Fuel Pump Hold Pressure Inspection

WARNING: This page is about a different car, the 2005 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.

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 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.

Complete the "BEFORE REPAIR PROCEDURE ". (See BEFORE REPAIR PROCEDURE .)
Disconnect the negative battery cable.
Remove the battery and battery tray.
CAUTION:
- The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper.
Disconnect the quick release connector from the fuel tank as follows:
1. Push the tab on the locking coupler 90° until it stops.
2. Pull the fuel hose straight back.
  NOTE:
  - The stopper may be removed from the quick connector. Take care not to lose it. Reinstall it to the quick release connector before reconnecting the fuel line.
  - The locking coupler has two internal locking tabs which distributor pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.
    
    Fig 1: Identifying Stopper
    Courtesy of MAZDA MOTORS CORP.
    
    Fig 2: Identifying Locking Tab
    Courtesy of MAZDA MOTORS CORP.
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: Covering Disconnected Quick Release Connector With Vinyl Sheet
Courtesy of MAZDA MOTORS CORP.
Turn the lever 90° against the hose of the SST to plug the SST outlet.
Push the SST quick release connector into the fuel pipe until a click is heard.
Set the fuel hose into a container to avoid fuel spills.
Connect the negative battery cable.

Fig 4: Setting Fuel Hose Into A Container
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Connecting to the wrong check connector terminal may cause malfunction. Carefully connect only to the specified terminal.
Short the check connector terminal F/P to body GND using a jumper wire.

Fig 5: Identifying Connector Terminal
Courtesy of MAZDA MOTORS CORP.
Turn the ignition switch to the ON position to operate the fuel pump.
Turn the ignition switch to the LOCK position.
Measure the fuel pump hold pressure after 5 min.
- If not as specified, replace the fuel pump after inspecting the following:
  - Fuel line for clogging or leakage
Fuel pump hold pressure

L3: More than 200 kPa {2.0 kgf/cm ² , 29 psi}

AJ: More than 250 kPa {2.5 kgf/cm ² , 36 psi}
Disconnect the jumper wire.
Disconnect the SST .
NOTE:
- A checker tab is integrated with the quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.
Fig 6: Identifying Plastic Fuel Hose
Courtesy of MAZDA MOTORS CORP.
Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation, and replace if necessary.
- If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.
Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
Reconnect the plastic fuel hose straight to the fuel pipe until a click is heard.
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 or slipped, and reconnect the quick release connector.
Complete the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE .)