Mazda 2: Fuel Tank

FUEL TANK REMOVAL/INSTALLATION

WARNING:

CAUTION:

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.

Mazda 2. FUEL TANK

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

Without using M-MDS

Mazda 2. FUEL TANK

CAUTION:

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

Mazda 2. FUEL TANK

CAUTION:

8. Stop the fuel pump using the following procedure.

Using M-MDS

Without using M-MDS

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).

Mazda 2. FUEL TANK

Mazda 2. FUEL TANK

  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.

Mazda 2. FUEL TANK

Breather Hose Installation Note

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

Mazda 2. FUEL TANK

FUEL TANK INSPECTION

NOTE:

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.

Mazda 2. FUEL TANK

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

5. Remove the port C plug.

6. Turn the fuel tank upside down.

Mazda 2. FUEL TANK

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:

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:

5. Verify that the nonreturn valve is closed.

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