FUEL TANK 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.

1.  Level the vehicle.

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

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

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

5.  Remove the service hole cover.

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6.  Disconnect the following parts:

•  Fuel pump unit connector

•  Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.6].)

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

8.  Disconnect the HO2S connector.

9.  Remove the presilencer and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

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 1.6].)

Fuel tank type A

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1	Joint hose (See Joint Hose Installation Note.)
2	Breather hose (fuel-filler pipe side) (See Breather Hose Installation Note.)
3	Evaporative hose (See Evaporative Hose Installation Note.)
4	Fuel tank strap
5	Fuel tank (See Fuel Tank Removal Note.)
6	Fuel tank insulator (See Fuel Tank Insulator Installation Note.)
7	Breather hose (fuel tank side) (See Breather Hose Installation Note.)
8	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.6].)

Fuel tank type B

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1	Joint hose (See Joint Hose Installation Note.)
2	Breather hose (fuel-filler pipe side) (See Breather Hose Installation Note.)
3	Evaporative hose (check valve side)
4	Fuel tank strap
5	Fuel tank (See Fuel Tank Removal Note.)
6	Fuel tank insulator (See Fuel Tank Insulator Installation Note.)
7	Breather hose (fuel tank side) (See Breather Hose Installation Note.)
8	Quick release connector (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZR 1.6].)
9	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.6].)

Fuel Tank Removal Note

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

2.  Disconnect the evaporative hose (between charcoal canister and check valve) from the check valve side.

3.  Remove the following parts as single unit:

•  Breather hose

•  Evaporative hose

•  Fuel pump unit

•  Fuel tank insulator

•  Evaporative hose (type B)

•  Fuel tank

4.  Remove the fuel tank.

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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Fuel Tank Insulator Installation Note

Caution

•  If the fuel tank insulator installation nuts are tightened with excessive force, the fuel tank insulator may be damaged. To prevent damage to the fuel tank insulator, tighten the fuel tank insulator installation nuts using the following procedure.

Note

•  Control the tightening condition of the fuel tank insulator installation nuts by the bolt projection. The bolt projection can be adjusted by the number of tightening rounds in which the fuel tank insulator installation nuts are tightened.

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1.  Temporarily tighten the fuel tank insulator installation nuts until the upper surface of the nuts are flush with the bolt ends.

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2.  Tighten the fuel tank insulator installation nuts.

Evaporative Hose Installation Note

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

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Joint Hose Installation Note

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

Fuel tank side

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Fuel-filler pipe side

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