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Fuel Tank Removal/Installation: Notes

WARNING:
  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "FUEL LINE SAFETY PROCEDURE " to prevent the fuel from spraying.
    • Fuel may cause irritation if it comes in contact with skin and eyes.
    • If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
  • 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.
  1. Level the vehicle.
  2. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION ).
  3. Drain the fuel. (See FUEL DRAINING PROCEDURE ).
  4. Remove the following parts:
    1. Trunk end trim (See TRUNK END TRIM REMOVAL/INSTALLATION ).
    2. Trunk covering (See TRUNK COVERING REMOVAL/INSTALLATION ).
    3. Partition board (See PARTITION BOARD REMOVAL/INSTALLATION ).
    4. Trunk side trim (LH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION ).
    5. Trunk side trim (RH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION ).
  5. Remove the breather hose, joint hose.
    Fig 1: Removing Breather Hose And Joint Hose
    G11274437Courtesy of MAZDA MOTORS CORP.
    COMPONENT DESCRIPTION

    1 Breather hose
    (See Breather hose installation note .)
    2 Joint hose
    (See Joint hose installation note .)
  6. Using the retractable fastback switch, keep the retractable fastback half-open. (with retractable fastback)
    Fig 2: Identifying Front/Rear Roof
    G11274965Courtesy of MAZDA MOTORS CORP.
  7. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION ).
  8. Remove the following parts:
    1. Seat (LH) (See SEAT REMOVAL/INSTALLATION ).
    2. Selector lever knob (AT) (See AUTOMATIC TRANSMISSION SHIFT MECHANISM REMOVAL/INSTALLATION ).
    3. Shift lever knob (MT) (See TRANSMISSION REMOVAL/INSTALLATION ).
    4. Shift panel compartment (See SHIFT PANEL REMOVAL/INSTALLATION ).
    5. Upper panel (See UPPER PANEL REMOVAL/INSTALLATION ).
    6. Parking brake lever boot panel (See PARKING BRAKE LEVER BOOT PANEL REMOVAL/INSTALLATION ).
    7. Rear console (See REAR CONSOLE REMOVAL/INSTALLATION ).
    8. Scuff plate (See SCUFF PLATE REMOVAL/INSTALLATION ).
    9. Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION ).
    10. Seat back bar garnish (See SEAT BACK BAR GARNISH REMOVAL/INSTALLATION ).
    11. Quarter trim (See QUARTER TRIM REMOVAL/INSTALLATION ).
    12. Wind blocker (See WIND BLOCKER REMOVAL/INSTALLATION ).
    13. Roof hook lever (See ROOF HOOK REMOVAL/INSTALLATION ).
    14. Back trim (See BACK TRIM REMOVAL/INSTALLATION ).
    15. Retractable fastback control module (with retractable fastback) (See RETRACTABLE FASTBACK CONTROL MODULE REMOVAL/INSTALLATION ).
    16. CD player, CD player bracket (with CD player) (See CD PLAYER REMOVAL/INSTALLATION ).
    17. Side shelf (LH) (See SIDE SHELF REMOVAL/INSTALLATION ).
    18. Rear package trim (See REAR PACKAGE TRIM REMOVAL/INSTALLATION ).
  9. Remove the service hole cover.
    Fig 3: Removing Service Hole Cover With Screws
    G11274439Courtesy of MAZDA MOTORS CORP.
  10. Disconnect the following parts:
  11. Remove the following parts:
    1. Protector (See FUEL-FILLER PIPE REMOVAL/INSTALLATION ).
    2. TWC (See EXHAUST SYSTEM REMOVAL/INSTALLATION ).
    3. Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION ).
    4. Power plant frame (See POWER PLANT FRAME REMOVAL/INSTALLATION ). (See POWER PLANT FRAME REMOVAL ). (See POWER PLANT FRAME INSTALLATION ).
    5. Floor under cover (See FLOOR UNDER COVER REMOVAL/INSTALLATION ).
    6. Rear crossmember component (See REAR CROSSMEMBER REMOVAL/INSTALLATION ).
    7. Charcoal canister (U. S. A. and CANADA specs). (See CHARCOAL CANISTER REMOVAL/INSTALLATION ).
  12. Remove in the order indicated in the figure below.
  13. Install in the reverse order of removal.
  14. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION ).

U. S. A. and CANADA specs. 

Fig 4: Fuel Tank Components With Torque Specification (USA And CANADA Specs)
G11274440Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

1 Bracket
2 Fuel tank
(See Fuel Tank Removal Note .)
(See Fuel Tank Installation Note .)
3 Pressure control valve
(See Pressure Control Valve Installation Note .)
4 Insulator
(See Insulator Removal Note .)
5 Fuel pump unit
(See FUEL PUMP UNIT REMOVAL/INSTALLATION .)

Except U. S. A. and CANADA specs. 

Fig 5: Fuel Tank Components With Torque Specification (Except USA And CANADA Specs)
G11274441Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

1 Evaporative hose No. 3
(See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
2 Evaporative hose No. 1
(See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
3 Evaporative hose No. 2(checkvalve side)
4 Bracket
5 Charcoal canister component
6 Fueltank
(See Fuel Tank Removal Note .)
(See Fuel Tank Installation Note .)
7 Evaporative hose No. 2 (fuel tank side)
(See Evaporative Hose No. 2 (Fuel Tank Side) Installation Note .)
8 Insulator
(See Insulator Removal Note .)
9 Fuel pump unit
(See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
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