FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.6]

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Warning

•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

―  Fuel may cause irritation if it comes in contact with skin and eyes.

―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

•  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.

Fuel Pump Unit Type A

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 1.6].)

2.  Using the following procedure:

Caution

•  Because the fuel surface is higher than the fuel pump unit installation surface, if the set plate is removed, it may result in fuel leakage. If the fuel gauge level indicates 1/2 or more, refer to the fuel draining procedure and drain 20 liters of fuel.

Fuel gauge indicates 3/4 or more

1.  Drain the fuel. (See FUEL DRAINING PROCEDURE [MZR 1.6].)

Fuel gauge indicates less than 3/4

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

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

4.  Remove the service hole cover.

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5.  Remove in the order indicated in the table.

Packing part No. D350-*****

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1	Fuel pump unit connector
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.6].)
3	Fuel pump cap (See Fuel pump cap removal note.) (See Fuel pump cap installation note (packing part No. D350-*****).)
4	Fuel pump unit (See Fuel pump unit installation note.)
5	Packing (See Packing installation note.)

Except packing part No. D350-*****

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1	Fuel pump unit connector
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.6].)
3	Fuel pump cap (See Fuel pump cap removal note.) (See Fuel pump cap installation note (except packing part No. D350-*****).)
4	Fuel pump unit (See Fuel pump unit installation note.)
5	Packing (See Packing installation note.)

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.6].)

Fuel pump cap removal note

Caution

•  The fuel pump 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 fuel pump cap using the SST.

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Packing installation note

1.  Install the packing so that it is adhered around the entire fuel tank opening.

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Fuel pump unit installation note

1.  After installing the fuel pump unit, verify by hand that the packing is installed correctly all the way around without any slippage.

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Fuel pump cap installation note (packing part No. D350-*****)

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the packing. Thoroughly wipe away all gasoline from the packing.

•  Make the markings to be easily visible when the fuel pump cap is installed.

•  Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

•  Tighten the fuel pump cap using a torque wrench to prevent fuel leakage.

1.  Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

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2.  Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

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3.  Align the fuel tank and fuel pump cap markings.

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4.  Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

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5.  While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180 ° clockwise.

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Caution

•  The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.

6.  Set the SST as shown in the figure.

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Note

•  The total rotation angle is 450—495 ° if the approx. 180° from Step 5 is included.

7.  Using a torque wrench, tighten the fuel pump cap with both of the following specified rotation angle and specified torque met being careful not to shift the marks on the fuel pump unit and fuel tank.

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Caution

•  To avoid exceeding the specified rotation angle due to excessive torque, tighten the fuel pump cap starting from the minimum value of 80 N·m {8.2 kgf·m, 60 ft·lbf} and gradually increase the tightening torque without exceeding the maximum value of 180 N·m {18 kgf·m, 132 ft·lbf}, and secure the specified rotation angle of 270—315°.

•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.

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

Note

•  The total rotation angle is 450—495 °if the approx.180 ° from Step 5 is included.

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Fuel pump cap installation note (except packing part No. D350-*****)

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the packing. Thoroughly wipe away all gasoline from the packing.

•  Make the markings to be easily visible when the fuel pump cap is installed.

•  Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

•  Tighten the fuel pump cap using a torque wrench to prevent fuel leakage.

1.  Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

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2.  Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

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3.  Align the fuel tank and fuel pump cap markings.

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4.  Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

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5.  While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180 ° clockwise.

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Caution

•  The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.

6.  Set the SST as shown in the figure.

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Note

•  The total rotation angle is 390—420 ° if the approx. 180° from Step 5 is included.

7.  Using a torque wrench, tighten the fuel pump cap with both of the following specified rotation angle and specified torque met being careful not to shift the marks on the fuel pump unit and fuel tank.

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Caution

•  To avoid exceeding the specified rotation angle due to excessive torque, tighten the fuel pump cap starting from the minimum value of 50 N·m {5.1 kgf·m, 37 ft·lbf} and gradually increase the tightening torque without exceeding the maximum value of 140 N·m {14 kgf·m, 103 ft·lbf}, and secure the specified rotation angle of 210—240°.

•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.

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

Note

•  The total rotation angle is 390—420 °if the approx.180 ° from Step 5 is included.

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Fuel Pump Unit Type B

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 1.6].)

2.  Using the following procedure:

Caution

•  Because the fuel surface is higher than the fuel pump unit installation surface, if the set plate is removed, it may result in fuel leakage. If the fuel gauge level indicates 1/2 or more, refer to the fuel draining procedure and drain 20 liters of fuel.

Fuel gauge indicates 3/4 or more

1.  Drain the fuel. (See FUEL DRAINING PROCEDURE [MZR 1.6].)

Fuel gauge indicates less than 3/4

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

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

4.  Remove the service hole cover.

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5.  Remove in the order indicated in the table.

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1	Fuel pump unit connector
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.6].)
3	Set plate (See Set plate removal note.)
4	Fuel pump unit
5	O-ring

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.6].)

Set plate removal note

1.  Install the SST shown in the figure.

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2.  Remove the set plate using the SST.