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HOMESERVICE MANUALSMAZDA20086 S SPORT, 4D HATCHBACK, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 30 (ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION)FUEL SYSTEMFUEL PUMPINSTALLATION
2008 Mazda 6 s Sport, 4D Hatchback, Standard

Fuel Pump: Installation

2008 Mazda 6 s Sport, 4D Hatchback, StandardSECTION Installation
WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2002 Mazda Tribute, 2002 Mazda Protege5, 2002 Mazda Protege, 2002 Mazda Millenia, and 2002 Mazda MX-5 Miata. However, it is still accessible from the selected car via links, so may be relevant.

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (310-069). See TORQUE SPECIFICATIONS . Install fuel tank.



CAUTION: Do not apply excessive side force when pushing fuel hose onto fuel pump fitting.

Install fuel pump into sending unit assembly. Pull fuel pump down so that it is flush against bracket on sending unit. To complete installation, reverse removal procedure.



Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (49-U014-001). To complete installation, reverse removal procedure.



Using NEW seal and fuel filter retainer washer, install fuel pump in sending unit assembly. Install fuel pump and sending unit assembly into fuel tank using NEW gasket. See Fig 1. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Fig 1: Identifying Fuel Tank Sender Assembly Components (MPV, Protege & Protege5)
G00143757Courtesy of MAZDA MOTORS CORP.


Install fuel pump into sending unit assembly using NEW seal and fuel filter retainer washer. Install fuel pump and sending unit assembly into fuel tank using new gasket. See Figure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.



Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (310-069). See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.



NOTE: Fuel gauge unit may be replaced separately from fuel pump assembly.

Clean gasket surface on fuel tank. Use NEW gasket. Install fuel pump assembly into fuel tank. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure fittings are clean before connecting fuel lines to fuel pump fittings. To complete installation, reverse removal procedure.

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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.