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Fuel Tank Removal/Installation: AWD: Notes

  1. Level the vehicle.
  2. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
  3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)
  4. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION .)
  5. Perform the work using the following procedure.
    1. Set the air cleaner cover aside.
    2. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
    3. Connect the thick end of SST  (49 T013 102) to the quick release connector until a click sound is heard.
    4. Connect a long hose to the SST  (49 T013 102) and drain the fuel into a container used for collecting gasoline.
      Fig 1: Connecting Long Hose To SST (49 T013 102)
      G06727558Courtesy of MAZDA MOTORS CORP.
  6. Start the fuel pump using the following procedure.

    Using M-MDS 

    1. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)
    2. Connect the M-MDS to the DLC-2.
      Fig 2: Identifying Data Link Connector Location
      G04970859Courtesy of MAZDA MOTORS CORP.
    3. Using the simulation function FP, start the fuel pump.

    Without using M-MDS 

    1. Remove the fuel pump relay.
      Fig 3: Locating Fuel Pump Relay
      G00512286Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • Short the specified terminals because shorting the wrong terminal of the main fuse block may cause malfunctions. 
    2. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.
      Fig 4: Identifying Fuel Pump Relay Terminals
      G04969552Courtesy of MAZDA MOTORS CORP.
    3. Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION .)
      CAUTION:
      • The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when the fuel discharge amount becomes unstable. 
  7. Stop the fuel pump using the following procedure.

    Using M-MDS 

    1. Using the simulation function "FP", start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST .)
    2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)

    Without M-MDS 

    1. Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION .)
  8. To remove the propeller shaft, remove the following parts:
    1. Presilencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
    2. Presilencer insulator
    3. Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
  9. To remove the fuel pump unit, remove the following parts:
    1. Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
    2. Edge cover (See LONG SLIDER REMOVAL/INSTALLATION .)
    3. Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION .)
    4. Rear heat duct No. 3 (See REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION .)
    5. Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
      Fig 5: Presilencer Insulator With Torque Specifications
      G04969564Courtesy of MAZDA MOTORS CORP.
  10. Remove in the order indicated in the table.
  11. Install in the reverse order of removal.
  12. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)
    Fig 6: Fuel Tank Components With Torque Specifications
    G06727566Courtesy of MAZDA MOTORS CORP.
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