Mazda Protege 5. Manual - part 97

 

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Mazda Protege 5. Manual - part 97

 

 

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–41

01–03A

End Of Sie

NO.19 EXHAUST SMOKE [ZM]

A3U010318881W61

3

Remove thermostat and inspect operation.
(See 01–12–5 THERMOSTAT REMOVAL/
INSTALLATION.)
(See 01–12–7 THERMOSTAT 
INSPECTION.)

Is thermostat okay?

Yes

Inspect cooling fan and condenser fan operation.

If both or either fan operate abnormally, inspect for 
following:
— Cooling fan relay is stuck closed.
— Condenser fan relay is stuck closed.
— Short to GND between cooling fan relay and PCM 

terminal 47

— Short to GND between condenser fan relay and PCM 

terminal 45

— Circuit between cooling fan relay and fan motor 

shorts to battery supply line

— Circuit between condenser fan relay and fan motor 

shorts to battery supply line

No

Access ECT PID on WDS or equivalent.
Inspect both ECT and temperature gauge on instrument 
cluster readings.

If temperature gauge on instrument cluster indicates 
normal range but ECT is not same as temperature 
gauge reading, inspect ECT sensor.

If temperature gauge on instrument cluster indicates 
cold range but ECT is normal, inspect temperature 
gauge and heat gauge unit.

4

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.

STEP

INSPECTION

ACTION

19

Exhaust smoke

DESCRIPTION

Blue, black, or white smoke from exhaust system

POSSIBLE 

CAUSE

Blue smoke (Burning oil):

PCV valve malfunction

Engine internal oil leakage

White smoke (Water in combustion):

Cooling system malfunction (coolant loss)

Engine internal coolant leakage

Black smoke (Rich fuel mixture):

Air cleaner restriction

Intake-air system is collapsed or restricted.

Fuel return line is restricted.

Excessive fuel pressure

Improper engine compression

Injector fuel leakage

Ignition 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.)

1712-1U-01G(01-03A).fm  41 ページ  2001年6月29日 金曜日 午後4時45分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–42

Diagnostic procedure

End Of Sie

STEP

INSPECTION

ACTION

1

What color is smoke coming from exhaust 
system?

Blue

Burning oil is indicated.
Go to next step.

White Water in combustion is indicated.

Go to Step 3.

Black Rich fuel mixture is indicated.

Go to Step 4.

2

Remove and shake PCV valve.

Does PCV valve rattle?

Yes

Inspect for following:

Damaged valve guide, stems or valve seals

Blocked oil drain passage in cylinder head

Piston rings for not seated, seized or worn

Damaged cylinder bore
— If other drivability symptoms are present, return to 

diagnostic index to service any additional symptoms.

No

Replace PCV valve.

3

Does cooling system hold pressure?

Yes

Inspect for following:

Cylinder head gasket leakage

Intake manifold gasket leakage

Engine block cracks or porosity
— If other driveability symptoms are present, return to 

diagnostic index to service any additional symptoms.

No

Inspect for cause.

4

Inspect for following:
— Air cleaner restriction
— Collapsed or restricted intake-air system
— restricted fuel return line

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 4.

5

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

No DTC is displayed:

Go to next step.

6

Install fuel pressure gauge between fuel filter 
and fuel distributor.

Start engine and run it at idle.

Measure fuel line pressure at idle.

Is fuel line pressure correct at idle?

Fuel line pressure
210—250 kPa {2.1—2.6 kgf/cm

2

, 30—36 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.

High:

Inspect pressure regulator for high pressure cause.

Inspect for clogged fuel return line.

7

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

Yes

Inspect spark plugs and CMP sensor.

No

Inspect following:

High-tension leads

Ignition coil and connector

8

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.

1712-1U-01G(01-03A).fm  42 ページ  2001年6月29日 金曜日 午後4時45分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–43

01–03A

NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [ZM]

A3U010318881W62

Diagnostic procedure

End Of Sie

20

Fuel odor (in engine compartment)

DESCRIPTION

Gasoline fuel smell or visible leakage

POSSIBLE 

CAUSE

Excessive fuel pressure

Purge solenoid valve malfunction

Fuel tank vent system blockage

Charcoal canister 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

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

Service as necessary.

Is fuel line pressure held after ignition switch 
is turned off?
(See 01–14–28 Operation 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.

2

Inspect for blockage/restriction or open 
between engine vacuum port and charcoal 
canister.

Inspect for blockage in fuel tank vent system.

Is fault indicated?

Yes

Replace vacuum hose.

No

Go to next step.

3

Inspect purge solenoid valve.
(See 01–16–12 PURGE SOLENOID VALVE 
INSPECTION.)

Is solenoid operating properly?

Yes

Go to next step.

No

Replace purge solenoid valve.

4

Connect WDS or equivalent to DLC-2.

Turn ignition switch on.

Retrieve any DTC.

Is “DTC” displayed?

Yes

No DTC is displayed:

Inspect charcoal canister for fuel saturation.

If excess amount of liquid fuel is present, replace 
charcoal canister.

No

DTC is displayed:

Go to appropriate DTC test.

5

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.

1712-1U-01G(01-03A).fm  43 ページ  2001年6月29日 金曜日 午後4時45分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–44

NO.21 ENGINE NOISE [ZM]

A3U010318881W63

Diagnostic procedure

End Of Sie

21

Engine noise

DESCRIPTION

Engine noise from under hood

POSSIBLE 

CAUSE

Squeal, click or chirp noise:

Improper engine oil level

Improper drive belt tension

Rattle sound noise:

Loose parts

Hiss sound noise:

Vacuum leakage

Loose spark plug

Air leakage from intake-air system

Rumble or grind noise:

Improper drive belt tension

Rap or roar sound noise:

Exhaust system looseness

Other noise:

Camshaft friction gear noise or MLA noise

STEP

INSPECTION

ACTION

1

Is squeal, click or chirp sound present?

Yes

Inspect engine oil level or drive belts.

No

Go to next step.

2

Is rumble or grind sound present?

Yes

Inspect drive belt.

No

Go to next step.

3

Is rattle sound present?

Yes

Inspect location of rattle for loose parts.

No

Go to next step.

4

Is hiss sound present?

Yes

Inspect for following:

Vacuum leakage

Spark plug looseness

Intake-air system leakage

No

Go to next step.

5

Is rap or roar sound present?

Yes

Inspect exhaust system for loose parts.

No

Go to next step.

6

Is knock sound present?

Yes

Go to symptom troubleshooting “NO.13 KNOCKING/ 
PINGING —ACCELERATION/CRUISE[ZM]”.

No

If noise comes from engine internal, inspect for friction gear 
or MLA noise.

7

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.

1712-1U-01G(01-03A).fm  44 ページ  2001年6月29日 金曜日 午後4時45分

 

 

 

 

 

 

 

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