Mazda Protege 5. Manual — part 144

FUEL SYSTEM

01–14–1

01–14

01–14

FUEL SYSTEM

FUEL SYSTEM LOCATION INDEX . . . . 01–14–2

Engine Room Side . . . . . . . . . . . . . . . . 01–14–2

FUEL SYSTEM DIAGRAM . . . . . . . . . . . 01–14–4
BEFORE REPAIR PROCEDURE . . . . . . 01–14–4

Fuel Line Safety Procedure . . . . . . . . . 01–14–4

AFTER REPAIR PROCEDURE. . . . . . . . 01–14–5

Fuel Leakage Inspection . . . . . . . . . . . 01–14–5

FUEL PRESSURE INSPECTION . . . . . . 01–14–6
FUEL TANK

REMOVAL/INSTALLATION . . . . . . . . . 01–14–9

Plastic Fuel Hose Removal Note . . . . . 01–14–11
Nonreturn Valve Installation Note . . . . 01–14–11
Joint Hose Installation Note . . . . . . . . . 01–14–12
Evaporative Hose Installation Note . . . 01–14–12
Plastic Fuel Hose Installation Note . . . 01–14–12

FUEL TANK INSPECTION . . . . . . . . . . . 01–14–13
FUEL SHUT-OFF VALVE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–14–14

NONRETURN VALVE INSPECTION . . . 01–14–14
FUEL PUMP UNIT

REMOVAL/INSTALLATION . . . . . . . . . 01–14–14

FUEL PUMP UNIT

DISASSEMBLY/ASSEMBLY . . . . . . . . 01–14–15

FUEL PUMP UNIT INSPECTION . . . . . . 01–14–15

Continuity Inspection . . . . . . . . . . . . . . 01–14–15
Circuit Open/Short Inspection . . . . . . . 01–14–16
Fuel Pump Maximum Pressure

Inspection. . . . . . . . . . . . . . . . . . . . . . 01–14–17

Fuel Pump Hold Pressure

Inspection. . . . . . . . . . . . . . . . . . . . . . 01–14–19

FUEL FILTER (HIGH-PRESSURE)

REMOVAL/INSTALLATION . . . . . . . . . . 01–14–21

FUEL INJECTOR

REMOVAL/INSTALLATION . . . . . . . . . . 01–14–21

Plastic Fuel Hose Removal Note . . . . . 01–14–23
Fuel Injector Installation Note

(FS only) . . . . . . . . . . . . . . . . . . . . . . . 01–14–23

FUEL INJECTOR INSPECTION. . . . . . . . 01–14–24

Simulation Test . . . . . . . . . . . . . . . . . . . 01–14–24
Resistance Inspection . . . . . . . . . . . . . . 01–14–24
Circuit Open/Short Inspection . . . . . . . . 01–14–24
Fuel Leakage Test . . . . . . . . . . . . . . . . 01–14–25
Volume Test . . . . . . . . . . . . . . . . . . . . . 01–14–26
Using the SST . . . . . . . . . . . . . . . . . . . . 01–14–26
Using a Fuel Injector Tester . . . . . . . . . 01–14–27

PRESSURE REGULATOR

REMOVAL/INSTALLATION . . . . . . . . . . 01–14–27

PRESSURE REGULATOR

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–14–28

Simulation Test . . . . . . . . . . . . . . . . . . . 01–14–28
Operation Inspection . . . . . . . . . . . . . . . 01–14–28

PULSATION DAMPER

REMOVAL/INSTALLATION . . . . . . . . . . 01–14–30

PULSATION DAMPER INSPECTION . . . 01–14–31
PRC SOLENOID VALVE

REMOVAL/INSTALLATION . . . . . . . . . . 01–14–31

PRC SOLENOID VALVE INSPECTION . . 01–14–31

Airflow Inspection . . . . . . . . . . . . . . . . . 01–14–31
Circuit Open/Short Inspection . . . . . . . . 01–14–32

End of Toc

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FUEL SYSTEM

01–14–2

FUEL SYSTEM LOCATION INDEX

A3U011401006W01

Engine Room Side

Z3U0114W985

1

Pressure regulator
(See 01–14–27 PRESSURE REGULATOR
REMOVAL/INSTALLATION)
(See 01–14–28 PRESSURE REGULATOR
INSPECTION)

2

Quick release connector
(See 01–14–22 Plastic Fuel Hose Removal Note)
(See 01–14–23 Plastic Fuel Hose Installation Note)

3

PRC solenoid valve
(See 01–14–31 PRC SOLENOID VALVE
REMOVAL/INSTALLATION)
(See 01–14–31 PRC SOLENOID VALVE
INSPECTION)

4

Pulsation damper
(See 01–14–30 PULSATION DAMPER REMOVAL/
INSTALLATION)
(See 01–14–31 PULSATION DAMPER
INSPECTION)

5

Fuel injector
(See 01–14–21 FUEL INJECTOR REMOVAL/
INSTALLATION)
(See 01–14–24 FUEL INJECTOR INSPECTION)

6

Fuel pump relay
(See 09–21–5 RELAY INSPECTION)

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FUEL SYSTEM

01–14–3

01–14

.

End Of Sie

A3U0114W003

1

Quick release connector
(See 01–14–22 Plastic Fuel Hose Removal Note)
(See 01–14–23 Plastic Fuel Hose Installation Note)

2

Nonreturn valve
(See 01–14–11 Nonreturn Valve Installation Note)

3

Fuel-filler pipe

4

Fuel-filler cap
(See 01–16–13 FUEL-FILLER CAP INSPECTION)

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FUEL SYSTEM

01–14–4

FUEL SYSTEM DIAGRAM

A3U011401006W02

End Of Sie

BEFORE REPAIR PROCEDURE

A3U011401006W03

Warning

••••

Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.

••••

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, always complete the following “Fuel
Line Safety Procedure”.

Fuel Line Safety Procedure

Note

•

Fuel in the fuel system is under high pressure even when the engine is not running.

1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Remove the fuel pump relay.
3. Start the engine.
4. After the engine stalls, crank the engine several

times.

5. Turn the ignition switch off.
6. Install the fuel pump relay.

End Of Sie

Z3U0114W997

X3U114WA0

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