Fuel Tank: Service and Repair Fuel Tank Removal/Installation FUEL TANK REMOVAL/INSTALLATION
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1 2004 Mazda 3 L4-2.3L Copyright 2013, ALLDATA Page 1 Fuel Tank: Service and Repair Fuel Tank Removal/Installation 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. 1. Park the vehicle on a level surface. 2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. WARNING: 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 a vehicle. 3. Drain the fuel from the fuel tank using the following procedure: 1. Disconnect the quick release connector (in the engine compartment). 2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle. 3. Start the fuel pump using the following procedure: Using WDS or equivalent 1. Connect the WDS or equivalent to the DLC Start the fuel pump using the "FP" simulation function. Not using WDS or equivalent 1. Disconnect the negative battery cable. 2. Remove the fuel pump relay. CAUTION: Be careful to short the specified terminal as shorting the wrong terminal of the main fuse block may cause a malfunction.
2 2004 Mazda 3 L4-2.3L Copyright 2013, ALLDATA Page 2 3. Using a jumper wire, short fuel pump relay terminals C and D and connect the negative battery cable to start the fuel pump. CAUTION: The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged. 4. When essentially no fuel is being discharged from the hose, stop the fuel pump using the following procedure: Using WDS or equivalent 1. Stop the fuel pump using the "FP" simulation function. Not using WDS or equivalent 1. Disconnect the negative battery cable to stop the fuel pump. 4. Disconnect the negative battery cable, (using WDS or equivalent) 5. Remove the rear seat cushion. 6. Remove the service hole cover. 7. Disconnect the fuel pump unit connector. 8. Remove the charcoal canister protector. 9. Lower the main silencer so that the insulator can be removed. (See EXHAUST SYSTEM REMOVAL/ INSTALLATION.) 10. Remove the insulator. 11. Remove the rear under cover (LH).
3 2004 Mazda 3 L4-2.3L Copyright 2013, ALLDATA Page 3 Part 1 Part 2
4 2004 Mazda 3 L4-2.3L Copyright 2013, ALLDATA Page Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Inspect all parts by performing "AFTER SERVICE PRECAUTION". vaporative Hose Removal/Installation Note - Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to disconnect the quick release connector of the front side of the fuel tank. (See Type B Removal.) - Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to disconnect the quick release connector connected to the charcoal canister. (See Type C Removal.) - Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to reconnect the quick release connector of the front side of the fuel tank. (See Type B Installation.) - Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to reconnect the quick release connector connected to the charcoal canister. (See Type C Installation.) oint Hose Removal Note 1. Remove the fuel-filler pipe installation bolt. 2. Loosen the tie band connecting with the fuel tank. 3. Pull down the fuel-filler pipe to disconnect the joint hose. reather Hose Removal Note
5 2004 Mazda 3 L4-2.3L Copyright 2013, ALLDATA Page 5 - Except for California emission regulation applicable model, refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION)" to disconnect the quick release connector connecting to the fuel shut-off valve. (See Type B Removal.) Fuel-filler Pipe Removal Note 1. Remove the rear tire (RH). 2. Remove the rear mudguard (RH). 3. Support the rear crossmember using a transmission jack. 4. Remove the rear shock absorber (RH) lower bolts. 5. Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember 30 mm {1.2 in}. 6. Remove the fuel-filler pipe. Breather Hose Installation Note Except for California emission regulation applicable model - Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION)" to reconnect the quick release connector connecting to the fuel shut-off valve. (See Type B Installation.) For California emission regulation applicable model - Connect the breather hose connecting with the fuel tank and clamp as shown in the figure. Joint Hose Installation Note 1. Install the joint hose and clamp as shown in the figure.
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