Mazda RX-8 2004-06

Removal & Installation

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CAUTION
Fuel tank removal, installation and repair containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

  1. Park the vehicle on a level surface.
  2.  
  3. Relieve the fuel system pressure, as outlined in this section.
  4.  
  5. Remove the rear seat.
  6.  
  7. Drain fuel from the fuel tank, as follows:
    CAUTION
    A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.


    WARNING
    When the fuel gauge is at a level of ¾ full or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle).

    1. Disconnect the quick release connector (engine compartment side

      Click image to see an enlarged view

      Fig. Detach the quick release connector

    2.  
    3. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
    4.  
    5. Ground check connector terminal F/P to the body using a jumper wire
      WARNING
      Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.



      Click image to see an enlarged view

      Fig. Ground check connector terminal F/P to the body using a jumper wire

    6.  
    7. Turn the ignition switch to the ON position and operate the fuel pump for about. 20 min.
      WARNING
      The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.

    8.  
    9. When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.
      NOTE
      When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.

    10.  
    11. Disconnect the jumper wire.
    12.  
    13. Disconnect the negative battery cable.
    14.  

  8.  
  9. Remove the following components:
    1. Fuel pump unit.
    2.  
    3. Main silencer and middle pipe.
    4.  
    5. Power plant frame.
    6.  
    7. Propeller shaft.
    8.  
    9. Position the parking brake cable out of the way.
    10.  

  10.  
  11. Remove the fuel tank and components as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel tank and related components-Note that the removal order corresponds with the key list number

  12.  
  13. Installation is the reverse of the removal procedure.
  14.  
  15. After installation is complete, inspect all parts by performing the following Fuel Line Inspection procedure:
    CAUTION
    Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the -Fuel Line Inspection-.


    WARNING
    Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.

    1. Ground the check connector terminal F/P to the body using a jumper wire.
    2.  
    3. Turn the ignition switch to the ON position and operate the fuel pump.

      Click image to see an enlarged view

      Fig. Ground the check connector terminal F/P to the body using a jumper wire

    4.  
    5. Check that that there is no fuel leakage from the pressurized parts.

      If there is leakage, replace the fuel hoses.
       
      If there is damage to the seal on the fuel pipe side, replace the fuel pipe.
       
      There should not be any fuel leakage after 5 minutes.
       

    6.  

  16.  
  17. After reinstallation, repeat the fuel leakage inspection.
  18.  

 
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