2002 MAZDA 6 fuel

FUEL SYSTEM
F2–51
F2
FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLYA6E4012348022021. Disassemble in the order indicated in the table..
2. Assemble in the reverse order of removal.
Sedimentor Switch Installation Note
1. Apply a small amount of fuel to a new O-ring.
2. Tighten the sedimentor switch enough to the fuel
filter by hand.
Fuel Filter Installation Note
1. Apply a small amount of fuel to the fuel filter O-ring.
2. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump.
End Of Sie
FUEL WARMER INSPECTIONA6E401234802203For Cold Areas
1. Remove the fuel warmer. (See F2–51 FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLY.)
2. Verify that the resistance between terminal A and
the fuel warmer body is within the specification
when vacuum of –31.3— –38.0 kPa {–235— –
285 mmHg, –9.2— –11.2 inHg} is applied to port
A of the fuel warmer.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
•If not as specified, replace the fuel warmer.
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•If there is open/short circuit, repair or replace
wiring harnesses.
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Fuel warmer terminal A (harness-side) and
GND
—Fuel warmer terminal B (harness-side) and
power supply
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Fuel warmer terminal B (harness-side) and GND
End Of Sie
1 Connector
2 Fuel hose
3 Priming pump
4Fuel filter
(See F2–51 Fuel Filter Installation Note)
5Sedimentor switch
(See F2–51 Sedimentor Switch Installation Note)
6 Drain plug
7 Fuel warmer
R
17.6—26.5
{1.8—2.7,
13.0—19.8}
7
5
4
3
6
1
2
N.m {kgf·m, ft·lbf}
A6E40122036
Ambient temperature (°C {°F}) Resistance (ohms)
20 {68} 0.5—1.5
FUEL WARMER
B
A6E40122013
A B FUEL WARMER
HARNESS SIDE CONNECTOR
A6E40122014

F2–52
FUEL SYSTEM
SEDIMENTOR WATER DRAININGA6E4012348022041. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Loosen the drain plug located at the bottom of the fuel filter.
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the drain plug.
6. Complete the “AFTER REPAIR PROCEDURE”. (See F2–45 AFTER REPAIR PROCEDURE.)
7. Reconnect the negative battery cable.
End Of Sie
SEDIMENTOR SWITCH INSPECTIONA6E401213840201
Note
•Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Drain fuel from the fuel filter. (See F2–52 SEDIMENTOR WATER DRAINING.)
4. Remove the sedimentor switch.
5. Inspect for continuity of the sedimentor switch
using an ohmmeter.
•If as specified, inspect the following and carry
out the “Circuit Open/Short Inspection.”
•If not as specified, replace the sedimentor
switch.
Specification
6. Install the sedimentor switch.
7. Reconnect the negative battery cable.
8. Complete the “AFTER REPAIR PROCEDURE”.
(See F2–45 AFTER REPAIR PROCEDURE.)
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open.
Repair or replace the harness.
—Sedimentor switch terminal B (harness-
side) and GND.
—Sedimentor switch terminal A (harness-
side) and instrument cluster terminal 1C.
Short circuit
•If there is continuity, the circuit is shorted.
Repair of replace the harness.
—Sedimentor switch terminal A (harness-
side) and GND.
—Sedimentor switch terminal B (harness-
side) and power supply.
End Of Sie
Float Continuity
Up Yes
Down No
UP
DOWN
FLOATA
B
A6E40122015
1O 1M 1K 1I 1G 1E 1C 1A
1P 1N 1L 1J 1H 1F 1D 1B INSTRUMENT CLUSTER CONNECTOR
SEDIMENTOR SWITCH
HARNESS SIDE CONNECTOR
A
B
A6E40122016

