Mazda 2: Fuel Pump Unit

FUEL PUMP UNIT REMOVAL/INSTALLATION

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 "BEFORE SERVICE PRECAUTION".
• 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, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak Inspection After Fuel Pump Unit Installation".
• 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.

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

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

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

4. Remove the service hole cover.

5. Remove in the order indicated in the table.

1. Fuel pump unit connector
2. Quick release connector
3. Fuel pump cap
4. Fuel pump unit

6. Install in the reverse order of removal.

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

Fuel Pump Cap Removal Note

CAUTION:

• The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1. Remove the fuel pump cap using the SST.

Fuel Pump Cap Installation Note

NOTE:

• The fuel pump unit will rotate and cannot be secured in the specified position if there is any fuel on the gasket. Thoroughly wipe away all fuel from the gasket.
• Marks are provided on the fuel pump unit and fuel tank for correct installation of the fuel pump unit.

1. Align the fuel tank mark (No.1) with the fuel pump unit mark as shown in the figure.

2. Align the threading start point of the fuel pump cap with the fuel tank mark (No.2) as shown in the figure.

3. While keeping the fuel pump unit from rising up, tighten the fuel pump cap by hand 220- 260

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