Note

1.  Install the breather hose 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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