Fuel Tank Removal/Installation: Notes

WARNING:

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
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 the vehicle body.

CAUTION:

Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

Level the vehicle.
Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)

Fig 1: Quick Release Connector
Courtesy of MAZDA MOTORS CORP.
Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
Drain the fuel from the fuel tank using the following procedure:
Using M-MDS
- Connect the M-MDS to the DLC-2.
- Using the simulation function "FP", start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST .)
  Without using M-MDS
- Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION .)
- Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)
- Remove the fuel pump relay.
  
  Fig 2: Locating Fuel Pump Relay
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
- Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
  
  Fig 3: Shorting Fuel Pump Relay Terminals C And D
  Courtesy of MAZDA MOTORS CORP.
- Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION .)
  CAUTION:
  - The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
Stop the fuel pump using the following procedure.
Using M-MDS
- Using the simulation function "FP", stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST .)
- Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)
  Without using M-MDS
- Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION .)
Remove the second-row seat. (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
Remove the rear package tray lid. (See REAR PACKAGE TRAY LID REMOVAL/INSTALLATION .)
Remove the sub-trunk. (See SUB-TRUNK REMOVAL/INSTALLATION .)
Remove the third-row seat. (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
Remove the rear scuff plate. (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
Partially peel back the floor covering.
Remove the service hole cover.

Fig 4: Service Hole Cover
Courtesy of MAZDA MOTORS CORP.
Disconnect the fuel pump unit connector.
Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
Remove the TWC. (See ENGINE EXHAUST SYSTEM REMOVAL/INSTALLATION .)
Remove the insulator (No. 2) and insulator (No. 3). (See ENGINE EXHAUST SYSTEM REMOVAL/INSTALLATION .)
Remove in the order indicated in the table.
Install in the reverse order of removal.
Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)

Fig 5: Exploded View Of Fuel Tank Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.