2005 Mazda 3 i, AutomaticFACTORY OEM SERVICE PROCEDURE

Fuel Tank Removal/Installation: Notes

WARNING:
  • Repairing 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.
  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 )
    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.
  3. Drain the fuel from the fuel tank using the following procedure:
    1. Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION )
    2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
    3. Start the fuel pump using the following procedure:

      Using WDS or equivalent 

      1. Connect the WDS or equivalent to the DLC-2.
        Fig 1: Identifying DLC-2 Connector
        G03635865Courtesy of MAZDA MOTORS CORP.
      2. Start the fuel pump using the "FP" simulation function.

      Not using WDS or equivalent 

      1. Disconnect the negative battery cable.
      2. 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.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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