MAZDA 6 2002 Workshop Manual Suplement

FUEL SYSTEM
F1–23
F1
FUEL TANK REMOVAL/INSTALLATIONA6E391242110201
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly 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.
1. Level the vehicle.
2. Complete the “BEFORE REPAIR PROCEDURE”.
3. Disconnect the negative battery cable.
4. Remove the fuel pump unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.)
5. Remove the fuel gauge sender sub-unit. (See T–27 Fuel Gauge Sender Sub-Unit.)
6. Siphon the fuel from the service hole.
7. Remove the presilencer. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
9. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
FUEL SYSTEM

F1–24
FUEL SYSTEM
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Complete the “AFTER REPAIR PROCEDURE”.
.
44—60
{4.5—6.1, 33—44}
7
5
4
3
2
1
6
A
N·m {kgf·m, ft·lbf} 44—60
{4.5—6.1, 33—44}
44—60
{4.5—6.1, 33—44}8.9—12.7 N·m
{91—120 kgf·cm, 79—110 in·lbf}
8.9—12.7 N·m
{91—120 kgf·cm, 79—110 in·lbf}
A6E39122008
1 Joint hose
(See F1–25 Joint Hose Installation Note)
2 Breather hose
(See F1–25 Breather Hose Installation Note)
3 Evaporative hose
(See F1–25 Evaporative Hose Installation Note)4 Fuel tank
5 Fuel-filler pipe
6 C-ring
7 Filler cap

FUEL SYSTEM
F1–25
F1
Evaporative Hose Installation Note
1. Fit the evaporative hose until it hits the check
valve as shown.
Breather Hose Installation Note
1. Fit the breather hose onto the respective fittings,
and install clamps as shown.
Joint Hose Installation Note
1. Fit the joint hose onto the respective fittings, and
install clamps as shown.
End Of Sie
EVAPORATIVE HOSECHECK VALVE
A6E39122006
10 {0.39}
mm {in}
UPPER SIDE
VIEW FROM A
A6E39122004
VIEW FROM AAPPROX. 45 °STOPPER
JOINT HOSE
A6E39122005

F1–26
FUEL SYSTEM
FUEL PUMP UNIT REMOVAL/INSTALLATIONA6E391213350202
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly 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.
Note
•Since the fuel pump unit is integrated with the fuel filter, it needs to be replaced every 75,000 km.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel Leak Inspection After Fuel
Pump Unit Installation.“ (See F1–28 Fuel Leak
Inspection After Fuel Pump Unit Installation.)
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, main fuel pipe part)
(See F1–27 Plastic Fuel Hose Removal Note)
(See F1–28 Plastic Fuel Hose Installation Note)
4 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
5Fuel pump cap
(See F1–27 Fuel Pump Cap Removal Note)
(See F1–28 Fuel Pump Cap Installation Note)
6 Packing
7 Fuel pump unit
3
7
1
4
5
2
6
80—90 {8.2—9.1, 60—66}
R
SST
N·m {kgf·m, ft·lbf}
A6E39122009

FUEL SYSTEM
F1–27
F1
Plastic Fuel Hose Removal Note
Caution
•The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab
over the stopper.
1. Disconnect the quick release connector.
(1) Push the tab on the locking coupler 90
degrees until it stops.
(2) Pull the fuel hose straight back.
Note
•The stopper may be removed from the quick
connector. Take care not to lose it.
Reinstall it to the quick release connector
before reconnecting the fuel line.
•The locking coupler has two internal locking
tabs which retain the fuel pipe. Be sure that
the tab on the locking coupler is rotated until
it stops to release two internal locking tabs.
2. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Fuel Pump Cap Removal Note
1. Using the SST, remove the fuel pump cap.
FUEL PIPE
STOPPER TAB
A6E3912W001
LOCKING TAB
A6E3912W002
A6E39122015
49 T042 001A
A6E39122012

F1–28
FUEL SYSTEM
Fuel Pump Cap Installation Note
1. Verify that the fuel tank mark is aligned with the
fuel pump unit mark as shown.
2. Using the SST, tighten the fuel pump cap without
shifting the mark.
Tightening torque
80—90 N·m {8.2—9.1 kgf·m, 60—66 ft·lbf}
Plastic Fuel Hose Installation Note
Note
•A checker tab is integrated with quick
release connector for new plastic fuel hoses.
The checker tab will be released from the
quick release connector after it is completely
engaged with the fuel pipe.
1. Inspect the fuel pump unit sealing surface for
damage and deformation, and replace as
necessary.
•If the quick release connector O-ring is
damaged, replace the plastic fuel hose.
2. Slightly apply clean engine oil to the sealing
surface of the fuel pump unit.
3. Align the fuel pipe on the fuel pump unit and quick
release connector so that the tabs of the retainer
are correctly fitted into the quick release
connector. Push the quick release connector
straight into the retainer until a click is heard.
4. Lightly pull and push the quick release connector
a few times by hand and verify that it can move
2.0—3.0 mm {0.08—0.11 in} and it is connected
securely.
•If quick release connector does not move at
all, verify that O-ring is not damaged and
slipped, and reconnect the quick release
connector.
Fuel Leak Inspection After Fuel Pump Unit Installation
1. Drive the vehicle.
2. Perform a quick start and a hard brake 5—6 times.
3. Stop the vehicle.
4. Verify that there is no fuel leakage near the fuel pump unit in the vehicle interior.
End Of Sie
A6E39122013
CHECKER
TA B
NEW PLASTIC
FUEL HOSE
A6E3912W004
OILOIL
PLASTIC FUEL HOSE QUICK RELEASE
CONNECTOR SEALING
SURFACE
A6E3912W006

