Mazda Protege 5. Manual - part 44

ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM)]

01–02A–142

Diagnostic procedure

End Of Sie

STEP

INSPECTION

ACTION

1

VERIFY RELATED REPAIR INFORMATION 
AVAILABILITY

•

Check for related Service Bulletins availability.

•

Is any related repair information available? 

Yes Perform repair or diagnosis according to available repair 

information.

•

If vehicle is not repaired, go to next step.

No

Go to next step.

2

INSPECT DRIVE BELT CONDITION

•

Verify that drive belt auto tensioner indicator 
mark in not exceeding limit.
(See 01–10A–3 DRIVE BELT INSPECTION 
[ZM].)

•

Is front drive belt okay?

Yes Go to next step.

No

Replace and/or adjust drive belt, then go to Step 9.

3

INSPECT PCM CONNECTOR FOR POOR 
CONNECTION

•

Turn ignition key to OFF.

•

Disconnect PCM connector.

•

Check for poor connection (damaged/pulled-
out terminals, corrosion, etc.).

•

Is there malfunction?

Yes Repair terminals, then go to Step 9.

No

Go to next step.

4

INSPECT GENERATOR CONNECTOR FOR 
POOR CONNECTION

•

Disconnect generator connector.

•

Check for poor connection (damaged/pulled-
out terminals, corrosion, etc.).

•

Is there malfunction?

Yes Repair or replace terminals, then go to Step 9.

No

Go to next step.

5

INSPECT GENERATOR CONTROL CIRCUIT 
FOR SHORT TO GROUND

•

Check for continuity between generator 
terminal D (harness-side) and body ground.

•

Is there continuity?

Yes Repair or replace harness for short to ground, then go to 

Step 9.

No

Go to next step.

6

INSPECT GENERATOR OUTPUT VOLTAGE 
MONITOR CIRCUIT FOR GROUND

•

Check continuity between generator terminal P 
(harness-side) and body ground.

•

Is there continuity?

Yes Repair or replace harness for short to ground, then go to 

Step 9.

No

Go to next step.

7

INSPECT GENERATOR CONTROL CIRCUIT 
FOR OPEN CIRCUIT

•

Connect breakout box with PCM disconnected.

•

Measure resistance between generator 
terminal D (harness-side) and breakout box 
terminal 53.

•

Is there continuity?

Yes Go to next step.

No

Repair or replace harness for open circuit, then go to Step 
9.

8

INSPECT GENERATOR OUTPUT VOLTAGE 
MONITOR CIRCUIT FOR OPEN CIRCUIT

•

Measure resistance between generator 
terminal P (harness-side) and breakout box 
terminal 30.

•

Is there continuity?

Yes Repair or replace generator, then go to next step.

No

Repair or replace harness for open, then go to next step.

9

VERIFY TROUBLESHOOTING OF DTC P1631 
COMPLETED

•

Make sure to reconnect all disconnected 
connectors.

•

Clear DTC from memory using WDS or 
equivalent.

•

Turn ignition switch to OFF, then start engine.

•

Is same DTC present?

Yes Replace PCM, then go to next step.

No

No concern is detected. Go to next step.

10

VERIFY AFTER REPAIR PROCEDURE

•

Perform “After Repair Procedure”.
(See 01–02A–10 AFTER REPAIR 
PROCEDURE [ZM].)

•

Is there any DTC present?

Yes Go to applicable DTC inspection.

(See 01–02A–15 DTC TABLE [ZM].)

No

Troubleshooting completed.

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ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM)]

01–02A–143

01–02A

DTC P1632 [ZM]

A3U010201083W37

Diagnostic procedure

End Of Sie

DTC P1632

Battery voltage monitor signal circuit malfunction

DETECTION 

CONDITION

•

PCM monitors voltage of battery positive terminal at PCM terminal 4. If PCM detects battery positive 
terminal voltage below 7.97 V for 5 seconds, PCM determines that battery positive voltage circuit has 
malfunction.

POSSIBLE 

CAUSE

•

Open circuit in wiring between battery positive terminal and PCM terminal 4

•

Poor connection of PCM connector

•

PCM malfunction

STEP

INSPECTION

ACTION

1

VERIFY RELATED REPAIR INFORMATION 
AVAILABILITY

•

Check for related Service Bulletins availability.

•

Is any related repair information available? 

Yes Perform repair or diagnosis according to available repair 

information.

•

If vehicle is not repaired, go to next step.

No

Go to next step.

2

INSPECT PCM CONNECTOR FOR POOR 
CONNECTION

•

Disconnect PCM connector.

•

Check for poor connection (damaged/pulled-
out terminals, corrosion, etc.).

•

Is there malfunction?

Yes Repair terminals, then go to Step 4.

No

Go to next step.

3

INSPECT MONITOR CIRCUIT FOR OPEN

•

Disconnect battery cables.

•

Check for continuity between Battery positive 
terminal and PCM terminal 4.

•

Is there continuity?

Yes Go to next step.

No

Repair or replace harness, then go to next step.

4

VERIFY TROUBLESHOOTING OF DTC P1632 
COMPLETED

•

Make sure to reconnect all disconnected 
connectors.

