Mazda 6. Manual - part 123

F–28

FUEL SYSTEM 

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FUEL INJECTOR REMOVAL/INSTALLATION

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Caution

• Disconnecting/connecting the quick release connector without cleaning it may possibly cause 

damage to the fuel pipe and quick release connector. Always clean the quick release connector 
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is 
free of foreign material.

1. Complete the “BEFORE REPAIR PROCEDURE”. (See 

F–17 BEFORE REPAIR PROCEDURE

.)

2. Disconnect the negative battery cable.
3. Remove in the order indicated in the table.

.

4. Install in the reverse order of removal.
5. Complete the “AFTER REPAIR PROCEDURE”. 

(See 

F–17 AFTER REPAIR PROCEDURE

.)

Plastic Fuel Hose Removal Note

Caution

• The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab 

over the stopper.

1. Disconnect the quick release connector.

(1) Push the tab on the locking coupler 90 degrees until it stops.
(2) Pull the fuel hose straight back.

Note

• The stopper may be removed from the quick connector. Take care not to lose it.

Reinstall it to the quick release connector 
before reconnecting the fuel line.

1

Fuel injector connectors

2

Plastic fuel hose
(See 

F–28 Plastic Fuel Hose Removal Note

)

(See 

F–30 Plastic Fuel Hose Installation Note

)

2

Hose

4

Fuel distributor

5

Fuel injector
(See 

F–29 Fuel Injector Removal Note

)

(See 

F–30 Fuel Injector Installation Note

)

6

Snap ring

7

Pulsation damper

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FUEL SYSTEM 

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F

• The locking coupler has two internal locking 

tabs which retain the fuel pipe. Be sure that 
the tab on the locking coupler is rotated until 
it stops to release two internal locking tabs.

2. Cover the disconnected quick release connector 

and fuel pipe with vinyl sheets or the like to 
prevent them from being scratched or 
contaminated with foreign material.

Fuel Injector Removal Note

Caution

• Use of a deformed injector retaining clip will cause the injector to not engage correctly. Always 

use a new clip when reattaching the injector, otherwise it may cause the injector to rotate.

1. Insert a screwdriver between the injector cup and 

the clip fingers.

Note

• When rotating the screwdriver to spread the 

clip fingers, deform them sufficiently to make 
sure they release from the notched edge of 
the injector cup.

2. Rotate the screwdriver to spread the clip fingers 

and remove them from the injector cup.

3. Pull the injector and clip out of the rail.
4. Remove the clip from the injector according to the 

following:
(1) Grasp the clip with a pair of pliers.

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FUEL SYSTEM 

(2) Pull the clip parallel to the injector groove, and 

remove it from the injector.

(3) Discard the clip.

Fuel Injector Installation Note

1. Lightly lubricate the injector groove and O-ring.
2. Pre-attach a new clip in the injector groove.

Note

• When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.

3. Hold the injector firmly, push the clip into the 

injector until the clip stops sliding.

4. Verify that the injector connector position is 

correct, and press the injector and clip into the 
injector cup. Continue pressing until the clip 
contacts the lower surface of the injector cup.

5. Verify that the injector and clip are correctly 

attached with the clip locked onto the injector cup 
notch.

Plastic Fuel Hose Installation Note

Note

• A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will 

be released from the quick release connector after it is completely engaged with the fuel pipe.

1. When the retainer is not removed, perform the 

following procedure.
(1) Inspect the fuel pump unit sealing surface for 

damage and deformation, and replace as 
necessary.

• If the quick release connector O-ring is 

damaged, replace the plastic fuel hose.

(2) Slightly apply clean engine oil to the sealing 

surface of the fuel pump unit.

(3) Align the fuel pipe on the fuel pump unit and 

quick release connector so that the tabs of the 
retainer are correctly fitted into the quick 
release connector. Push the quick release 
connector straight into the retainer until a click 
is heard.

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FUEL SYSTEM 

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(4) Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 

mm {0.08—0.11 in} and it is connected securely.

• If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and 

reconnect the quick release connector.

2. When the retainer is removed, perform the following procedure.

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FUEL INJECTOR INSPECTION

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Operation Test

1. Carry out the “Fuel Injector Operation Inspection”. (See 

F–231 Fuel Injector Operation Inspection

.)

• If not as specified, perform the further inspection for the fuel injectors.

Resistance Inspection

Note

• Perform the following test only when directed.

1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable.
3. Disconnect the fuel injector connectors.
4. Measure the resistance of the fuel injector using 

an ohmmeter.

• If not as specified, replace the fuel injector. 

(See 

F–28 FUEL INJECTOR REMOVAL/

INSTALLATION

.)

• If as specified but “Operation Test” is failed, 

carry out the “Circuit Open/Short Inspection”. 
Inspect for open or short circuit.

Resistance

11.4—12.6 ohms [20 

°C {68 °F}]

Circuit Open/Short Inspection

1. Disconnect the PCM connector. (See 

F–43 PCM 

REMOVAL/INSTALLATION

.)

2. Inspect the following wiring harness for open or 

short (continuity check).

Open circuit

• If there is no continuity, the circuit is open. Repair 

or replace the harness.
— No.1 cylinder fuel injector terminal B 

(harness-side) and PCM terminal 4Z.

— No.2 cylinder fuel injector terminal B 

(harness-side) and PCM terminal 4W.

— No.3 cylinder fuel injector terminal B 

(harness-side) and PCM terminal 4AD.

— No.4 cylinder fuel injector terminal B (harness-side) and PCM terminal 4AA.
— No.1 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through 

common connector.

— No.2 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through 

common connector.

— No.3 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through 

common connector.

— No.4 cylinder fuel injector terminal A (harness-side) and main relay (harness-side) terminal C through 

common connector.

Short circuit

•  If there is continuity, the circuit is short. Repair or replace the harness.

— No.1 cylinder fuel injector terminal B (harness-side) and body GND.
— No.2 cylinder fuel injector terminal B (harness-side) and body GND.
— No.3 cylinder fuel injector terminal B (harness-side) and body GND.
— No.4 cylinder fuel injector terminal B (harness-side) and body GND.
— No.1 cylinder fuel injector terminal A (harness-side) and power supply.

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