FUEL SYSTEM
F2–53
F2
SUPPLY PUMP REMOVAL/INSTALLATIONA6E401213350201
Caution
•Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
•To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
•To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
•The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
1. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Remove in the order indicated in the table.
.
4. Install in the reverse order of removal.
5. Complete the “AFTER REPAIR PROCEDURE”.
(See F2–45 AFTER REPAIR PROCEDURE.)
Common Rail Installation Note
1. Temporarily tighten the common rail.
2. Temporarily tighten the injection pipes.
3. Fully tighten the injector side injection pipes, then tighten the common rail side.
Tightening torque
50—60 N·m {5—6 kgf·m, 37—44 ft·lbf}
4. Fully tighten the supply pump side and common rail side injection pipes.
Tightening torque
50—60 N·m {5—6 kgf·m, 37—44 ft·lbf}
5. Fully tighten the common rail.
Tightening torque
20—30 N·m {2.0—3.1 kgf·m, 15—22 ft·lbf}
End Of Sie
1 Injection pipe
2 Nozzle seal
3 Return fuel hose
4Common rail
(See F2–53 Common Rail Installation Note)
5Supply pump
(See B2–17 Supply Pump Pulley Removal Note)
19—25
{1.9—2.6, 14—18}19—25
{1.9—2.6,
14—18} 50—60
{5—6,
37—44}
50—60
{5—6, 37—44}
N·m {kgf·m, ft·lbf}
A
R
A
5
43
12
1
A6E40122033

F2–54
FUEL SYSTEM
SUPPLY PUMP INSPECTIONA6E401213350202
Caution
•The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
•Consult an authorized DENSO parts distributor for repair if any of the following supply pump parts
are possibly malfunctioning.
1. Supply pump inner parts
2. Suction control valve
3. Fuel temperature sensor
End Of Sie
SUCTION CONTROL VALVE INSPECTIONA6E401213350203
Caution
•The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
•Consult an authorized DENSO parts distributor for repair if suction control valve is possibly
malfunctioning.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the suction control valve connector.
3. Measure the resistance between the suction
control valve terminals using an ohmmeter.
•If not as specified, repair the supply pump.
(See F2–54 SUPPLY PUMP INSPECTION.)
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Specification
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM REMOVAL/INSTALLATION.)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair of replace the harness.
—Suction control valve terminal A (harness-side) and PCM terminal 93
—Suction control valve terminal B (harness-side) and PCM terminal 94
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Suction control valve terminal A (harness-side) and power supply
—Suction control valve terminal A (harness-side) and GND
—Suction control valve terminal B (harness-side) and power supply
—Suction control valve terminal B (harness-side) and GND
End Of Sie
COMMON RAIL INSPECTIONA6E401213015201
Caution
•Do not remove the fuel pressure sensor nor the fuel pressure limiter from the common rail. Since
fuel pressure in the common rail is extremely high, the fuel pressure sensor, fuel pressure limiter,
or the common rail can be damaged, leading to fuel leakage if any of them are removed.
1. Visually inspect the common rail for damage and cracks. Also verify that there is no extreme rust which will
cause fuel leakage.
•If either is observed, replace the common rail.
End Of Sie
Ambient temperature (°C {°F}) Resistance (ohms)
20 {68} Approx. 2.1
SUCTION
CONTROL VALVE A B
A6E40122018

FUEL SYSTEM
F2–55
F2
FUEL INJECTOR REMOVAL/INSTALLATIONA6E401213250201
Caution
•Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
•To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
•To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
•The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
Note
•Perform “Correction after Parts Installation” after replacing fuel injector. (See F2–34 Correction after Parts
Installation.)
1. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Complete the “AFTER REPAIR PROCEDURE”. (See F2–45 AFTER REPAIR PROCEDURE.)
.
Fuel Injector Installation Note
1. Temporarily tighten the injector bracket.
Tightening torque
10—20 N·m {1.1—2.0 kgf·m, 7.4—14.8 ft·lbf}
2. Temporarily tighten the injection pipes.
3. Tighten the injector side injection pipes, then
tighten the common rail side.
Tightening torque
50—60 N·m {5—6 kgf·m, 37—44 ft·lbf}
4. Fully tighten the injector bracket.
Tightening torque
52—62 N·m {5.3—6.3 kgf·m, 39—45 ft·lbf}
1 Injection pipe
2 Calibration register
3 Cylinder head cover
4 Nozzle seal
5Side wall
6 Injector bracket
7Fuel injector
(See F2–55 Fuel Injector Installation Note)
RR
R50—60
{5—6,
37—44} 52—61
{5.3—6.3,
39—45}
N·m {kgf·m, ft·lbf} 7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
5
4
3
1
2
7
6
A6E40122019

