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Fuel Tank: Removal

WARNING:
  • Do not smoke or carry an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
WARNING:
  • Do not carry personal electronic devices such as cell pones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNING:
  • Fuel in the fuel system remains under high pressure, even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.
WARNING:
  • The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. See LIFTING .
  2. Release the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE  .
  3. Disconnect the battery ground cable. See BATTERY DISCONNECT .
  4. Remove the fuel tank filler cap.
  5. Insert the fuel drain hose SST  310-102 into the fuel filler pipe until it reaches the fuel tank check valve.
  6. Attach the fuel storage tanker SST  164-R3202 or equivalent to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.

    7. 4WD vehicles 

  7. Support the exhaust system with a suitable stand, release the 3 rear exhaust hangers and carefully lower the exhaust system to allow enough clearance to remove the fuel tank.
  8. On 4WD vehicles, remove the driveshaft. See DRIVESHAFT .

    9. All vehicles 

  9. Lift the LH rear seat cushion and position the carpet aside.
  10. Remove the 4 screws and the fuel pump module access cover.
  11. Disconnect the fuel pump module electrical connector.
  12. Disconnect the fuel tank pressure sensor electrical connector.
  13. Disconnect the fuel supply tube quick connect coupling.
  14. Using a suitable fuel pump lock ring remover, rotate the lock ring counterclockwise and remove.
    Fig 1: Rotating Lock Ring
    G04320139Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The fuel pump module must be handled carefully to avoid damage to the float arm and filter.
  15. Prior to completely removing the fuel pump, position it aside and using the fuel drain hose SST  and the fuel storage tanker SST  164-R3202 or equivalent, drain the fuel tank.
    Fig 2: Draining Fuel Tank
    G04320140Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Some fuel will remain in the fuel pump module after draining the fuel tank. Carefully drain the fuel pump module into a suitable container.
  16. To release the bottom-mounted fuel pump module, reach into the fuel pump module opening and squeeze the retainer tabs on the pump module housing and pull upward and remove the fuel pump module.
    Fig 3: Removing Fuel Pump Module
    G04320141Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Be careful that no foreign material falls into tank.
  17. Remove and discard the fuel pump module O-ring seal, making sure the mounting area is clean and free of foreign material.
  18. Reposition the clamp and disconnect the fuel filler pipe hose from the fuel tank.
  19. Position a suitable lifting device under the fuel tank.
  20. Disconnect the pin-type retainer from the fuel tank strap and position the parking brake cable aside.
    Fig 4: Disconnecting Pin-Type Retainer From Fuel Tank Strap
    G04320142Courtesy of MAZDA MOTORS CORP.
  21. Remove the bolts and the fuel tank straps.
  22. Partially lower the fuel tank enough to access and release the fuel vapor control tube assembly valve quick connect.
    Fig 5: Removing Fuel Tank
    G04320143Courtesy of MAZDA MOTORS CORP.
    • Remove the fuel tank.
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