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 packing. Thoroughly wipe away all gasoline from the packing.
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 Fuel Pump Cap And Fuel Tank
Courtesy of MAZDA MOTORS CORP.
Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

Fig 2: Aligning 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 Fuel Pump Cap Markings
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
Courtesy of MAZDA MOTORS CORP.
While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180 ° clockwise.

Fig 5: Identifying Fuel Pump Cap Tightening Angle
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The cap could be damaged if the SST (wrench) is used with any play between the cap and the SST (wrench). Securely install the SST (wrench) so that there is no gap between the SST (wrench) tabs and the side of the cap.
Set the SST (wrench) as shown in the figure.

Fig 6: Setting SST (Wrench)
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The total rotation angle is 450-495 ° if the approx. 180 ° from Step 5 is included.
Using the SST (wrench) , 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.

Fig 7: Identifying Fuel Pump Cap With Rotation Angle
Courtesy of MAZDA MOTORS CORP.

Rotation angle
- 270-315°
Fuel pump cap tightening torque
- 50-140 N.m {5.1-14 kgf.m, 37-103 ft.lbf}
NOTE:
- The total rotation angle is 450-495 ° if the approx.180 ° from Step 5 is included.
  
  Fig 8: Identifying Fuel Pump Cap Total Rotation Angle
  Courtesy of MAZDA MOTORS CORP.
- If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.
- If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and packing, replace the fuel tank.