Mazda Protege 5. Manual - part 91

 

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Mazda Protege 5. Manual - part 91

 

 

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–17

01–03A

End Of Sie

12

Connect vacuum hose to pressure regulator.

Install vacuum gauge to intake manifold.

Start engine.

Does fuel pressure gauge reading increase 
as vacuum gauge reading decreases and/or 
fuel pressure gauge reading decreases as 
vacuum gauge reading increases?

Yes

Go to next step.

No

Connect vacuum pump to pressure regulator.
Start engine.
Verify that fuel pressure gauge reading changes as vacuum 
changes.

If changes, inspect vacuum line.

If does not change, replace pressure regulator.

13

Disconnect vacuum hose from purge 
solenoid valve and plug opening end of 
vacuum hose.

Attempt to start engine.

Is starting condition improved?

Yes

Inspect if purge solenoid valve sticks open.

No

Go to next step.

14

Inspect for contaminated MAF sensor.

Is there any contamination?

Yes

Replace MAF sensor.

No

Go to next step.

15

Is there a restriction in exhaust system?

Yes

Inspect exhaust system.

No

Go to next step.

16

Inspect engine condition while tapping EGR 
valve housing.

Does engine condition improve?

Yes

Replace EGR valve.

No

Go to next step.

17

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

Is starting system normal?

Yes

Inspect for loose connectors or poor terminal contact.

If okay, remove EGR valve and visually inspect for 
mechanically stuck EGR valve.

No

Repair or replace components as required.

18

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

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–18

NO.5 ENGINE STALLS-AFTER START/AT IDLE [ZM]

A3U010318881W47

Diagnostic procedure

5

Engine stalls—after start/at idle

DESCRIPTION

Engine stops unexpectedly.

POSSIBLE 

CAUSE

A/C system improper operation

Air leakage from intake-air system parts

Purge solenoid valve malfunction

Improper operation of IAC valve

EGR valve malfunction

No signal from CKP sensor due to sensor, related wire or wrong installation

Vacuum leakage

Low engine compression

Spark leakage from high-tension leads

Poor fuel quality

PCV valve malfunction

Air cleaner restriction

Restriction in exhaust system

Electrical connector disconnection

Open or short circuit in fuel pump and related harness

No battery power supply to PCM or poor GND

Inadequate fuel pressure

Fuel pump mechanical malfunction

Fuel leakage from fuel injector

Fuel injector clogging

Immobilizer system and/or circuit 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)

STEP

INSPECTION

ACTION

1

Inspect for following:
— Vacuum connection
— Air cleaner element
— No air leakage from intake-air system
— No restriction of intake-air system
— Proper sealing of intake manifold and 

components attached to intake manifold: 
EGR valve, IAC valve

— Ignition wiring
— Fuel quality: proper octane, 

contamination, winter/summer blend

— Electrical connections
— Smooth operation of throttle

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

2

Turn ignition switch off.

Disconnect TP sensor connector.

Measure voltage at TP sensor connector 
VREF terminal with ignition switch on.

Voltage
4.5—5.5 V

Is voltage okay?

Yes

Go to next step.

No

Go to symptom troubleshooting “NO.30 CONSTANT 
VOLTAGE”.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–19

01–03A

3

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

No DTC is displayed:

Go to next step.

4

Attempt to start engine at part throttle.

Does engine run smoothly at part throttle?

Yes

Inspect IAC valve and wiring harness.

No

Go to next step.

5

Connect WDS or equivalent to DLC-2.

Access RPM PID.

Is RPM PID indicating engine speed during 
cranking of engine?

Yes

Go to next step.

No

Inspect for following:

Open or short circuit in CKP sensor

Open or short circuit between CKP sensor and PCM 
terminal 21 or 22

Open or short circuit in CKP sensor harnesses

If CKP sensor and harness are okay, go to next step.

6

Visually inspect CKP sensor and teeth of 
crankshaft pulley.

Are CKP sensor and teeth of crankshaft 
pulley okay?

Yes

Go to next step.

No

Replace malfunctioning parts.

7

Measure gap between CKP sensor and teeth 
of crankshaft pulley.

Gap
0.5—1.5 mm {0.020—0.059 in}

Is gap within specification?

Yes

Go to next step.

No

Adjust CKP sensor.

8

Inspect for cracks on high-tension leads.

Are there any cracks on high-tension leads?

Yes

Repair suspected high-tension leads.

No

Go to next step.

9

Is strong blue spark visible at each 
disconnected high-tension lead while 
cranking engine?

Yes

Go to next step.

If symptom occurs with A/C on, go to Step 15.

No

Inspect for following:

Open or short circuit in ignition coil

Open circuit in high-tension leads

Open circuit between ignition coil connector GND 
terminal and body GND

Open circuit between ignition switch and ignition coil

Open circuit between ignition coil and PCM terminal 26 
or 52

10

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 injector.

Spark plug is grayish white:

Inspect for clogged fuel injector.

No

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

11

Remove and shake PCV valve.

Does PCV valve rattle?

Yes

Go to next step.

No

Replace PCV valve.

12

Inspect for a restriction in exhaust system.

Is there any restriction?

Yes

Inspect exhaust system.

No

Go to next step.

STEP

INSPECTION

ACTION

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–20

End Of Sie

13

Install fuel pressure gauge between fuel filter 
and fuel distributor.

Connect jumper wire between F/P terminal at 
DLC in engine compartment and GND.

Turn ignition switch on.

Is fuel line pressure correct with ignition 
switch on?

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

2

, 39—45 psi}

Yes

Go to next step

No

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.

14

Visually inspect for fuel leakage at fuel 
injector O-ring and fuel line.

Service as necessary.

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

Yes

Go to next step.

No

Inspect pressure regulator diaphragm condition.

If condition is okay, inspect fuel injector.

If condition is not okay, replace pressure regulator.

15

Note

The following test is for stall concerns with 
A/C on. If other symptoms exist, go to 
next step.

Connect pressure gauges to A/C low and 
high pressure side lines.

Turn A/C on and measure low side and high 
side pressure.

Are pressures within specifications?
(See 07–10–3 REFRIGERANT PRESSURE 
CHECK.)

Yes

Go to next step.

No

If A/C is always on, go to symptom troubleshooting 
“NO.24 A/C IS ALWAYS ON/A/C COMPRESSOR 
RUNS CONTINUOUSLY”.

For other symptoms, inspect following:

Refrigerant charging amount

Condenser fan operation

16

Disconnect vacuum hose between purge 
solenoid valve and intake manifold from 
purge solenoid side.

Plug opening end of vacuum hose.

Start engine.

Is engine stall now eliminated?

Yes

Inspect if purge solenoid valve sticks open.
Inspect evaporative emission control system.

No

Go to next step.

17

Is air leakage felt or heard at intake-air 
system components while racing engine to 
higher speed?

Yes

Repair or replace.

No

Go to next step.

18

Inspect engine condition while tapping EGR 
valve housing.

Does engine condition improve?

Yes

Replace EGR valve.

No

Go to next step.

19

Is engine compression correct?

Yes

Inspect valve timing.

No

Inspect for cause.

20

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

1712-1U-01G(01-03A).fm  20 ページ  2001年6月29日 金曜日 午後4時45分

 

 

 

 

 

 

 

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