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HOMESERVICE MANUALSMAZDA20086 S SPORT, 4D HATCHBACK, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 629 (FUEL SYSTEM)FUEL TANK REMOVAL/INSTALLATIONCAP INSTALLATION NOTE
2008 Mazda 6 s Sport, 4D Hatchback, Standard

Cap Installation Note

2008 Mazda 6 s Sport, 4D Hatchback, StandardSECTION Cap Installation Note
WARNING: This page is about a different car, the 2008 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.
  1. Align the alignment mark of the fuel suction pipe bracket and the retainer notch as shown in the figure.
    Fig 1: Aligning Alignment Mark Of Fuel Suction Pipe Bracket & Retainer Notch
    G04562823Courtesy of MAZDA MOTORS CORP.
  2. Align the positions of the cap and retainer as shown in the figure, and tighten them one full rotation  by hand.
    • If the retainer and cap cannot be tighten by hand, remove the cap, verify that there is no damage or misalignment on the retainer and cap, and then tighten again.
    CAUTION:
    • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap. 
      Fig 2: Aligning Positions Of Cap & Retainer
      G04562824Courtesy of MAZDA MOTORS CORP.
  3. While keeping the alignment mark and the retainer notch aligned, tighten the cap to the rotation angle and specified torque using the SST  .
    • If the specified torque cannot be obtained even when the cap is rotated to the specified rotation angle, replace with a new cap and retainer and repeat Step  3.

    Rotation angle 

    50-140° 

    (Total angle for Step   2  and Step   3  is 410-500°). 

    Cap tightening torque 

    80-135 N.m {8.2-13.7 kgf.m, 59-99 ft.lbf} 

RENDER: 1.0x

NO RELATED

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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.