Protege 1999-2000

Removal & Installation

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CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

  1. Level the vehicle.
  2.  
  3. Relieve the fuel system pressure. See -Relieving Fuel System Pressure- in this section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the rear seat cushion.
  8.  
  9. Remove the service hole cover.
  10.  
  11. Remove the fuel pump unit.
  12.  
  13. Siphon the fuel from the fuel tank.
  14.  
  15. Remove the exhaust system pre-silencer.
  16.  
  17. Remove the plastic fuel hose (1) and note the following:
    CAUTION
    The retainer must be replaced if removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced.

  18.  
  19. Inspect that the quick release connector joint area is free of foreign material.
  20.  
  21. Clean as necessary.
  22.  
  23. Set the special tool (49 N013 103, or equivalent) as shown and push into the quick release connector to disconnect the plastic fuel hose.
    NOTE
    Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.



    Click image to see an enlarged view

    Fig. Set the special tool (49 N013 103, or equivalent) as shown and push into the quick release connector to disconnect the plastic fuel hose.

  24.  
  25. Remove the evaporative hose (2).
  26.  
  27. Remove the joint hose (3).
  28.  
  29. Remove the fuel tank (4)
  30.  
  31. If needed to transfer to a new fuel tank, remove:

    Fuel tank pressure sensor (5)
     
    Fuel filler pipe (6)
     
    Non-return valve (7)

    Click image to see an enlarged view

    Fig. Exploded view of the fuel tank and related components

     

  32.  

<To install:>

  1. Install in the reverse order of removal, noting the following:
  2.  

Evaporative Hose Installation Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Fit evaporative hose onto the respective fittings within 0.39 in. (10 mm) of the hose end and install clamps.
  2.  

Joint Hose Installation Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Fit the joint hose onto the respective fittings within 1.4-1.5 in. (35-40 mm) and install clamps as shown.

    Click image to see an enlarged view

    Fig. Fit the joint hose onto the respective fittings within 1.4-1.5 in. (35-40 mm) and install clamps as shown.

  2.  

Non-Return Valve Installation Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Align the non-return valve with the notch in the fuel-filler pipe as shown, then install.

    Click image to see an enlarged view

    Fig. Align the non-return valve with the notch in the fuel-filler pipe as shown, then install.

  2.  

Plastic Fuel Hose Installation Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003


NOTE
A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.



Click image to see an enlarged view

Fig. A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.

  1. When the retainer is not removed, perform the following procedure:
    1. Inspect the fuel pump unit sealing surface for damage and deformation, and replace as necessary.
    2.  
    3. If the quick release connector O-ring is damaged, replace the plastic fuel hose.
    4.  
    5. Apply a small amount of clean engine oil to the sealing surface of the fuel pump unit.
    6.  
    7. Align the fuel pipe on the fuel pump unit and quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector. Push the quick release connector straight into the retainer until a click is heard.
    8.  
    9. Lightly pull and push the quick release connector a few times by hand and verify that it can move 0.08-0.11 in. (2-3 mm) and it is connected securely.
    10.  
    11. If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.
    12.  

  2.  
  3. When the retainer is removed, perform the following procedure:
    1. Use the designated genuine retainer only.
    2.  
    3. Inspect the plastic fuel hose and fuel pump unit sealing surface for damage and deformation, and replace as necessary.
    4.  
    5. If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.
    6.  
    7. Install a new retainer onto the quick release connector. Visually inspect that the tabs of the retainer are securely fitted into the quick release connector.
    8.  
    9. Slightly apply clean engine oil to the sealing surface of the fuel pump unit.
    10.  
    11. Push the quick release connector straight into the fuel pump unit until a click is heard.
    12.  
    13. Lightly pull and push the quick release connector a few times by hand and verify that it can move 0.08-0.11 in. (2-3 mm) and it is connected securely.
    14.  
    15. If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.
    16.  

  4.  

 
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