FUEL SYSTEM
F1–29
F1
FUEL HOSE (FUEL TANK SIDE, TRANSFER HOSE PART) REMOVAL/INSTALLATIONA6E391242692202
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly 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.
Removal
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
Note
•Squeezing the tab while lightly pushing the fuel hose on the fuel pipe side will make removal easier.
3. Squeeze the tabs on the quick release connector
and disconnect the quick release connector from
the fuel pipe by pulling it straight back.
4. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Installation
Caution
•If the quick release connector O-ring is damaged, replace the plastic fuel hose. A fuel leak may be
caused.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
2. Slightly apply clean engine oil to the sealing surface of the fuel pump unit.
3. Align the fuel pipe and quick release connector. Push the quick release connector straight into the fuel pipe
until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 mm
{0.08—0.11 in} and it is connected securely.
•If the quick release connector does not move at all, verify that O-ring is not damaged and slipped, and
reconnect the quick release connector.
5. Complete the “AFTER REPAIR PROCEDURE”.
End Of Sie
QUICK RELEASE
CONNECTOR TA BDISCONNECT
FUEL PIPE
A6E39122007
A6E39122014

F1–30
EXHAUST SYSTEM
EXHAUST SYSTEM REMOVAL/INSTALLATIONA6E391440000203
Warning
•When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
.
EXHAUST SYSTEM
R
37.3—52.0
{3.9—5.3, 28—38} 40—55
{4.1—5.6, 30—40} 43—64
{4.4—6.5, 32—47}
2
1
R
R
R
7
4
36
5
8
RA
SST
29—49 {3.0—4.9, 22—36}SST
R
A
10
38—51 {3.9—5.2, 29—37}N·m {kgf·m, ft·lbf} 38—51 {3.9—5.2, 29—37} 38—51 {3.9—5.2, 29—37} 38—51 {3.9—5.2, 29—37} 7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf}
7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf} 7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf} 29—49 {3.0—4.9, 22—36}
9
A6E39142004

EXHAUST SYSTEM
F1–31
F1HO2S Removal Note
1. Using the SST, remove the HO2S.
Exhaust Manifold Insulator (Lower) Installation Note
1. Tighten the exhaust manifold insulator (lower)
installation bolts in the order shown.
2. Verify that there is 3.0—7.0 mm {0.12—0.27 in}
gap between the exhaust manifold and the
exhaust manifold insulator (lower).
1 Main silencer
2 Presilencer
3TWC
4 Exhaust manifold insulator (upper)
(See F1–32 Exhaust Manifold Insulator (Upper)
Installation Note)
5Bracket
(See F1–32 Bracket Installation Note)
6 Exhaust manifold
(See F1–32 Exhaust Manifold Installation Note)7 Exhaust manifold gasket
8 Exhaust manifold insulator (lower)
(See F1–31 Exhaust Manifold Insulator (Lower)
Installation Note)
9 HO2S (front)
(See F1–31 HO2S Removal Note)
10 HO2S (rear)
(See F1–31 HO2S Removal Note)
49 L018 001
A6J39142003
5
4
3
1
2
A6E39142005
3.0—7.0 {0.12—0.27}
EXHAUST MANIFOLD
EXHAUST MANIFOLD
INSULATOR (LOWER)
mm {in}
A6E39142002

F1–32
EXHAUST SYSTEM
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in
the order shown.
Bracket Installation Note
1. Temporarily tighten the bracket installation bolt by the side of the exhaust manifold.
2. Verify that there is 2.0—4.0 mm {0.08—0.15 in}
gap between the exhaust manifold and the
bracket.
3. Tighten the bracket installation bolt by the side of
the cylinder block.
Tightening torque
37.3—52.0 N·m {3.81—5.30 kgf·m, 27.6—38.3
ft·lbf}
4. Tighten the bracket installation bolt by the side of
the exhaust manifold.
Tightening torque
40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf}
Exhaust Manifold Insulator (Upper) Installation Note
1. Tighten the exhaust manifold insulator (upper)
installation bolts in the order shown.
End Of Sie
75
4
3
1
2
6
A6J3914W003
2.0—4.0 {0.08—0.15}
mm {in}EXHAUST MANIFOLDBRACKET
A6E39142003
5
4
3
12
A6E39142006