Mazda Protege 5. Manual - part 98

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–45

01–03A

NO.22 VIBRATION CONCERNS (ENGINE) [ZM]

A3U010318881W64

Diagnostic procedure

End Of Sie

NO.23 A/C DOES NOT WORK SUFFICIENTLY [ZM]

A3U010318881W65

Diagnostic procedure

22

Vibration concerns (engine)

DESCRIPTION

•

Vibration from under hood or driveline

POSSIBLE 

CAUSE

•

Loose attaching bolts or worn parts

•

Components malfunction such as worn parts

STEP

INSPECTION

ACTION

1

•

Inspect following components for loose 
attaching bolts or worn parts:
— Cooling fan
— Drive belt and pulleys
— Engine mounts

•

Are all items okay?

Yes

Inspect following systems:

•

Wheels

•

Automatic transaxle

•

Driveline

•

Suspension

No

Readjust or retighten engine mount installation position.
Service as necessary for other parts.

2

•

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.

23

A/C does not work sufficiently.

DESCRIPTION

•

A/C compressor magnetic clutch does not engage when A/C switch is turned on.

POSSIBLE 

CAUSE

•

Improper refrigerant charging amount

•

Open A/C magnetic clutch

•

Open circuit between A/C relay and A/C magnetic clutch

•

Poor GND of A/C magnetic clutch

•

Refrigerant pressure switch is stuck open.

•

A/C relay is stuck open.

•

Seized A/C compressor

•

Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier

STEP

INSPECTION

ACTION

1

•

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.

2

•

Disconnect A/C compressor connector.

•

Start engine and turn A/C switch on.

•

Is there correct voltage at terminal of A/C 
compressor magnetic clutch connector?

Specification
More than 10.5 V

Yes

Inspect for GND condition of magnetic clutch on A/C 
compressor.

•

If GND condition is okay, inspect for open circuit of 
magnetic clutch coil.

No

Go to next step.

3

•

Disconnect refrigerant pressure switch 
connector.

•

Connect jumper wires between terminals of 
refrigerant pressure switch connector.

•

Turn ignition switch on.

•

Turn A/C switch on and set blower fan at any 
speed.

•

Does A/C work?

Yes

Inspect refrigerant pressure switch operation.

•

If switch is okay, go to next step.

No

Inspect for following:

•

A/C switch is stuck open.

•

Open circuit between refrigerant pressure switch and 
PCM terminal 41

•

Open circuit of blower motor fan switch and resister (if 
blower motor does not operate)

•

Evaporator temperature sensor and A/C amplifier

4

•

Remove jumper wires from switch connector.

•

Reconnect connector to refrigerant pressure 
switch.

•

Start engine and turn A/C switch on.

•

Does fan operate?

Yes

Inspect for stuck open A/C relay.
Replace as necessary.

No

Inspect following and repair or replace as necessary:

•

Refrigerant charging amount

•

A/C compressor for being seized

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–46

End Of Sie

NO.24 A/C IS ALWAYS ON/A/C COMPRESSOR RUNS CONTINUOUSLY [ZM]

A3U010318881W66

Diagnostic procedure

End Of Sie

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.

STEP

INSPECTION

ACTION

24

A/C is always on/A/C compressor runs continuously.

DESCRIPTION

•

A/C compressor magnetic clutch does not disengage.

POSSIBLE 

CAUSE

•

Stuck engagement

•

A/C relay is stuck closed.

•

Short to GND between A/C switch and PCM

•

Short to GND circuit between A/C relay and PCM

•

A/C relay to magnetic clutch circuit shorts to battery power.

STEP

INSPECTION

ACTION

1

•

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.

2

•

Start engine and run it at idle.

•

Turn A/C switch on.

•

Remove A/C relay.

•

Does A/C magnetic clutch disengage?

Yes

Inspect for following:

•

A/C relay is stuck closed.

•

Short to GND circuit between A/C relay and PCM 
terminal 96
— If both items are okay, go to next step.

No

Inspect if circuit between A/C relay and magnetic clutch 
shorts to battery power circuit.

•

If circuit is okay, inspect magnetic clutch stuck 
engagement or clearance.

3

•

Disonnect refrigerant pressure switch 
connector.

•

Start engine and turn A/C switch on.

Note

•

A/C should not work when disconnecting 
connector. If A/C remains working, short 
to GND circuit may be present.

•

Does A/C remain working?

Yes

Inspect for short to GND circuit between refrigerant 
pressure switch and PCM terminal 41.

No

Go to next step.

4

•

Reconnect refrigerant pressure switch 
connector.

•

Turn off A/C switch.

Note

•

A/C should not work when turning the A/C 
switch off. If A/C remains working, short to 
GND circuit may be present.

•

Does A/C remain working?

Yes

Inspect following:

•

Short to GND circuit between A/C switch and A/C 
amplifier

•

Short to GND circuit between A/C amplifier and 
refrigerant pressure switch

No

Inspect for stuck closed A/C switch.

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.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–47

01–03A

NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [ZM]

A3U010318881W67

Diagnostic procedure

End Of Sie

NO.26 EXHAUST SULPHUR SMELL [ZM]

A3U010318881W68

Diagnostic procedure

25

A/C does not cut off under wide open throttle conditions.

DESCRIPTION

•

A/C compressor magnetic clutch does not disengage under wide open throttle.

POSSIBLE 

CAUSE

•

TP sensor malfunction

•

TP sensor misadjustment

•

TP sensor not securely installed

STEP

INSPECTION

ACTION

1

•

Does A/C compressor disengage when A/C 
switch is turned off?

Yes

Go to next step.

No

Go to symptom troubleshooting “NO.24 A/C IS ALWAYS 
ON/A/C COMPRESSOR RUNS CONTINUOUSLY [ZM]”.

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:

•

Inspect TP sensor for proper adjustment.

3

•

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.

26

Exhaust sulphur smell

DESCRIPTION

•

Rotten egg smell (sulphur) from exhaust

POSSIBLE 

CAUSE

•

Electrical connectors are disconnected or connected poorly.

•

Charcoal canister malfunction

•

Vacuum lines are disconnected or connected improperly.

•

Improper fuel pressure

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

•

Are any driveability or exhaust smoke 
concerns present?

Yes

Go to appropriate flow chart.

No

Go to next step.

2

•

Inspect following:
— Electrical connections
— Vacuum lines

•

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 2.

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.

No

No DTC is displayed:

•

Go to next step.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–48

End Of Sie

NO.27 FUEL REFILL CONCERNS [ZM]

A3U010318881W69

Diagnostic procedure

End Of Sie

4

•

Install fuel pressure gauge between fuel filter 
and fuel distributor.

•

Start engine and run it 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.

5

•

Inspect charcoal canister for fuel saturation.

•

Is excess amount of liquid fuel present in 
canister?

Yes

Replace charcoal canister.

No

Inspect fuel tank vent system.

•

If fuel tank vent system is okay, since sulfur content can 
vary in different fuels, suggest trying a different brand.

•

If fuel tank vent system is not okay, repair or replace 
malfunctioning parts.

6

•

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

27

Fuel refill concerns

DESCRIPTION

•

Fuel tank does not fill smoothly.

POSSIBLE 

CAUSE

•

Clogged evaporative emission pipes

•

Nonreturn valve malfunction

•

Pressure control valve malfunction

•

Improper use of fuel nozzle

•

Inadequate fuel filling speed

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

•

Retrieve DTCs.

•

Are there any DTCs displayed?

Yes

Go to appropriate DTC test.

No

Go to next step.

2

•

Remove fuel-filler pipe.

•

Make sure nonreturn valve is installed 
properly.

•

Inspect nonreturn valve operation.

•

Is nonreturn valve okay?

Yes

Inspect following:

•

Improper use of fuel nozzle

•

Inadequate fuel filling speed

•

Pressure control valve

No

If nonreturn valve is installed improperly:

•

Reinstall nonreturn valve to proper position.

If nonreturn valve does not operate properly:

•

Replace nonreturn valve.

3

•

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.

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