Fuel Tank Removal / Installation

Fig 1: Fuel Tank Replacement Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

WARNING:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.

WARNING:

Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

Relieve the fuel pressure. See FUEL PRESSURE RELIEF , .
Disconnect the fill pipe main hose from the main fill pipe.

Fig 2: Fill Pipe Main Hose With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Drain the fuel tank.
If equipped, remove the 4 nuts (two each side) and remove the skid plate.
Tightening torque:

30 Nm {3.1 kgf-m, 22 ft-lbf}
Support the fuel tank.
Remove the bolts and pivot the fuel tank support straps away from the fuel tank.

Fig 3: Fuel Tank Support Straps Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Disconnect the fuel pump connector.
- Lower the fuel tank slightly.
- Disconnect the fuel pump electrical connector.
Fig 4: Locating Fuel Pump Connector
Courtesy of MAZDA MOTORS CORP.
Disconnect the fuel supply tube, vapor tube and the fill tube vent hose from the fuel pump. See FUEL PRESSURE RELIEF , .

Fig 5: Fuel Tank Support Straps Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Disconnect the vapor tube fitting at the rear of the fuel tank.
Lower the fuel tank.
To install, reverse the removal procedure.

Fig 6: Locating Vapor Tube Fitting

Courtesy of MAZDA MOTORS CORP.