Fuel Pump Cap Installation Note

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.
Make the markings to be easily visible when the fuel pump cap is installed.
Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

Fig 1: Identifying Mark Of Fuel Pump Cap And Fuel Tank At Point
Courtesy of MAZDA MOTORS CORP.
Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

Fig 2: Identifying Fuel Tank Alignment Mark With Fuel Pump Unit
Courtesy of MAZDA MOTORS CORP.
Align the fuel tank and fuel pump cap markings.

Fig 3: Aligning Fuel Tank And Pump Cap Marking
Courtesy of MAZDA MOTORS CORP.
Rotate the fuel pump cap counterclockwise until the cap marking is approx, 15° away from the fuel tank marking as shown in the figure.

Fig 4: Rotating Fuel Pump Cap Counterclockwise Cap Marking
Courtesy of MAZDA MOTORS CORP.
While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180 ° clockwise.
CAUTION:
- The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.
Fig 5: Tightening Fuel Pump Cap
Courtesy of MAZDA MOTORS CORP.
Set the SST as shown in the figure.
NOTE:
- The total rotation angle is 450-495 °if the approx. 180° from Step 5 is included.
Fig 6: Installing SST (49 F042 001)
Courtesy of MAZDA MOTORS CORP.
Using the SST , tighten the fuel pump cap within the specified rotation angle and cap tightening torque without shifting the fuel tank and fuel pump unit alignment marks.
Rotation angle

270-315°

Fuel pump cap tightening torque

80-90 N.m {8.2-9.1 kgf.m, 59-66 ft.lbf}

Fig 7: Shifting Fuel Tank And Fuel Pump Unit Alignment Marks
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The total rotation angle is 450-495 ° if the approx.180 ° from Step 5 is included.
- If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.
- If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.
Fig 8: Identifying Fuel Pump Cap Marking
Courtesy of MAZDA MOTORS CORP.