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”.

•  Fuel line spills and leakage are dangerous. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel gauge sender 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.

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.  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].)

6.  Remove the fuel gauge sender unit. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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

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

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-CD 2.2].)

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1	Fuel tank strap
2	Fuel tank
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.)

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 reinstalling 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). (WGN) (See GENERAL PROCEDURES (SUSPENSION).)

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

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

4.  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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