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Mazda CX-9 Grand Touring. Manual - part 406

1. Remove the rear tire (RH).

2. Remove the spare tire.

3. Remove the main silencer (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-

3.7] .)

4. Remove the main silencer insulator (LH).

5. To lower the rear crossmember, perform the following procedure:

1. Set the rear ABS wheel-speed sensor out of the way. (See REAR ABS WHEEL-SPEED

SENSOR REMOVAL/INSTALLATION [AWD] .)

2. Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION .)

3. Lowered the rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION

[AWD] .)

6. Remove the fuel-filler pipe.

FUEL TANK INSPECTION [MZI-3.7]

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel

from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)

3. To disconnect the fuel pump unit connector, remove the following parts:

1. Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)

2. Edge cover (See LONG SLIDER REMOVAL/INSTALLATION .)

3. Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION .)

4. Rear heat duct No.3 (See REAR HEAT DUCT COMPONENT

REMOVAL/INSTALLATION .)

5. Disconnect the fuel pump unit connector.

4. Disconnect the quick release connector and the fuel pump unit connector. (See QUICK RELEASE

CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)

5. Disconnect the joint hose. (See FUEL TANK INSPECTION [MZI-3.7].)

6. Disconnect the evaporative hose. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)

7. Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION

[MZI-3.7].)

8. Perform the following procedure to verify the fuel tank air-tightness.

1. Plug the fuel pump unit pipe and port B.

2WD

NOTE:



This inspection is for three rollover valves and fuel shut-off valve
integrated in the fuel tank.

2008 Mazda CX-9 Grand Touring

2008 ENGINE Fuel System (MZI-3.7) - Mazda CX-9

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Sunday, November 15, 2009 10:04:45 AM

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Fig. 21: Identifying Fuel Pump Unit & Plug (2WD)
Courtesy of MAZDA MOTORS CORP.

AWD

2. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

3. Verify that there is no air leakage from the fuel tank.



If there is airflow, replace the fuel tank.

9. Level the fuel tank.

10. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port B and wait for a while.

11. With the pressure still applied, verify that there is airflow from port A and the pressure is 0-3 kPa {0-22

mmHg, 0-0.8 inHg}.



If malfunction, replace the fuel tank.

12. Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port B and wait for a while.

Fig. 22: Identifying Fuel Pump Unit & Plug (4WD)
Courtesy of MAZDA MOTORS CORP.

13. With the pressure still applied, verify that there is airflow from port A and the pressure is -0.5-0 kPa {-

3.8-0 mmHg, -0.2-0 inHg}.



If malfunction, replace the fuel tank.

2008 Mazda CX-9 Grand Touring

2008 ENGINE Fuel System (MZI-3.7) - Mazda CX-9

Microsoft

Sunday, November 15, 2009 10:04:45 AM

Page 19



If there is airflow, place the fuel tank upside down.

14. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port B and wait for a while.

2WD

Fig. 23: Identifying Fuel Pump Unit & Plug (2WD)
Courtesy of MAZDA MOTORS CORP.

AWD

15. With the pressure still applied, verify that there is no airflow from port A.



If there is airflow, replace the fuel tank.

16. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [MZI-

3.7].)

Fig. 24: Identifying Fuel Pump Unit & Plug (4WD)
Courtesy of MAZDA MOTORS CORP.

NONRETURN VALVE INSPECTION [MZI-3.7]

WARNING:



Fuel is very flammable liquid. If fuel spills or leaks from the
pressurized fuel system, it will cause serious injury or death and

2008 Mazda CX-9 Grand Touring

2008 ENGINE Fuel System (MZI-3.7) - Mazda CX-9

Microsoft

Sunday, November 15, 2009 10:04:45 AM

Page 20

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel

from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

2. Disconnect the negative battery cable.

3. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)

4. Siphon the fuel from the fuel tank.

5. Verify that the nonreturn valve is closed.



If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-
3.7].)

6. Verify that the nonreturn valve is not stuck open and does not open even when pulled up by a finger.



If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-
3.7].)

Fig. 25: Identifying Nonreturn Valve
Courtesy of MAZDA MOTORS CORP.

FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7]

facility breakage. Fuel can also irritate skin and eyes. To prevent
this, always complete the "Fuel Line Safety Procedure", while
referring to the "BEFORE SERVICE PRECAUTION".

NOTE:



Nonreturn valve is integrated in the fuel tank.



The nonreturn valve is normally closed by the spring force.



Verify the nonreturn valve operation using a mirror.

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".



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, before performing the fuel pump unit

2008 Mazda CX-9 Grand Touring

2008 ENGINE Fuel System (MZI-3.7) - Mazda CX-9

Microsoft

Sunday, November 15, 2009 10:04:45 AM

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