Fuel Pump Cap Installation Note

WARNING: This page is about a different car, the 2005 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Make sure there is no foreign material on each of the parts. If there is foreign material on the parts, the fuel pump unit cannot be assembled correctly, which could result in fuel leakage.

NOTE:

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

Replace the packing, fuel pump cap and the retainer with new parts.
CAUTION:
- New parts can deform depending on the temperature. If the parts deform, the fuel pump unit cannot be assembled correctly, which could result in fuel leakage. Therefore, keep new parts at room temperature for the specified period of time to stabilize the shape.
Leave new parts inside for the following period of time:
Stand-by time 12 h or more
Install a new retainer to the fuel tank.
1. Align the retainer tabs (3 locations) with the fuel tank grooves.
2. Verify that the tabs are inserted into the grooves and the retainer is installed correctly.
3. Verify the retainer is not damaged.
Install a new packing to the fuel tank.
1. Verify the packing groove is clean and free of foreign material.
2. Install the packing to the fuel tank so that it is inserted into the fuel tank grooves.
  CAUTION:
  - Install the fuel pump unit to the fuel tank being careful not to bend the fuel sender unit arm. If the arm is bent, the fuel sender unit will not operate correctly.
    
    Fig 1: Identifying Retainer
    Courtesy of MAZDA MOTORS CORP.
Install the fuel pump unit to the fuel tank.
1. Align the fuel pump unit alignment mark and the floating lines on the fuel tank.
  
  Fig 2: Aligning Fuel Pump Unit Alignment Mark And Floating Lines On Fuel Tank
  Courtesy of MAZDA MOTORS CORP.
2. Verify the tab on the fuel pump unit flange with the notch on the retainer.
  
  Fig 3: Identifying Fuel Pump Unit Flange
  Courtesy of MAZDA MOTORS CORP.
Set on a new fuel pump cap.
1. Apply downward force (push down) on the center of the fuel pump unit flange.
  NOTE:
  - Align the fuel pump cap with the tightening start position of the retainer and tighten the fuel pump cap with the start position as 0°.
  - The fuel pump cap tightening start position is the position where the spaces between the ribs become narrow. The retainer tightening start position is the notch position.
    
    Fig 4: Identifying Fuel Pump Cap
    Courtesy of MAZDA MOTORS CORP.
2. Align the tightening start position on the fuel pump cap and the tightening start point of the retainer.
  WARNING:
  - No grease or lubrication allowed on parts during installation. Parts could slide or they cannot be tightened to the specified torque. As a result, fuel leakage could occur.
  - When tightening the fuel pump cap, be careful that the fuel pump unit alignment mark and the floating lines on the fuel tank have not deviated. If there is deviation, the fuel pump unit cannot be installed correctly, which could result in fuel leakage.
    
    Fig 5: Checking Fuel Pump Unit Alignment
    Courtesy of MAZDA MOTORS CORP.
Tighten the fuel pump cap.
1. Tighten the fuel pump cap by hand to the specified angle or more until the flange is fixed.
  Fuel pump cap rotation angle 270° or more
  
  Fig 6: Tightening Fuel Pump Cap
  Courtesy of MAZDA MOTORS CORP.
2. Verify that the fuel pump cap is tightened correctly.
  1. The gap between the bottom of the fuel pump cap and the tank surface is even all around.
    - If the fuel pump cap is not tightened uniformly, loosen it by hand and re-install it.
  CAUTION:
  - The cap could be damaged if the SST is used with any play 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.
3. Install the SST with two of the four brackets removed.
  NOTE:
  - The fuel pump cap rotation angle is the angle from the 0° position. The angle tightened to using the SST includes the angle tightened by hand.
    
    Fig 7: Identifying Bracket
    Courtesy of MAZDA MOTORS CORP.
4. Tighten the fuel pump cap to the specified torque and to the specified angle or more.
  Fuel pump cap rotation angle
  
  570-630°
  
  Fuel pump cap tightening torque
  
  67-77 N.m {6.8-7.8 kgf.m, 49-56 ft.lbf}
  
  Fig 8: Tightening Fuel Pump Cap To Specified Torque
  Courtesy of MAZDA MOTORS CORP.
5. Verify that the fuel pump cap is tightened correctly.
  1. The gap between the top of the fuel pump unit flange and the fuel pump cap is even all around.
    - If it is not tightened uniformly, re-install it using the following procedure.
  2. The gap between the fuel pump unit and fuel tank is even all around.
    - If it is not tightened uniformly, re-install it using the following procedure.
  3. Verify that the fuel pump unit alignment mark and the floating lines on the fuel tank are aligned.
    - If they are not aligned, re-install it using the following procedure.
  CAUTION:
  - The cap could be damaged if the SST is used with any play 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. Install the SST with two of the four brackets removed.
  2. Remove the fuel pump cap, fuel pump unit, packing, and retainer.
  3. Verify that the retainer is not damaged.
    - If both of the retainer anti-rotation tabs are broken, replace it with new one.
  4. Return to Step 2 and re-install.
    
    Fig 9: Identifying Bracket
    Courtesy of MAZDA MOTORS CORP.