Safety Recall 5121I – Repair Procedure – 2009-2011 Mazda RX-8

RX-8 Fuel Pump Ring Replacement Procedure

Preparation for Repair

Warm the retainer and fuel pump ring of KIT parts

Soak in hot water no hotter than 140 ° F no more than 15 minutes (5 mins is usually sufficient)

  • This will make it easier to assemble the retainer

* Be sure to wipe off the water from the retainer and fuel pump ring after warming.

 


B. REPAIR PROCEDURE

WARNING

  • Fuel is extremely flammable. Always keep sparks and flames away from fuel. Ignition may cause death or serious injury, or damage to equipment.
  • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious damage, injury, or death. 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 Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

 

CAUTION

If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, when the quick release connector has been disconnected, clean the connecting area before reconnecting it.

 

Perform Fuel Line Safety Procedure

a. Remove the fuel-filler cap to release the pressure inside the fuel tank.

 

b. Remove the fuel pump relay.

 

c. Start the engine.

d. After the engine stalls, crank the engine several limes.

e. Check the fuel level on the gauge.

f. Turn the ignition switch to the LOCK position.

g. Install the fuel pump relay.

 

1. Remove the rear seat cushion. (Both right and left sides)

Lift the point A in the direction of the arrow and then remove the rear seat cushion.

 

2. Remove the 5ervice hole cover

NOTE: If the fuel gauge indicates 1 / 4 or less, go to Step 11 skipping Steps 3-10.

 

3. Drain fuel from the fuel tank. (Only when the fuel gauge indicates l / 4 or more)

CAUTION: When the fuel gauge indicates 1 /4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing next steps. Therefore, make sure to drain out fuel until the fuel tank becomes 1/4 full or less (according to the fuel gauge indication).

 

WARNING: A person charged with static electricity could cause a fire or explosion. resulting in death or seriou5 injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

 

4. Disconnect the quick release connector (engine compartment side).

 

5. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.

 

6. Ground the check connector terminal F/P to the body using a jumper

CAUTION: Shorting a wrong terminal of the check connector may cause electrical malfunctions. Make sure to short only the specified terminal.

 

7. Turn the ignition switch to the ON position and operate the fuel

CAUTION: The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when no fuel is being discharged.

 

8. When no fuel is being discharged from the hose, turn the ignition switch to the LOCK

NOTE: When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the 1 / 4 position.

 

9. Disconnect the jumper

 

10. Disconnect the negative battery

 

11. Put on safety googles and use a pressurized air gun to lightly blow out any dirt, debris from the top of the fuel tank and around both fuel pump rings. You will more thoroughly clean that area in a later step

 

12. Disconnect the connectors and quick connector of fuel pump unit and fuel suction pipe bracket.

CAUTION: When disconnecting the quick connector, wrap it in a waste cloth to prevent fuel from splashing.

 

13. Remove the fuel pump ring using SST (Fuel Pump Ring Wrench).

 

CAUTION

  • The fuel pump ring could be damaged if the SST is used with any play between the fuel pump ring and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the fuel pump ring.
  • The fuel suction pipe might be damaged if the fuel pump unit is lifted too much. Make sure to lift the pump only a small amount.

 

14. Use SST to remove the Fuel suction pipe bracket (sub).

 

15. Lift the fuel suction pipe bracket up slightly and remove the gasket.

16. Remove the retainer.

 

CAUTION

DO NOT LEAVE THE FUEL TANK FOR A LONG TIME WITHOUT THE FUEL PUMP RING INSTALLED.

If the fuel tank is left for a long time without the new fuel pump ring installed, the shape of the fuel tank where the fuel pump ring is installed could be deformed by swelling, causing it to be difficult to install the new fuel pump ring.

Therefore, install the new fuel pump retainer, gasket, and ring immediately after cleaning the mounting surfaces once the old fuel pump ring has been removed as quickly as possible.

  • Complete the replacement at one side first then proceed to other side.
  • Put replacement parts near the vehicle before starting the replacement.

 

17. Replace the fuel pump ring, retainer, and gasket with new parts.

18. Prepare warmed fuel pump ring and retainer. (Sec: Preparation for repair)

 

19. Fit the retainer in the three dents of the fuel tank.

 

CAUTION

Before installing the retainer, clean up following portions of the fuel tank using clean shop rags (Sand, dust, and oil may have accumulated).

