Mazda Car 2002-04

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel from the tank.
  6.  
  7. Loosen the fuel tank retaining clamps.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hoses from the fuel tank
     
    Fuel pump electrical connector
     
    Fuel tank heat shield
     
    Fuel tank support brackets by supporting the fuel tank
     
    Fuel tank
     
    All fuel hoses from the fuel pump unit
     
    Fuel pump ring by turning counterclockwise
     
    Fuel pump and gaskets from the fuel tank

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-626

     

  10.  

To install:

  1. Install or connect the following:

    Fuel pump using a new gasket
     
    Fuel pump ring by turning it clockwise until the flange hits the stopper
     
    Fuel hoses to the fuel pump
     
    Fuel tank
     
    Fuel tank support brackets
     
    Fuel tank heat shield
     
    Fuel pump electrical connector
     
    Hoses to the fuel tank
     
    Fuel tank retaining clamps
     
    Negative battery cable
     

  2.  
  3. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
  4.  

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

    Negative battery cable
     
    Rear seat cushion
     
    Fuel pump/sending unit electrical connector
     
    Fuel pump/sending unit access cover
     
    Fuel supply and return hoses from the fuel pump/sending unit
     
    Fuel pump/sending unit from the fuel tank
     
    Sending unit electrical connector
     
    Sending unit from the fuel pump assembly
     

  6.  

To install:

  1. Install or connect the following:

    Sending unit to the fuel pump assembly
     
    Sending unit electrical connector
     
    Fuel pump/sending unit into the fuel tank with a new gasket
     
    Fuel supply and return lines
     
    Access cover
     
    Sending unit electrical connector
     
    Rear seat cushion
     
    Negative battery cable
     

  2.  
  3. Start the engine and check fuel leaks.
  4.  

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

    Negative battery cable
     
    Rear package trim
     
    Service hole cover
     
    Fuel pump cover
     
    Fuel pump connector
     
    Fuel hoses
     
    Fuel pump and gauge sender unit as an assembly
     
    Fuel pump from the sender bracket
     

  6.  

To install:



New O-ring set
 
Fuel pump to the sender bracket
 


NOTE
Pull the fuel pump down so that it is tight against the bracket.



Fuel pump and gauge sender unit as an assembly
 
Fuel hoses
 
Fuel pump connector
 
Fuel pump cover
 
Service hole cover
 
Rear package trim
 
Negative battery cable
 

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel from the tank.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump electrical connector
     
    Hoses from the fuel tank
     
    Pressure control valve
     
    Fuel tank pressure sensor
     
    Fuel pipe
     
    Pre-silencer insulator
     
    Fuel tank strap while supporting the fuel tank
     
    Fuel tank
     
    All fuel hoses from the fuel pump unit
     
    Fuel pump ring retainers and the ring
     
    Fuel pump and gaskets from the fuel tank

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-626



    Click image to see an enlarged view

    Fig. Exploded view of the fuel tank assembly-626

     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump using a new gasket
     
    Fuel pump ring and tighten the fasteners to 19 inch lbs. (2 Nm)
     
    Fuel hoses to the fuel pump
     
    Fuel tank
     
    Fuel tank strap while supporting the fuel tank. Refer to the illustration for torque specifications.
     
    Pre-silencer insulator
     
    Fuel pipe
     
    Fuel tank pressure sensor
     
    Pressure control valve
     
    Hoses to the fuel tank
     
    Fuel pump electrical connector
     
    Negative battery cable
     

  2.  
  3. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
  4.  

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

    Negative battery cable
     
    Rear seat cushion
     

  6.  
  7. Drain the fuel from the tank.

    Service hole cover
     
    Fuel pump electrical connector
     
    Hoses from the fuel tank
     
    Fuel tank strap while supporting the fuel tank
     
    Evaporative hose
     
    Fuel tank
     
    All fuel hoses from the fuel pump unit
     
    Fuel pump ring using tool 49 T042 011
     
    Fuel pump and gaskets from the fuel tank

    Click image to see an enlarged view

    Fig. Remove the fuel pump ring-Millenia

     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump using a new gasket
     
    Fuel pump ring and tighten the fasteners to 75 ft. lbs. (102 Nm)
     
    Fuel hoses to the fuel pump
     
    Fuel tank
     
    Evaporative hose
     
    Fuel tank strap while supporting the fuel tank. Tighten the strap bolts to 44 ft. lbs. (60 Nm).
     
    Hoses to the fuel tank
     
    Fuel pump electrical connector
     
    Service hole cover
     
    Rear seat cushion
     
    Negative battery cable
     

  2.  
  3. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Exploded view of the fuel tank and related components-Mazda 3 California emission models



Click image to see an enlarged view

Fig. Exploded view of the fuel tank and related components-Mazda 3 non-California emission models

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the quick release connector in the engine compartment.
  6.  
  7. Attach a long hose to the disconnect fuel pipe and drain the fuel into a suitable container as follows:
    1. Using a jumper wire, ground the Powertrain Control Module (PCM) terminals. If equipped with an immobilizer, ground terminal 1AR, if not equipped with an immobilizer, ground terminal 1AQ. Refer to the illustration for terminal location.
    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
      CAUTION
      The fuel pump can be damaged if all fuel is removed from the tank, monitor the hose and stop when no fuel is being discharged from the tank.



      Click image to see an enlarged view

      Fig. If equipped with an immobilizer, ground PCM terminal 1AR, if not equipped with an immobilizer, ground PCM terminal 1AQ-Mazda 3 models

    4.  
    5. Once no more fuel is being discharged, turn the ignition OFF.
    6.  

