Fuel Tank Removal/Installation: Notes

WARNING:

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 a vehicle.
Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".

CAUTION:

When the fuel gauge indicates 3/4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle.)

Park the vehicle on a level surface.
Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Remove the rear seat. (See REAR SEAT REMOVAL/INSTALLATION .)
Disconnect the quick release connector from the fuel pump unit. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
Connect the hose to the fuel pump unit 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
1. Connect the M-MDS to the DLC-2
2. Using the simulation function "FP", start the fuel pump. (Refer to the ON-BOARD DIAGNOSTIC TEST [13B-MSP] in the appropriate Engine article .)
  CAUTION:
  - Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.
  Fig 1: Identifying DLC-2 Connector
  Courtesy of MAZDA MOTORS CORP.
Without using M-MDS
1. Ground check connector terminal F/P to the body using a jumper wire.
  CAUTION:
  - The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling.) Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.
  Fig 2: Identifying Check Connector Terminal F/P
  Courtesy of MAZDA MOTORS CORP.
2. Turn the ignition switch to the ON position and operate the fuel pump.
NOTE:
- When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.
Stop the fuel pump using the following procedure.
Using M-MDS
1. Using the simulation function "FP", stop the fuel pump. (Refer to the ON-BOARD DIAGNOSTIC TEST [13B-MSP] in the appropriate Engine article .)
Without using M-MDS
1. Turn the ignition switch to the LOCK position and stop the fuel pump.
2. Disconnect the jumper wire.
Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [13B-MSP] .)
Remove the following parts:
1. Fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
2. Main silencer and middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
3. Power plant frame. (See TRANSMISSION REMOVAL/INSTALLATION .) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION .)
4. Propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
Position the parking brake cable out of the way. (See PARKING BRAKE LEVER 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 3: Exploded View Of Fuel Tank Components With Torque Specifications
Courtesy of MAZDA MOTORS CORP.