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Mazda Protege 5. Manual - part 90

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–13

01–03A

NO.1 MELTING OF MAIN OR OTHER FUSES [ZM]

A3U010318881W43

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Melting of main or other fuses

[TROUBLESHOOTING HINTS]
Inspect condition of fuse.

•

If malfunction remains, refer to related Service Bulletins and perform repair or diagnosis.
— If vehicle is repaired, troubleshooting completed.
— If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–14

NO.2 MIL ILLUMINATES [ZM]

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Diagnostic procedure

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NO.3 WILL NOT CRANK [ZM]

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Diagnostic procedure

Mil illuminates

DESCRIPTION

•

MIL is illuminated incorrectly.

POSSIBLE

CAUSE

•

PCM illuminates for emission-related concern (DTC are stored in PCM)

•

Short to GND circuit between MIL (located on instrument cluster) and PCM

Note

•

If MIL blinks at steady rate, misfire condition could possibly exist.

STEP

INSPECTION

ACTION

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC is displayed:

•

Go to appropriate DTC test.

No DTC is displayed:

•

Inspect for short to GND circuit between MIL (located on
instrument cluster) and PCM terminal 2.

•

Verify test results.
— If okay, return to diagnostic index to service any additional symptoms.
— If malfunction remains, inspect related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting is completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

Will not crank

DESCRIPTION

•

Starter does not work.

POSSIBLE

CAUSE

•

Open starter circuit between ignition switch and starter

•

Transaxle range switch malfunction (ATX)

•

Transaxle range switch misadjustment (ATX)

•

Starter interlock switch malfunction (MTX)

•

Starter malfunction

•

Seized/hydrolocked engine, flywheel or drive plate

STEP

INSPECTION

ACTION

•

Inspect for following:
— Battery connection
— Battery condition
— Transaxle is in Park or Neutral. (ATX)
— Clutch is fully depressed. (MTX)
— Fuses

•

Are all items okay?

Yes

Go to next step.

Service as necessary.
Repeat Step 1.

•

Is clicking sound heard from starter when
ignition switch is turned to START?

Yes

Go to next step.

Go to Step 4.

•

Inspect starting system.
(See 01–19–2 STARTER INSPECTION.)

•

Is starting system okay?

Yes

Inspect for seized/hydrolocked engine, flywheel or drive
plate.

Repair or replace components as required.

•

Do any other electrical accessories work?

Yes

Go to next step.

Inspect charging system.
(See 01–17–1 BATTERY INSPECTION.)
(See 01–17–3 GENERATOR INSPECTION.)

Note

•

Following test should be performed on
ATX only. For MTX, go to next step.

•

Inspect adjustment of transaxle range
switch.

•

Is transaxle range switch adjusted properly?

Yes

Go to next step.

Inspect for open circuit between transaxle range switch and
PCM terminal 64 or starter.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–15

01–03A

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NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [ZM]

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•

Connect WDS or equivalent to DLC-2.

•

Turn ignition switch on.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC is displayed:

•

Go to appropriate DTC test.

Communication error message is displayed:

•

Inspect for following:
— Open circuit between main relay and PCM terminal

71 or 97

— Open main relay GND circuit
— Main relay is stuck open
— Open or poor GND circuit (PCM terminal 24, 51, 76,

77 or 103)

— Poor connection of vehicle body GND

No DTC is displayed:

•

Inspect following:
— START circuit in ignition switch
— Open circuit between ignition switch and starter
— Starter interlock switch (MTX)

•

Verify test results.
— If okay, return to diagnostic index to service any additional symptoms.
— If malfunction remains, refer to related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

STEP

INSPECTION

ACTION

Hard to start/long crank/erratic start/erratic crank

DESCRIPTION

•

Starter cranks engine at normal speed but engine requires excessive cranking time before start.

•

Battery is in normal condition.

