Fuel Tank Removal/Installation: Notes

WARNING:

Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
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.

Level the vehicle.
Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION ).
Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION ).
Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
Drain the fuel from the fuel tank using the following procedure:

Fig 1: Identifying Quick Release Connector
Courtesy of MAZDA MOTORS CORP.

Using M-MDS
1. Connect the M-MDS to the DLC-2.
2. Using the simulation function "FP", start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST ).
Without using M-MDS
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
  
  Fig 2: Identifying DLC-2
  Courtesy of MAZDA MOTORS CORP.
3. Remove the fuel pump relay.
  CAUTION:
  - Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
    
    Fig 3: Identifying Fuel Pump Relay
    Courtesy of MAZDA MOTORS CORP.
4. Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
5. Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
  CAUTION:
  - The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
    
    Fig 4: Shorting Fuel Pump Relay Terminals C And D In Relay And Fuse Block Using Jumper Wire
    Courtesy of MAZDA MOTORS CORP.
Stop the fuel pump using the following procedure.
Using M-MDS
1. Using the simulation function "FP", stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST ).
2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
Without using M-MDS
1. Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION [L3 WITH TC] ).
To remove the fuel pump unit, remove the following parts:
1. Rear seat cushion (See REAR SEAT CUSHION REMOVAL/INSTALLATION ).
2. Service hole cover
3. fuel pump unit connector
Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION ).
Remove the under cover. (See REAR TRAILING LINK REMOVAL/INSTALLATION ).
Remove the insulator (middle No. 1). (See EXHAUST SYSTEM 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 5: Identifying Service Hole Cover And Screw
Courtesy of MAZDA MOTORS CORP.

Fig 6: Exploded View Of Fuel Tank With Torque Specifications
Courtesy of MAZDA MOTORS CORP.