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Fuel System (L3): Removal & Installation Mazda 5 I

Fuel System 14 illustrations ~1244 words

FUEL TANK REMOVAL/INSTALLATION [L3]

WARNINGRepairing 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.

Scheme 19

Scheme 19
Scheme 19
  1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system.
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  3. Disconnect the negative battery cable.
  4. Remove the second-row seat. (See «SECOND-ROW SEAT REMOVAL/INSTALLATION»(ref-244372-S37010876322006092100000) ).
  5. Remove the rear package tray lid (See «REAR PACKAGE TRAY LID REMOVAL/INSTALLATION»(ref-244361-S18906244912006092100000) ).
  6. Remove the sub-trunk
  7. Remove the third-row seat (See «THIRD-ROW SEAT REMOVAL/INSTALLATION»(ref-244372-S17463966512006092100000) ).
  8. Remove the rear scuff plate (See «REAR SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S08969594692006092100000) ).
  9. Remove the trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-244361-S41938693372006092100000) ).
  10. Remove the third-row seat belt lower anchor installation bolt (See «THIRD-ROW SEAT BELT REMOVAL/INSTALLATION»(ref-244398-S28594203972006092100000) ).
  11. Remove the cargo compartment light (See «CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION»(ref-244399-S02348388242006092100000) ).
  12. Remove the trunk side trim. (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S40694322992006092100000) ).
  13. Partially peel back the floor covering.
  14. Remove the service hole cover.
  15. Disconnect the fuel pump unit connector.
  16. Disconnect the quick release connector.
  17. Park the vehicle on a level surface. 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.
  18. Drain the fuel.
  19. Remove the flange nuts between the catalytic converter and pre-silencer, and between the pre-silencer and main silencer, to allow the insulator to be removed.
  20. Remove the rear under cover.
  21. Remove the insulator.
  22. Remove in the order indicated in the table.
  23. Install in the reverse order of removal.
  24. Inspect all parts by performing "AFTER SERVICE PRECAUTION".

Fuel-Filler Pipe Removal Note

  1. Remove the rear tire (RH).
  2. Remove the fuel-filler pipe.

Protector Removal Note

CAUTIONBe careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, It may cause fuel leakage.

Note. The protector is installed using rivets. When reinstalling the rivet, install the same rivet or M5 bolt and nut.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).
  2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

Scheme 22

Scheme 22: Joint Hose Installation Note
Scheme 22: Joint Hose Installation Note
  1. Install the joint hose and clamp as shown in the figure.

FUEL PUMP UNIT REMOVAL/INSTALLATION [L3]

WARNINGFuel 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".

Scheme 23

Scheme 23
Scheme 23
  1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system.
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  3. Disconnect the negative battery cable.
  4. Remove the second-row seat. (See «SECOND-ROW SEAT REMOVAL/INSTALLATION»(ref-244372-S37010876322006092100000) ).
  5. Remove the rear package tray lid (See «REAR PACKAGE TRAY LID REMOVAL/INSTALLATION»(ref-244361-S18906244912006092100000) ).
  6. Remove the sub-trunk
  7. Remove the third-row seat (See «THIRD-ROW SEAT REMOVAL/INSTALLATION»(ref-244372-S17463966512006092100000) ).
  8. Remove the rear scuff plate (See «REAR SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S08969594692006092100000) ).
  9. Remove the trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-244361-S41938693372006092100000) ).
  10. Remove the third-row seat belt lower anchor installation bolt (See «THIRD-ROW SEAT BELT REMOVAL/INSTALLATION»(ref-244398-S28594203972006092100000) ).
  11. Remove the cargo compartment light (See «CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION»(ref-244399-S02348388242006092100000) ).
  12. Remove the trunk side trim. (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S40694322992006092100000) ).
  13. Partially peel back the floor covering.
  14. Remove in the order indicated in the table. FUEL PUMP UNIT REMOVING ORDER 1 Service hole cover 2 Fuel pump unit connector 3 Quick release connector (Type B) (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3]»(ref-244329-S37413676872006092100000) ). 4 Packing 5 Fuel pump unit
  15. Install in the reverse order of removal.
  16. Inspect all related parts by performing "AFTER SERVICE PRECAUTION".

QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3]

WARNINGFuel 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".

Type B Removal

CAUTIONBe careful not to damage the pipe when unlocking the retainer.

Note. If the quick release connector is removed, replace the retainer with a new one.

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25
  1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. NOTE: The retainer is attached to the pipe even after the connector is disconnected.
  2. Pinch the retainer tabs using the SST and pull the connector side.
  3. Raise a retainer tab using the SST and remove the retainer.

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 26

Scheme 26: Type A Installation
Scheme 26: Type A Installation
  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".

Type B Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the piping component. 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 27

Scheme 27: Type B Installation
Scheme 27: Type B Installation
  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. B3E0114W041
  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".

Scheme 28

Scheme 28: FUEL INJECTOR REMOVAL/INSTALLATION [L3]
Scheme 28: FUEL INJECTOR REMOVAL/INSTALLATION [L3]
  1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [L3]»(ref-244329-S37225093542006092100000) ).
  2. Remove the plug hole plate.
  3. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  4. Disconnect the negative battery cable.
  5. Disconnect the fuel injector connector.
  6. Remove in the order indicated in the table. FUEL INJECTOR REMOVING ORDER 1 Quick release connector 01-14-13 QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3]). 2 Fuel distributor 3 Injector clip (See «FUEL INJECTOR REMOVAL NOTE»(ref-244329-S08297637452006092100000) ). 4 Fuel injector (See «FUEL INJECTOR INSTALLATION NOTE»(ref-244329-S00746580022006092100000) ).
  7. Install in the reverse order of removal.
  8. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [L3]»(ref-244329-S24490073762006092100000) ).

Fuel Injector Removal Note

CAUTIONUse of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the injector to rotate. Therefore, always replace the clip when the injector is removed.

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31
  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 32

Scheme 32: Fuel Injector Installation Note
Scheme 32: Fuel Injector Installation Note
  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.

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