Mazda Trucks 1987-1993 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Pickup

See Figure 1



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Fig. Fig. 1: Fuel tank assembly

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the fuel filler cap. Raise and safely support the vehicle.
  4.  
  5. Position a suitable container under the fuel tank. Remove the drain plug and drain the tank.
  6.  
  7. Disconnect the electrical connector from the sending unit or sending unit/fuel pump assembly.
  8.  
  9. Disconnect the fuel filler hose, evaporative hoses, breather hose and fuel lines.
  10.  
  11. Position a jack under the fuel tank and remove the tank attaching nuts. Lower the tank from the vehicle.
  12.  

To install:
  1. Raise the tank into position and install the attaching nuts. Remove the jack.
  2.  
  3. Connect the fuel lines and evaporative hoses, making sure they are pushed onto the fuel tank fittings at least 1 inch (25mm). Connect the breather hose.
  4.  
  5. Connect the fuel filler hose, making sure the hose is pushed onto the fuel tank pipe and filler pipe at least 1.4 inch (35mm).
  6.  
  7. Connect the electrical connector to the sending unit or sending unit/fuel pump assembly.
  8.  
  9. Install the drain plug and lower the vehicle.
  10.  
  11. Fill the fuel tank and install the filler cap. Check for leaks.
  12.  
  13. Start the engine and check for leaks.
  14.  

MPV

See Figure 1

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the fuel filler cap. Raise and safely support the vehicle.
  4.  
  5. Position a suitable container under the fuel tank. Remove the drain plug and drain the tank.
  6.  
  7. Disconnect the fuel pump electrical connector.
  8.  
  9. Disconnect the fuel lines, evaporative hoses, breather hose and fuel filler hose.
  10.  
  11. Support the tank with a jack. Remove the retaining bolts and the fuel tank straps.
  12.  
  13. Lower the fuel tank from the vehicle.
  14.  

To install:
  1. Raise the fuel tank into position and install the straps and retaining bolts. Tighten to 32-44 ft. lbs. (43-61 Nm). Remove the jack.
  2.  
  3. Connect the fuel lines and evaporative hoses, making sure they are pushed onto the fuel tank fittings at least 1 inch (25mm). Connect the breather hose.
  4.  
  5. Connect the fuel filler hose, making sure the hose is pushed onto the fuel tank pipe and filler pipe at least 1.4 inch (35mm).
  6.  
  7. Connect the fuel pump electrical connector.
  8.  
  9. Install the drain plug and lower the vehicle.
  10.  
  11. Fill the fuel tank and install the filler cap. Check for leaks.
  12.  
  13. Start the engine and check for leaks.
  14.  

Navajo

See Figures 2 and 3



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Fig. Fig. 2: Exploded view of the fuel filler assembly



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

  1. Disconnect the negative battery cable and relieve the fuel system pressure.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the fuel from the fuel tank.
  6.  
  7. Remove the shield, skid plate and fuel tank front strap.
  8.  
  9. Support the tank with a jack and remove the bolt from the fuel tank rear strap.
  10.  
  11. Disconnect the filler pipe and vent pipe and lower the tank. Disconnect the vapor hose, fuel lines and electrical connector.
  12.  
  13. Lower the tank from the vehicle.
  14.  

To install:
  1. Raise the fuel tank and connect the electrical connector, fuel lines and vapor hose.
  2.  
  3. Connect the filler pipe and vent pipe. Attach the rear fuel tank strap.
  4.  
  5. Install the shield, skid plate and front strap.
  6.  
  7. Remove the jack and lower the vehicle.
  8.  
  9. Fill the fuel tank and check for leaks. Connect the negative battery cable.
  10.  

 
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