Mazda Car 2002-04

Removal & Installation

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The fuel level sending unit is an integral part of the fuel pump assembly and is monitored by the PCM, which then relays this information to the fuel gauge. If the sending unit is defective, the whole pump assembly must be replaced as the pump cannot be disassembled.

The fuel level sending unit is an integral part of the fuel pump assembly and is monitored by the PCM, which then relays this information to the fuel gauge. If the sending unit is defective, the whole pump assembly must be replaced as the pump cannot be disassembled.

  1. Remove the fuel pump.
  2.  
  3. Move the float to the top travel and bottom travel positions, and verify that the resistance between terminals A and D of the unit and the position of the float are as indicated in the illustration. If they are not as specified, replace the fuel pump.

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    Fig. Fuel pump unit sender terminals and resistance specifications

  4.  

The fuel level sending unit is an integral part of the fuel pump assembly and is monitored by the PCM, which then relays this information to the fuel gauge. If the sending unit is defective, the whole pump assembly must be replaced as the pump cannot be disassembled.

  1. Inspect the fuel pump continuity as follows:
    1. Disconnect the negative battery cable.
    2.  
    3. Disconnect the fuel pump unit connector.
    4.  
    5. Inspect for continuity between fuel pump unit terminals B and C on California emission models or terminals A and E on non-California emission models
    6.  
    7. If there is no continuity, replace the fuel pump. If there is continuity, check the wiring harnesses for open or short circuit as follows:
    8.  

  2.  
  3. If there is no continuity, there is an open circuit. Repair or replace the harness at the fuel pump unit terminal C 1 on California emission regulation applicable model, or except for California emission regulation applicable model and fuel pump relay terminal C. Also fuel pump unit terminal B on California emission regulation applicable model, or E except for California emission regulation applicable model and body ground.
  4.  
  5. If there is continuity, there is a short circuit. Repair or replace the harness at the fuel pump unit terminal C California emission regulation applicable model, or A except for California emission regulation applicable model and body ground. Also at fuel pump unit terminal B on California emission regulation applicable model, or E except for California emission regulation applicable mode and power supply.

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    Fig. Fuel pump unit connector terminal-California emission models-Mazda 3



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    Fig. Fuel pump unit connector terminal-Non-California emission models-Mazda 3



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    Fig. Fuel pump relay connector terminal-Mazda 3

  6.  

  1. Inspect for continuity between fuel pump unit connector terminals B and D.
  2.  
  3. If there is no continuity, replace the fuel pump body.
  4.  
  5. If there is no continuity, there is an open circuit. Repair or replace the wiring harness at:
    1. Fuel pump unit terminal D and body GND.
    2.  
    3. Fuel pump unit terminal B and fuel pump relay terminal C.
    4.  

  6.  
  7. If there is continuity, there is a short circuit. Repair or replace the wiring harness at:
    1. Fuel pump unit terminal D and power supply.
    2.  
    3. Fuel pump unit terminal B and body GND.

      Click image to see an enlarged view

      Fig. Fuel pump unit connector terminal- -Mazda 6

    4.  

  8.  

 
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