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Fuel Pump

REMOVAL AND INSTALLATION

CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

1993-94 323 1.6L (B6E) and 1993-97 Protege 1.8L (BPD, BPE), 1.5L (Z5D) and 1994 MX3 1.8L (B6-ZE) Engines
  1. Relieve the fuel pressure and disconnect the negative battery cable.
  2. Depress the clips on each end of the rear seat cushion and remove the cushion.
  3. Disconnect the electrical connector from the fuel pump/sending unit.
  4. Remove the attaching screws from the fuel pump/sending unit access cover and remove the cover.
  5. Disconnect the fuel supply and return hoses from the fuel pump/sending unit.
  6. Remove the attaching screws and the fuel pump/sending unit from the fuel tank.
  7. Disconnect the sending unit electrical connector, remove the sending unit attaching nuts and remove the sending unit from the fuel pump assembly.

    To install:

  8. Attach the sending unit to the fuel pump assembly and install the nuts. Connect the sending unit electrical connector.
  9. Install the fuel pump/sending unit into the fuel tank with a new gasket and install the mounting screws.
  10. Connect the fuel supply and return lines.
  11. Install the access cover and the mounting screws.
  12. Connect the sending unit electrical connector.
  13. Position the rear seat cushion over the floor, making sure to align the retaining pins with the clips. Push down firmly until the 2 retaining pins are locked into the rear seat retaining clips.
  14. Connect the negative battery cable, start the engine and check for proper system operation and for fuel leaks.
1995 MX3 1.6L (B6-ZE) and 1.8L (K8) Engines

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Remove the rear seat cushion from the vehicle.
  4. Remove any dirt that has accumulated around the fuel pump cover so it will not enter the tank during pump removal and installation.
  5. Remove the fuel pump cover.
  6. Disconnect the fuel gauge connector, hoses, and the gauge.
  7. Disconnect the fuel pump electrical connector.
  8. Remove the fuel pump from the bracket assembly. Remove and discard the seal ring.

    To install:

  9. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
  10. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
  11. Install the fuel pump to the bracket assembly carefully to ensure the filter is not damaged. Make sure the seal ring remains in the groove.
  12. Hold the pump assembly in place, and pull the fuel pump down so that it is tight against the bracket.
  13. Connect the fuel pump electrical connector.
  14. Install the fuel gauge, hoses, and gauge connector.
  15. Install the fuel pump cover.
  16. Install the rear seat cushion.
  17. Connect the negative battery cable, start the engine and check for proper system operation and for fuel leaks.
1993-95 929 3.0L (JE-ZE) Engines

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Relieve the fuel system pressure, and disconnect the negative battery cable.
  2. Remove the amplifier and CD changer, if equipped.
  3. Open the trunk and lift the carpet or mat.
  4. Remove the fuel pump access cover.
  5. Disconnect the fuel pump connector and the fuel lines.
  6. Remove the screws and remove the fuel pump/sending unit assembly from the fuel tank.
  7. If necessary, remove the fuel pump from the tank gauge sending unit.

    To install:

  8. Using a new rubber seal, install the fuel pump into the fuel tank.
  9. Connect the fuel pump connector and the fuel lines.
  10. Install the access cover, and replace the mat or carpet.
  11. Install the amplifier and CD changer, if removed.
  12. Connect the negative battery cable.
    Fig. 1:Fuel pump assembly -- 1993-94 929 3.0L (JE-ZE) engines

1995-97 Millenia 2.3L (KJS), 2.5L (KLD) and 1993 MX3 (K8) and 1993-97 626, MX6, 2.0L (FS) and 2.5L (KL) Engines

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Remove the fuel tank and place it on a bench.
  4. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
  5. Turn the fuel pump locking ring counterclockwise and remove the locking ring.
  6. Remove the fuel pump and bracket assembly. Remove and discard the seal ring.

    To install:

  7. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
  8. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
  9. Install the fuel pump and bracket assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
  10. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
  11. Rotate the locking ring clockwise until the ring is against the stops.
  12. Install the fuel tank in the vehicle. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
  13. Connect the negative battery cable. Start the engine and check for proper system operation and for fuel leaks.
1993-97 Miata 1.6L (B6-ZE) and 1.8L (BPD) Engines

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Properly relieve the fuel pressure, and disconnect the negative battery cable.
  2. Remove the rear package trim and remove the service hole cover.
  3. Remove the fuel pump cover and disconnect the fuel pump connector. Disconnect the fuel hoses.
  4. Remove the fuel pump and the fuel gauge sender unit as an assembly. Remove the fuel pump.
  5. Installation is the reverse of removal. Use a NEW O-ring set when installing. After install the fuel pump to the bracket, pull the fuel pump down so that it is tight against the bracket.
1993-95 RX7 1.3L (13B) Engines

CAUTION
Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2. Open the trunk or hatch and lift the carpet or mat.
  3. Remove the fuel pump access cover.
  4. Disconnect the fuel pump connector and the fuel lines.
  5. Remove the screws and remove the fuel pump/sending unit assembly from the fuel tank. If necessary, remove the fuel pump from the tank gauge sending unit.
  6. Installation is the reverse of the removal procedure. Use a new rubber seal and tighten the mounting bolts to 70-95 inch lbs. (8-11 Nm).
 
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