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Home >> Mazda >> 2009 >> Tribute s Touring, FWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System - Non-Hybrid >> Fuel Pump Module Removal/Installation

Fuel Pump Module Removal/Installation

WARNING:
  • Do not smoke, or carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury.
WARNING:
  • Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING:
  • When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
WARNING:
  • Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. Release the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE  .
  2. Disconnect the battery ground cable. See BATTERY DISCONNECT .
  3. Remove the Fuel Pump (FP) module access cover.
  4. Disconnect the FP module electrical connector.
    NOTE:
    • Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
  5. Disconnect the fuel tube-to-FP module quick connect coupling.
    NOTE:
    • Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
  6. Connect the Fuel Storage Tanker to the FP module outlet fitting and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange.
    Fig 1: Locating FP Module Outlet Fitting
    G06157133Courtesy of MAZDA MOTORS CORP.
  7. Disconnect the fuel supply tube and fuel vapor recirculation tube-to-FP module quick connect couplings. See QUICK RELEASE COUPLING - DOUBLE LOCKING  .
  8. Using a suitable FP lock ring remover, rotate the lock ring counterclockwise and remove the FP module.
    NOTE:
    • Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring.
      Fig 2: Identifying Fuel Tank Sender Unit Wrench
      G06157142Courtesy of MAZDA MOTORS CORP.
  9. Completely remove the FP module from the fuel tank.
  10. Remove and discard the FP module O-ring seal.
    NOTE:
    • Inspect the surfaces of the FP module flange and fuel tank seal contact surfaces. Do not polish or adjust the seal contact area of the FP module flange or fuel tank. Install a new FP module or fuel tank if the seal contact area is bent, scratched or corroded.
    NOTE:
    • Apply clean engine oil to the FP module O-ring seal.
  11. To install, reverse the removal procedure.
    • Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.
    • Tighten the FP.
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