B. Inspection Procedure

NOTE:
Prior to starting the Inspection Procedure, make certain the Check Engine Light turns off when the engine is started. If the Check Engine Light does not turn off, do not perform the procedure until the DTC(s) are identified and the concern(s) are resolved.

CAUTION:
^ The following Inspection Procedure must be performed in a well ventilated area, away from direct sunlight, flames, or sparks.

^ Gasoline is very flammable, use extreme caution when working near or around gasoline.

^ Appropriate hand and eye protection must be worn when working with gasoline.

1. Turn ignition switch to "ON" position.





2. Using the fuel gauge in the meter set, check the amount of fuel in the tank.

^ If the fuel gauge reads less than 1/2 tank, proceed to the next step.

^ If the fuel gauge reads more than 1/2 tank, drain the fuel until the fuel gauge reads 1/2 or less.

NOTE:
Note the amount of fuel that is drained from the tank. The fuel will need to be returned to the tank later.

CAUTION:
If the Inspection Procedure is performed with more than 1/2 tank of fuel, fuel leakage will occur when the fuel pump lock ring is removed.

3. Secure the vehicle on a hoist, but do not lift the vehicle at this time.

4. Place automatic transmission vehicle in "P" range or manual transmission vehicle in "N" range.

5. Set the parking brake.

6. Record all of the customer's preset radio stations.

7. Move and tilt both front seats to the most forward position.

8. Open all doors.

9. Flip the rear floor mats over to protect them from damage or from becoming dirty.

10. Unbuckle all rear seat belts.





NOTE:
Release the center seat belt by inserting a key into the access slot.





11. Push all the seat belt buckles between the seats.





12. Release the left and right side seat bottom locks by pushing the lock levers to the right.

NOTE:

^ The locks are located on the bottom of the seat.

^ On some early production vehicles, the seat locks are a different design. They do not have a release lever. In this case, the seat bottom is removed by grasping the seat at the bottom and

13. Lift seat bottom upward and remove it from the vehicle.

NOTE:
Place the seat bottom on a clean surface.





14. Remove the fuel tank access cover by removing four (4) phillips head machine screws.





15. Inspect the top portion of the fuel tank for fuel odor and/or the presence of fuel.

If fuel odor or the presence of fuel is found, proceed to "C. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal)."

If no fuel odor or presence of fuel is found, proceed to the next step.





16. Disconnect the gray and black connectors.





17. To prevent damage to the connector/wires, tape the female side of the gray connector to the vehicle body and tuck the male side of both the black connector and gray connector inside the floor carpet.

18. To release the fuel pressure, start the engine and wait until it stalls, then crank the engine for an additional five (5) seconds.

19. Turn ignition switch to "OFF" position.

20. Disconnect the negative side battery cable.





21. Clean all debris from the top of the fuel tank using compressed air.





22. Wipe the area clean with a clean cloth.

NOTE:
It is important to clean the area thoroughly. A tool will be used to measure the gap between the bottom of the fuel pump lock ring and fuel tank.





23. Remove the green fuel line retainer clip by gently expanding it.

CAUTION:
To prevent clip breakage, do not over-expand the clip.





24. Cover the end of the fuel line with a clean cloth and detach it from the fuel pump coupler by pulling outward on the fuel line.

CAUTION:
Detach the fuel line slowly, some fuel pressure may still exist.





25. After removing the fuel line, make sure the blue plastic cage is not lost.

26. Wrap the fuel line with a clean cloth and tuck it away from the main opening.





27. Check the black number molded into the top of the lock ring. This identifies if the correct lock ring is installed.

If the number "1" or "2" is found, proceed to "B. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal Inspection)."

If the number 3" or 4" is found, proceed to the next step.





28. Check for the presence of a black arrow molded into the top edge of the lock ring.

^ If the arrow is present, proceed to the next step.

^ If the arrow is not present, proceed to "B. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal Inspection)."

29. Lift the vehicle on the hoist.

30. Locate the white label attached to the exterior of the fuel tank (on passenger side of vehicle).





NOTE:
If there is no label on the fuel tank, note the production date stamping on the bottom of the tank.

31. Record the production date printed on the label or bottom of fuel tank.

32. Lower the vehicle and proceed to the next step.

33. Using the production date of the fuel tank, inspect the position of the lock ring arrow.

NOTE:
There are two (2) correct positions for the lock ring arrow depending on the fuel tank production date.





