Mazda 6. Manual - part 122

F–24

FUEL SYSTEM 

Fuel Pump Unit Installation Note

1. Verify that the fuel tank mark is aligened with the 

fuel pump mark as shown.

Plastic Fuel Hose Installation Note

Note

• A checker tab is integrated with 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.

1. When the retainer is not removed, perform the 

following procedure.
(1) Inspect the fuel pump unit sealing surface for 

damage and deformation, and replace as 
necessary.

• If the quick release connector O-ring is 

damaged, replace the plastic fuel hose.

(2) Slightly apply clean engine oil to the sealing 

surface of the fuel pump unit.

(3) Align the fuel pipe on the fuel pump unit and 

quick release connector so that the tabs of the 
retainer are correctly fitted into the quick 
release connector. Push the quick release 
connector straight into the retainer until a click 
is heard.

(4) 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.

2. When the retainer is removed, perform the following procedure.

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FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY

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Warning

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and 

damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of 
the fuel pump unit when removing or installing.

1. Disassemble in the order indicated in the table.

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FUEL SYSTEM 

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2. Assemble in the reverse order of disassembly.

.

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FUEL PUMP UNIT INSPECTION

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Caution

• It is normal to hear the fuel pump operating when the ignition switch is turned to the ON position.

Note

• To improve startability, the fuel pump control operates the fuel pump unit when the ignition switch is 

turned to the ON position. Due to this, fuel pressure is rapidly increased and fuel control is stabilized.

Continuity Inspection

Note

• Perform the following inspection only when directed.

1. Disconnect the negative battery cable.
2. Remove the service hole cover. (See 

F–22 FUEL PUMP UNIT REMOVAL/INSTALLATION

.)

3. Disconnect the fuel pump unit connector.
4. Inspect for continuity between fuel pump unit 

connector terminals B and D.

• If there is no continuity, replace the fuel pump 

body.

• If as specified carry out the “Circuit Open/

Short Inspection”.

Circuit Open/Short Inspection

1. Inspect the following wiring harnesses for open or 

short circuit (continuity check).

Open circuit

• If there is no continuity, the circuit is open. Repair 

or replace the harness.
— Fuel pump unit terminal D (harness-side) and 

body GND.

— Fuel pump relay terminal D (harness-side) 

and fuel pump unit terminal B (harness-side).

Short circuit

• If there is continuity, the circuit is short. Repair or 

replace the harness.
— Fuel pump unit terminal D (harness-side) and 

power supply.

— Fuel pump unit terminal B (harness-side) and body GND.

1

Packing

2

Fuel pump unit

3

Fuel gauge sender unit

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FUEL SYSTEM 

Fuel Pump Hold 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 

F–17 BEFORE REPAIR PROCEDURE

.)

2. Disconnect 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 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 loose it.

Reinstall it to the quick release connector 
before reconnecting the fuel line.

• The 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.

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FUEL SYSTEM 

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5. Cover the disconnected quick release connector 

with vinyl sheet or the like to prevent it from being 
scratched or contaminated with foreign material.

6. Turn the lever 90 degrees 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.

Caution

• Connecting to the wrong check 

connector terminal may possibly cause 
malfunction. Carefully connect to the 
specified terminal only.

10. Short the check connector terminal F/P to body 

GND using a jumper wire.

11. Turn the ignition switch to ON to operate the fuel 

pump.

12. Turn the ignition switch to LOCK position.
13. Measure the fuel pump hold pressure after 5 

minutes.

• If not as specified, replace the fuel pump after 

inspecting the following:
— Fuel line for clogging or leakage

Fuel pump hold pressure

More than 200 kPa {2.0 kgf/cm

2

, 29 psi}

14. Disconnect the jumper wire.
15. 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.

16. 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.

17. Apply a small amount of clean engine oil to the 

sealing surface of the fuel pipe.

18. Reconnect the plastic fuel hose straight to the fuel 

pipe until a click is heard.

19. 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.

20. Complete the “AFTER REPAIR PROCEDURE”. (See 

F–17 AFTER REPAIR PROCEDURE

.)

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