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Fuel Leakage and Volume Test: Notes

WARNING:
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
  1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (+)
  2. Disconnect the negative battery cable.
  3. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) (+) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) (+)
  4. Remove the fuel injectors together with the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION (+)
  5. Fasten the fuel injectors firmly to the fuel distributor with wire and connect the fuel pipe connector.
  6. Connect the negative battery cable.
    CAUTION:
    • Connecting to the wrong DLC terminals may cause a malfunction. Carefully connect only to the specified terminals.
    Fig 1: Identifying Fuel Injectors
    G03637846Courtesy of MAZDA MOTORS CORP.
  7. Connect DLC terminal F/P and body GND using a jumper wire.
  8. Turn the ignition switch to the ON position to operate the FP.
    Fig 2: Connecting DLC Terminal F/P And Body Gnd Using Jumper Wire
    G03637847Courtesy of MAZDA MOTORS CORP.
  9. Tilt the fuel injectors approx.60 deg.  and verify that fuel leaking from the fuel injector nozzles is within the specification.
    • If not as specified, replace the fuel injector.

    Fuel leakage 

    1. Less than 1 drop/2 min 
  10. Turn the ignition switch to the LOCK position.
    Fig 3: Identifying Tilt Fuel Injectors
    G03637848Courtesy of MAZDA MOTORS CORP.
  11. Connect the SST  as shown in Fig 4 the figure.
  12. Turn the ignition switch to the ON position to operate the FP.
  13. Measure the injection volume of each fuel injector using a graduated container.
    • If not as specified, replace the fuel injector.

    Injection volume 

    1. 66-82 ml {66-82 cc, 2.3-2.7 fl oz}/15 s 
    Fig 4: Measuring Injection Volume Of Fuel Injector Using Graduated Container
    G03637849Courtesy of MAZDA MOTORS CORP.
  14. Turn the ignition switch to the LOCK position and disconnect the jumper wire.
  15. Install the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) (+) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WI (+)
  16. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (+)
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