Mazda Car 2002-04

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Upper intake manifold
     
    Fuel lines at the fuel rail
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel rail mounting bracket
     
    Fuel rail mounting bolts, spacers and insulators
     
    Fuel rail, with the injectors attached
     
    Fuel injectors, grommets and O-rings from the fuel rail
     
    O-rings from the fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors
     
    Insulators and injectors on the intake manifold
     
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel line bracket. Torque the bolts to 70-95 inch lbs. (8-11 Nm).
     
    Fuel lines to the fuel rail
     
    Fuel injector wiring harness
     
    Upper intake manifold
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for leaks and correct as necessary, before starting the engine.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cables and the cable bracket
     
    Fuel injector connectors and wiring harness
     
    Fuel lines at the fuel rail
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel rail mounting bolts, spacers and insulators
     
    Fuel rail, with the injectors attached
     
    Fuel injectors, grommets and O-rings from the fuel rail
     
    O-rings from the fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors
     
    Insulators and injectors on the intake manifold
     
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Vacuum hose to the fuel pressure regulator
     
    Fuel lines to the fuel rail
     
    Fuel injector wiring harness
     
    Cable bracket. Torque the bolt to 70-95 inch lbs. (8-11 Nm).
     
    Accelerator cables, if removed, adjust as necessary
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for leaks and correct as necessary, before starting the engine.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the plug hole plate.
  6.  
  7. Remove the battery cover and disconnect the negative battery cable.
  8.  
  9. Unplug the injector electrical connections.
  10.  
  11. Disconnect the fuel lines from the rail.
  12.  
  13. Remove the fuel rail bolts.
  14.  
  15. Remove the rail and injectors as an assembly.
  16.  
  17. Insert a flat head screwdriver between the injector cup and clip finger as illustrated.
  18.  
  19. Push the clip finger out using the screwdriver. Deform the finger until it is completely removed from the cup notch.
  20.  
  21. Remove the injector from the clip.
  22.  
  23. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector. Discard the clip.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda 3 models

  24.  

To install:

  1. Use new O-rings and coat them with clean engine oil.
  2.  
  3. Temporarily attach a new clip to the injector groove.
    NOTE
    When the clip is correctly installed, the central area of the injector and clip finger positions are aligned.

  4.  
  5. While firmly holding the injector, push the clip into the injector until the clip stops. Make sure the injector connector is correctly positioned.
  6.  
  7. Press the injector into the cup until the cup contacts the lower surface of the cup. Make sure the injector and clip are installed properly and the clip is hooked into the injector cup notch.
  8.  
  9. Install the injectors and fuel rail as an assembly.
  10.  
  11. Install the fuel rail bolts and tighten to 15-19 ft. lbs. (20-26 Nm).
  12.  
  13. Attach the fuel lines to the rail.
  14.  
  15. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, ground the Powertrain Control Module (PCM) terminals. If equipped with an immobilizer, ground terminal 1AR, if not equipped with an immobilizer, ground terminal 1AQ. Refer to illustration 67162-mazc-g22 for terminal location.
    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
    4.  
    5. Check the hoses, clips and other fuel system components for leaks.
    6.  
    7. If there are any leaks, replace the fuel hoses and clips. If the is damage to the seal on the fuel pipe side, replace the pipe.
    8.  
    9. The system must be leak free for five minutes with the terminal grounded. If any component is replaced because of a system, leak, turn the ignition key OFF; remove the jumper wire from the terminal. reapply the jumper wire, turn the ignition On and check for leaks.
    10.  

  16.  
  17. Install the remaining components.
  18.  


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration for component location and torque specifications.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector wiring harness
     
    Fuel lines at the fuel rail
     
    Hose from the pressure regulator
     
    Fuel rail with the injectors attached
     
    Fuel injectors, grommets and O-rings from the fuel rail
     
    O-rings from the fuel injectors

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-626 2.0L (FS)

     

  8.  

To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors.
     
    Insulators and injectors on the intake manifold
     
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines to the fuel rail
     
    Fuel injector wiring harness
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for leaks and correct as necessary, before starting the engine.
  6.  

2.3L (Kj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold cover
     
    Charge air cooler air duct
     
    Air cleaner assembly, as necessary, for clearance
     
    Resonator
     
    Left and right-hand charge air coolers
     
    Accelerator cable
     
    Air intake pipe assembly
     
    Vacuum hose assembly
     
    Fuel injector electrical connectors
     
    Fuel supply/return lines and discard the copper washers
     
    Fuel rail
     
    Insulators
     
    Distribution harness (accumulated connector) from the fuel rails
     
    Spacer from the top of each fuel injector and discard it
     
    Fuel injectors from the fuel rails by rotating back and forth
     
    Fuel pressure regulator, if necessary
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pressure regulator, if removed. Torque the bolts to 61-86 inch lbs. (7-10 Nm).
     
    New O-rings lubricated with engine oil on the injectors
     
    Fuel injectors into the fuel rails
     
    New spacers on the injectors
     
    Distribution harness. Torque the screws to 22-31 inch lbs. (2.5-3.5 Nm).
     
    6 insulators and the fuel rails. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel supply and return lines using new copper washers
     
    Fuel injector electrical connectors
     
    Vacuum hose assembly. Torque the nuts to 70-95 inch lbs. (8-11 Nm).
     
    Air intake pipe assembly. Torque the nuts to 70-95 inch lbs. (8-11 Nm) and the bolts to 44-78 inch lbs. (5-9 Nm).
     
