2002 MAZDA 6 fuel tank removal

F2–30
LOCATION INDEX
Fuel tank side
.
End Of Sie
21
A6E40002004
1 Fuel tank
(See F2–45 FUEL TANK REMOVAL/
INSTALLATION)
(See F2–49 FUEL TANK INSPECTION)
2 Nonreturn valve
(See F2–50 NONRETURN VALVE INSPECTION)
3 Sedimentor switch
(See F2–52 SEDIMENTOR SWITCH INSPECTION)
4 Fuel filter
(See F2–50 FUEL FILTER COMPONENT
REMOVAL/INSTALLATION)
(See F2–51 FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY)
5 Fuel warmer
(See F2–51 FUEL WARMER INSPECTION)6 Priming pump
(See F2–52 SEDIMENTOR WATER DRAINING)
7 Supply pump
(See F2–53 SUPPLY PUMP REMOVAL/
INSTALLATION)
(See F2–54 SUPPLY PUMP INSPECTION)
8 Suction control valve
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
9 Common rail
(See F2–54 COMMON RAIL INSPECTION)
10 Fuel injector
(See F2–55 FUEL INJECTOR REMOVAL/
INSTALLATION)
(See F2–56 FUEL INJECTOR INSPECTION)

FUEL SYSTEM
F2–45
F2
BEFORE REPAIR PROCEDUREA6E401201006203
Warning
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leads are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel
Line Safety Procedures”.
Fuel Line Safety Procedures
Note
•Fuel in the fuel system is under high pressure when the engine is not running.
1. Avoid fuel line spills and leaks by completing the following procedures.
(1) Remove the fuel-filler cap and release the pressure in the fuel tank.
(2) When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage.
(3) Plug the hose after removal.
End Of Sie
AFTER REPAIR PROCEDUREA6E401201006204
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. When installing the fuel hose, observe “Fuel Hose Installation” described below.
Fuel Line Air Bleeding
Caution
•Continuously cranking the engine for over 30 s can damage the battery and the starter.
1. Continue cranking the engine for 30 s and stop for 5—10 s until the engine starts.
Fuel Hose Installation
1. Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
End Of Sie
FUEL TANK REMOVAL/INSTALLATIONA6E401242110201
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•Fuel line spills and leakage are dangerous. Fuel can also irritate skin and eyes. To prevent this, do
not damage the sealing surface of the fuel gauge sender unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
FUEL SYSTEM

F2–46
FUEL SYSTEM
1. Verify that vehicle is level.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Disconnect the negative battery cable.
4. Remove the rear seat cushion.
5. Remove the service hole cover.
6. Remove the plastic fuel hose from the fuel gauge sender unit. (See F2–47 Plastic Fuel Hose Removal Note.)
(See F2–48 Plastic Fuel Hose Installation Note.)
7. Remove the fuel gauge sender unit connector.
8. Remove the fuel tank gauge cap. (See F2–47 Fuel Tank Gauge Cap Removal Note.)
9. Remove the fuel gauge sender unit. (See F2–48 Fuel Gauge Sender Unit Installation Note.)
10. Siphon the fuel from the fuel tank.
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
13. Complete the “AFTER REPAIR PROCEDURE”. (See F2–45 AFTER REPAIR PROCEDURE.)
.
44—60
{4.4—6.2, 32—44}44—60
{4.4—6.2, 32—44} 44—60
{4.4—6.2, 32—44}
N·m {kgf·m, ft·lbf}
8.9—12.7 N·m
{90—130 kgf·cm,
79—112 in·lbf}
8.9—12.7 N·m
{90—130 kgf·cm,
79—112 in·lbf}
5
4
3
2
1
6
80—90
{8.2—9.1, 59—66}
R
PLASTIC
FUEL HOSE
FUEL GAUGE
SENDER UNITFUEL TANK
GAUGE CAP
SST
A6E40122025
1Joint hose
(See F2–48 Joint Hose Installation Note)
2Breather hose
(See F2–48 Breather Hose Installation Note)3 Fuel tank
4 Fuel-filler pipe
5 C-ring
6 Filler cap

