Fuel System (Lf, L3): Removal & Installation Mazda 3 BL

FUEL TANK REMOVAL/INSTALLATION [LF, L3]

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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. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
3. Drain the fuel from the fuel tank using the following procedure: Disconnect the quick release connector (in the engine compartment). (See «QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345209-S35791301002009102000000) ). Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle. Start the fuel pump using the following procedure: Using M-MDS Connect the M-MDS to the DLC-2. Start the fuel pump using the "FP" simulation function. Without using M-MDS Disconnect the negative battery cable. 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. 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. When essentially no fuel is being discharged from the hose, stop the fuel pump using the following procedure: Using M-MDS Stop the fuel pump using the "FP" simulation function. Without using M-MDS Disconnect the negative battery cable to stop the fuel pump.
4. Disconnect the negative battery cable. (using M-MDS)
5. Remove the rear seat cushion. (See «REAR SEAT REMOVAL/INSTALLATION»(ref-345253-S19841861632009102000000) .)
6. Remove the service hole cover.
7. Disconnect the fuel pump unit connector.
8. Remove the charcoal canister protector. (See «CHARCOAL CANISTER REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S20898710432009102000000) .)
9. Lower the main silencer so that the insulator can be removed. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [LF, L3]»(ref-345213-S35458237782009102000000) .)
10. Remove the insulator.
11. Remove the rear under cover (LH).
12. 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". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ). California emission regulation applicable model Except for California emission regulation applicable model

Evaporative Hose Removal/Installation Note

1. 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 «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S33636172962009102000000) .)
2. Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to disconnect the quick release connector connected to the charcoal canister. (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S33636172962009102000000) .)
3. 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 «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S33636172962009102000000) .)
4. Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to reconnect the quick release connector connected to the charcoal canister. (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S33636172962009102000000) .)

Joint 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.

Breather Hose Removal Note

1. 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 «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF, L3]»(ref-345261-S33636172962009102000000) .)

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. (See «REAR SHOCK ABSORBER REMOVAL/INSTALLATION»(ref-345299-S21659066612009102000000) .)
5. Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember 30 mm {1.2 in} . (See «REAR CROSSMEMBER REMOVAL/INSTALLATION»(ref-345299-S12346880182009102000000) .)
6. Remove the fuel-filler pipe.

FUEL PUMP UNIT REMOVAL/INSTALLATION [LF, L3]

Note. Gasket must be replaced anytime fuel pump is removed or replaced.

Scheme 23

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
2. Disconnect the negative battery cable.
3. Remove the fuel tank. (See «FUEL TANK REMOVAL/INSTALLATION [LF, L3]»(ref-345209-S02557428952009102000000) ).
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Scheme 24

1. Remove the retainer ring by tapping a retainer ring projection using a flathead screwdriver as shown in the figure.

Fuel pump unit removal note

Note. The fuel pump unit is secured by the two retainer clips with the bracket on the bottom surface of the fuel tank.

Scheme 25

1. Using a fiber stick, disengage the retainer clips until the pump can be removed.
2. Remove the fuel pump gauge connection area from the fuel pump unit.
3. Set the fuel pump gauge out of the way and remove the fuel pump unit from the fuel tank.

Fuel pump unit installation note

Note. Keep the fuel pump gauge set out of the way.

1. Insert the fuel pump unit to the fuel tank.
2. Install the fuel pump gauge to the fuel pump unit.
3. Engage the retainer clips with the fuel pump unit.

Scheme 26

1. Tap a retainer ring projection using a flathead screwdriver as shown in the figure and tighten the retainer until it is fixed in place.

Scheme 27

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
2. Disconnect the negative battery cable.
3. Remove the fuel tank. (See «FUEL TANK REMOVAL/INSTALLATION [LF, L3]»(ref-345209-S02557428952009102000000) ).
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Fuel pump cap removal note

Scheme 28

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 gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.

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Scheme 36

1. Replace the packing, fuel pump cap and the retainer with new parts. CAUTION: New parts can deform depending on the temperature. If the parts deform, the fuel pump unit cannot be assembled correctly, which could result in fuel leakage. Therefore, keep new parts at room temperature for the specified period of time to stabilize the shape.
2. Leave new parts inside for the following period of time: Stand-by time 12 h or more
3. Install a new retainer to the fuel tank. Align the retainer tabs (3 locations) with the fuel tank grooves. Verify that the tabs are inserted into the grooves and the retainer is installed correctly. Verify the retainer is not damaged.
4. Install a new packing to the fuel tank. Verify the packing groove is clean and free of foreign material. Install the packing to the fuel tank so that it is inserted into the fuel tank grooves. CAUTION: Install the fuel pump unit to the fuel tank being careful not to bend the fuel sender unit arm. If the arm is bent, the fuel sender unit will not operate correctly.
5. Install the fuel pump unit to the fuel tank. Align the fuel pump unit alignment mark and the floating line on the fuel tank. Verify the tab on the fuel pump unit flange with the notch on the retainer.
6. Set on a new fuel pump cap. Apply downward force (push down) on the center of the fuel pump unit flange. NOTE: Align the fuel pump cap with the tightening start position of the retainer and tighten the fuel pump cap with the start position as 0° . The fuel pump cap tightening start position is the position where the spaces between the ribs become narrow. The retainer tightening start position is the notch position. Align the tightening start position on the fuel pump cap and the tightening start point of the retainer. WARNING: No grease or lubrication allowed on parts during installation. Parts could slide or they cannot be tightened to the specified torque. As a result, fuel leakage could occur. When tightening the fuel pump cap, be careful that the points indicated below have not deviated. If there is deviation, the fuel pump unit cannot be installed correctly, which could result in fuel leakage. The fuel pump unit alignment mark and the floating line on the fuel tank The fuel pump unit nipple and the retainer gap.
7. Tighten the fuel pump cap. Tighten the fuel pump cap by hand to the specified angle or more until the flange is fixed. Fuel pump cap rotation angle 270 ° or more Verify that the fuel pump cap is tightened correctly. The gap between the bottom of the fuel pump cap and the tank surface is even all around. If the fuel pump cap is not tightened uniformly, loosen it by hand and reinstall it. Install the SST . NOTE: The fuel pump cap rotation angle is the angle from the 0 ° position. The angle tightened to using the SST includes the angle tightened by hand. Tighten the fuel pump cap to the specified torque and to the specified angle or more. Fuel pump cap rotation angle 620-680 ° Fuel pump cap tightening torque 110 N.m {12 kgf.m, 82 ft.lbf} or more Verify that the fuel pump cap is tightened correctly. The gap between the top of the fuel pump unit flange and the fuel pump cap is even all around. If it is not tightened uniformly, re-install it using the following procedure. The gap between the fuel pump unit and fuel tank is even all around. If it is not tightened uniformly, re-install it using the following procedure. Verify that the fuel pump unit alignment mark and the floating line on the fuel tank are aligned. If they are not aligned, re-install it using the following procedure. Verify that the fuel pump unit nipple and the retainer gap are aligned. If it is not aligned, re-install using the following procedure. Install the SST . Remove the fuel pump cap, fuel pump unit, packing, and retainer. Verify that the retainer is not damaged. If both of the retainer anti-rotation tabs are broken, replace it with new one. Return to Step 2 and re-install.

