Mazda Protege 5. Manual - part 147

 

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Mazda Protege 5. Manual - part 147

 

 

FUEL SYSTEM 

01–14–13

01–14

(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.

Note

Use the designated genuine retainer only.

(1) Inspect the plastic fuel hose and fuel pump unit 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.

(2) Install a new retainer onto the quick release connector. Visually inspect that the tabs of the retainer are 

securely fitted into the quick release connector.

(3) Slightly apply clean engine oil to the sealing surface of the fuel pump unit.
(4) Push the quick release connector straight into 

the fuel pump unit until a click is heard.

(5) 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.

End Of Sie

FUEL TANK INSPECTION

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Note

This inspection is for the 2 rollover valves integrated in the fuel tank. The evaporative gas check valve 
(two-way) is integrated with each rollover valve.

1. Remove the fuel tank. (See 01–14–9 FUEL TANK REMOVAL/INSTALLATION.)
2. Connect the SST to an air compressor.
3. Plug the fuel main pipe and fuel return pipe of the fuel pump unit.
4. Connect the SST to port B and plug port A.
5. Level the fuel tank.
6. Apply pressure of +5.9 kPa {+44 mmHg, +1.7 inHg} to port B and verify that there is airflow from port C.

If there is no airflow, replace the fuel tank.

If there is airflow, connect the SST to port C with port A plugged.

7. Apply pressure of +2.0 kPa {+15 mmHg, +0.59 

inHg} to port C and verify that there is airflow 
from port B.

If there is no airflow, replace the fuel tank.

If there is airflow, connect the SST to port B 
and turn the fuel tank upside-down.

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FUEL SYSTEM 

01–14–14

8. Apply pressure of +0.99 kPa {+7.4 mmHg, 0.29 

inHg} to port B and verify that there is no airflow 
from port C.

If there is airflow, replace the fuel tank.

End Of Sie

FUEL SHUT-OFF VALVE INSPECTION

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Note

The fuel shut-off valve is located in the fuel tank.

Carry out the “FUEL TANK INSPECTION”. (See 01–14–13 FUEL TANK INSPECTION.)

End Of Sie

NONRETURN VALVE INSPECTION

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1. Remove the nonreturn valve. (See 01–14–9 FUEL TANK REMOVAL/INSTALLATION.)
2. Verify that the nonreturn valve opens up to 90

°°°°

 when it is pushed from the fuel-filler pipe side, and it returns to 

the normal position by the spring force.

If the nonreturn valve does not open up to 90

°°°°

 or does not return to the normal position, replace the 

nonreturn valve.

End Of Sie

FUEL PUMP UNIT REMOVAL/INSTALLATION

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1. Remove and install the fuel pump unit. (See 01–14–9 FUEL TANK REMOVAL/INSTALLATION.)

End Of Sie

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FUEL SYSTEM 

01–14–15

01–14

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.

2. Assemble in the reverse order of disassembly.

End Of Sie

FUEL PUMP UNIT INSPECTION

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Continuity Inspection

Note

Perform the following test only when directed.

1. Disconnect the negative battery cable.
2. Remove the rear seat cushion. (See 09–13–5 REAR SEAT REMOVAL/INSTALLATION.)
3. Remove the service hole cover.
4. Disconnect the fuel pump unit connector.
5. 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”.

1

Fuel pump unit cover

2

Fuel filter (high-pressure)

3

Spacer

4

Rubber mount

5

Fuel filter (low-pressure)

6

Fuel pump body

7

Fuel gauge sender unit

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FUEL SYSTEM 

01–14–16

Circuit Open/Short Inspection

1. Remove the PCM.
2. Connect the SST (104 Pin Breakout Box) to the 

PCM as shown.

3. Tighten the connector attaching screw.

Tightening torque

7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 

in·lbf}

4. Inspect for an open or short circuit in the following 

wiring harnesses by probing the applicable 
sensor and SST (104 Pin Breakout Box) terminals 
with ohmmeter leads.
Open circuit

GND circuit (Fuel pump unit connector 
terminal D and body GND)

Power circuit (Fuel pump relay connector terminal C and fuel pump unit connector terminal B through 
common connector)

Short circuit

Fuel pump relay connector terminal C and 
fuel pump unit connector terminal B through 
common connector to GND

5. Repair or replace faulty areas.
6. Reconnect the fuel pump unit connector.
7. Install the service hole cover.
8. Install the rear seat cushion.
9. Reconnect the negative battery cable.

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