Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Tank Assembly

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REMOVAL & INSTALLATION



GLC with Rear Wheel Drive, 1979-87 626 and 1986-87 323

See Figure 1

On sedans and coupes, the fuel tank is located behind the partition board in the trunk. On wagons, it is under the rear of the car.

  1. On sedans and coupes, open the trunk and remove the partition board. For fuel injected vehicles, be sure to properly relieve fuel system pressure.
  2.  
  3. On the 626, push the access hole cover inward toward the tank. On the 626 diesel, remove the lower cushion for the rear seat.
  4.  
  5. Raise and safely support wagon models on axle stands.
  6.  
  7. Disconnect the inlet line from the fuel filter on 1978-85 carbureted vehicles. Remove the tank filler hose clamp, and disconnect the hose at the tank. On fuel injected vehicles, there will be two hoses to disconnect at the top of the tank.
  8.  
  9. Raise and safely support the vehicle on axle stands (all models).
  10.  
  11. Disconnect the condensing tank hoses.
  12.  
  13. Unfasten the mounting bolts and remove the tank.
  14.  
  15. Installation is the reverse of removal. Where clamps are used, make sure that the clamp is firmly positioned on the hose, so that there is one clamp width of bare hose at the end. On the 626, install the large filler hose so that it is at least 1.42 in. (36mm) onto the tank fitting and filler tube at each end.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Hose routing on the GLC Wagon fuel tank

GLC with Front Wheel Drive

The fuel tank is located under the rear of the car.

  1. Remove the rear seat.
  2.  
  3. Remove the fuel tank gauge unit and drain the gas tank. Siphon if necessary.
  4.  
  5. Raise the rear of the car and safely support it on jackstands.
  6.  
  7. Disconnect all hoses at the tank.
  8.  
  9. Remove the mountings, then lower the fuel tank from the car.
  10.  
  11. Installation is the reverse of removal.
  12.  

1988-89 323, 626 and MX-6
EXCEPT TURBO WITH 4WD OR 4WS
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat cushion from the 323. Detach the connector from the fuel tank gauge unit, then remove the cover plate and gasket.
  4.  
  5. Disconnect the fuel main and return the hoses. Plug the ends of the hoses to prevent leakage.
  6.  
  7. Raise the vehicle and support it safely on jackstands. Position a suitable waste container under the fuel tank and remove the fuel filler cap. Remove the drain plug and drain all the fuel from the tank into the waste container. Disconnect all the remaining fuel, evaporative, filler or breather hoses and label them for assembly reference.
  8.  
  9. Support the fuel tank and disconnect it from its mounting by removing the retaining straps. Carefully lower the fuel tank to the ground and slide it out from under the vehicle. Send the fuel tank to a repair shop where it can be steam cleaned to remove all the explosive gases from the tank. Check the tank for cracks. If the tank is not to be reinstalled for an extended period of time, store it outside in a cool and shady area.
  10.  

To install:
  1. Raise the fuel tank onto its mounting and secure it with the retaining straps. Connect the fuel hoses that were disconnected in Step 4. Push the hose ends at least 0.98 in. (25mm) onto the end of each connection. On the section of hose that connects the filler neck to the fuel tank, push the hose at least 1.5 in. (38mm) over the connections. Install and tighten the drain plug, then lower the vehicle.
  2.  
  3. Connect the main and return fuel hoses. Install the fuel tank cover plate with a new gasket. Fasten the electrical connector to the gauge unit.
  4.  
  5. Fill the fuel tank and install the filler cap, then start the engine and conduct a thorough inspection of all fuel line connections to be sure that there are no leaks. Run the tip of your finger around the edge of the drain plug and check for leaks. When the integrity of the fuel system is verified, install the rear seat cushion on the 323.
  6.  

323 TURBO WITH 4WD
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat cushion. Unfasten the connector from the fuel tank gauge unit, then remove the cover plate and gasket.
  4.  
  5. Disconnect the fuel main and return hoses. Plug the ends of the hoses to prevent leakage.
  6.  
  7. Disconnect the section of exhaust pipe that runs between the catalytic converter and muffler.
  8.  
  9. Disconnect and remove the propeller shaft. For details, please refer to Drive Train .
  10.  
  11. Detach the transfer pump connector. Loosen the transfer pump retaining screws and remove the transfer pump from the fuel tank. Refer to the previous procedure for 323 non-4WD models for the remainder of the removal and installation procedure.
  12.  

626 AND MX-6 TURBO WITH 4WS
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Detach the electrical connectors from the main and transfer fuel pumps.
  4.  
  5. Remove the cover plates and disconnect the steering angle transfer shaft. Remove the cross member. Refer to the previous procedure for 626 non-4WS models for the remainder of the removal and installation procedure. Torque the retaining strap bolts to 32-45 ft. lbs. (43-61 Nm).
  6.  

929
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Open the trunk and disconnect the evaporative hoses, fuel hoses and the fuel pump electrical connector.
  4.  
  5. Raise the vehicle and support it safely on jackstands. Position a suitable waste container under the fuel tank. Remove the filler cap, then unfasten the drain plug and drain all the fuel from the tank into the waste container. Disconnect all the remaining fuel, evaporative, filler or vent hoses and label them for assembly reference.
  6.  
  7. Support the fuel tank and disconnect it from its mounting by removing the two retaining straps. Carefully lower the fuel tank to the ground and slide it out from under the vehicle. Send the fuel tank to a repair shop where it can be steam cleaned to remove all the explosive gases from the tank. Check the tank for cracks. If the tank is not to be reinstalled for an extended period of time, store it outside in a cool and shady area.
  8.  

To install:
  1. Raise the fuel tank onto its mounting and secure it with the retaining straps. Working from underneath the vehicle, connect the fuel hoses that were disconnected in Step 3. Push the hose ends at least 0.98 in. (25mm) onto the end of each connection. On the section of hose that connects the filler neck to the fuel tank, push the hose at least 1.5 in. (38mm) over the connections. Install and tighten the drain plug, then lower the vehicle.
  2.  
  3. Working from inside the trunk, attach the fuel pump connector, the fuel (main and return) lines, and the evaporative hoses. Make sure that all connections are tight.
  4.  
  5. Fill the fuel tank and install the filler cap. Start the engine and conduct a thorough inspection of all fuel line connections to be sure that there are no leaks. Run the tip of your finger around the edge of the drain plug and check for leaks.
  6.  

RX-7
  1. On fuel injected models, relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. On 1986-89 models, remove the fuel pump as described previously in this section.
  4.  
  5. Disconnect the fuel filler hose from the tank.
  6.  
  7. Raise the rear of the vehicle and safely support it with jackstands.
  8.  
  9. Remove the front and side tank protectors.
  10.  
  11. Disconnect the fuel main hose, fuel return hose and evaporation hoses from the fuel tank.
  12.  
  13. Remove the fixing band attaching bolts and lower the fuel tank.
  14.  
  15. Installation is the reverse of removal. Be sure to insert the tank fittings at least 1.0 in. (25.4mm) into the hose ends. Also, be sure to install the large filler hose so that it extends at least 1.6 in. (40mm) onto the tank fitting and filler tube at each end.
  16.  

 
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