Here's a general outline. This is not a complete, step-by-step guide and may not be entirely accurate for your specific model and trim level. Consult a repair manual specific to your 1986 Mazda 323 for detailed instructions and diagrams. Failure to follow proper procedures can lead to injury or damage.
1. Preparation:
* Gather tools: You'll need socket wrenches (various sizes), a fuel line disconnect tool (or pliers), a wrench for the fuel pump retaining ring (if applicable), safety glasses, rags, and possibly a fuel pump pressure gauge (for testing after installation). A jack and jack stands are recommended for easier access.
* Locate the fuel pump: On most 1986 Mazda 323s, the fuel pump is located inside the fuel tank. This means dropping the tank is usually necessary.
* Drain the fuel tank: This significantly reduces the risk of spillage and makes the job easier. Siphon the fuel into a suitable container. Never smoke or use any open flame near the gasoline.
2. Dropping the Fuel Tank:
* Disconnect the fuel lines: Carefully disconnect the fuel supply and return lines. Use a fuel line disconnect tool to avoid damage. Have rags ready to absorb any spilled fuel.
* Disconnect the electrical connector: Unplug the fuel pump's electrical connector.
* Disconnect the fuel tank straps: These are typically located on either side of the tank. Loosen and remove the bolts or clamps securing the tank.
* Lower the fuel tank: Carefully lower the fuel tank. You may need to support it with a jack or rope. Be mindful of any fuel lines and electrical connections that may still be attached.
3. Fuel Pump Replacement:
* Access the fuel pump: The fuel pump is usually accessed through a hole in the top of the fuel tank. You may need to remove a retaining ring or cover. Consult your repair manual for specifics.
* Remove the old fuel pump: Carefully remove the old fuel pump assembly. Note the orientation and any seals or gaskets.
* Install the new fuel pump: Install the new fuel pump assembly, ensuring it's correctly seated and oriented. Replace any seals or gaskets.
* Reassemble the tank: Reverse the steps used to remove the fuel tank, ensuring all connections are secure.
4. Post-Installation:
* Reconnect the fuel lines and electrical connector: Double-check all connections before raising the fuel tank.
* Raise the fuel tank: Securely attach the fuel tank straps.
* Reconnect the battery: Connect the battery's negative terminal.
* Prime the fuel system: You may need to crank the engine several times (without actually starting it) to prime the fuel pump. Consult your repair manual.
* Check for leaks: Inspect all connections for leaks.
* Test drive: After a successful test drive, verify that there are no fuel leaks and the vehicle runs properly. You might want to check fuel pressure with a gauge.
Disclaimer: This is a simplified overview. Incorrect procedures can cause serious damage or injury. Always refer to a repair manual specific to your 1986 Mazda 323 before attempting this repair. If you're not comfortable performing this task yourself, consult a qualified mechanic.
