Fuel Pump (FP) Pressure Inspection

WARNING: This page is about a different car, the 2005 Mazda MX-5 Miata. 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 SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (+)
Disconnect the negative battery cable.
Lift up the vehicle with safety stands.
Remove the fuel filter cover.
Verify that the quick release connector joint area is free of foreign material.
Clean if necessary.
Set the SST to the fuel filter outlet pipe and push it into the quick release connector, and disconnect the fuel pipe.
- If removal of the retainer is required, remove it by squeezing the tabs of the retainer.
  
  Fig 1: Disconnecting Fuel Pipe
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Removing the retainer from the disconnected fuel pipe will reduce the effectiveness of the retainer. The retainer must be replaced when any of the following applies:
    
    Scratches or damage is observed on the retainer.
    
    Fuel pipe has been replaced.
    
    Fuel filter (high-pressure) has been replaced.
Cover the disconnected quick release connector and fuel filter outlet pipe to prevent them from being scratched or contaminated with foreign material.
Turn the lever as shown in Fig 2 to plug the SST outlet.
Push the SST into the fuel filter outlet pipe until a click is heard.
Connect a fuel hose and clamp to the SST outlet pipe.
Set the fuel hose into a container to avoid fuel spills.
Pull the quick release connector by hand and verify that it is installed securely.
Connect the negative battery cable.
CAUTION:
- Connecting to the wrong DLC terminals may cause a malfunction. Carefully connect only to the specified terminals.
Short the DLC terminals F/P and body GND using a jumper wire.

Fig 2: Setting Fuel Hose Into A Container To Fuel Spills
Courtesy of MAZDA MOTORS CORP.
Turn the lever 90° against the hose of the SST.
Turn the ignition switch to the ON position to operate the FP.
Measure the FP maximum pressure.
- If not as specified, inspect the following:
  - FP
  - FP RLY
  - Fuel filter for clogging
  - Fuel line for clogging or leakage
FP maximum pressure
1. Less than 637 kPa {6.5 kgf/cm2, 92 psi}
Fig 3: Shorting DLC Terminals F/P And Body Gnd
Courtesy of MAZDA MOTORS CORP.
Turn the ignition switch to the ON position for 10 s to operate the FP.
Turn the ignition switch to the LOCK position.
Measure the FP hold pressure after 5 min.
- If not as specified, replace the FP.
FP hold pressure
1. More than 343 kPa {3.5 kgf/cm2, 50 psi}
Disconnect the jumper wire.
Disconnect the SST.
Inspect the fuel pipe for kinks.
Replace the fuel pipe if necessary.
Verify that the inside of the fuel filter outlet pipe and the quick release connector is free of foreign material and damage.
Clean if necessary, taking care not to damage the sealing surfaces.
Push the fuel pipe into the fuel filter outlet pipe until a click is heard.
Pull the quick release connector by hand and verify that it is installed securely.
Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (+)