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.
Tighten the fuel pump cap using a torque wrench to prevent fuel leakage.

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

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Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

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Align the fuel tank and fuel pump cap markings.

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Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

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While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180° clockwise.

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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.

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NOTE:
- The total rotation angle is 450-495° if the approx. 180° from Step 5 is included.
Using a torque wrench, tighten the fuel pump cap with both of the following specified rotation angle and specified torque met being careful not to shift the marks on the fuel pump unit and fuel pump cap.

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CAUTION:
- To avoid exceeding the specified rotation angle due to excessive torque, tighten the fuel pump cap starting from the minimum value of 50 N.m {5.1 kgf.m, 37 ft.lbf} and gradually increase the tightening torque without exceeding the maximum value of 140 N.m {14 kgf.m, 103 ft.lbf}, and secure the specified rotation angle of 270-315°.
Rotation angle

270-315°

Fuel pump cap tightening torque

50-140 N.m {5.1-14 kgf.m, 37-103 ft.lbf}
- 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.
NOTE:
- The total rotation angle is 450-495° if the approx. 180° from Step 5 is included.
Courtesy of MAZDA MOTORS CORP.