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HOMESERVICE MANUALSMAZDA2006B4000 BASE, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE SYMPTOM TROUBLESHOOTING - (5 OF 5)GENERAL TEST INDEXGENERAL PINPOINT TEST 5: FUEL DELIVERY SYSTEM
2006 Mazda B4000 Base, Automatic

General Pinpoint Test 5: Fuel Delivery System

2006 Mazda B4000 Base, AutomaticSECTION General Pinpoint Test 5: Fuel Delivery System
GENERAL PINPOINT TEST 5: FUEL DELIVERY SYSTEM

PINPOINT TEST 5 INTERMITTENT
STEP INSPECTION ACTION
1 CHECK SYSTEM INTEGRITY
  • Visually inspect the complete fuel delivery system, including fuel lines, connections, relays, damage to fuel tank, fuel pump, fuel pressure regulator, fuel pulse damper and fuel injector areas for leaks, looseness, cracks, kinks, pinching, or abrasion caused by a collision or mishandling.
  • Visually inspect electrical harnesses and connectors for loose pins, corrosion, abrasion, or other damage from collision or mishandling.
  • Verify vehicle has followed maintenance schedule.
  • Verify fuel pump shutoff switch is set. See INERTIA FUEL SHUTOFF SWITCH REMOVAL / INSTALLATION .
  • Verify battery is fully charged (12.5 volts or greater).
  • Verify electrical/fuse integrity.
  • Verify fuel level is sufficient.
  • Has any concern been found?
 Yes Repair as necessary.
Rerun quick test.
See ON - BOARD DIAGNOSTIC TESTS .
No Go to next step.
2 CHECK FOR VOLTAGE AT FUEL PUMP HARNESS CONNECTOR
  • WDS or equivalent tester connected.
  • Verify fuel pump shutoff switch state. Follow the fuel pump shutoff switch reset procedure. See INERTIA FUEL SHUTOFF SWITCH REMOVAL / INSTALLATION .
  • Disconnect fuel pump harness connector 0114-02 at the fuel pump.
  • Key ON, Engine OFF (KOEO).
  • Connect a multimeter between fuel pump power circuit P/B and fuel pump ground B/Y circuit at the fuel pump harness connector 0114-02.
  • Enter Output Test Mode and turn on fuel pump circuit and monitor the voltage reading.
  • Is the voltage greater than 12.5 volts? 
 Yes Exit Output Test Mode.
Connect fuel pump harness connector.
Restore vehicle.
Go to next step.
No Check for opens and shorts in the fuel pump power and ground circuits.
Restore vehicle.
3 CHECK FUEL FILTER FOR PROPER MAINTENANCE
  • Locate and inspect the vehicle maintenance schedule and fuel filter. Check for last service date.
  • Was the fuel filter serviced in the last 1609 Km (1000 miles)? 
 Yes Go to next step.
No Replace fuel filter.
See FUEL FILTER REMOVAL / INSTALLATION .
Go to next step.
4 CHECK FUEL PRESSURE
  • Install fuel pressure tester.
  • Release fuel pressure.
  • WDS or equivalent tester connected.
  • Key ON, Engine OFF (KOEO).
  • Access Output Test Mode and run the fuel pump to obtain maximum fuel pressure.
    NOTE:
    • The fuel pump will only operate for approximately 8 seconds when Output Test Mode is selected and activated.
  • Is fuel pressure between 207-448 kPa (30-65 psi)? 
 Yes Go to next step.
No For fuel system with more than 448 kPa (65 psi):
Replace fuel pump.
See FUEL PUMP REMOVAL / INSTALLATION .
Restore vehicle.
Check fuel pressure.
For fuel system with less than 207 kPa (30 psi):
Go to step 7.
5 CHECK FUEL PULSE DAMPER DIAPHRAGM
  • Install fuel pressure tester.
  • Start engine and run engine for 10 seconds.
  • Key OFF, wait 10 seconds.
  • Start engine and run engine for 10 seconds.
  • Key OFF, remove vacuum hose from pulse damper port.
  • Inspect for fuel in the vacuum hose pulse damper.
  • Is the vacuum hose and pulse damper port free of fuel? 
 Yes Go to next step.
No Replace fuel pulse damper.
6 CHECK FUEL INJECTOR FLOW AND LEAKAGE
  • Check injectors for leakage and flow rate using an injector tester
    • Flow rate specification:

      9.5 kg/hr (21 lb/hr) for 2.3L engine / 5.5 kg/hr (12 lb/hr) for 3.0L engine / 8.7 kg/hr (19 lb/hr) for 4.0L engine.

  • Is the flow rate and leakage rate for the injectors tested within specification? 
 Yes Verify no other leak exists. Replace fuel pump.
See FUEL PUMP REMOVAL / INSTALLATION .
No Replace failed fuel injector(s). See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL / INSTALLATION or see FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 3.0L REMOVAL / INSTALLATION or see FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 4.0L REMOVAL / INSTALLATION .
Restore vehicle.
Check fuel pressure.
7 CHECK FUEL SUPPLY LINE FOR RESTRICTION
  • Disconnect fuel supply line at the fuel rail.
  • Disconnect fuel supply line at the fuel pump.
  • Check the fuel supply line for restrictions due to blockage, kinking, or pinching.
  • Apply 21-34 kPa (3-5 psi) regulated shop air pressure to the supply line.
  • Does air flow freely through the supply line?
 Yes Air flows freely.
Replace fuel pump.
See FUEL PUMP REMOVAL / INSTALLATION .
No Repair cause of restriction.
Restore vehicle.
Check fuel pressure.
RENDER: 1.0x

NO RELATED

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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.