    Accelerator cable and adjust it. Torque the bolt to 70-95 inch lbs. (8-11 Nm).
     
    Both charge air coolers with new O-rings. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Resonator. Torque the nuts to 70-95 inch lbs. (8-11 Nm).
     
    Air cleaner assembly. Torque the nuts to 70-95 inch lbs. (8-11 Nm).
     
    Charge air cooler air duct. Torque the nuts to 70-95 inch lbs. (8-11 Nm).
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for fuel leaks and correct as necessary before starting the engine.
  6.  

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Unplug the injector electrical connections.
  8.  
  9. Disconnect the fuel lines from the rail.
  10.  
  11. Remove the fuel rail bolts.
  12.  
  13. Remove the rail and injectors as an assembly.
  14.  
  15. Insert a flat head screwdriver between the injector cup and clip finger as illustrated.
  16.  
  17. Push the clip finger out using the screwdriver. Deform the finger until it is completely removed from the cup notch.
  18.  
  19. Remove the injector from the clip.
  20.  
  21. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector. Discard the clip.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Insert a flat head screwdriver between the injector cup and clip finger-Mazda 3 and 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Deform the finger until it is completely removed from the cup notch-Mazda 3 and 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector-Mazda 3 and 6 models with the 2.3L (L3) engine

  22.  

To install:

  1. Use new O-rings and coat them with clean engine oil.
  2.  
  3. Temporarily attach a new clip to the injector groove.
    NOTE
    When the clip is correctly installed, the central area of the injector and clip finger positions are aligned.

  4.  
  5. While firmly holding the injector, push the clip into the injector until the clip stops. Make sure the injector connector is correctly positioned.
  6.  
  7. Press the injector into the cup until the cup contacts the lower surface of the cup. Make sure the injector and clip are installed properly and the clip is hooked into the injector cup notch.
  8.  
  9. Install the injectors and fuel rail as an assembly.
  10.  
  11. Install the fuel rail bolts and tighten to 15-19 ft. lbs. (20-26 Nm).
  12.  
  13. Attach the fuel lines to the rail.
  14.  
  15. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, short the check connector to terminal F/P to a body ground.

      Click image to see an enlarged view

      Fig. Using a jumper wire, short the check connector to terminal F/P to a body ground-Mazda 6 models

    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
    4.  
    5. Check the hoses, clips and other fuel system components for leaks.
    6.  
    7. If there are any leaks, replace the fuel hoses and clips. If the is damage to the seal on the fuel pipe side, replace the pipe.
    8.  
    9. The system must be leak free for five minutes with the terminal grounded. If any component is replaced because of a system, leak, turn the ignition key OFF; remove the jumper wire from the terminal. reapply the jumper wire, turn the ignition On and check for leaks.
    10.  

  16.  
  17. Install the remaining components.
  18.  

2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector wiring harness
     
    Fuel lines at the fuel rail
     
    Fuel rail
     
    Accumulated connector
     
    Spacer
     
    Fuel injectors, grommets and O-rings from the fuel rail
     
    O-rings from the fuel injectors

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-626 2.5L (KL) engine

     

  6.  

To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors. Fit the injector squarely into the rail while using a twisting motion. Fit the injector tab into the notch on the rail.
     
    Insulators and injectors on the intake manifold
     
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines to the fuel rail
     
    Fuel injector wiring harness
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for leaks and correct as necessary, before starting the engine.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Fuel injector wiring harness
     
    Fuel lines at the fuel rail
     
    Fuel rail
     
    Insulator
     
    Accumulated connector
     
    Spacer
     
    Fuel injectors, grommets and O-rings from the fuel rail
     
    O-rings from the fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors. Fit the injector squarely into the rail while using a twisting motion. Fit the injector tab into the notch on the rail.
     
    Insulators and injectors on the intake manifold
     
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines to the fuel rail
     
    Fuel injector wiring harness
     
    Negative battery cable
     

  2.  
  3. Turn the ignition switch ON to pressurize the fuel system.
  4.  
  5. Check for leaks and correct as necessary, before starting the engine.
  6.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the upper intake manifold (dynamic chamber).
  8.  
  9. Disconnect the fuel injector connectors.
  10.  
  11. Disconnect the fuel hoses from the rail.
  12.  
  13. Remove the rail and injectors as an assembly.
  14.  
  15. Gently twist the fuel injector out of the manifold
  16.  
  17. Check the O-rings and replace if damaged.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda 6 models with the 3.0L (AJ) engine

  18.  

To install:

  1. Install the fuel injector(s) using new O-rings lubricated with clean engine oil.
  2.  
  3. Attach the fuel injector into the supply manifold.
  4.  
  5. Install the fuel rail and injectors as an assembly. Tighten the rail bolts to 72-101 inch . lbs. (8-11 Nm).
  6.  
  7. Connect the fuel hoses to the rail.
  8.  
  9. Install the injector connectors.
  10.  
  11. Install the upper intake manifold.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, short the check connector to terminal F/P to a body ground.
    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
    4.  
    5. Check the hoses, clips and other fuel system components for leaks.
    6.  
    7. If there are any leaks, replace the fuel hoses and clips. If the is damage to the seal on the fuel pipe side, replace the pipe.
    8.  
    9. The system must be leak free for five minutes with the terminal grounded. If any component is replaced because of a system, leak, turn the ignition key OFF; remove the jumper wire from the terminal. reapply the jumper wire, turn the ignition On and check for leaks.
    10.  

  16.  

 
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