Mazda 323/MX-3/626/MX-6/Millenia/Protégé 1990-1998 and Ford Probe 1993-1997

Tank

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REMOVAL & INSTALLATION



323 and Protege-Except 4WD

See Figure 1

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Depress the clips on each end of the rear seat cushion and remove the cushion.
  6.  
  7. Detach the sending unit electrical connector, remove the 4 attaching screws and the sending unit access cover.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the 323 and Protege (Except 4WD) fuel tank assembly

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the fuel hoses and the evaporative hoses from the sending unit and from the fuel tank itself.
  4.  
  5. Position a suitable container under the fuel tank and drain the fuel tank.
  6.  
  7. Remove the attaching screws and the fuel tank insulator from the front of the fuel tank.
  8.  
  9. Support the fuel tank and remove the 2 fuel tank straps.
  10.  
  11. Remove the fuel tank.
  12.  
  13. Position the fuel tank in place and install the 2 tank straps. Tighten the bolts to 27-38 ft. lbs. (37-52 Nm).
  14.  
  15. Install the fuel tank insulator and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  16.  
  17. Connect the evaporative and fuel hoses. Push the hoses on at least 1.4 inches (35mm).
  18.  
  19. Attach the sending unit electrical connector and install the cover.
  20.  
  21. Install the rear seat and connect the negative battery cable.
  22.  

4WD 323 and Protege

See Figure 2

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Depress the clips on each end of the rear seat cushion and remove the cushion.
  6.  
  7. Remove both fuel pump covers and detach the sending unit electrical connectors.
  8.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the 323 and Protege (4WD) fuel tank assembly

  1. Disconnect the fuel hoses and the evaporative hoses from the sending unit/fuel pumps.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Position a suitable container under the fuel tank and drain the fuel tank.
  6.  
  7. Remove the exhaust system intermediate pipe and muffler from below the fuel tank.
  8.  
  9. Remove the driveshaft.
  10.  
  11. Disconnect the fuel hoses from the fuel tank.
  12.  
  13. Support the fuel tank and remove the 2 fuel tank straps.
  14.  
  15. Remove the fuel tank.
  16.  
  17. Position the fuel tank in place and install the 2 tank straps. Tighten the bolts to 32-45 ft. lbs. (43-61 Nm).
  18.  
  19. Connect the hoses to the fuel tank.
  20.  
  21. Install the driveshaft. Tighten the shaft end nuts to 20-22 ft. lbs. (27-30 Nm) and the center shaft support nuts to 27-38 ft. lbs. (37-51 Nm).
  22.  
  23. Install the exhaust intermediate pipe/muffler with new gaskets and tighten the nuts to 30-41 ft. lbs. (40-55 Nm).
  24.  
  25. Attach the hoses and electrical connectors to the fuel sending unit/pump assemblies. Push the hoses on at least 1.4 inches (35mm).
  26.  
  27. Install the fuel pump cover assemblies and install the rear seat.
  28.  
  29. Connect the negative battery cable.
  30.  

MX-3

See Figure 3

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Depress the clips on each end of the rear seat cushion and remove the cushion.
  6.  
  7. Detach the sending unit electrical connector, remove the 4 attaching screws and the sending unit access cover.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Disconnect the fuel hoses and the evaporative hoses from the sending unit and from the fuel tank itself.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the MX-3 fuel tank assembly

  1. Position a suitable container under the fuel tank and drain the fuel tank.
  2.  
  3. Remove the attaching screws and the fuel tank insulator from the front of the fuel tank.
  4.  
  5. Support the fuel tank and remove the 2 fuel tank straps.
  6.  
  7. Remove the fuel tank.
  8.  
  9. Position the fuel tank in place and install the 2 tank straps. Tighten the bolts to 32-45 ft. lbs. (43-62 Nm).
  10.  
  11. Install the fuel tank insulator and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  12.  
  13. Connect the evaporative and fuel hoses. Push the hoses on at least 1.4 inches (35mm).
  14.  
  15. Attach the sending unit electrical connector and install the cover.
  16.  
  17. Install the rear seat and connect the negative battery cable.
  18.  

1990-92 626 and MX-6

See Figure 4

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Depress the clips on each end of the rear seat cushion and remove the cushion.
  6.  
  7. Detach the sending unit electrical connector, remove the 4 attaching screws and the sending unit access cover. Disconnect the fuel hoses from the sending unit.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the 1990-92 626 and MX-6 fuel tank assembly

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the fuel hoses and the evaporative hoses from the fuel tank itself.
  4.  
  5. Position a suitable container under the fuel tank and remove the drain plug to drain the fuel tank.
  6.  
  7. Support the fuel tank.
  8.  
  9. Remove the 2 fuel tank straps and the corner mounting bolts.
  10.  
  11. Remove the fuel tank.
  12.  
  13. Position the fuel tank in place and install the 2 tank straps. Tighten the bolts to 32-45 ft. lbs. (43-61 Nm).
  14.  
  15. Install the corner mounting bolts and tighten them to 16-22 ft. lbs. (22-30 Nm).
  16.  
  17. Connect the evaporative and fuel hoses. Push the hoses on at least 1.4 inches (35mm).
  18.  
  19. Lower the vehicle and attach the sending unit electrical connector and hoses. Install the cover.
  20.  
  21. Install the rear seat and connect the negative battery cable.
  22.  

1993-98 626/MX-6/Probe

See Figure 5

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank and disconnect the negative battery cable.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the 626/MX-6/Probe fuel tank assembly

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the pre-silencer exhaust pipe.
  4.  
  5. Remove the exhaust pipe insulator assembly.
  6.  
  7. Detach the electrical connectors from the top of the fuel tank.
  8.  
  9. Disconnect the fuel and evaporative hoses from the fuel tank.
  10.  
  11. While having an assistant support the fuel tank, remove the fuel tank support straps and lower the fuel tank from the vehicle.
  12.  

