Mazda 6. Manual — part 123

F–28

FUEL SYSTEM

End Of Sie

FUEL INJECTOR REMOVAL/INSTALLATION

A6E391213250W01

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.

1. Complete the “BEFORE REPAIR PROCEDURE”. (See

F–17 BEFORE REPAIR PROCEDURE

.)

2. Disconnect the negative battery cable.
3. Remove in the order indicated in the table.

.

4. Install in the reverse order of removal.
5. Complete the “AFTER REPAIR PROCEDURE”.

(See

F–17 AFTER REPAIR PROCEDURE

.)

Plastic Fuel Hose Removal Note

Caution

• The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab

over the stopper.

1. Disconnect the quick release connector.

(1) Push the tab on the locking coupler 90 degrees 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.

1

Fuel injector connectors

2

Plastic fuel hose
(See

F–28 Plastic Fuel Hose Removal Note

)

(See

F–30 Plastic Fuel Hose Installation Note

)

2

Hose

4

Fuel distributor

5

Fuel injector
(See

F–29 Fuel Injector Removal Note

)

(See

F–30 Fuel Injector Installation Note

)

6

Snap ring

7

Pulsation damper

A6E3912W005

A6E3912W001

FUEL SYSTEM

F–29

F

• The locking coupler has two internal locking

tabs which retain the fuel pipe. Be sure that
the tab on the locking coupler is rotated until
it stops to release two internal locking tabs.

2. Cover the disconnected quick release connector

and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.

Fuel Injector Removal Note

Caution

• Use of a deformed injector retaining clip will cause the injector to not engage correctly. Always

use a new clip when reattaching the injector, otherwise it may cause the injector to rotate.

1. Insert a screwdriver between the injector cup and

the clip fingers.

Note

• When rotating the screwdriver to spread the

clip fingers, deform them sufficiently to make
sure they release from the notched edge of
the injector cup.

2. Rotate the screwdriver to spread the clip fingers

and remove them from the injector cup.

3. Pull the injector and clip out of the rail.
4. Remove the clip from the injector according to the

following:
(1) Grasp the clip with a pair of pliers.

A6E3912W002

A6E3912W039

A6E3912W040

A6E3912W041

F–30

FUEL SYSTEM

(2) Pull the clip parallel to the injector groove, and

remove it from the injector.

(3) Discard the clip.

Fuel Injector Installation Note

1. Lightly lubricate the injector groove and O-ring.
2. Pre-attach a new clip in the injector groove.

Note

• When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.

3. Hold the injector firmly, push the clip into the

injector until the clip stops sliding.

4. Verify that the injector connector position is

correct, and press the injector and clip into the
injector cup. Continue pressing until the clip
contacts the lower surface of the injector cup.

5. Verify that the injector and clip are correctly

attached with the clip locked onto the injector cup
notch.

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.

A6E3912W042

A6E3912W043

A6E3912W004

A6E3912W006

FUEL SYSTEM

F–31

F

(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.

End Of Sie

FUEL INJECTOR INSPECTION

A6E391213250W02

Operation Test

1. Carry out the “Fuel Injector Operation Inspection”. (See

F–231 Fuel Injector Operation Inspection

.)

• If not as specified, perform the further inspection for the fuel injectors.

Resistance Inspection

Note

• Perform the following test only when directed.

1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable.
3. Disconnect the fuel injector connectors.
4. Measure the resistance of the fuel injector using

an ohmmeter.

• If not as specified, replace the fuel injector.

(See

F–28 FUEL INJECTOR REMOVAL/

INSTALLATION

.)

• If as specified but “Operation Test” is failed,

carry out the “Circuit Open/Short Inspection”.
Inspect for open or short circuit.

Resistance

11.4—12.6 ohms [20

°C {68 °F}]

Circuit Open/Short Inspection

1. Disconnect the PCM connector. (See

F–43 PCM

REMOVAL/INSTALLATION

.)

2. Inspect the following wiring harness for open or

short (continuity check).

Open circuit

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

or replace the harness.
— No.1 cylinder fuel injector terminal B

(harness-side) and PCM terminal 4Z.

— No.2 cylinder fuel injector terminal B

(harness-side) and PCM terminal 4W.

— No.3 cylinder fuel injector terminal B

(harness-side) and PCM terminal 4AD.

— No.4 cylinder fuel injector terminal B (harness-side) and PCM terminal 4AA.
— No.1 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through

common connector.

— No.2 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through

common connector.

— No.3 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through

common connector.

— No.4 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through

common connector.

Short circuit

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

— No.1 cylinder fuel injector terminal B (harness-side) and body GND.
— No.2 cylinder fuel injector terminal B (harness-side) and body GND.
— No.3 cylinder fuel injector terminal B (harness-side) and body GND.
— No.4 cylinder fuel injector terminal B (harness-side) and body GND.
— No.1 cylinder fuel injector terminal A (harness-side) and power supply.

A6E3912W007

A6E3912W008