Mazda Protege 5. Manual - part 94

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–29

01–03A

NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, 
SURGES [ZM]

A3U010318881W53

Diagnostic procedure

11

Engine stalls/quits —acceleration/cruise
Engine runs rough — acceleration/cruise
Misses — acceleration/cruise
Buck/jerk — acceleration/cruise/deceleration
Hesitation/stumble — acceleration
Surges — acceleration/cruise

DESCRIPTION

•

Engine stops unexpectedly at beginning of acceleration or during acceleration.

•

Engine stops unexpectedly while cruising.

•

Engine speed fluctuates during acceleration or cruising.

•

Engine misses during acceleration or cruising.

•

Vehicle bucks/jerks during acceleration, cruising or deceleration.

•

Momentary pause at beginning of acceleration or during acceleration

•

Momentary minor irregularity in engine output

POSSIBLE 

CAUSE

•

A/C system improper operation

•

Erratic signal or no signal from CMP sensor

•

Air leakage from intake-air system parts

•

Purge solenoid valve malfunction

•

IAC valve improper operation

•

EGR valve malfunction

•

Erratic signal from CKP sensor

•

Low engine compression

•

Vacuum leakage

•

Poor fuel quality

•

Spark leakage from high-tension leads

•

Air cleaner restriction

•

PCV valve malfunction

•

Improper valve timing due to jumping out of timing belt

•

Restriction in exhaust system

•

Intermittent open or short in fuel pump circuit

•

Inadequate fuel pressure

•

Fuel pump mechanical malfunction

•

Fuel leakage from fuel injector

•

Fuel injector clogging

•

Intermittent open or short of MAF sensor, TP sensor and VSS

•

ATX malfunction

•

Clutch slippage

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.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–30

2

•

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.

3

•

Is engine overheating?

Yes

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

No

Go to next step.

4

•

Connect WDS or equivalent to DLC-2.

•

Access RPM PID, MAF PID,TP PID, and 
VSS PID.

•

Drive vehicle with monitoring PIDs.

•

Are PIDs within specification?

Yes

Go to next step.

No

RPM PID:

•

Inspect CKP sensor and related harness: vibration, 
intermittent open/short circuit.

MAF PID:

•

Inspect for open circuit of MAF sensor and related wire 
harness intermittently.

TP PID:

•

Inspect if output signal from TP sensor changes 
smoothly.

VSS PID:

•

Inspect for open circuit of VSS and related wire harness 
intermittently.

5

•

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.

6

•

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.

7

•

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.

No

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

8

•

Remove and shake PCV valve.

•

Does PCV valve rattle?

Yes

Go to next step.

No

Replace PCV valve.

9

•

Verify that throttle lever is resting on throttle 
valve stop screw and/or throttle valve orifice 
plug.

•

Is lever in correct position?

Yes

Go to next step.

No

Adjust as necessary.

10

•

Are there any restrictions in the exhaust 
system?

Yes

Inspect exhaust system.

No

Go to next step.

11

•

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.

•

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.

High:

•

Inspect pressure regulator for high pressure cause.

•

Inspect for clogged fuel return line.

12

•

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 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.

STEP

INSPECTION

ACTION

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–31

01–03A

End Of Sie

13

Note

•

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

•

Connect pressure gauge 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 [ZM]”.
For other symptoms, inspect following:

•

Refrigerant charging amount

•

Condenser fan operation

14

Note

•

The following test is performed for 
symptom with cruise control on. If other 
symptoms exist, go to next step.

•

Inspect cruise control system.

•

Is cruise control system okay?

Yes

Go to next step.

No

Repair or replace malfunctioning parts.

15

•

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

•

Plug opening end of vacuum hose.

•

Drive vehicle.

•

Does engine condition improve?

Yes

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

No

Go to next step.

16

•

Visually inspect CMP sensor and projections 
of camshaft pulley.

•

Are CMP sensor and projections of camshaft 
pulley okay?

Yes

Go to next step.

No

Replace malfunctioning parts.

17

•

Inspect EGR valve.
(See 01–16–15 EGR VALVE INSPECTION.)
— Is EGR valve okay?

Yes

Go to next step.

No

Replace malfunctioning parts.

18

•

Is engine compression correct?

Yes

Inspect following:

•

Valve timing

•

Internal transaxle part (ATX)

•

Clutch (MTX)

No

Inspect for cause.

19

•

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–32

NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [ZM]

A3U010318881W54

Diagnostic procedure

12

Lack/loss of power — acceleration/cruise

DESCRIPTION

•

Performance is poor under load (e.g., power down when climbing hills).

POSSIBLE 

CAUSE

•

Improper A/C system operation

•

Erratic signal or no signal from CMP sensor

•

Air leakage from intake-air system parts

•

Tumble swirl control system malfunction

•

Purge control solenoid malfunction

•

EGR valve malfunction

•

Brake dragging

•

Erratic signal from CKP sensor

•

Low engine compression

•

Vacuum leakage

•

Poor fuel quality

•

Spark leakage from high-tension leads

•

Air cleaner restriction

•

PCV valve malfunction

•

Improper valve timing due to jumping out of timing belt

•

Restriction in exhaust system

•

Intermittent open or short in fuel pump circuit

•

Inadequate fuel pressure

•

Fuel pump mechanical malfunction

•

Fuel leakage from fuel injector

•

Fuel injector clogging

•

Intermittent open or short of MAF sensor, TP sensor and VSS

•

ATX malfunction

•

Clutch slippage

Warning
The following troubleshooting flow chart 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

— Fuel quality: proper octane, 

contamination, winter/summer blend

•

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

2

•

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.

3

•

Is engine overheating?

Yes

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

No

Go to next step.

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