To install:
  1. Lift the fuel tank into place and install the fuel tank straps. Tighten the bolts to 32-45 ft. lbs. (43-61 Nm).
  2.  
  3. Connect the fuel and evaporative hoses to the fuel tank, making sure to push the hose on at least 1.4 inches (35mm).
  4.  
  5. Attach the electrical connector to the top of the fuel tank.
  6.  
  7. Install the exhaust pipe insulator assembly and tighten the nut to 70-95 inch lbs. (7.9-10.7 Nm).
  8.  
  9. Install the pre-silencer exhaust pipe with new gaskets and tighten the rear nuts to 28-38 ft. lbs. (38-51 Nm). Tighten the front nuts to 48-65 ft. lbs. (64-89 Nm).
  10.  
  11. Lower the vehicle and connect the negative battery cable.
  12.  

Millenia

See Figure 6

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat cushion.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the fuel tank assembly for Millenia

  1. Detach the fuel pump connector, located beneath the rear seat cushion.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the fuel lines at the tank.
  8.  
  9. Disconnect the fuel filler hose from the tank.
  10.  
  11. Disconnect the fuel tank vapor and breather hoses.
  12.  
  13. Properly support the fuel tank and remove the tank retaining straps.
  14.  
  15. Lower the fuel tank and remove it from the vehicle.
  16.  

To install:
  1. Raise the fuel into position and install the tank retaining straps. Tighten the bolts to 32-44 ft. lbs. (44-60 Nm).
  2.  
  3. Connect the fuel vapor, breather and filler hoses to the tank.
  4.  
  5. Connect the fuel lines to the tank.
  6.  
  7. From inside the vehicle, attach the fuel pump electrical connector.
  8.  
  9. Fill the tank with fuel.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Cycle the ignition switch ON and OFF several times to pressurize the fuel system.
  14.  
  15. Check all hose connections for leaks. Repair any leaks which are found (loose hose clamps, worn or damaged hoses, etc.).
  16.  
  17. Lower the vehicle and install the rear seat cushion.
  18.  

SENDING UNIT REPLACEMENT



MX-3, 323, Protege and 1990-92 626 and MX-6
  1. Relieve the fuel pressure and disconnect the negative battery cable.
  2.  
  3. Depress the clips on each end of the rear seat cushion and remove the cushion.
  4.  
  5. Detach the electrical connector from the fuel pump/sending unit.
  6.  
  7. Remove the attaching screws from the fuel pump/sending unit access cover and remove the cover.
  8.  
  9. Disconnect the fuel supply and return hoses from the fuel pump/sending unit.
  10.  
  11. Remove the attaching screws and the fuel pump/sending unit from the fuel tank.
  12.  
  13. Detach the sending unit electrical connector, remove the sending unit attaching nuts and remove the sending unit from the fuel pump assembly.
  14.  

To install:
  1. Attach the sending unit to the fuel pump assembly and install the nuts. attach the sending unit electrical connector.
  2.  
  3. Install the fuel pump/sending unit into the fuel tank and install the mounting screws.
  4.  
  5. Connect the fuel supply and return lines.
  6.  
  7. Install the access cover and the mounting screws.
  8.  
  9. Attach the sending unit electrical connector.
  10.  
  11. Position the rear seat cushion over the floor, making sure to align the retaining pins with the clips. Push down firmly until the 2 retaining pins are locked into the rear seat retaining clips.
  12.  
  13. Connect the negative battery cable, start the engine and check for proper system operation and for fuel leaks.
  14.  

1993-98 626/MX-6/Probe
  1. Relieve the fuel system pressure and disconnect the negative battery cable. Drain the fuel tank and remove the fuel tank from the vehicle as follows.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the pre-silencer exhaust pipe and the heat shield.
  6.  
  7. Detach the electrical connectors from the top of the fuel tank.
  8.  
  9. Disconnect the fuel and evaporative hoses from the fuel tank.
  10.  
  11. While having an assistant support the fuel tank, remove the fuel tank support straps and lower the fuel tank from the vehicle.
  12.  
  13. Disconnect all fuel hoses from the fuel pump unit.
  14.  
  15. Turn the fuel pump ring counterclockwise and remove it.
  16.  
  17. Remove the fuel pump/sending unit assembly and gaskets from the fuel tank. Separate the sending unit from the fuel tank.
  18.  

To install:
  1. Connect the sending unit to the fuel pump. Install the fuel pump with a new gasket. Turn the fuel pump ring clockwise to tighten it until the flange hits the stopper.
  2.  
  3. Attach the fuel hoses to the fuel pump.
  4.  
  5. Install the fuel tank to the vehicle as follows:
    1. Have an assistant support the fuel tank in place and install the fuel tank straps. Tighten the strap bolts to 32-45 ft. lbs. (43-61 Nm).
    2.  
    3. Connect the fuel and evaporative hoses, making sure to push the hoses on at least 1.4 inches (35 mm).
    4.  
    5. Attach the fuel pump electrical connector.
    6.  
    7. Install the exhaust pre-silencer pipe heat shield. Tighten the bolt to 70-90 inch lbs. (7.9-10 Nm).
    8.  
    9. Install the exhaust pre-silencer pipe with new gaskets intact. Tighten the front nuts to 28-38 ft. lbs. (38-51 Nm). Tighten the rear bolts to 48-65 ft. lbs. (64-89 Nm).
    10.  

  6.  
  7. Lower the vehicle and connect the negative battery cable.
  8.  

 
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