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HOMESERVICE MANUALSMAZDA1999626 ES, 2.5 D, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 335 (SYMPTOM TROUBLESHOOTING (ENGINE CONTROL SYSTEM AJ))NO. 27 FUEL REFILL CONCERNSDIAGNOSTIC PROCEDURE
1999 Mazda 626 ES, 2.5 D, Standard

Diagnostic procedure

1999 Mazda 626 ES, 2.5 D, StandardSECTION Diagnostic procedure
WARNING: This page is about a different car, the 2005 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
NO. 27 FUEL REFILL CONCERNS [AJ] DIAGNOSTIC PROCEDURE

STEP INSPECTION ACTION
1
  • Connect WDS or equivalent to DLC-2.
  • Turn ignition switch to ON position (Engine OFF).
  • Retrieve any DTCs.
  • Are there any DTCs displayed?
  • No
 Yes DTC is displayed: 
  • Go to appropriate DTC test.
No No DTC is displayed: 
  • Go to the next step.
2
  • Remove fuel-filler pipe.
  • Make sure nonreturn valve is installed properly.
  • Inspect nonreturn valve operation.
  • Is nonreturn valve okay?
 Yes Inspect for the following:
  • Improper use of fuel nozzle
  • Inadequate fuel filling speed
No Nonreturn valve is installed improperly: 
  • Reinstall nonreturn valve to proper position.

Nonreturn valve does not operate properly: 
  • Replace nonreturn valve.
3
  • Verify test results.
    • If okay, return to diagnostic index to service any additional symptoms.
    • If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or diagnosis.
      • If vehicle is repaired, troubleshooting completed.
      • If vehicle is not repaired or additional diagnostic information is not available, reprogram PCM if later calibration is available. Retest.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.