Fuel Pump Unit Removal/Installation

WARNING:

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, always complete the "Fuel Line Safety Procedure".
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, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation".
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:

Because the fuel tank is constructed such that the fuel level is higher than the installation surface of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more, perform the following Steps 1- 6 to drain approx. 10 L {11 US gal, 8.8 Imp gal} of fuel.
Disconnecting/connecting the quick release connector without cleaning it may possibly 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.
To prevent the Special Service Tool from coming off the fuel pump cap while performing the work, always perform the removal/installation procedure with 2 people. One person presses the Special Service Tool against cap from directly above, while the other person rotates the Special Service Tool .

Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Remove the rear seat cushion.
Remove the service hole cover.

Fig 1: View Of Service Hole Cover
Courtesy of MAZDA MOTORS CORP.
Disconnect the quick release connector connected to the fuel pump unit.
Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
Start the fuel pump using the following procedure.
Using M-MDS

Fig 2: Identifying Quick Release Connector & Hose
Courtesy of MAZDA MOTORS CORP.
1. Connect the M-MDS to the DLC-2.
2. Using the simulation function "FP", start the fuel pump.
Without using M-MDS
1. Remove the fuel pump relay.
  CAUTION:
  - Short the specified terminals because shorting the wrong terminal of the main fuse block may cause malfunctions.
    
    Fig 3: Locating DLC-2 Connector
    Courtesy of MAZDA MOTORS CORP.
2. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.
3. Connect the negative battery cable and operate the fuel pump.
  CAUTION:
  - The fuel pump could be damaged if it is operated (fuel pump idling) 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: Identifying Fuel Pump Relay Terminals
    Courtesy of MAZDA MOTORS CORP.
When essentially no fuel is being discharged, stop the fuel pump.
Using M-MDS
1. Using the simulation function "FP", stop the fuel pump.
Without using M-MDS
1. Turn the ignition switch to LOCK position to stop the fuel pump.
2. Disconnect the jumper wire from the check connector.
Disconnect the negative battery cable.
Remove the fuel pump bracket installation screws.
Remove in the order indicated in the table in the illustration.

Fig 5: Exploded View Of Fuel Pump Unit
Courtesy of MAZDA MOTORS CORP.
Install in the reverse order of removal.
Complete the "AFTER SERVICE PRECAUTION" (See AFTER SERVICE PRECAUTION .)