TSB: 01-029/04

2004 MAZDA3 - FUEL DELIVERY MODULE (FDM) INSTALLATION

APPLICABLE MODEL(S)/VINS

2004 Mazda3 Federal specification 2.0 / 2.3L, California specification 2.3L

DESCRIPTION

When replacing the fuel delivery module (FDM) for service related concerns, care must be taken during installation to maintain proper sealing.

Use the following repair procedure whenever removal or replacement of the fuel pump is necessary. It will be made available in the Workshop Manual in future revisions.

REPAIR PROCEDURE

Obtain the following new parts: Retainer, Packing, and Fuel pump cap.

NOTE:

• Parts must be clean and free of foreign material.

• Prior to assembly, all new parts must be kept at room temperature for minimum 12 hours to stabilize the shape.

1. Install the new retainer onto the top of the fuel tank.

NOTE:

• Ensure that the retainer is fully seated into the fuel tank grooves and the anti-rotation tabs are not damaged.

• On some Mazda3, the retainers may have one anti-rotation tab only. This is not a defective part and it is okay to use.

2. Ensure the packing groove on top of the fuel tank is clean and free of foreign material.

3. Install a new packing to the fuel tank.

NOTE: Make sure the packing lays flat in the fuel tank groove.

4. Install the fuel pump unit to the fuel tank.

NOTE: Be careful not to bend the fuel sender unit arm during the installation.

5. Align the alignment mark on top of the fuel pump with the mold on the fuel tank as shown.

NOTE:

• The mold lines may be under a foam insulator.

• Ensure the flange on the fuel pump is seated inside the notch of the retainer as shown.

  

6. Set a new fuel pump cap on top of the fuel pump and apply downward force (push down) on the center of the fuel pump.

7. While continuing to apply downward force on the fuel pump, align the fuel pump caps start position (the position where the spaces between the ribs become narrow) with the retainers notch, and tighten the fuel pump cap by hand to a minimum of (1) complete turn 360 degrees.

NOTE: When tightening the fuel pump cap, make sure the fuel pump flange has not come out of the retainers notch. If the fuel pump flange has come out of the retainers notch, the alignment mark on top of the fuel pump will no longer be aligned with the mold marks on the fuel tank.

NOTE: Also make sure that the fuel pump flange is in the correct position by verifying the fuel pump nipple reinforcement is precisely in line with retainer splitting.

8. Ensure that no cross threading has occurred during fuel pump cap installation by checking that the gap between the bottom of the fuel pump cap and the fuel tank surface is even all around. If cross threading, occurs, loosen the fuel pump cap by hand and repeat step 7.

9. Using the SST (49-F042-001), tighten the fuel pump cap with one smooth sweeping motion to the specified torque.

Fuel pump cap tightening torque: minimum 110 N.m (12 kgf-m, 82 ft-lbf)

Using the mark on the fuel pump cap, ensure that the angle achieved after installation is between 620 - 680 degrees (Approximately 1.8 turns).

NOTE:

• Do not use grease or lubrication on any parts during installation. If the fuel pump cap has cross threaded or the fuel pump flange has moved during assembly, remove fuel pump cap, fuel pump, and packing then repeat steps 3 - 9.

• If both of the retainer anti-rotation tabs are broken, use a new retainer.

10. Verify repair.

PART(S) INFORMATION