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Home >> Mazda >> 1997 >> MX-6 Base, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Fuel System) >> Fuel Tank Removal/Installation >> Notes
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Fuel Tank Removal/Installation: Notes

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
  1. Park the vehicle on a level surface.
  2. Perform the fuel line safety procedure referring to the before repair procedure. (See BEFORE REPAIR PROCEDURE .)
  3. Remove the rear seat. (See REAR SEAT REMOVAL/INSTALLATION .)
  4. Drain fuel from the fuel tank.
    WARNING:
    • 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 a vehicle.
    CAUTION:
    • When the fuel gauge indicates 3/4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle).
    1. Disconnect the quick release connector (engine compartment side). (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
    2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
      Fig 1: Locating Quick Release Connector
      G01345744Courtesy of MAZDA MOTORS CORP.
    3. Ground check connector terminal F/P to the body using a jumper wire.
      CAUTION:
      • Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.
    4. Turn the ignition switch to the ON position and operate the fuel pump for approx. 20 min. 
      Fig 2: Connecting Check Connector Terminal F/P To Body
      G01345745Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.
    5. When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.
      NOTE:
      • When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min  but will continue for approx. 10 min  more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.
    6. Disconnect the jumper wire.
    7. Disconnect the negative battery cable.
  5. Remove the following parts:
    1. Fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
    2. Main silencer and middle pipe. (See EXHAUST SYSTEM .)
    3. Power plant frame. (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION or TRANSMISSION REMOVAL/INSTALLATION .
    4. Propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
  6. Position the parking brake cable out of the way. (See PARKING BRAKE ASSEMBLY
  7. Remove in the order indicated. See Fig 3.
  8. Install in the reverse order of removal.
  9. Inspect all parts by performing theAFTER REPAIR PROCEDURE .
    Fig 3: Removing/Installing Fuel Tank
    G01345746Courtesy of MAZDA MOTORS CORP.
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