F2–56
FUEL SYSTEM
End Of SieFUEL INJECTOR INSPECTIONA6E401213250202Resistance Inspection
Note
•Perform the following test only when directed.
•Perform “Correction after Parts Installation” after replacing the fuel injector. (See F2–34 Correction after
Parts Installation.)
1. Disconnect the negative battery cable.
2. Disconnect the fuel injector connectors.
3. Measure the resistance of the fuel injector using
an ohmmeter.
•If not as specified, replace the fuel injector.
(See F2–55 FUEL INJECTOR REMOVAL/
INSTALLATION.)
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Resistance
approx. 0.45 ohm
Circuit Open/Short Inspection
1. Disconnect the IDM connector.
2. Inspect the following wiring harnesses for an
open or short circuit (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 IDM terminal 1E.
—No.2 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1G.
—No.3 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1H.
—No.4 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1F.
—No.1 cylinder fuel injector terminal D
(harness-side) and IDM terminal 1D.
—No.2 cylinder fuel injector terminal D (harness-side) and IDM terminal 1C.
—No.3 cylinder fuel injector terminal D (harness-side) and IDM terminal 1D.
—No.4 cylinder fuel injector terminal D (harness-side) and IDM terminal 1C
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 GND.
—No.2 cylinder fuel injector terminal B (harness-side) and GND.
—No.3 cylinder fuel injector terminal B (harness-side) and GND.
—No.4 cylinder fuel injector terminal B (harness-side) and GND.
—No.1 cylinder fuel injector terminal D (harness-side) and power supply.
—No.2 cylinder fuel injector terminal D (harness-side) and power supply.
—No.3 cylinder fuel injector terminal D (harness-side) and power supply.
—No.4 cylinder fuel injector terminal D (harness- side) and power supply.
End Of Sie
A B
A6E40122021
A
B C
D
A6E40122020

CONTROL SYSTEM
F2–77
F2
FUEL TEMPERATURE SENSOR INSPECTIONA6E404013350201
Note
•Perform the following test only when directed.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Remove the supply pump. (See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION.)
3. Measure the resistance between the fuel
temperature sensor terminals using an
ohmmeter.
•If not as specified, repair the supply pump.
(See F2–54 SUPPLY PUMP INSPECTION.)
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•If there is open/short circuit, repair or replace wiring harness.
Open circuit
•Signal circuit
—Fuel temperature sensor terminal A and PCM terminal 35
•GND circuit
—Fuel temperature sensor terminal B and PCM terminal 91
Short circuit
•Signal circuit
—Fuel temperature sensor terminal A and PCM terminal 35 to power circuit
—Fuel temperature sensor terminal A and PCM terminal 35 to GND
End Of Sie
Ambient temperature (°C
{°F})Resistance (kilohm)
20 {68} 2.0—3.0
A
B
A6E40702047

CONTROL SYSTEM
F2–79
F2
FUEL PRESSURE SENSOR INSPECTIONA6E404013015201
Note
•Perform the following test only when directed.
Voltage Inspection
1. Start the engine and warm up the engine completely.
2. Measure the voltage between fuel pressure sensor terminals A and B using a voltmeter at idle.
•If not as specified, perform the “Circuit Open/Short Inspection”.
—If there is no open/short circuit, replace the common rail.
Specification
1.4—1.7 V
3. Turn off the engine and wait three minutes.
4. Turn the engine switch to ON.
5. Measure the voltage between fuel pressure
sensor terminals A and B using a voltmeter.
•If not as specified, perform the “Circuit Open/
Short Inspection”.
—If there is no open/short circuit, replace
the common rail.
Specification
0.9—1.1 V
CIrcuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•If there is open/short circuit, repair or replace wiring harnesses.
Open circuit
•Power circuit
—Fuel pressure sensor terminal C and PCM terminal 90
•Signal circuit
—Fuel pressure sensor terminal B and PCM terminal 61
•GND circuit
—Fuel pressure sensor terminal A and PCM terminal 91
Short circuit
•Power circuit
—Fuel pressure sensor terminal C and PCM terminal 90 to GND
•Signal circuit
—Fuel pressure sensor terminal B and PCM terminal 61 to power circuit
—Fuel pressure sensor terminal B and PCM terminal 61 to GND
End Of Sie
FUEL PRESSURE SENSOR
HARNESS SIDE CONNECTOR
A
B C
A6E40702049