Protege 1999-2000

Injection Pressure Regulator

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Removal & Installation



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Relieve fuel system pressure. See -Relieving Fuel System Pressure- in -GASOLINE FUEL INJECTION SYSTEM- section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the vacuum hose (1).
  6.  
  7. Remove the plastic fuel hose (2) as follows:
    CAUTION
    The quick release connector may be damaged when the tab is turned overly. Do not turn the tab over the stopper.

    1. Disconnect the quick release connector from the pulsation damper by pushing apart the lock clip to unlock it.
    2.  
    3. Lift the tab on the blue locking coupler until the fuel line can be released.
    4.  
    5. Pull the fuel hose straight back.
      NOTE
      The blue stopper may be removed from the quick connector. Take care not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line.


      NOTE
      The orange locking coupler has two internal locking tabs which retrain the pulsation damper pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.

    6.  
    7. Cover the disconnected quick release connector and pulsation damper with vinyl sheet or the like to prevent it from being scratched or contaminated with foreign materials.
    8.  

  8.  
  9. Remove the pressure regulator (3).

    Click image to see an enlarged view

    Fig. Removing the fuel injection pressure regulator

  10.  

<To install:>

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install the pressure regulator.
  4.  
  5. Install the plastic fuel hose as follows:
    1. A checker tab is integrated with the 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 pulsation damper.
    2.  
    3. Inspect the plastic fuel hose and pulsation damper sealing surface for damage and deformation, and replace as necessary.
    4.  
    5. If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.
    6.  
    7. Apply a small amount of clean engine oil to the sealing surface of the pulsation damper.
    8.  
    9. Push the quick release connector straight into the pulsation damper until a click is heard.
    10.  
    11. Lightly pull and push the quick release connector a few times by hand and verify that it can move 0.08-0.11 in. (2-3 mm) and it is connected securely.
    12.  
    13. If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.
    14.  
    15. Attach the lock clip to the quick release connector in the direction of the fuel distributor and lock it
    16.  

  6.  
  7. Install the vacuum hose.
  8.  
  9. Connect the battery cable.
  10.  

Testing



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003


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, and make sure that it is free of foreign material.

Operation Inspection

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Disconnect the battery negative cable.
  2.  
  3. 3. Disconnect the quick release connector from the pulsation damper as follows:
    1. Push apart the lock clip and unlock it.
    2.  
    3. Lift the tab on the blue locking coupler until the fuel line can be released.
    4.  
    5. Pull the fuel hose straight back.
      CAUTION
      The blue stopper may be removed from the quick connector. Take care not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line.


      NOTE
      The orange locking coupler has two internal locking tabs which retain the pulsation damper pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.

    6.  

  4.  
  5. Push the fuel pressure gauge quick release connector into the fuel distributor and fuel main hose into the fuel pressure gauge until a click is heard.
  6.  
  7. Turn the lever on the fuel pressure gauge to the ON position.
  8.  
  9. Connect the battery negative cable.
  10.  
  11. Start the engine and let it idle.
  12.  
  13. Measure the fuel line pressure after approx. 2 minutes, fuel line pressure should be 30-36 psi (210-250 kPa).
  14.  
  15. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure. It should be 39-45 psi (270-310 kPa).
  16.  
  17. Turn the ignition switch ON.
  18.  
  19. Disconnect the fuel pressure gauge.
  20.  

Simulation Test

Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Install a fuel pressure gauge and check the fuel system pressure. It should be 39-45 psi (270-310 kPa).
    1. If not as specified, perform the further inspection for the pressure regulator.

      Click image to see an enlarged view

      Fig. Install a fuel pressure gauge and check the fuel system pressure.

    2.  

  2.  

 
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