fuel filter MAZDA MX-5 1994 User Guide

F TROUBLESHOOTING GUIDE INSPECTION ACTION Check if throttle linkage is correctly installed and operates freely Yes Go to next step Correct, clean, or replace as required any binding or dam- aged linkage and adjust cable deflection at throttle body r@ page F-103 Check for correct intake manifold vacuum at idle Vacuum: More than 450 mmHg I17.7 inHg) VACUUM GAUGE / Yes Go to next step No - Yes Check for air leakage of intake air system components r@ page F-100 Go to next step Check if air cleaner element is clean page F-76 Replace air cleaner element page F-99 Check for correct ignition timing at idle page F-76 Yes - No Check if ignition timing advances when accelerating .I, If advances, go to next step o If no advance, replace PCME page F-143 Adjust r@ page M6 Ignition timing: 10" -r- lo BTDC Check for correct fuel line pressure at idle page F-110 Yes Check if fuel line pressure decreases when accelerating quickly Fuel line pressure: 265-314 kPa (2.7-3.2 kgf/cm2, 38-46 psi) (Vacuum hose to pressure regulator discon- nected) o If decreases, check fuel line and filter for clogging 0 If no decrease, go to next step No - Yes Low pressure Check fuel line pressure while pinching fuel return hose 0 If fuel line pressure quickly increases, check pressure regulator page F-113 0 If fuel line pressure gradually increases, check for clog- ging between fuel pump and pressure regulator If not clogged, check fuel pump maximum pressure page F-115 INSTALL CLAPS Repair or replace Check for EGR system malfunction page F-124 No - Yes - No Go to next step - -- Check if exhaust system is restricted page F-128 -- - Repair or replace So to next step Try known good PCME and check if condition im- 3roves page F-144 Gartner Banana

TROUBLESHOOTING GUIDE INSPECTION ACTION :heck for correct intake manifold vacuum at idle Iacuum: More than 450 mmHg i17.7 inHg} VACUUM GAUGE / :heck if air cleaner element is clean page F-76 Check for fuel injector operating sound at idle Check if battery positive voltage exists at fuel injec- tor connector B terminal Check if PCME terminal voltages are OK (1 R, 1 T, 2D, 20 and 2Q) page F-146 Check for correct fuel line pressure at idle page F-110 Fuel line pressure: 265--314 kPa i2.7-3.2 kgf/cm2, 38-46 psi) (Vacuum hose to pressure regulator discon- nected) INSTALL CLAPS Yes - No Yes - No - Yes No - Yes Yes No - Yes - No Go to next step -- - --- Check for air leakage of intake air system components r@= page F-100 Go to next step Replace air cleaner element ~8 page F-99 Go to Step 14 Go to Step 13 check if fuel injector resistance is OK page F-119 Resistance: 12-16R 6 If OK, check wiring between PCME and fuel injector E+Y page F-7 6 If not OK, check fuel injector for fuel leakage page F-120 Check wiring between PCME and fuel injector page F-7 Go to next step Check for cause (Refer to "Check Point for Each Termi- nal") page F-148 Check if fuel line pressure decreases when accelerating quickly c:, If decreases, check fuel pump maximum pressure @r page F-115 If OK, check fuel line and filter for clogging o If no decreases, go to next step Low pressure Check fuel line pressure while pinching fuel return hose ~2 If fuel line pressure quickly increases, check pressure regulator I@= page F-118 o If fuel line pressure gradually increases, check for clog- ging between fuel pump and pressure regulator r@= page F-119 If not clogged, check fuel pump maximum pressure page F-115 Gartner Banana

