FUEL TANK REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5]

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Warning
•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
•  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 1.8, MZR 2.0, MZR 2.5].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

4.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

5.  Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

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

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

Using M-MDS
1.  Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
2.  Connect the M-MDS to the DLC-2.
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3.  Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Without using M-MDS
1.  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.
2.  Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
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3.  Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
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.

8.  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 1.8, MZR 2.0, MZR 2.5].)
2.  Disconnect the negative battery cable.
Without using M-MDS
1.  Disconnect the negative battery cable to stop the fuel pump.

9.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

10.  Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

11.  Remove the rear trailing link under cover. (See REAR TRAILING LINK REMOVAL/INSTALLATION.)

12.  Set the rear parking brake cable out of the way. (See REAR PARKING BRAKE CABLE REMOVAL/INSTALLATION.)

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 [MZR 1.8, MZR 2.0, MZR 2.5].)

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1
Fuel tank strap
2
Fuel tank
(See Fuel Tank Removal Note.)
3
Joint hose
(See Joint Hose Installation Note.)
4
Breather hose
(See Breather Hose Installation Note.)
5
protector
(See Protector Installation Note.)
6
Insulator
(See Insulator Removal Note.)
7
Fuel-filler cap
8
Dust cover
9
Fuel-filler pipe
(See Fuel-Filler Pipe Removal Note.)
10
Nonreturn valve


Fuel Tank Removal Note

1.  Perform the following procedure.

4SD
1.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION [4SD].)
5HB/WAGON
1.  Lift up the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION [5HB/WAGON].)

2.  Remove the service hole cover.

3.  Disconnect the following parts shown in the figure.

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(1)  Fuel pump unit connector
(2)  Evaporative hose
(3)  Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

4.  Remove the fuel tank component.

5.  Remove the fuel pump unit from the fuel tank. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)


Insulator Removal Note

Caution
•  Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.
Note
•  The insulator is installed using rivets.
•  When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel-Filler Pipe Removal Note

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

2.  Remove the main silencer (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

3.  Remove the splash shield (LH).(See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Set the rear mudguard (LH) out of the way. (See REAR MUDGUARD REMOVAL/INSTALLATION.)

5.  Remove the fuel-filler pipe.


Protector Installation Note

1.  Install the protector as shown in the figure.

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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 as shown in the figure.

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