Mazda MPV 1999-06

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.5L Engine

WARNING
Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable vapors are always present and can ignite. Failure to follow these instructions can result in personal injury.


WARNING
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly release the fuel pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies, if equipped.

  6.  
  7. Properly disconnect the fuel line.
  8.  
  9. Disconnect the fuel injector electrical connectors.
  10.  
  11. Disconnect the fuel pressure regulator electrical connector and the vacuum hose.
  12.  
  13. Disconnect the fuel injector harness retaining clips from the fuel injection supply manifold.
  14.  
  15. Disconnect the fuel tube.
  16.  
  17. Remove the bolts and the fuel injection supply manifold and injectors, as an assembly.
  18.  
  19. If equipped, remove the fuel rail spacers.
    NOTE
    Remove and discard the fuel injector O-rings.

  20.  
  21. Remove the fuel injectors from the fuel rail assembly.
  22.  

To install:

  1. Install new O-rings and lubricate them with clean engine oil.
    NOTE
    Never use silicone grease. Silicone grease may clog the fuel injectors.

  2.  
  3. Install the injectors to the fuel rail.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Tighten the fuel supply manifold bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Start the engine and check for leaks. Correct, as required.
  10.  

3.0L Engine

WARNING
Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable vapors are always present and can ignite. Failure to follow these instructions can result in personal injury.


WARNING
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly release the fuel pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies, if equipped.

  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Disconnect the fuel tube quick release coupling.
  10.  
  11. Disconnect the fuel rail pressure and temperature sensor vacuum tube
  12.  
  13. Disconnect the fuel rail pressure and temperature sensor electrical connector.
  14.  
  15. Disconnect the fuel injector electrical connectors.
  16.  
  17. Remove the fuel rail bolts.
  18.  
  19. Remove the fuel rail and fuel injectors, as an assembly.
  20.  
  21. Remove the fuel injector.
  22.  
  23. Remove the fuel injector O-ring seals.
  24.  

To install:

  1. Install new O-rings and lubricate them with clean engine oil.
    NOTE
    Never use silicone grease. Silicone grease may clog the fuel injectors.

  2.  
  3. Install the injectors to the fuel rail.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Tighten the fuel supply manifold bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Start the engine and check for leaks. Correct, as required.
  10.  

 
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