TROUBLESHOOTING GUIDE INSPECTION Sheck if air cleaner element is clean page F-76 1 :: :heck for EGR system malfunction Yes page F-124 Check for fuel injector operating sound at idle Yes Check if battery positive voltage exists at fuel injec- Yes tor connector B terminal Check if PCME terminal voltages are OK [I B, 1 T, 2D, 20 and 2Q) Check for correct fuel line pressure at idle Yes @T page F-110 Fuel line pressure: 265-314 kPa (2.7--3.2 kgf/cm2, 38--46 psi} (Vacuum hose to pressure regulator discon- nected) i INSTALL CLAPS I ACTION Go to next step Replace air cleaner element G= page F-99 Repair or replace Go to next step Go to Step 15 Go to Step 14 Check if fuel injector resistance is OK ccsf page F-119 Resistance: Approx. 12-16R - 0 If OK, check wiring between PCME and fuel injector a? page F-7 O If not OK, check fuel injector for fuel leakage page F-120 Check wiring between PCME and fuel injector ccsf page F-7 Go to next step Check for cause (Refer to "Check Point for Each Termi- nal") mzf page F-148 Check if fuel line pressure decreases when accelerating quickly O If decreases, check fuel pump maximum pressure page F-115 If OK, check fuel line and filter for clogging O If no decreases, go to next step Low pressure Check fuel line pressure while pinching fuel return hose 13 If fuel line pressure quickly increases, check pressure regulator mzf page F-118 6 If fuel line pressure gradually increases, check for clog- ging between fuel pump and pressure regulator If not clogged, check fuel pump maximum pressure @ page F-115 Gartner Banana

FUEL SYSTEM F FUEL SYSTEM DESCRIPTION . This system supplies the necessary fuel for combustion at a constant pressure to the fuel injectors. Fuel is metered and injected into the intake manifold according to the injection control signals from the power- train control module (engine). The system consists of the fuel tank, the fuel pump, the fuel filters, the fuel distributor, the pressure regulator, the fuel injectors, and the fuel pump relay. I I 1. Fuel tank 5. Fuel pump relay Removal / Inspection / Inspection .................. page F-117 Installation ................ page F-111 Replacement ............... page F-117 2. Fuel filter 6. Pressure regulator Replacement ............... page F-113 Inspection .................. page F-118 3. Fuel pump Replacement ............... page F-119 .................. w Inspection page F-114 7. Fuel injector Replacement ............... page F-115 Inspection .................. page F-119 4. Fuel distributor Removal ................... page F-119 Installation ................. page F-121 Gartner Banana

FUEL SYSTEM Fuel Line Pressure Inspection Warning Fuel line spills and leaks 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 "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel pipe and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON. 6. Measure the fuel line pressure. Fuel line pressure: 265-31 4 kPa {2.7-3.2 kgf/cm2, 38-46 psi) Pressure low- Check fuel pump maximum pressure. (Refer to page F-115.) If as specified, fuel line or fuel filter might be clogged or restricted. Pressure high- Replace the pressure regulator. (Refer to page F-118.) Gartner Banana

FUEL SYSTEM 1. Fuel filler hoses 7. Rear crossmem ber assembly 2. Fuel hoses Removal Note ............. page F-112 3. Evaporative hoses 8. Fuel tank unit 4. Fuel filter bolts 9. Two-way check valve ~4 Removal Note ............. page F-112 10. Fuel vapor valve 5. Brake pipe joint 11. Fuel pump Removal Note ............. page F-112 6. Battery cable Removal Note ............. page F-112 Removal note Fuel filter bolts 1. Remove the fuel filter cover. 2. Remove the fuel filter bolts. (MT) 3. Remove the fuel filter nuts. (AT) 4. Remove the fuel filter with the fuel hoses still connected. Brake pipe joint 1. Remove the brake pipe joint nuts. 2. Remove the brake pipe joint with the brake pipe and brake hose still connected. Battery cable Remove the battery cable clamp as shown in the figure. Rear crossmember assembly 1. Support the rear crossmember assembly with a trans- mission jack. 2. Remove the rear crossmember mounting bolts and nuts. 3. Lower the rear crossmember assembly. Gartner Banana