FUEL FILTER REMOVAL/INSTALLATION

Note. High and low pressure fuel filter are attached to fuel pump located in fuel tank

Scheme 37

1. Remove fuel pump assembly. Refer to «FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [LF, L3]»(ref-345209-S10335792832009102000000) .
2. Locate and remove fuel filters. On some applications filter removal is not possible and complete fuel pump unit may need to be replaced.
3. To install, reverse removal procedure. Refer to «FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [LF, L3]»(ref-345209-S10335792832009102000000) .

QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF, L3]

Scheme 38

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Scheme 40

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ). CAUTION: The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper. NOTE: The fuel hose can be removed by pushing it to the pipe side to release the lock.
2. Rotate the release tab on the quick release connector to the stopper position.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

Scheme 41

1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
2. Push the release tab on the retainer to unlock.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

Type C Removal

Note. When a prompt connector is detached, following SST can be used. 49 N013 103A 49 E042 001

Scheme 42

1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
2. Verify that the quick release connector joint area is free of foreign material. Clean if necessary.
3. Install the SST as shown in the figure and push into the quick release connector to disconnect the fuel pipe.
4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

Type A Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the fuel hose. A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.

Scheme 43

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
3. Reconnect the fuel hose straight to the fuel pipe until a click is heard. NOTE: If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely.
5. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Type B Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
4. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Type C Installation

Note. Use only the designated genuine retainer when replacing the retainer.

Scheme 44

1. Verify that the sealing surfaces of the fuel hose or fuel pipe have no damage or deformation. Replace if necessary. If the O-ring of the quick release connector is damaged or displaced, replace the fuel hose.
2. Install a new retainer to the quick release connector, then visually verify that the retainer tab is installed securely to the connector.
3. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
4. Push the quick release connector into the fuel pipe until a click is heard.
5. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely. If the quick release connector does not move at all, verify that the O-ring is not damaged or has slipped, and then reconnect the connector.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Scheme 45

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) ).
2. Remove the plug hole plate.
3. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
4. Disconnect the negative battery cable.
5. Disconnect the fuel injector connector.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) ).

Fuel Injector Removal Note

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1. Insert a flathead screwdriver between the injector cup and clip finger. NOTE: When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.
2. Push the clip finger outward using a flathead screwdriver.
3. Remove the injector with the clip.
4. Remove the clip from the fuel injector using the following procedure: NOTE: The clip will not be reused. Hold the clip using pliers. Pull the clip parallel to the injector groove and remove it from the injector.

Scheme 49

1. Verify that the O-ring is not damaged. If there is any damage, replace the O-ring.
2. Apply a small amount of clean oil to the injector groove and the O-ring.
3. Temporarily attach a new clip to the injector groove. NOTE: When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.
4. Hold the injector firmly and push the clip into the injector until the clip stops sliding.
5. Verify that the injector connector position is correct.
6. Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.
7. Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.

Scheme 50

1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable.
3. Disconnect the fuel injector connector.
4. Inspect the resistance between fuel injector terminals A and B using a tester. If within the specification, perform the " «CIRCUIT OPEN/SHORT INSPECTION»(ref-345209-S00858951582009102000000) ". If not within the specification, replace the fuel injector. Fuel injector resistance California emission regulation applicable model: 13.1-14.5 ohms [20 °C {68 °F}] Except for California emission regulation applicable model: 11.4-12.6 ohms [20 °C {68 °F}]

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1. Disconnect the PCM connector. (See «PCM REMOVAL/INSTALLATION [LF, L3]»(ref-345210-S40556685212009102000000) .)
2. Inspect the following wiring harnesses for open or short circuit (continuity check).

Scheme 53

1. If there is no continuity, there is an open circuit. Repair or replace the wiring harness. Fuel injector No.1 terminal A and PCM terminal 2BB Fuel injector No.2 terminal A and PCM terminal 2BC Fuel injector No.3 terminal A and PCM terminal 2BD Fuel injector No.4 terminal A and PCM terminal 2AZ Fuel injector No.1 terminal B and main relay terminal A Fuel injector No.2 terminal B and main relay terminal A Fuel injector No.3 terminal B and main relay terminal A Fuel injector No.4 terminal B and main relay terminal A