Fuel tank date on or before 03/02/03: Locking arrow should be between 9:00 & 12:00.





Fuel tank date on or after 03/03/03: Lock ring arrow should be between 12:00 & 3:00.

NOTE:
The 12:00 location is oriented at the two (2) molded ribs of the fuel tank.

34. Determine the position of the lock ring arrow.

^ If the lock ring arrow position is incorrect, proceed to the next step.

^ If the lock ring arrow position is correct, proceed to Step 36.





35. Mount the SST (Fuel Pump Ring Removal Wrench) onto the lock ring and tighten in a clockwise direction until the arrow is in the correct position. Remove the SST and proceed to the next step.





36. Using the SST (Fuel Pump Lock Ring Gauge) as a "go/no go" gauge insert the thinnest side (.5 mm) between the bottom of the lock ring and the fuel tank.

NOTE:
Only the very tip of the SST is .5 mm. This is the only portion of the SST that needs to be inserted between the lock ring and fuel tank.





37. Check all twelve (12) points around the lock ring (in between each lock ring rib).

^ If the SST can be inserted into all twelve (12) points of the lock ring, proceed to the next step.

^ If the SST cannot be inserted into all twelve (12) points of the lock ring, the fuel tank must be replaced. DO NOT disturb the condition of the lock ring. Contact the Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal).

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





38. Using the SST (Fuel Pump Lock Ring Gauge), attempt to insert the thickest side (6.0 mm) between the bottom of the lock ring and the fuel tank.





39. Check all twelve (12) points around the lock ring (in between each lock ring rib).

If the SST can be inserted into any of the twelve (12) points of the lock ring, proceed to "B. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal Inspection)".

If the SST cannot be inserted into any of the twelve (12) points of the lock ring, proceed to the next step.

40. Obtain the SST (Fuel Pump Position Retainer).

NOTE:
Prior to using the SST for the first time, the securing bolt (M6) may be difficult to thread onto the SST by hand. If so, "clean" the threads by partially threading the bolt on by hand, then use a 10 mm wrench to further clean the threads.





41. Carefully lower the SST (Fuel Pump Position Retainer) onto the top of the fuel pump and insert the SST "leg" into the square shape slot.

NOTE:
The installation of the SST keeps the fuel pump from popping upward (the fuel pump is under spring pressure) and/or the fuel pump seal from moving when the lock ring is removed. Ignore the dates stamped on the top surface of the SST.





42. Secure the SST by inserting the bolt through the square shape slot, threading it onto the SST, then snug the bolt down.





43. Mount the SST (Fuel Pump Lock Ring Removal Wrench) over the SST (Fuel Pump Position Retainer) and remove the lock ring in a counterclockwise direction.





44. Using a mirror and a flashlight, inspect the complete circumference of the fuel pump seal for a "rolled" seal condition.

NOTE:
The fuel pump seal is between the fuel pump and the top of the fuel tank.

^ If the seal is not rolled, proceed to the next step.

^ If the seal is rolled, proceed to "A. REPAIR PROCEDURE (Replacement of Fuel Pump Seal)."





45. During the removal of the lock ring, the fuel pump may have moved slightly. Ensure the white molded arrow on top of the fuel pump is centered between the molded ribs on the fuel tank. If not, grasp the top of the fuel pump and move it until the arrow is centered.





46. Obtain the original lock ring and align the molded arrow on the lock ring with the machined line (Lock Ring Start) on the SST.

NOTE:
The arrow on the lock ring represents the starting thread.

47. Lower the lock ring straight down until the threads just contact the fuel tank threads. At this time the lock ring should be laying flat on the fuel tank threads.





48. Using both hands, push down on the lock ring and turn it clockwise approx. 1" until the threads engage, then release the lock ring. Push downward on the lock ring on the opposite side of the black molded arrow. A "click" noise should be heard just as the threads "catch". Once the threads catch, proceed to the next step.





49. Install the SST onto the lock ring and tighten in a clockwise direction for 3/4 of a turn.

NOTE:
When the lock ring is being tightened, it may feel slightly rough. If excessive effort is required to turn the lock ring, the lock ring threads may not be correctly fitted onto the fuel tank threads. If this is the case, remove the lock ring and repeat Steps 46-49.