FUEL SYSTEM Installation note Fuel hoses and fuel filler hoses Push the ends of the main fuel hose, fuel return hose, and evaporation hose onto the fuel tank fittings L at least 25mm (1.0 in). Push the fuel filler hose onto the fuel tank pipe and filler pipe at least 35117171 (1.4 in). Power plant frame Install the power plant frame referring to the installation procedure on section J. FUEL FILTER Replacement Low-pressure side (In-tank filter) (Refer to page F-116.) High-pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule. Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Warning Fuel line spills and leaks are dangerous. Fuel can ~SJOFX-226 ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures" on page F-108. 1. Raise the rear of the vehicle and support it with safety stands. 2. Remove the fuel filter protector. 3. Disconnect the fuel hoses from the fuel filter. 4. Remove the fuel filter and bracket. 5. Install in the reverse order of removal. 6. Verify that the fuel hoses are pushed fully onto the fuel filter nipples. Tightening torque: 7.9-10.7 N.m (80-110 kgfam, 70-95.4 in-lbf) Gartner Banana

TD TECHNICAL DATA Idle speed rpm 1 800-900 (850 2 50) [MT]', 750-850 (800 f 50) [ATJ' lanition timina BTDC I 9"-11' (10' f 1")' u' F. FUEL AND EMISSION CONTROL SYSTEMS - Engine ltem Item 1 Throat diameter mm {in) 1 55 (2.2) 1 Antifreeze solution BP DOHC Specification 1 Throttle body Fuel pump TY pe I Impeller (in-tank) Coolant protection Above -1 6°C (3°F) Above -26°C (-15°F) Above -40°C {-40°n Tv~e -. Output pressure kPa (kgf/cm2, psi) I 294-437 {3.0--6.5,43--92) Fuel filter Specific gravity at 20°C {WF) 1.054 1.066 1.078 Volume percentage % Horizontal draft Water 65 55 45 -. . - Regulating pressure kPa {kgf/cm2, psi) I 280-289 I2.85--2.95, 40.141.9) Fuel iniector Coolant 35 45 55 TY pe IAC valve Solenoid resistance n 1 10.7-1 2.3 (at 20°C (68°F)) Low-pressure side TYP~ Type of drive Resistance n Purge solenoid valve Solenoid resistance n 1 23-27 (at 20°C (68°F)) I Nylon element Pressure regulator TY pe High-ohmic Voltage 13.8 (at 20°C (68"FI) Engine coolant temperature sensor 7 20°C {68"F) I 2.21 -2.69 Resistance kn I 80°C (1 76OF} I 0.287-0.349 High-pressure side Diaphragm i/ Crankshaft position sensor Air valve Openin~l temperature OC {OF) I Below 45 (1 131 Paper element Twe 1 Fuel tank I Hall effect . . . . . . . Capacity L {US gal, Imp gal) I 48 {12.7, 10.5) Air cleaner housing Element type Free play mm (in) I 1-3 {0.039--0.118) I Fuel Oil permeated Specification Accelerator cable Unleaded regular (RON 87 or higher) J +....with system selector (49 B019 9AO) test switch at SELF TEST Gartner Banana

1320 -1 FUEL SYSTEM CLIP CLAMPIHOSE FILTER,FLIEL WISE HOSE FUEL-EGI COHNECTOR BRACKET ,CAN1 STER CANISTER HOSE, VEKTILAV f OH HOSE, EVAPORAT ION HOSE, URAI N HOSE, EVAYOXAl ION TUBE,VACUUY TUBE, YACUUH FLF! UAlW P IPG, ,OSIZ~- FUEL RETURN I t Pk, EVAPORAT I ON Gartner Banana

I 4200 -1 FUEL TANK t FILTER ,FUEL PUHP WhSIlER LOCK-I'UNP Ftl TER HIPPONBEHSO i JAPhN 1 HOSE ,FUEL PUKP- IH f A HK Gartner Banana