How to Install a Fuel Pump on a 2001 Mazda 626by Robert Moore
The 2001 Mazda 626 came standard with a 2.0-liter four-cylinder engine and a manual or automatic transmission. The fuel pump is located inside the gas tank, so you must remove the gas tank to service the fuel pump. Replacing the fuel pump is an involved job that requires the help of an assistant at several times throughout the process.This process will also work for models equipped with the 2.5-liter six-cylinder.
Park the vehicle on a level surface and set the parking brake. Open the vehicle hood and support it with the hood prop rod. Install the 9-volt battery to the memory saver and plug the memory saver into the cigarette lighter socket. Disconnect the negative battery cable from the battery with the socket and ratchet. Open the relay center that is between the battery and strut tower on the left side of the engine bay. The fuel pump relay is in the third row of relays from the strut tower and it is the second relay from the driver's side in that row.
Start the engine and allow it to run until it stalls out and then crank it for an additional 10 seconds to relieve the fuel pressure. Turn the ignition key to the “Off” position. Remove the gas cap to relieve any fuel vapor pressure.
Place the wheel chocks around the front wheels. Lift the rear of the vehicle into the air with the floor jack and place the jack stands under the rear suspension. Lower the floor jack until the vehicle rests securely on the jack stands. Remove the floor jack.
Place a 5-gallon gas can directly under the fuel fill door. Install one end of the siphon pump into the fuel filler neck and direct the other end into the 5-gallon gas can. Siphon as much fuel from the tank as possible, making sure not to over fill each gas can. Store the removed fuel in a safe place for later use.
Lie down under the vehicle and look to the front of the tank to locate the fuel line connections. Squeeze the plastic tabs for each fuel tank line and separate the sending and return lines from the fuel tank lines. Disconnect the wiring harness from the fuel pump connector. Squeeze the pressure clamp for the fuel filter neck and no return valve and slide the clamp away from the tank. Remove the fuel filler neck, no return valve and the evaporative emissions vent hose.
Place the floor jack directly under the fuel tank and raise the jack arm until there is just enough room to fit the block of wood between the tank and the jack arm.
Place the block of wood between the tank and jack arm. Raise the jack arm until the wood makes contact with the fuel tank and shield, but do not apply any additional pressure. Instruct the helper to hold the fuel tank in place. Remove the tank strap bolts with the socket and ratchet. Swing the tank straps down and remove them from under the vehicle.
Instruct the helper to balance the tank on the floor jack while the fuel tank is lowered from its position under the vehicle. Remove the fuel tank and shield from the block of wood and jack. Slide the fuel tank and shield from under the vehicle.
Squeeze the plastic quick connectors securing the fuel tank lines to the fuel pump inlet and outlet hoses, then disconnect the fuel tank hoses from the fuel pump. Remove the screws securing the fuel pump to the fuel tank with the ratchet and bit-driver attachment. Lift the fuel pump out of the fuel tank and discard its mounting gasket.
Place the new fuel pump mounting gasket onto the fuel tank opening. Line up the holes in the gasket with the threaded holes in the fuel tank. Set the new fuel pump into position. Install the mounting screws and tighten to 10 to 19 inch-pounds with the inch pounds torque wrench and bit driver.
Slide the fuel tank under the vehicle. Place the block of wood and floor jack under the fuel tank mounting location. Lift the fuel tank onto the block of wood and jack arm with the assistance of your helper. Instruct the helper to maintain the tank balance and lift the fuel tank into position with the floor jack.
Hook the fuel straps into position on the front side of the tank and shield, and swing them into position at the rear of the tank. Install the tank strap bolts and tighten to 32 to 44 foot-pounds with the torque wrench. Lower the floor jack and block of wood.
Install the new fuel line retainer clips onto the fuel pump connections by sliding them over the fuel lines on the fuel pump. Clip the sending and return lines into place on the fuel pump. Install the fuel filler neck and no return valve, and then install the clamps. Install the evaporative emission lines to its respective connection.
Lift the rear of the vehicle off of the jack stands with the floor jack and remove the jack stands. Lower the rear of the vehicle to the ground and remove the floor jack.
Fill the fuel tank with the gas that was removed previously and stored in gas cans. Install the fuel filler cap and tighten until it clicks three times.
Inspect the socket for the fuel pump relay and locate terminal number 30, which is the bottom left terminal. Connect the jumper wire to terminal 30. Loosen the body ground on the core support near the hood latch with the socket and ratchet. Install the opposite end of the jumper wire to the body ground and tighten the ground bolt snug with the socket and ratchet.
Connect the negative battery cable to the battery and tighten the terminal with the socket and ratchet. The fuel pump will turn on as soon as the negative battery terminal is connected to the battery. Allow the fuel pump to operate continuously for the next five minutes. While the fuel pump is running inspect the fuel system for any leaks and replace any leaking lines or hoses as necessary.
Loosen the body ground at the core support with the socket and ratchet. Remove the jumper wire from the body ground. Tighten the body ground bolt snug with the socket and ratchet. Disconnect the jumper wire from fuel pump relay socket 30.
Install the fuel pump relay. Install the fuse center lid and shut the vehicle hood.
- Do not smoke or use an open flame at any time while working on the fuel system.