Fuel pump cap installation note

NOTE:

The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the packing. Thoroughly wipe away all gasoline from the packing.
Make the markings to be easily visible when the fuel pump cap is installed.
Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.
Tighten the fuel pump cap using a torque wrench to prevent fuel leakage.

Mark the fuel pump cap and the fuel tank at the point where the threading of each part begins as shown in the figure.

Fig 1: Marking Fuel Pump Cap And Fuel Tank At Threading Point
Courtesy of MAZDA MOTORS CORP.
Align the fuel tank alignment mark with the fuel pump unit as shown in the figure.

Fig 2: Aligning Fuel Tank Alignment Mark With Fuel Pump Unit
Courtesy of MAZDA MOTORS CORP.
Align the fuel tank and fuel pump cap markings.

Fig 3: Aligning Fuel Tank And Fuel Pump Cap Markings
Courtesy of MAZDA MOTORS CORP.
Rotate the fuel pump cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.

Fig 4: Rotating Fuel Pump Cap Counterclockwise
Courtesy of MAZDA MOTORS CORP.
While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 180° clockwise.

Fig 5: Tightening Fuel Pump Cap 180° Clockwise
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The cap could be damaged if the SST is used with any play between the cap and the SST. Securely install the SST so that there is no gap between the SST tabs and the side of the cap.
Set the SST as shown in the figure.

Fig 6: Installing SST
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The total rotation angle is 450-495 "if the approx. 180° from step 5 is included.
Using a torque wrench, tighten the fuel pump cap with both of the following specified rotation angle and specified torque met being careful not to shift the marks on the fuel pump unit and fuel tank.

Fig 7: Tightening Fuel Pump Cap Using Torque Wrench

Courtesy of MAZDA MOTORS CORP.

CAUTION:

To avoid exceeding the specified rotation angle due to excessive torque, tighten the fuel pump cap starting from the minimum value of 80 N-m {8.2 kgf-m, 60 ft-lbf} and gradually increase the tightening torque without exceeding the maximum value of 180 N-m {18 kgfm, 132 ft-lbf}, and secure the specified rotation angle of 270-315°.

Rotation angle

270-315°

Fuel pump cap tightening torque

80-180 N-m {8.2-18 kgf-m, 60-132 ft-lbf}

If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.
If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and packing, replace the fuel tank.

NOTE:

The total rotation angle is 450-495° if the approx.180° from step 5 is included.

Fig 8: Rotating Fuel Pump Cap Marking

Courtesy of MAZDA MOTORS CORP.

Fuel Tank Type C, D

Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Using the following procedure:
CAUTION:
- Because the fuel surface is higher than the fuel pump unit installation surface, if the set plate is removed, it may result in fuel leakage. If the fuel gauge level indicates 1/2 or more, refer to the fuel draining procedure and drain 20 liters of fuel.
Fuel gauge indicates 3/4 or more
1. Drain the fuel. (See FUEL DRAINING PROCEDURE .)
Fuel gauge indicates less than 3/4
1. Disconnect the negative battery cable. (See NEGAWE BATTERY CABLE DISCONNECTION/CONNECTION .)
Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION .)
Remove the service hole cover.

Fig 9: Removing Service Hole Cover - (Fuel Tank Type C, D)
Courtesy of MAZDA MOTORS CORP.

Remove in the order indicated in the table.

Fig 10: Removing Fuel Pump Unit Parts

Courtesy of MAZDA MOTORS CORP.

COMPONENT DESCRIPTION

1	Fuel pump unit connector
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
3	Set plate (See Set Plate Removal Note .)
4	Fuel pump unit
5	O-ring