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Home >> Mazda >> 2006 >> 6 s, 4D Wagon, Automatic >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrumentation/Driver Info >> Fuel Gauge Sender Unit Removal/Installation [AWD] >> Fuel Gauge Sender Sub-Unit

Fuel Gauge Sender Sub-Unit

WARNING:
  • Fuel line spills and leakage 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 "Fuel Line Safety Procedure".
  • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.
CAUTION:
  • Because the fuel tank is constructed such that the fuel level is higher than the installation surface of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more, perform the following Steps  1-- 14 to drain the fuel.
  • 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.
  1. Complete the "BEFORE REPAIR PROCEDURE".
  2. Remove the plug hole plate.
  3. Disconnect the quick release connector connected to the fuel distributor.
  4. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
  5. Start the fuel pump using the following procedure.

    Using WDS or equivalent 

    Fig 1: Locating Fuel Line Quick Release Connector
    G04327787Courtesy of MAZDA MOTORS CORP.
    1. Connect the WDS or equivalent to the DLC-2.
    2. Using the simulation function "FP", start the fuel pump.

    Without using WDS or equivalent 

    Fig 2: Locating DLC-2 Connector
    G04324072Courtesy of MAZDA MOTORS CORP.
    1. Short the check connector terminal F/P to body GND using a jumper wire.
    2. Turn the ignition switch to ON position to operate the fuel pump.
      CAUTION:
      • The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
      Fig 3: Locating & Identifying Check Connector Terminals
      G04327789Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • If the fuel tank is full, drain approx. 40 L {10.6 US gal, 8.8 Imp gal}  of fuel until the fuel gauge indicates approx. 3/8  of a tank.
  6. Stop operation of the fuel pump when essentially no fuel is being discharged.
  7. Reconnect the quick release connector to the fuel distributor.
  8. Start the engine and Idle it for 15 min (to transfer fuel from the sub-tank to the main tank).
  9. Stop the engine.
  10. Complete the "BEFORE REPAIR PROCEDURE".
  11. Remove the plug hole plate.
    Fig 4: Fuel Gauge
    G04327790Courtesy of MAZDA MOTORS CORP.
  12. Disconnect the quick release connector connected to the fuel distributor.
  13. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
  14. Start the fuel pump using the following procedure.
    Fig 5: Locating Fuel Line Quick Release Connector
    G04327791Courtesy of MAZDA MOTORS CORP.

    Using WDS or equivalent 

    Connect the WDS or equivalent to the DLC-2. 

    Using the simulation function "FP", start the fuel pump. 

    Fig 6: Locating DLC-2 Connector
    G04324072Courtesy of MAZDA MOTORS CORP.

    Without using WDS or equivalent 

    1. Short the check connector terminal F/P to body GND using a jumper wire.
    2. Turn the ignition switch to ON position to operate the fuel pump.
      CAUTION:
      • The fuel pump could be damaged if it is operated (fuel pump idling) while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
        Fig 7: Locating & Identifying Check Connector Terminals
        G04327793Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • If the fuel tank is full, drain approx. 55 L {15 US gal, 12 Imp gal}  of fuel until the fuel gauge indicates E position.
  15. Stop operation of the fuel pump when essentially no fuel is being discharged.
  16. Disconnect the negative battery cable.
  17. Complete the following in order to the work area.
    1. Loosen the bolt of the fuel tank strap.
    2. Lower the fuel tank to a position where the SST  can be attached from the service hole cover.
  18. Remove the rear seat cushion.
    Fig 8: Fuel Gauge
    G04327794Courtesy of MAZDA MOTORS CORP.
  19. Remove in the order indicated in the table.
    Fig 9: Fuel Gauge Sender Sub-Unit & Torque Specification
    G04327795Courtesy of MAZDA MOTORS CORP.
  20. Install in the reverse order of removal.
  21. Complete the "AFTER REPAIR PROCEDURE".
  22. Complete the "Fuel leak inspection after fuel gauge sender sub-unit installation." (See FUEL LEAK INSPECTION AFTER FUEL GAUGE SENDER SUB-UNIT INSTALLATION ).
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