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Home >> Mazda >> 2004 >> MPV ES >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Pump Unit Inspection >> Fuel Pump Pressure Inspection
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Fuel Pump Pressure Inspection

WARNING:
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
CAUTION:
  • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.
NOTE:
  • Perform the following test only when directed.
  1. Complete the "BEFORE REPAIR PROCEDURE". (See BEFORE REPAIR PROCEDURE .)
  2. Disconnecting the negative battery cable.
  3. Remove the air cleaner.
    CAUTION:
    • The quick release connector may be damaged if the tab is turned too far. Do not turn the tab over the stopper.
  4. Disconnect the quick release connector from the fuel tank as follows:
    1. Push the tab on the orange locking coupler 90°  until it stops.
    2. Pull the fuel hose straight back.
    NOTE:
    • The blue stopper may be removed from the quick connector. Take care not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line.
      Fig 1: Disconnecting Quick Release Connector From The Fuel Tank
      G00991558Courtesy of MAZDA MOTORS CORP.
    • The orange locking coupler has two internal locking tabs which retain the pulsation damper pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.
    Fig 2: Locating Locking Tab
    G00991559Courtesy of MAZDA MOTORS CORP.
  5. Cover the disconnected quick release connector with vinyl sheet or the like to prevent it from being scratched or contaminated with foreign material.
    Fig 3: Protecting Disconnected Quick Release Connector With Vinyl Sheet
    G00991560Courtesy of MAZDA MOTORS CORP.
  6. Turn the lever 90°  against the hose of the SST  to plug the SST  outlet.
  7. Push the SST  quick release connector into the fuel pipe until a click is heard.
  8. Set the fuel hose into a container to avoid fuel spills.
  9. Connect the negative battery cable.
    Fig 4: Checking Fuel Pressure
    G00991561Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Connecting to the wrong DLC terminal may possibly cause a malfunction. Carefully connect to the specified terminal only.
  10. Short the DLC terminal F/P to body GND using a jumper wire.
    Fig 5: Shorting DLC terminal F/P To Body GND Using Jumper Wire
    G00991562Courtesy of MAZDA MOTORS CORP.
  11. Turn the ignition switch to ON to operate the fuel pump.
  12. Measure the fuel pump maximum pressure.
    • If not as specified, replace the fuel pump after inspecting the following:
    • Fuel filter (low-pressure, high-pressure) for clogging
    • Fuel line for clogging or leakage
    1. Fuel pump maximum pressure 
    2. 0.59-0.80 MPa 
    3. {6.1-8.1 kgf.cm 2  , 86-116 psi} 
  13. Turn the ignition switch to LOCK position.
  14. Measure the fuel pump hold pressure after 5 minutes. 
    • If not a specified, replace the fuel pump after inspecting the following:
    • Fuel filter (low-pressure, high-pressure) for clogging
    • Fuel line for clogging or leakage
    1. Fuel pump hold pressure 
    2. More than 0.408 MPa {4.16 kgf/cm 2  , 59.2 psi} 
  15. Disconnect the jumper wire.
  16. Disconnect the SST. 
    NOTE:
    • A checker is integrated with the quick release connector for new fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.
    Fig 6: Removing Checker Tab From New Plastic Fuel Hose
    G00991563Courtesy of MAZDA MOTORS CORP.
  17. Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
    • If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.
  18. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
  19. Reconnect the plastic fuel hose straight to the fuel pipe until a click is heard.
  20. Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0-3.0 mm {0.08-0.11 in}  and it is connected securely.
    • If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.
  21. Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE .)
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