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).


- Fuel pump unit
- Quick release connector
- Joint hose
- Breather hose
- Fuel tank
- Fuel-filler cap
- Fuel-filler cap cover
- O-ring
- Dust cover
- Fuel-filler pipe protector
- 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.
- Plug the fuel pump unit pipe, ports B and C.

- Apply a pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a
while.
- 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:
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.
QUICK RELEASE CONNECTOR 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 b
FUEL INJECTOR REMOVAL/INSTALLATION
WARNING:
Fuel line spills and leakage are dangerous. Fuel can ignite and cause
serious injuries or
death. Fuel can also irritate skin and eyes. To prevent this,
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To decrease the volume, press down the
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Seek Switch
AM/FM radio (Type A/Type C/Type D),
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Press the
FRONT OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable.
2. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
Crankshaft pulley lock bolt
Crankshaft pulley
Front oil seal
Crank
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