Mazda 2: Fuel Tank

FUEL TANK REMOVAL/INSTALLATION

WARNING:

• Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
• 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 the vehicle body.

CAUTION:

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Level the vehicle.

2. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION).

3. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION).

4. Remove the service hole cover.

5. Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION).

6. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

7. Drain the fuel from the fuel tank using the following procedure:

Using M-MDS

• Connect the M-MDS to the DLC-2.
• Using the simulation function "FP", start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST).

Without using M-MDS

• Disconnect the negative battery cable.
• Remove the fuel pump relay.

CAUTION:

• Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

• Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.

• Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION).

CAUTION:

• The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

8. Stop the fuel pump using the following procedure.

Using M-MDS

• Using the simulation function "FP", stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST).
• Disconnect the negative battery cable.

Without using M-MDS

• Disconnect the negative battery cable to stop the fuel pump.

9. Disconnect the fuel pump unit connector.

10. Remove the tunnel member. (See EXHAUST SYSTEM REMOVAL/INSTALLATION).

11. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION).

12. Remove the insulator No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION).

13. Remove in the order indicated in the table.

14. Install in the reverse order of removal.

15. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION).

1. Fuel pump unit
2. Quick release connector
3. Joint hose
4. Breather hose
5. Fuel tank
6. Fuel-filler cap
7. Fuel-filler cap cover
8. O-ring
9. Dust cover
10. Fuel-filler pipe protector
11. Fuel-filler pipe

Fuel Tank Component Removal Note

1. Set the parking cable out of the way.

2. Remove the fuel tank component.

Fuel-filler Pipe Protector Removal Note

1. Remove the splash shield (LH). (See SPLASH SHIELD REMOVAL/INSTALLATION).

2. Remove the fuel-filler pipe protector.

Fuel-filler Pipe Removal Note

1. Remove the air filter. (See AIR FILTER REMOVAL/INSTALLATION).

2. Remove the fuel-filler pipe.

Joint Hose Installation Note

1. Install the joint hose and clamp as shown in the figure.

Breather Hose Installation Note

1. Install the breather hose and clamp as shown in the figure.

FUEL TANK INSPECTION

NOTE:

• The rollover valve built into the fuel tank and fuel tank leakage are inspected in this inspection.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION).

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

3. Remove the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION).

4. Perform the following procedure to verify the fuel tank airtightness.

1. Plug the fuel pump unit pipe, ports B and C.

2. Apply a pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.
3. Verify that there is no change in the pressure and no air leakage from the fuel tank.

• If there is air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION).

5. Remove the port C plug.

6. Turn the fuel tank upside down.

7. Apply a pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port C and wait for a while.

8. Verify that there is no change in the pressure and no air leakage from the fuel tank.

If it cannot be verified, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION).

NONRETURN VALVE INSPECTION

WARNING:

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION".

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION).

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

3. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION).

4. Siphon the fuel from the fuel tank.

NOTE:

• Nonreturn valve is integrated in the fuel tank.
• The nonreturn valve is normally closed by the spring force.

5. Verify that the nonreturn valve is closed.

• If the nonreturn valve is stuck open and dose not open even when pulled up by a finger, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION).

READ NEXT: