Hello Mazda heads,
I have a puzzling problem, my sons 2006 Mazda 3, which has an intermittent starting problem (cranks, but does not turn over); rejects it's fuel line after a few drive episodes.

Details; it seems that if when you attemp to start the car, you turn the key (allow the ignition to be on about 3 seconds) the car will start 80%. Turning the key immediately seems to fail more frequently. Once the car is driven the fuel line pressure blows the fuel line off the injector. I have replaced the standard fuel line with standard 1/4 fuel line with clamps; still blows the hose off at the fuel injectors.

Thanks in advance for any help...

 

Update; just in case anyone is listening...

I purchased a new fuel line, with the correct quick connect ends, the line has remained in place... however, the interminptent starting persists. I have read several forum threads (1) starter ground wire corrosion (no, looks fine), (2) fuel pump (no, pumps fine), tested with pressure gauge, maintained 55 psi for several days. (3) fuel pump relay (good), fuses (good). (4) purge valve solenoid (tested good), except at first it seemed to not be working. Wondering now if this purge valve solenoid sticks closed.
I will probably change it, assuming I can get one quickly. I also lost the silly blue quick connect cover on the exit side of the hose.

I will update this after I get this done.

Thanks....

 

Ok, I have another update; with the new fuel line installed I decided to disconnect the purge valve solenoid. Ran fine for a couple days, but I did have a no start situation which made me rule out the purge valve solenoid. Next morning I reconnect the purge valve solenoid, start the car, almost! The fuel line bursts at the injector rail connection. I wish I could figure out how to post the photo...

So anyone out there have any ideas on how I could get enough built up pressure in my fuel line to actually burst thru??? if anyone out there has any ideas I would love to hear them.

Thanks

 

I have another update;

Today I used an in line fuel pressure gauge to monitor the fuel pressure; Started the car normally (pressure at 45psi); drove about 10 miles, stopped engine and checked pressure. With engine OFF, pressure was around 50psi, BUT started increasing, within about 5 minutes pressure was 100psi. came back 10 minutes later pressure now exceeding the gauge limit ~120psi.
Was concerned that I would burst the make shift fuel line, so I removed the Fuel Pump fuse and started the car (pressure dropped) car ran until the fuel was drained out of the line.

Apparently the pressure regulator is built into the fuel pump, so replacing the fuel pump is probably what I will do. However, since the regulator only regulates pressure, it does not fully explain why the pressure is building with the engine off (No, I cannot hear the pump still working).
There is some evidence that the gas tank may was removed previously; which means there is a high possibility that someone already changed the fuel pump. I'm theorizing that perhaps the fuel pump that was installed was not the correct model (after-market or non-california) and MAYBE that is what is causing the problem.

If this strikes a chord with any of you Mazda junkies out there; maybe one of you Mazda Speed guys who tried to bump up the fuel delivery to get extra performance, please chime in.

Right now I'm looking at about $500 for the pump and $300-$500 labor if I pay someone else to put it in; and another $80 for a new fuel line to replace the last one that burst.

Thanks in advance...

 

Problem Solved!

Hi Mazda Heads, I thought I would post this as a follow up; So I changed the fuel pump and the car is running Excellent, no problem starting, fuel line is not exploding. However, the problem was not the fuel pump; the problem was the aircraft quality check valve (cost about $200) some joker installed into the fuel line coming directly off the fuel pump (see photos).
I have been trying to figure out why someone would go thru the trouble of dropping the tank and adding this one way check valve. Any ideas any one has would be welcome...
Thanks

 

The may have believed that the check valve in the fuel pump had failed. Check the old pump and see if it was.

 

Aussiblue,

Thanks for the reply, I was beginning to think no one ever read these threads.

I did check that the fuel pump regulator on the original fuel pump, functioned correctly; performed a leak down test using a fuel pressure gauge and a hand pump. Did the same thing on the new fuel pump prior to installing, to make sure it was good.

 

Yes it a pretty quiet forum. My family and I have mainly large Australian Fords although one of my sons sold his Falcon to get a Mazda 3 (2010 2.5 SP Manual) so I check every week or so.

 

The more I learn about the Mazda's the more I like them; I Have owned lots of Honda's over the years, lately (last 10-15 yrs) the quality has declined, Mazda might be my new go to car.

Thanks again...