Fuel Tank Removal/Installation: Notes

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.

Park the vehicle on a level surface.
Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION )
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.
Drain the fuel from the fuel tank using the following procedure:
1. Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION )
2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
3. Start the fuel pump using the following procedure:
  Using WDS or equivalent
  1. Connect the WDS or equivalent to the DLC-2.
    
    Fig 1: Identifying DLC-2 Connector
    Courtesy of MAZDA MOTORS CORP.
  2. Start the fuel pump using the "FP" simulation function.
  Not using WDS or equivalent
  1. Disconnect the negative battery cable.
  2. Remove the fuel pump relay.
    CAUTION:
    Be careful to short the specified terminal as shorting the wrong terminal of the main fuse block may cause a malfunction.
    Fig 2: Identifying Fuel Pump Relay
    Courtesy of MAZDA MOTORS CORP.
  3. Using a jumper wire, short fuel pump relay terminals C and D and connect the negative battery cable to start the fuel pump.
    
    Fig 3: Jumping Fuel Pump Relay Terminals C And D
    Courtesy 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.
4. When essentially no fuel is being discharged from the hose, stop the fuel pump using the following procedure:
  Using WDS or equivalent
  1. Stop the fuel pump using the "FP" simulation function.
  Not using WDS or equivalent
  1. Disconnect the negative battery cable to stop the fuel pump.
Disconnect the negative battery cable. (using WDS or equivalent)
Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION .)
Remove the service hole cover.
Disconnect the fuel pump unit connector.
Remove the charcoal canister protector. (See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
Lower the main silencer so that the insulator can be removed. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
Remove the insulator.
Remove the rear under cover (LH).
Remove in the order indicated in the table. See Except for California emission regulation applicable model and For California emission regulation applicable model .
Install in the reverse order of removal.
Inspect all parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION )