Mazda CX-5 Service & Repair Manual: Fuel Tank Removal/Installation

WARNING:

• 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, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

• 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 the vehicle body.

CAUTION:

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

U.S.A. And CANADA

2WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”..

3. Drain the fuel..

4. Using the following procedure:

6:4 split type

• Remove the rear seat cushion..

4:2:4 split type

• Set the rear seat aside as shown in the figure..

  

  
  

5. Partially peel back the floor mat as shown in the figure.

6. Remove the service hole cover.

7. Disconnect the following parts:

• Fuel pump unit connector

• Quick release connector.

8. Remove the floor under cover..

9. Disconnect the HO2S connector.

10. Remove the TWC and HO2S as a single unit..

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Complete the “AFTER SERVICE PRECAUTION”..

1	Joint hose (See Joint hose installation note.)
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
3	Quick release connector (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
4	Fuel tank strap
5	Fuel tank insulator (See Fuel tank insulator removal note.)
6	Fuel tank (See Fuel tank removal note.)
7	Breather hose (See Breather hose installation note.)
8	Pressure control valve (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
9	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

Fuel tank insulator removal note

NOTE:

• The fuel tank insulator are installed using rivets.

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).

Fuel tank removal note

1. Remove the rear parking brake cable bracket installation bolts..

2. Remove the following parts as single unit.

• Breather hose

• Pressure control valve

• Fuel pump unit

• Fuel tank

3. Remove the fuel tank.

Breather hose installation note

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

Fuel tank side

Breather pipe side

Joint hose installation note

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

Fuel tank side

Fuel-filler pipe side

AWD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”..

3. Drain the fuel..

4. Using the following procedure:

6:4 split type

• Remove the rear seat cushion..

4:2:4 split type

• Set the rear seat aside as shown in the figure..

  Main side

  

  
  

  Sub side

  

  
  

5. Partially peel back the floor mat as shown in the figure.

Main side

Sub side

6. Remove the service hole cover.

Main side

Sub side

7. Disconnect the following parts:

Main side

• Fuel pump unit connector

• Quick release connector.

Sub side

• Fuel gauge sender unit (sub) connector

8. Remove the floor under cover..

9. Disconnect the HO2S connector.

10. Remove the TWC and HO2S as a single unit..

11. Remove the propeller shaft..

12. Remove in the order indicated in the table.

13. Install in the reverse order of removal.

14. Complete the “AFTER SERVICE PRECAUTION”..

1	Joint hose (See Joint hose installation note.)
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
3	Quick release connector (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
4	Fuel tank strap
5	Fuel tank insulator (See Fuel tank insulator removal note.)
6	Breather hose (See Breather hose installation note.)
7	Pressure control valve (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
8	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
9	Fuel gauge sender unit (sub) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [AWD].)
10	Fuel tank (See Fuel tank removal note.)

Fuel tank insulator removal note

NOTE:

• The fuel tank insulator are installed using rivets.

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).

Fuel tank removal note

1. Remove the rear parking brake cable bracket installation bolts..

2. Remove the following parts as single unit.

• Breather hose

• Pressure control valve

• Fuel pump unit

• Fuel gauge sender unit (sub)

• Fuel tank

3. Remove the fuel tank.

Breather hose installation note

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

Fuel tank side

Breather pipe side

Joint hose installation note

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

Fuel tank side

Fuel-filler pipe side

Except U.S.A. And CANADA

2WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”..

3. Drain the fuel..

4. Using the following procedure:

6:4 split type

• Remove the rear seat cushion..

4:2:4 split type

• Set the rear seat aside as shown in the figure..

  

  
  

5. Partially peel back the floor mat as shown in the figure.

6. Remove the service hole cover.

7. Disconnect the following parts:

• Fuel pump unit connector

• Quick release connector.

8. Remove the floor under cover..

9. Disconnect the HO2S connector.

10. Remove the TWC and HO2S as a single unit..

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Complete the “AFTER SERVICE PRECAUTION”..

1	Joint hose (See Joint hose installation note.)
2	Fuel tank strap
3	Fuel tank insulator (See Fuel tank insulator removal note.)
4	Fuel tank (See Fuel tank removal note.)
5	Evaporative hose (See Evaporative hose installation note.)
6	Breather hose (See Breather hose installation note.)
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

Fuel tank insulator removal note

NOTE:

• The fuel tank insulator are installed using rivets.

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).

Fuel tank removal note

1. Remove the rear parking brake cable bracket installation bolts..

2. Disconnect the breather hose from the fuel-filler pipe.

3. Disconnect the evaporative hose from the check valve.

4. Remove the following parts as single unit.

• Breather hose

• Evaporative hose

• Fuel pump unit

• Fuel tank

5. Remove the fuel tank.

Evaporative hose installation note

1. Install the evaporative hose as shown in the figure.

Breather hose installation note

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

Fuel tank side

Fuel-filler pipe side

Joint hose installation note

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

Fuel tank side

Fuel-filler pipe side

AWD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”..

3. Drain the fuel..

4. Using the following procedure:

6:4 split type

• Remove the rear seat cushion..

4:2:4 split type

• Set the rear seat aside as shown in the figure..

  Main side

  

  
  

  Sub side

  

  
  

5. Partially peel back the floor mat as shown in the figure.

Main side

Sub side

6. Remove the service hole cover.

Main side

Sub side

7. Disconnect the following parts:

Main side

• Fuel pump unit connector

• Quick release connector.

Sub side

• Fuel gauge sender unit (sub) connector

8. Remove the floor under cover..

9. Disconnect the HO2S connector.

10. Remove the TWC and HO2S as a single unit..

11. Remove the propeller shaft..

12. Remove in the order indicated in the table.

13. Install in the reverse order of removal.

14. Complete the “AFTER SERVICE PRECAUTION”..

1	Joint hose (See Joint hose installation note.)
2	Fuel tank strap
3	Fuel tank insulator (See Fuel tank insulator removal note.)
4	Fuel tank (See Fuel tank removal note.)
5	Evaporative hose (See Evaporative hose installation note.)
6	Breather hose (See Breather hose installation note.)
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
8	Fuel gauge sender unit (sub) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [AWD].)

Fuel tank insulator removal note

NOTE:

• The fuel tank insulator are installed using rivets.

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).

Fuel tank removal note

1. Remove the rear parking brake cable bracket installation bolts..

2. Disconnect the breather hose from the fuel-filler pipe.

3. Disconnect the evaporative hose from the check valve.

4. Remove the following parts as single unit.

• Breather hose

• Evaporative hose

• Fuel pump unit

• Fuel tank

5. Remove the fuel tank.

Evaporative hose installation note

1. Install the evaporative hose as shown in the figure.

Breather hose installation note

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

Fuel tank side

Fuel-filler pipe side

Joint hose installation note

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

Fuel tank side

Fuel-filler pipe side