Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMAZDA1999PROTEGE LX L4-1.6L DOHCREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTFUEL DELIVERY AND AIR INDUCTIONFUEL TANKTESTING AND INSPECTION
1999 Mazda Protege LX L4-1.6L DOHC
Fuel Tank: Testing and Inspection
1999 Mazda Protege LX L4-1.6L DOHCSECTION Testing and Inspection
NOTE: This inspection is for the two 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.
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.
8. Apply pressure of +0.98 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.
1. Remove the fuel tank.
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.
8. Apply pressure of +0.98 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.
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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.