•

Clear DTC from memory using WDS or 
equivalent.

•

Turn ignition key to OFF, then start engine.

•

Is same DTC present?

Yes Replace PCM, then go to next step.

No

No concern is detected. Go to next step.

5

VERIFY AFTER REPAIR PROCEDURE

•

Perform “After Repair Procedure”.
(See 01–02A–10 AFTER REPAIR 
PROCEDURE [ZM].)

•

Is there any DTC present?

Yes Go to applicable DTC inspection.

(See 01–02A–15 DTC TABLE [ZM].)

No

Troubleshooting completed.

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ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM)]

01–02A–144

DTC P1633 [ZM]

A3U010201083W38

Diagnostic procedure

DTC P1633

Battery overcharge

DETECTION 

CONDITION

•

PCM monitors input voltage from generator and battery positive terminal. If PCM detects generator output 
voltage above 18.47 V or battery voltage above 15.94 V for 5 seconds while engine running, PCM 
determines that charging system has malfunction.

POSSIBLE 

CAUSE

•

Short to power circuit between generator connector terminal D and PCM connector terminal 53

•

Generator malfunction

•

PCM malfunction

STEP

INSPECTION

ACTION

1

VERIFY RELATED REPAIR INFORMATION 
AVAILABILITY

•

Check for related Service Bulletins availability.

•

Is any related repair information available? 

Yes Perform repair or diagnosis according to available repair 

information.

•

If vehicle is not repaired, go to next step.

No

Go to next step.

2

INSPECT GENERATOR CONNECTOR FOR 
POOR CONNECTION

•

Turn ignition key to OFF.

•

Disconnect generator connector.

•

Check for poor connection (damaged/pulled-
out terminals, corrosion, etc.).

•

Is there malfunction?

Yes Repair or replace terminals, then go to Step 7.

No

Go to next step.

3

CLASSIFY GENERATOR MALFUNCTION OR 
OTHER MALFUNCTION

•

Turn ignition key to ON (Engine OFF).

•

Measure voltage between generator terminal D 
(harness-side) and body ground.

•

Is voltage B+?

Yes Go to next step.

No

Malfunction at generator.
Go to Step 6.

4

INSPECT PCM CONNECTOR FOR POOR 
CONNECTION

•

Turn ignition key to OFF.

•

Disconnect PCM connector.

•

Check for poor connection (damaged/pulled-
out terminals, corrosion, etc.).

•

Is there malfunction?

Yes Repair or replace pins, then go to Step 7.

No

Go to next step.

5

INSPECT GENERATOR CONTROL CIRCUIT 
FOR SHORT TO POWER

•

Turn ignition key to ON (Engine OFF).

•

Measure voltage between generator terminal D 
(harness-side) and body ground.

•

Is voltage B+?

Yes Repair or replace harness for short to power, then go to 

Step 7.

No

Go to Step 7.

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ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM)]

01–02A–145

01–02A

End Of Sie

DTC P1634 [ZM]

A3U010201083W39

Diagnostic procedure

6

INSPECT GENERATOR CONTROL TERMINAL 
FOR SHORT TO POWER

•

Measure resistance between generator 
terminal D (part-side) and body ground.

•

Is voltage B+?

Yes Repair or replace generator, then go to Step 7.

No

Go to next step.

7

VERIFY TROUBLESHOOTING OF DTC P1633 
COMPLETED

•

Make sure to reconnect all disconnected 
connectors.

•

Clear DTC from PCM memory using WDS or 
equipment.

•

Turn ignition key to OFF, then start engine.

•

Is same DTC present?

Yes Replace PCM, then go to next step.

No

No concern is detected. Go to next step.

8

VERIFY AFTER REPAIR PROCEDURE

•

Perform “After Repair Procedure”.
(See 01–02A–10 AFTER REPAIR 
PROCEDURE [ZM].)

•

Is there any DTC present?

Yes Go to applicable DTC inspection.

(See 01–02A–15 DTC TABLE [ZM].)

No

Troubleshooting completed.

STEP

INSPECTION

ACTION

DTC P1634

Generator terminal B circuit open

DETECTION 

CONDITION

•

PCM monitors input voltage from generator and battery positive terminal. If PCM detects generator output 
voltage above 16.97 V and battery voltage below 10.94 V for 5 seconds while engine running, PCM 
determines that charging system has malfunction.

POSSIBLE 

CAUSE

•

Open circuit between generator terminal B and battery positive terminal

•

Battery malfunction

•

PCM malfunction

STEP

INSPECTION

ACTION

1

VERIFY RELATED REPAIR INFORMATION 
AVAILABILITY

•

Check for related Service Bulletins availability.

•

Is any related repair information available? 

Yes Perform repair or diagnosis according to available repair 

information.

•

If vehicle is not repaired, go to next step.

No

Go to next step.

2

INSPECT BATTERY

•

Turn ignition key to OFF.

•

Inspect battery.
(See 01–17–1 BATTERY INSPECTION.)

•

Is battery okay?

Yes Replace battery, then go to Step 6.

No

Go to next step.

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