Fuel Gauge Sender Unit (Sub): Installation

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.

Install the fuel gauge sender unit (sub) to the fuel gauge sender unit stay.
Insert the fuel suction pipe bracket into the installation hole.

Fig 1: Installing Fuel Gauge Sender Unit To Fuel Gauge Sender Unit Stay
Courtesy of MAZDA MOTORS CORP.
Align the fuel suction pipe bracket alignment marks and the retainer notch as shown in the figure.
Install the packing.

Fig 2: Aligning Fuel Suction Pipe Bracket Alignment Marks & Retainer Notch
Courtesy of MAZDA MOTORS CORP.
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.
While keeping the alignment mark and the retainer notch aligned, tighten the cap to the rotation angle and specified torque using the SST.

Fig 3: Aligning Positions Of Cap & Retainer
Courtesy of MAZDA MOTORS CORP.

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.
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.
Rotation angle

50-140°

(Total angle for Step 5 and Step 6 is 410-500°.)

Cap tightening torque

80-135 N.m {8.2-13.7 kgf.m, 59-99 ft.lbf}
Install the service hole cover.
Install the rear seat. (See SEATS .)
Connect the negative battery cable.
Inspect all parts by performing the ". (See AFTER REPAIR PROCEDURE .)
Perform the "Fuel leak inspection after fuel gauge sender unit (sub) installation". (See FUEL LEAK INSPECTION AFTER FUEL GAUGE SENDER UNIT (SUB) INSTALLATION .)