Mazda B-Series 1998-06

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel tank pump locking retainer ring
     
    Fuel pump mounting gasket and discard the gasket
     
    Fuel pump
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump and a new mounting gasket
     
    Fuel tank pump locking retainer ring. Torque the ring to 66 ft. lbs. (90 Nm).
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove or disconnect the following:

    Fuel tank
     
    Fuel tank pump locking retainer ring
     
    Fuel pump mounting gasket and discard the gasket
     
    Fuel pump
     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump and a new mounting gasket
     
    Fuel tank pump locking retainer ring. Torque the ring to 66 ft. lbs. (90 Nm).
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  



Click image to see an enlarged view

Fig. Fuel pump and related components-2004-2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove the fuel tank.
  8.  
  9. Clean the area around the fuel pump mounting flange.
  10.  
  11. Using the special tool, remove the fuel tank pump assembly locking retainer ring.
    WARNING
    The fuel pump assembly must be removed and handled carefully to avoid damage to the float arm and filter.

  12.  
  13. Remove the fuel pump assembly.
  14.  
  15. Remove and discard the fuel pump mounting gasket.
  16.  

To install:

  1. Clean the fuel pump mounting flange and the fuel tank mounting surface.
  2.  
  3. Install a new fuel pump mounting gasket.
  4.  
  5. Install the fuel pump and sender assembly with the float toward the rear of the tank. Align the arrows molded into the tank and flange.
  6.  
  7. Install the locking ring while compressing the pump assembly into the tank.
  8.  
  9. Using the special tool, tighten the fuel pump assembly locking ring retainer ring until it locks in place.
  10.  
  11. Install the fuel tank.
  12.  

Testing




CAUTION
Fuel pressure must be relieved before attempting to disconnect any fuel lines.

The diagnostic pressure valve (Schrader valve) is located on the fuel supply manifold (rail). This valve provides a convenient point for service personnel to monitor fuel pressure, release the system pressure prior to maintenance, and to bleed out air which may become trapped in the system during pressure replacement. A pressure gauge with an adapter is required to perform pressure tests.



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Fig. Fuel pressure can be checked using an inexpensive pressure/vacuum gauge

If the pressure tap is not installed or an adapter is not available, use a T-fitting to install the pressure gauge between the fuel filter line and the throttle body fuel inlet or fuel rail.

To test the fuel pump, follow the accompanying diagnostic charts. Testing fuel pressure requires the use of a special pressure gauge (Ford Tool T80L-9974-B, Rotunda Fuel Pressure Testing Kit 014-00447, or equivalent) that attaches to the diagnostic pressure tap fitting. To perform the fuel system test a scan tool is necessary to access the different test modes.

Depressurize the fuel system before disconnecting any lines.



Click image to see an enlarged view

Fig. Fuel pressure test chart-part 1



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Fig. Fuel pressure test chart-part 2



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Fig. Fuel pressure test chart-part 3

 
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