FUEL SYSTEM
F2–47
F2
Plastic Fuel Hose Removal Note
Caution
•The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab
over the stopper.
1. Disconnect the quick release connector.
(1) Push the tab on the locking coupler 90 degrees until it stops.
(2) Pull the fuel hose straight back.
Note
•The stopper may be removed from the quick
connector. Take care not to lose it.
Reinstall it to the quick release connector
before reconnecting the fuel line.
•The locking coupler has two internal locking
tabs which retain the fuel pipe. Be sure that
the tab on the locking coupler is rotated until
it stops to release two internal locking tabs.
2. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Fuel Tank Gauge Cap Removal Note
1. Using the SST, remove the fuel tank gauge cap.
FUEL PIPE
STOPPER TAB
A6E3912W001
LOCKING TAB
A6E3912W002
A6E3912W039
49 T042 001A
A6A3912W007

FUEL SYSTEM
F2–49
F2
(2) Apply a slight amount of clean engine oil to
the sealing surface of the fuel pump unit.
(3) Align the fuel pipe on the fuel pump unit and
quick release connector so that the tabs of the
retainer are correctly fitted into the quick
release connector. Push the quick release
connector straight into the retainer until a click
is heard.
(4) Lightly pull and push the quick release
connector a few times by hand and verify that
it can move 2.0—3.0 mm {0.08—0.11 in} and
it is connected securely.
•If the quick release connector does not
move at all, verify that O-ring is not
damaged of that is has not slipped, and reconnect the quick release connector.
2. When the retainer is removed, perform the following procedure.
End Of Sie
FUEL TANK INSPECTIONA6E401242110202
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
Note
•This inspection is for two rollover valves and check valve (two-way) integrated in the fuel tank.
1. Remove the fuel tank with the fuel gauge sender unit. (See F2–45 FUEL TANK REMOVAL/INSTALLATION.)
2. Plug the fuel pipe of the fuel gauge sender unit.
3. Plug port C.
4. Connect the pump to port B.
5. Level the fuel tank.
6. Apply pressure of +2.0 kpa {+34 mmHg, +1.3
inHg} to port B.
(1) Verify there is airflow from port A.
•If there is no airflow, replace the fuel tank.
7. Apply pressure of –5.9 kPa {–44 mmHg, –1.7
inHg} to port B.
•If there is no vacuum, replace the fuel tank.
•If there is vacuum, turn the fuel tank
upside-down and proceed to next step.
8. Apply pressure of +2.0 kPa {+15 mmHg, +0.6
inHg} to port B.
(1) Verify there is no airflow from port A.
•If there is airflow, replace the fuel tank.
End Of Sie
OILOIL
PLASTIC FUEL HOSE QUICK RELEASE
CONNECTOR SEALING
SURFACE
A6E3912W006
B
C
APLUG
PLUG
CHECK VALVE
(TWO-WAY)
FUEL GAUGE SENDER UNIT
ROLLOVER VALVE
A6E40122034
B CA
PLUGPLUG
CHECK VALVE
(TWO-WAY)
FUEL GAUGE SENDER UNIT
ROLLOVER VALVE
A6E40122035

F2–50
FUEL SYSTEM
NONRETURN VALVE INSPECTIONA6E401242270201
Note
•Nonreturn valve is integrated in the fuel tank. Therefore, before inspecting the nonreturn valve perform the
follwing:
1. Remove the fuel gauge sender unit. (See F2–45 FUEL TANK REMOVAL/INSTALLATION.)
2. Siphon the fuel from the fuel tank.
Note
•The nonreturn valve is normally closed by the spring force.
3. Verify that the nonreturn valve is closed.
•If it is stuck open, replace the fuel tank.
4. Verify that the nonreturn valve opens when pulled up by a finger.
•If it does not open, replace the nonreturn valve.
End Of Sie
FUEL FILTER COMPONENT REMOVAL/INSTALLATIONA6E4012348022011. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Remove in the order indicated in the table.
L.H.D.
R.H.D.
.
4. Install in the reverse order of removal.
5. Complete the “AFTER REPAIR PROCEDURE”.
(See F2–45 AFTER REPAIR PROCEDURE.)
6. Start the engine and verify that fuel does not leak
from the fuel system.
•If fuel leaks, reinstall the fuel filter.
End Of Sie
1
4
23
A6E40122010
1 Connector
2Fuel hose
3 Installation nut
4 Fuel filter body
4
1
2
3
A6E40122011