50. Visually inspect for uneven gap(s) between the top inner edge of the lock ring and the top of the fuel pump.

^ If no uneven gaps are noted, proceed to the next step.

^ If any uneven gaps are present, remove the lock ring and repeat Steps 46-50.

51. Install a 19 mm socket onto the SST and tighten the lock ring until the arrow is in the correct position according to Step 33.

NOTE:
The lock ring can be rotated a maximum of 1-3/4 turns.

52. To ensure that the lock ring has reached minimum torque, mount a "click" type torque wrench on the top of the SST and apply 50 Nm (36.8 ft. lbf.) to the lock ring. The torque wrench should "click" and the lock ring should not rotate beyond the correct position.

NOTE:
Ensure the white molded arrow on top of the fuel pump has not moved and is still centered between the molded ribs on the fuel tank. If the arrow is not centered, the fuel gauge may read incorrectly.

^ If the torque wrench "clicks", proceed to the next step.

^ If the torque wrench does not "click", the fuel tank may need to be replaced. At this time, DO NOT disturb the condition of the lock ring. Contact Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)" once the new fuel tank arrives.

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





53. Remove both SSTs (Fuel Pump Ring Removal Wrench and Fuel Pump Position Retainer).





54. Using the SST (Fuel Pump Lock Ring Gauge) as a "go/no go" gauge, insert the thinnest side (.5 mm) between the bottom of the lock ring and the fuel tank.

NOTE:
Only the very tip of the SST is .5 mm. This is the only portion of the SST that needs to be inserted between the lock ring and fuel tank.





55. Check all twelve (12) points around the lock ring (in between each lock ring rib).

^ If the SST can be inserted into all twelve (12) points of the lock ring, proceed to the next step.

^ If the SST cannot be inserted into all twelve (12) points of the lock ring, the fuel tank must be replaced. DO NOT disturb the condition of the lock ring. Contact Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)" once the new fuel tank arrives.

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





56. Using the SST (Fuel Pump Lock Ring Gauge) attempt to insert the thickest side (6.0 mm) between the bottom of the lock ring and the fuel tank





57. Check all twelve (12) points around the lock ring (in between each lock ring rib).

If the SST can be inserted into any of the twelve (12) points of the lock ring, install SST (Fuel Pump Position Retainer) and repeat Steps 45-57.

If the SST cannot be inserted into any of the twelve (12) points of the lock ring, proceed to the next step.





58. The plastic cage may have fallen off during removal of the fuel line. Reinstall the cage by first aligning the grooves on the cage to the grooves on the fuel line, then push the cage inward.

NOTE:
There are four (4) grooves on the fuel line. Make sure to use the smaller grooves.





59. Reinstall the green fuel line retainer clip.

NOTE:
^ Position the clip so the tab is pointing towards the fuel line hose.

^ Align the lock tab to the fuel line openings and install the retainer clip.

60. Reinsert the fuel line into the fuel pump coupler by snapping it into the coupler until a "click" noise is heard.

NOTE:
To ensure that the fuel line is fully secure into the fuel pump coupler, slightly tug on the fuel line.





61. Reconnect the gray and black connectors.

62. Reconnect the negative battery cable.

63. Crank the engine until it starts and ensure there is no fuel leakage at the fuel line.

64. Turn the engine off.

65. Turn the ignition to the "ON" position and check the fuel gauge.

^ If the fuel gauge reads between 1/4 and 1/2, proceed to Step 67.

^ If the fuel gauge reads less than 1/4, make a note of the amount and proceed to the next step.





66. Add the necessary amount of fuel to bring the fuel gauge between 1/4 to 1/2.

NOTE:
The fuel level must not be more than 1/2 to run the WDS EVAP test.

67. Perform EVAP test using WDS.

^ If the vehicle passes the WDS EVAP test, proceed to the next step.

^ If the vehicle fails the WDS EVAP test, repeat Steps 41-67. 68. Reinstall the fuel pump access cover.

69. Reinstall the seat bottom.

NOTE:
Prior to installing the seat bottom, feed all seat belts through bottom of seat cushion.

70. Reprogram all of the customer's preset radio stations.

71. Proceed to "E. AUTHORIZED MODIFICATION LABEL INSTALLATION."

72. Return the vehicle to the customer.