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

FUEL TANK REMOVAL/INSTALLATION [L3]

Scheme 13

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-292887-S30644836642008080600000) .)
3. Disconnect the negative battery cable.
4. Remove the second-row seat. (See «SECOND-ROW SEAT REMOVAL/INSTALLATION»(ref-292922-S39990574142008080600000) .)
5. Remove the rear package tray lid (See «REAR PACKAGE TRAY LID REMOVAL/INSTALLATION»(ref-292888-S11741306112008080600000) .)
6. Remove the sub-trunk
7. Remove the third-row seat (See «THIRD-ROW SEAT REMOVAL/INSTALLATION»(ref-292922-S10467716332008080600000) .)
8. Remove the rear scuff plate (See «REAR SCUFF PLATE REMOVAL/INSTALLATION»(ref-292888-S27858191902008080600000) .)
9. Remove the trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-292888-S07958763512008080600000) .)
10. Remove the third-row seat belt lower anchor installation bolt (See «THIRD-ROW SEAT BELT REMOVAL/INSTALLATION»(ref-292923-S30538138522008080600000) .)
11. Remove the cargo compartment light (See «CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION»(ref-292924-S28232554992008080600000) .)
12. Remove the trunk side trim. (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-292888-S33319963922008080600000) .)
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

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

Scheme 14

Scheme 15

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 16

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

FUEL PUMP UNIT REMOVAL/INSTALLATION [L3]

Scheme 17

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-292887-S30644836642008080600000) .)
3. Disconnect the negative battery cable.
4. Remove the second-row seat. (See «SECOND-ROW SEAT REMOVAL/INSTALLATION»(ref-292922-S39990574142008080600000) .)
5. Remove the rear package tray lid (See «REAR PACKAGE TRAY LID REMOVAL/INSTALLATION»(ref-292888-S11741306112008080600000) .)
6. Remove the sub-trunk
7. Remove the third-row seat (See «THIRD-ROW SEAT REMOVAL/INSTALLATION»(ref-292922-S10467716332008080600000) .)
8. Remove the rear scuff plate (See «REAR SCUFF PLATE REMOVAL/INSTALLATION»(ref-292888-S27858191902008080600000) .)
9. Remove the trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-292888-S07958763512008080600000) .)
10. Remove the third-row seat belt lower anchor installation bolt (See «THIRD-ROW SEAT BELT REMOVAL/INSTALLATION»(ref-292923-S30538138522008080600000) .)
11. Remove the cargo compartment light (See «CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION»(ref-292924-S28232554992008080600000) .)
12. Remove the trunk side trim. (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-292888-S33319963922008080600000) .)
13. Partially peel back the floor covering.
14. Remove in the order indicated in the table.
15. Install in the reverse order of removal.
16. Inspect all related parts by performing "AFTER SERVICE PRECAUTION".

QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3]

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. 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 scratches or dirt.

Type B Removal

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

Scheme 22

1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See «BEFORE SERVICE PRECAUTION [L3]»(ref-292899-S28118030202008080600000) .)
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 23

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.

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"

Scheme 24

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-292899-S28118030202008080600000) .)
2. Remove the plug hole plate.
3. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000) .)
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 [L3]»(ref-292899-S15445028802008080600000) .)

Fuel Injector Removal Note

Scheme 25

Scheme 26

Scheme 27

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 28

1. Apply a small amount of clean oil to the injector groove and the O-ring.
2. 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.
3. Hold the injector firmly and push the clip into the injector until the clip stops sliding.
4. Verify that the injector connector position is correct.
5. Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.
6. Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.

Scheme 29

1. Turn the ignition switch to the LOCK position.
2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000) .)
3. Disconnect the negative battery cable.
4. Disconnect the fuel injector connector.
5. Inspect the resistance between fuel injector terminals A and B using a tester. If within the specification, perform the "Circuit Open/Short Inspection". If not within the specification, replace the fuel injector. Fuel injector resistance 11.3-12.7 ohms [20 °C {68 °F}]

Scheme 30

1. Disconnect the PCM connector. (See «PCM REMOVAL/INSTALLATION [L3]»(ref-292895-S11081898982008080600000) .)
2. Inspect the following wiring harnesses for open or short circuit (continuity check). Open circuit 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 C Fuel injector No.2 terminal B and main relay terminal C Fuel injector No.3 terminal B and main relay terminal C Fuel injector No.4 terminal B and main relay terminal C Short circuit If there is continuity, there is a short circuit. Repair or replace the wiring harness. Fuel injector No.1 terminal A and body ground Fuel injector No.1 terminal A and power supply Fuel injector N.2 terminal A and body ground Fuel injector No.2 terminal A and power supply Fuel injector No.3 terminal A and body ground Fuel injector No.3 terminal A and power supply Fuel injector No.4 terminal A and body ground Fuel injector No.4 terminal A and power supply Fuel injector No.1 terminal B and body ground Fuel injector No.2 terminal B and body ground Fuel injector No.3 terminal B and body ground Fuel injector No.4 terminal B and body ground