1) Top surface of fuel pump unit (main) (sub)

2) Retainer mounting surface of the fuel tank.

3) Retainer, pump ring (wipe off water after warming)

  • Warm the pump ring and retainer so that they can be smoothly assembled to the fuel tank.

 

20. Set the gasket on groove of fuel tank.

 

21. Make sure to put and push Fuel gauge unit (Sub) on groove of fuel tank from above by hand.

 

22. Align the right side of the notch in the retainer with the center of the three lines of the pump ring. This is the [Rotation start position] for tightening while rotating.

 

The notch on the right side of retainer is the rotation start position
The thread of the pump ring begins to hang to thread of retainer from here
Align the center of the three lines of the pump ring as the [Rotation start position]
Mark the tank side with [Rotation start position] ◎ so to recognize the rotation angle

 

23. As shown in the figure below, tighten the fuel pump ring by hand, one turn (360 °), while holding the top of pump unit by hand from above.

 

CAUTION: * If the Fuel Pump Ring cannot be tightened by hand, remove the pump ring, check that the retainer, gasket, and pump ring are free of foreign matter such as damage, misalignment, and sand, and then tighten again.

24. Tighten another half turn (180°) using SST. (When tightened for a total of one and a half turns (540°), the pump ring tightening start position mark (three lines) will be around position #3 (540°) in the figure.). Then tighten the pump ring to the specified torque.

Pump ring tightening torque: 74ft-lbs ± 14ft-lbs ( 100 N· m± 20 N· m) (Be sure to use a preset type torque wrench)

Tightening rotation range: 540° to 580° (limit angle: do not exceed 580°)

 

CAUTION

If SST is used with any gaps between the wall surface of the pump ring and the claws of the SST, the pump ring may be damaged. Make sure to install SST so that there are no gaps.

 

NOTE:

If the tightening torque exceeds the upper limit before reaching 540°, remove the pump ring and check that the retainer, gasket, and pump ring are free of foreign matter such as damage, misalignment, and sand. Tighten again.

If the tightening torque does not rise to the specified value even if the rotation limit exceeds 580 °, remove the retainer, gasket, and pump ring, check if the gasket has been forgotten to be installed, or if oil or water has adhered, and then tighten again. The same applies to the upper surface of the Fuel suction pipe bracket.

 

25. For the [Fuel pump unit] (main) side, replace the retainer, gasket, and pump ring in the same procedure.

 

26. Connect the fuel gauge unit (main) (sub) connector and the fuel quick connector.

 

CAUTION

After connecting the fuel system quick connector, lightly push and pull in the axial direction to check that there is no disconnection

 

27. Attach two heat insulation pads to the fuel tank.

 

28. Clean the fuel tank where the pad will be attached. There cannot be any dirt present, or the pads will fall off.

 

29. Remove the backing tape and attach the pad to the fuel tank as shown above.

 

NOTE

  • Attach the pad so it connects without clearance to the existing pad in the central portion of the fuel tank.
  • Stick the pad onto the tank without clearance between the body and the tank.
  • After sticking the pads, confirm that the tape is stuck securely.

 

30. After pasting the pads, make sure that the tape is firmly attached.

 

Fuel leak check

i. Fill the tank with the fuel you previously drained.

ii. Connect the battery(-) cable and start engine.

iii. Make sure there are no fuel leaks near the fuel pump unit.

iv. Drive the vehicle, go, and stop suddenly 5-6 times at low speed.

v. Stop the vehicle and check that there is no fuel leakage near the fuel pump and tank.

vi. Perform an on-board evap test to confirm no evaporative leak with IDS

 

32. Install the service hole cover with four (4) screws.

33. Install the rear seat cushions.

 


2009-2011 Mazda RX-8 & 2006-2007 MazdaSpeed6 5121I Fuel Leak From Fuel Pump Mounting Rings

 

2009-2011 Mazda RX-8 & 2006-2007 MazdaSpeed6 5121I Fuel Leak From Fuel Pump Mounting Rings

 


Remedy Instructions and TSB

RCRIT-21V744-9733.pdf 2254.954KB

RCRIT-21V744-9733

 


 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V744&docType=RCL

 


 

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