  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the rear seat cushion and remove the pump service hole cover.
  12.  
  13. Disconnect the fuel pump connector and remove the charcoal canister.
  14.  
  15. Lower the exhaust main silencer so the insulator can be removed and remove the insulator.
  16.  
  17. Remove the rear left hand under cover.
  18.  
  19. Disconnect the evaporator hose, quick release fuel connector on the fuel line and charcoal canister.
  20.  
  21. Support the fuel tank and remove the strap.
  22.  
  23. Remove the filler pipe bolt, loosen the tie band and pull down on the filler pipe to disconnect the joint hose.
  24.  
  25. Lower and remove the fuel tank.
  26.  
  27. Disconnect the fuel release connector.
  28.  
  29. Use tool 49 F042 001 to remove the pump cap on non-California emission models.
  30.  
  31. Use a brass drift and a hammer to remove the fuel pump retaining ring on California emission models.
  32.  
  33. Remove the fuel pump assembly.

    Click image to see an enlarged view

    Fig. Exploded view of the pump assembly and related components-Mazda 3 non-California emission models



    Click image to see an enlarged view

    Fig. Exploded view of the pump assembly and related components-Mazda 3 California emission models



    Click image to see an enlarged view

    Fig. Use tool 49 F042 001 to remove the pump cap-Mazda 3 non-California emission models



    Click image to see an enlarged view

    Fig. Use a brass drift and a hammer to remove the fuel pump retaining ring-Mazda 3 non-California emission models

  34.  

To install:

  1. Install the fuel pump assembly.
  2.  
  3. Clean all gasoline from the pump gasket to prevent it from turning during installation.
  4.  
  5. On non-California emission models, align the pump and tank assembly as illustrated.
  6.  
  7. Use tool 49 F042 001 to tighten the pump cap on non-California emission models. Tighten the cap to 59-66 ft. lbs. (80-90 Nm). If the torque cannot be reached, replace the pump cap and gasket. If the torque cannot still be reached, replace the fuel tank.
  8.  
  9. On California emission models, use a brass drift and a hammer to install the fuel pump retaining ring
  10.  
  11. Before installing the tank apply 1.7 inch Hg (5.9 kPa) of pressure to the tank to check for leakage around the pump.

    Click image to see an enlarged view

    Fig. Align the pump and tank assembly as shown-Mazda 3 non-non-California emission models



    Click image to see an enlarged view

    Fig. Use a brass drift and a hammer install the fuel pump retaining ring-Mazda 3 non-California emission models

  12.  
  13. Connect the fuel release connector.
  14.  
  15. Raise the fuel tank into position.
  16.  
  17. Install the joint hose and align the hose and clamp as illustrated.

    Click image to see an enlarged view

    Fig. Install the joint hose and align the hose and clamp as shown-Mazda 3

  18.  
  19. Install the strap. Tighten the bolts to 16-22 ft. lbs. (22-30 Nm).
  20.  
  21. Connect the evaporator hose, quick release fuel connector on the fuel line and charcoal canister.
  22.  
  23. Install the rear left hand under cover.
  24.  
  25. Install insulator and the exhaust main silencer.
  26.  
  27. Install the charcoal canister and connect the fuel pump connector.
  28.  
  29. Install the pump service hole cover and rear seat.
  30.  
  31. Disconnect the negative battery cable.
  32.  
  33. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, ground the Powertrain Control Module (PCM) terminals. If equipped with an immobilizer, ground terminal 1AR, if not equipped with an immobilizer, ground terminal 1AQ. Refer to the illustration for terminal location.
    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
    4.  
    5. Check the hoses, clips and other fuel system components for leaks.
    6.  
    7. If there are any leaks, replace the fuel hoses and clips. If the is damage to the seal on the fuel pipe side, replace the pipe.
    8.  
    9. The system must be leak free for five minutes with the terminal grounded. If any component is replaced because of a system, leak, turn the ignition key OFF; remove the jumper wire from the terminal. reapply the jumper wire, turn the ignition On and check for leaks.
    10.  

  34.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the rear seat cushion.
  8.  
  9. Remove the service hole cover.
  10.  
  11. Disconnect the fuel pump electrical connector.
  12.  
  13. Disconnect the hoses from the fuel tank.
    NOTE
    The fuel pump cap can be damaged if there is a gap between the removal/installation tool 49 F042 001. Make sure the tool is attached securely to the cap and that no gap exists between them.

  14.  
  15. Remove the fuel pump ring using tool 49 F042 001.
  16.  
  17. Remove the fuel pump and gaskets from the fuel tank.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-Mazda 6 models



    Click image to see an enlarged view

    Fig. Remove the fuel pump ring using tool 49 F042 001-Mazda 6 models

  18.  

To install:

  1. Install the fuel pump using a new gasket.
    NOTE
    The fuel pump cap can be damaged if there is a gap between the removal/installation tool 49 F042 001. Make sure the tool is attached securely to the cap and that no gap exists between them.

  2.  
  3. Align the fuel pump assembly alignment marks and the floating lines as illustrated.
  4.  
  5. Align the tightening start positions of the cap and the retainer notch as illustrated and tighten them one full turn by hand. If the cap cannot be tightened by hand , remove the cap and make sure the cap is not damaged or misaligned on the retainer or cap and retighten.
  6.  
  7. Make sure the alignment mark and the floating lines are still aligned, tighten the cap to 59-99 ft. lbs. (80-135 Nm) or a rotation angle of 50-140 degrees with the total angle of step 2 and 3 being 410-500 degrees.

    Click image to see an enlarged view

    Fig. Align the fuel pump assembly alignment marks and the floating lines-Mazda 6 models



    Click image to see an enlarged view

    Fig. Align the tightening start positions of the cap and the retainer notch-Mazda 6 models

  8.  

 
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