QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[MZ-CD 1.6 (Y6)]

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Warning

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

•  As this procedure involves handling fuel additives, be prepared for fuel additive spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

•  Eye, hand, ear protection and protective clothing are required to be worn during any general or removal and installation procedure of fuel additive system components. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

•  In case of fuel additive fluid contact with the skin or the eyes, flush immediately with water for a minimum of 15 minutes and seek prompt medical attention. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

•  If fuel additive fluid is swallowed, call a physician immediately. Rinse mouth immediately with water, do not induce vomiting. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

•  Always provide adequate ventilation when working on the fuel additive system or related components. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

•  Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. (High power-Euro 4)

Caution

•  Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction. (High power-Euro 4)

•  After completing the filling procedure, make sure the fuel additive refill kit and pipes are stored in a dry and secure area away from dust. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel additive fluid. (High power-Euro 4)

Note

•  Install the new blanking plugs to the open ends of the quick release connectors after disconnecting the quick release connectors.

•  Remove the blanking plug from quick release connectors before connecting the quick release connectors.

Quick Release Connector Type

Caution

•  There are seven types of quick release connectors. Verify the type and location, and install/remove properly.

Type A Removal

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Push the release tab on the quick release connector.

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3.  Pull out the hose straight from the pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type B Removal

Using the SST (Mazda SST number: 49 N013 103A)

Note

•  If the tube is wrapped around the fuel pipe to the connecting area of the quick release connector, disconnect the quick release connector by using the SST (49 E042 001).

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1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Insert the SST into the quick release connector.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

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Using the SST (49 E042 001)

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Push the release tab using the SST.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type C Removal

1.  Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Rotate the release tab on the quick release connector to the stopper position.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

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4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type D Removal

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Release the retainer using a flathead screwdriver or a similar tool.

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3.  Pull out the hose straight from the pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type E Removal

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Push the release tab on the retainer to unlock.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type F Removal

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Push the release tab on the retainer to unlock.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type G Removal

1.  Follow “ BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

2.  Push the release tab on the retainer to unlock.

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3.  Pull out the fuel hose straight from the fuel pipe and disconnect it.

4.  Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent scratches or dirt.

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Type A Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Verify that there is retainer in the quick release connector.

•  If there is no retainer in the quick release connector, install the retainer.

2.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

3.  When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the resin pipe end while pressing the end with a finger.

•  If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.

4.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

5.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

6.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type B Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

•  A checker tab is integrated with the quick release connector for new fuel hoses and hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.

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1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type C Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

•  A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.

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1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type D Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Push the retainer then remove the checker tab.

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4.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

5.  Perform the “AFTER FUEL ADDITIVE SYSTEM REPAIR PROCEDURE” when remove/disconnect the fuel additive hose. (High power-Euro 4) (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

6.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type E Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type F Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)

Type G Installation

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[MZ-CD 1.6 (Y6)].)