POSSIBLE

CAUSE

•

Spark leakage from high-tension leads

•

Vacuum leakage

•

Poor fuel quality

•

Starting system malfunction

•

Spark plug malfunction

•

Air leakage from intake-air system

•

Erratic signal from CKP sensor

•

Erratic signal from CMP sensor

•

Air cleaner restriction

•

IAC valve malfunction

•

PCV valve malfunction

•

Inadequate fuel pressure

•

Purge solenoid valve malfunction

•

MAF sensor contamination

•

Restriction in exhaust system

•

EGR valve malfunction

•

Pressure regulator control (PRC) system malfunction

Warning
The following troubleshooting flowchart contains fuel system diagnosis and repair procedures.
Read following warnings before performing fuel system services:

••••

Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.

••••

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01–14–4 BEFORE REPAIR PROCEDURE)
(See 01–14–5 AFTER REPAIR PROCEDURE)

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–16

Diagnostic procedure

STEP

INSPECTION

ACTION

•

Inspect for following:
— Vacuum leakage
— Fuel quality (e.g. proper octane,

contamination, winter/summer blend)

— Loose bands on intake-air system
— Cracks on intake-air system parts
— Air cleaner restriction

•

Are all items okay?

Yes

Go to next step.

Service as necessary.

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition switch on.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC is displayed:

•

Go to appropriate DTC test.

No DTC is displayed:

•

Go to next step.

•

Is engine overheating?

Yes

Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS — OVERHEATING [ZM]”.

Go to next step.

•

Inspect for cracks on high-tension leads.

•

Are there any cracks on high-tension leads?

Yes

Repair suspected high-tension leads.

Go to next step.

•

Inspect condition of spark plugs.

•

Is spark plug wet, covered with carbon or
grayish white?

Yes

Spark plug is wet or covered with carbon:

•

Inspect for fuel leakage from fuel injector.

Spark plug is grayish white:

•

Inspect for clogged fuel injector.

Install spark plugs on original cylinders.
Go to next step.

•

Visually inspect CKP sensor and teeth of
crankshaft pulley.

•

Is CKP sensor and teeth of crankshaft pulley
okay?

Yes

Go to next step.

Replace malfunctioning parts.

•

Measure gap between CKP sensor and teeth
of crankshaft pulley.

Specification
0.5—1.5 mm {0.020—0.59 in}

•

Is gap within specification?

Yes

Go to next step.

Adjust CKP sensor.

•

Remove PCV valve and inspect PCV valve.

•

Does PCV valve rattle?

Yes

Go to next step.

Replace PCV valve.

•

Install fuel pressure gauge between fuel filter
and fuel distributor.

•

Connect jumper wire between F/P terminal at
DLC in engine compartment and chassis
GND.
(See 01–14–5 AFTER REPAIR
PROCEDURE.)

•

Turn ignition switch on.

•

Is fuel line pressure correct?

Fuel line pressure
270—310 kPa {2.7—3.2 kgf/cm

, 39—45 psi}

Yes

Go to next step.

Zero or low:

•

Inspect fuel pump circuit.

•

Inspect for open fuel pump relief valve.

•

Inspect for fuel leakage inside pressure regulator.

•

Inspect for clogged main fuel line.

•

Inspect PRC solenoid valve and related vacuum hose
and harness.

High

•

Inspect pressure regulator for high pressure cause.

•

Inspect for clogged fuel return line.

•

Is fuel line pressure held after ignition switch
is turned off?
(See 01–14–28 PRESSURE REGULATOR
INSPECTION.)

Yes

Go to next step.

Inspect pressure regulator diaphragm condition.

•

If condition is okay, inspect fuel injector.

•

If condition is not okay, replace pressure regulator.

•

Disconnect vacuum hose from pressure
regulator and plug the hose.

•

Start engine.

•

Does fuel line pressure remain within

±±±±

kPa {0.21 kgf/cm

, 3 psi} while driving

vehicle?

Yes

Go to next step.

Inspect for clogged fuel filter.

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Content .. 88 89 90 91 ..