Fuel gauge sender unit cap removal note

1. Mark the fuel gauge sender unit cap and the fuel tank at the point where the threading of each part begins as shown in the figure.
   Fig 1: Marking Fuel Gauge Sender Unit Cap And Fuel Tank At Point

   Courtesy of MAZDA MOTORS CORP.
2. Align the fuel tank alignment mark with the fuel gauge sender unit as shown in the figure.
   Fig 2: Aligning Fuel Tank Alignment Mark

   Courtesy of MAZDA MOTORS CORP.
3. Align the fuel tank and fuel gauge sender unit cap markings.
   Fig 3: Aligning Fuel Tank And Fuel Gauge Sender Unit Cap Markings

   Courtesy of MAZDA MOTORS CORP.
4. Rotate the fuel gauge sender unit cap counterclockwise until the cap marking is approx. 15° away from the fuel tank marking as shown in the figure.
   Fig 4: Rotating Fuel Gauge Sender Unit Cap Counterclockwise

   Courtesy of MAZDA MOTORS CORP.
   CAUTION:

   • The cap could be damaged if the SST (wrench) is used with any play between the cap and the SST (wrench). Securely install the SST (wrench) so that there is no gap between the SST (wrench) tabs and the side of the cap.
5. While keeping the fuel gauge sender unit from rising up, tighten the fuel gauge sender unit cap by hand 180 ° clockwise.
   Fig 5: Rotating Fuel Gauge Sender Unit Cap

   Courtesy of MAZDA MOTORS CORP.
6. Set the SST (wrench) as shown in the figure.
   Fig 6: Setting SST (Wrench)

   Courtesy of MAZDA MOTORS CORP.
7. Using the SST (wrench), tighten the fuel gauge sender unit cap within the specified rotation angle and cap tightening torque without shifting the fuel tank and fuel gauge sender unit alignment marks.

Fig 7: Tightening Fuel Gauge Sender Unit Cap Using SST (Wrench)

Courtesy of MAZDA MOTORS CORP.

Rotation angle 

270-315°

Fuel gauge sender unit cap tightening torque 

50-140 N.m {5.1-14 kgf.m, 37-103 ft.lbf}

Fig 8: Rotating Fuel Gauge Sender Unit Cap Marking

Courtesy of MAZDA MOTORS CORP.

• If the specified tightening torque cannot be obtained, replace the fuel pump cap and packing.
• If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and packing, replace the fuel tank.