F2–124
ON-BOARD DIAGNOSTIC
DTC P0191A6E407001082221
Diagnostic procedure
End Of Sie
DTC P0191 Fuel pressure sensor circuit performance problem
DETECTION
CONDITION•PCM monitors fuel pressure in common rail from fuel pressure sensor while engine is running. PCM
calculates difference between actual fuel pressure and target fuel pressure. If pressure difference exceeds
preprogrammed criteria, PCM determines fuel pressure sensor circuit performance problem.
POSSIBLE
CAUSE•Fuel pressure sensor malfunction
•Suction control valve malfunction
•Clogged fuel line
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
2FOLLOW OTHER DETECTED DTC FIRST
•Turn engine switch to OFF.
•Start engine.
•Have P0091, P0092, P0192, P0193 been
detected?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Go to next step.
3INSPECT FUEL PRESSURE SENSOR
•Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
•Is there any malfunction?Yes Replace common rail, go to Step 6.
(See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION)
No Go to next step.
4INSPECT SUCTION CONTROL VALVE
•Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
•Is there any malfunction?Yes Repair supply pump, go to Step 6.
(See F2–54 SUPPLY PUMP INSPECTION)
No Go to next step.
5INSPECT FUEL LINE
•Turn engine switch to OFF.
•Inspect for clogs in following fuel lines for each
cylinder:
—Common rail and fuel injector.
—Common rail and fuel tank.
• Is there any malfunction?Yes Repair or replace suspected fuel line, go to next step.
No Go to next step.
6VERIFY TROUBLESHOOTING OF DTC P0016
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
7VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed.

F2–136
ON-BOARD DIAGNOSTIC
DTC P0300A6E407001082228
Diagnostic procedure
End Of Sie
DTC P0300 Random misfire detection
DETECTION
CONDITION•PCM monitors CKP sensor input signal interval time. PCM calculates change of interval time for each
cylinder. If the interval time exceeds preprogrammed criteria, PCM determines random misfire detection.
POSSIBLE
CAUSE•Fuel leakage or clogged in fuel line
•Fuel injector malfunction
•CKP sensor malfunction
•CMP sensor malfunction
•Inadequate engine compression
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
2FOLLOW OTHER DETECTED DTC FIRST
•Turn engine switch to OFF.
•Start engine.
•Has P0200 been detected?Yes Go to DTC P0200 inspection.
(See F2–129 DTC P0200)
No Go to next step.
3INSPECT FUEL LINE
•Turn engine switch to OFF.
•Inspect for fuel leakage or clogs in following
fuel lines for each cylinder:
—Common rail and fuel injector.
—Fuel injector and fuel tank.
• Is there any malfunction?Yes Repair or replace suspected fuel line, go to Step 8.
No Go to next step.
4INSPECT FUEL INJECTOR
•Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
•Is there any malfunction?Yes Replace fuel injector, go to Step 8.
(See F2–55 FUEL INJECTOR REMOVAL/INSTALLATION)
No Go to next step.
5INSPECT CKP SENSOR
•Inspect CKP sensor.
(See F2–82 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION)
•Is there any malfunction?Yes Replace CKP sensor, go to Step 8.
(See F2–81 CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION)
No Go to next step.
6INSPECT CMP SENSOR
•Inspect CMP sensor.
(See F2–80 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION)
•Is there any malfunction?Yes Replace CMP sensor, go to Step 8.
(See F2–80 CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION)
No Go to next step.
7INSPECT ENGINE COMPRESSION
•Inspect engine compression.
(See B2–8 COMPRESSION INSPECTION)
•Is there any malfunction?Yes Implement engine overhaul for repairs, go to next step.
No Go to next step.
8VERIFY TROUBLESHOOTING OF DTC P0300
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
9VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed.