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Diagnosis & Repair Procedure

WARNING: This page is about a different car, the 2002 Mazda 626. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform DTC confirmation procedure. See DTC CONFIRMATION PROCEDURE  under SELF-DIAGNOSTIC SYSTEM. See DTC CONFIRMATION PROCEDURE  under SELF-DIAGNOSTIC SYSTEM. Check for DTCs during KOEO and KOER self-test. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTC P0230 is present, go to next step. If DTC P0230 is not present, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
  2. Turn ignition off. Remove fuel pump relay. Fuel pump relay is located in main fuel block, in left side of engine compartment. Check for loose, damaged or corroded connector terminals. Repair as necessary, and go to step  13 . If connector terminals are okay, go to next step.
  3. Turn ignition on. Measure voltage between ground and fuel pump relay harness connector terminal "A" (Red/Black wire). See Figure . If battery voltage is present, go to next step. If battery voltage is not present, repair open circuit. See WIRING DIAGRAMS article. Go to step  13 .
  4. Turn ignition off. Check fuel pump relay for proper operation. See SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If fuel pump relay is okay, go to next step. If fuel pump relay is not okay, replace fuel pump relay and go to step  13 .
  5. Reconnect fuel pump relay. Disconnect Blue in-line connector located at back of joint box. See Fig 1 . Turn ignition on. Measure voltage between female side of Blue in-line connector terminal "D" (Light Green/Red wire with immobilizer system; Sky Blue wire without immobilizer system) and ground. See Fig 1 . If battery voltage is present, go to step  8 . If battery voltage is not present, go to next step.
  6. Remove fuel filler cap and listen for fuel pump operation sound at fuel tank. If fuel pump operating sound is not present, go to next step. If fuel pump operating sound is present, repair short to ground in Sky Blue wire between fuel pump relay and Blue in-line connector. See WIRING DIAGRAMS article. Go to step  13 .
  7. Disconnect fuel pump relay connector. Check for continuity of Sky Blue wire between fuel pump relay harness connector terminal "F" and female side of Blue in-line connector terminal "D". See Figure . If continuity is present, go to step  13 . If continuity is not present, repair open in Sky Blue wire. See WIRING DIAGRAMS article. Go to step  13 .
  8. Turn ignition off. Measure voltage between fuel pump relay harness connector terminal "F" (Sky Blue wire) and ground. See Figure . If battery voltage is present, go to step  11 . If battery voltage is not present, go to next step.
  9. Reconnect Blue in-line connector. Disconnect PCM connector. Turn ignition on. With fuel cap removed, check fuel pump operation sound at fuel tank. If fuel pump operation sound is not heard, go to next step. If fuel pump operation sound is heard, repair short to ground in Light Green/Red wire (with immobilizer system; Sky Blue wire without immobilizer system) between Blue in-line connector and PCM. See WIRING DIAGRAMS article. Go to step  13 .
  10. Disconnect Blue in-line connector. See Fig 1 . Check for continuity of Light Green/Red wire (with immobilizer system; Sky Blue wire without immobilizer system) between male side of Blue in-line connector terminal "D" and PCM harness connector terminal No. 70 (with immobilizer system; No. 80 without immobilizer system). See Figure and Fig 1 . If continuity is present, go to step  13 . If continuity is not present, repair open in Light Green/Red wire (with immobilizer system; Sky Blue wire without immobilizer system). See WIRING DIAGRAMS article. Go to step  13 .
  11. Disconnect fuel pump relay. Measure voltage between female side of Blue in-line connector terminal "D" and ground. If battery voltage is not present, go to next step. If battery voltage is present, repair short to power in Sky Blue wire between Blue in-line connector and fuel pump relay connector. See WIRING DIAGRAMS article. Go to step  13 .
  12. Measure voltage between male side of Blue in-line connector terminal "D" and ground. If battery voltage is not present, go to next step. If battery voltage is present, repair short to power in Light Green/Red wire (with immobilizer system; Sky Blue wire without immobilizer system) between Blue in-line connector and PCM connector. See WIRING DIAGRAMS article. Go to next step.
  13. Reconnect all connections. Turn ignition on. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Perform KOEO and KOER self-test. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTC P0230 is present, replace PCM and go to next step. See REMOVAL, OVERHAUL & INSTALLATION article. On vehicles equipped with immobilizer system, reprogram ignition key identification numbers. See COMPUTER RELEARN PROCEDURES - IMPORT article in GENERAL INFORMATION. If DTC P0230 is not present, go to next step.
  14. Perform DTC confirmation procedure. See DTC CONFIRMATION PROCEDURE  under SELF-DIAGNOSTIC SYSTEM. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If any other DTC is present, go to appropriate test.
Fig 1: Identifying Blue In-Line Connector Location
G00020980Courtesy of MAZDA MOTORS CORP.
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