Mazda Protege 5. Manual - part 100

 

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Mazda Protege 5. Manual - part 100

 

 

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–53

01–03A

Diagnostic procedure

STEP

INSPECTION

ACTION

1

Remove all spark plugs.

Inspect each spark plug.

Is condition of spark plugs okay?

Yes

Troubleshooting completed.

No

Specific plug is wet or covered with carbon:

Go to next step.

Specific plug looks grayish white:

Go to Step 7.

All plugs are wet or covered with carbon:

Go to Step 9.

All plugs look grayish white:

Go to Step 15.

2

Are any of sparks plug wet/covered with 
carbon from engine oil?

Yes

Working up and down, inspect all areas related to oil.

No

Go to next step.

3

Inspect spark plugs for following.
— Cracked insulator
— Heating value
— Air gap
— Worn electrode

Are spark plugs okay?

Yes

Go to next step.

No

Replace spark plug.

4

Inspect compression pressure at suspected 
faulty cylinder.

Is compression pressure correct?
(See 01–10A–8 COMPRESSION 
INSPECTION [ZM].)

Yes

Go to next step.

No

Repair or replace malfunctioning part.

5

Install all spark plugs.

Carry out spark test at suspected faulty 
cylinder.

Is strong blue spark visible? (Compare with 
normal cylinder.)

Yes

Go to next step.

No

Repair or replace malfunctioning part.

6

Perform fuel line pressure inspection.
(See 01–14–28 PRESSURE REGULATOR 
INSPECTION.)

Is fuel line pressure okay?

Yes

Inspect fuel injector for following:

Open or short in injector

Leakage

Injection volume

No

Zero or low:

Inspect fuel pump circuit.

Inspect for open fuel pump relief valve open.

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

Inspect spark plugs for following.
— Heating value
— Air gap

Are they okay?

Yes

Go to next step.

No

Replace spark plug.

8

Remove suspected fuel injector.

Inspect following:
— Resistance

(See 01–14–24 Resistance Inspection.)

— Fuel injection volume

(See 01–14–26 Volume Test.)

Are all above items okay?

Yes

Inspect for open circuit between suspected fuel injector 
connector terminal and PCM connector following terminals:

For #1 cylinder: 75

For #2 cylinder: 101

For #3 cylinder: 74

For #4 cylinder: 100

No

Replace fuel injector.

9

Is air cleaner element free of restrictions?

Yes

Go to next step.

No

Replace air cleaner element.

10

Carry out spark test.

Is strong blue spark visible at each cylinder?

Yes

Go to next step.

No

Repair or replace malfunctioning part.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–54

End Of Sie

11

Carry out fuel line pressure inspection.

Is fuel line pressure correct?

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.

12

Inspect following PIDs.
— ECT
— O2S11
— O2S12
— MAF

(See 01–40A–7 PCM Inspection Using 

the SST (WDS or equivalent).)

Are PIDs okay?

Yes

Go to next step.

No

Repair or replace malfunctioning part.

13

Inspect purge solenoid valve. (When engine 
can be started)

Is purge solenoid valve okay?

Yes

Go to next step.

No

Repair or replace malfunctioning part.

14

Carry out compression inspection.

Is compression correct?

Yes

Inspect for clogging in exhaust system.

No

Repair or replace malfunctioning part.

15

When engine cannot be started, inspect 
intake-air system for air leakage.

When engine can be started, carry out intake 
manifold vacuum inspection.

Is air sucked in from intake-air system?

Yes

Repair or replace malfunctioning part.

No

Go to next step.

16

Carry out fuel line pressure inspection.

Is fuel line pressure correct?

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

2

, 30—36 psi}

Yes

Inspect following PIDs.

ECT

O2S11

O2S12

MAF

Inspect PCM GND condition.

No

Zero or low:

Inspect fuel pump circuit.

Inspect for open fuel pump relief valve open.

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.

17

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

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–55

01–03A

ENGINE CONTROL SYSTEM OPERATION INSPECTION [ZM]

A3U010318881W74

Evaporative System Leak Inspection Using Leak Tester

1. Perform the following SST (Evaporative Emission System Tester MZ254AT3641) self-test:

Note

If the tester does not work correctly during self-test, refer to the tester operators manual for more detailed 
self test procedures.

(1) Verify the gas cylinder valve is closed and the control valve located on the tester is in the TEST position. All 

tester displays should be off at this time.

(2) Connect the long hose (part of SST) to the tester.
(3) Connect the manifold assembly (part of SST

to the long hose as shown.

(4) Open the gas cylinder valve and verify the 

gas cylinder regulator left gauge reads 10 to 
12 psi
 (preset at factory).

If not, refer to the tester operators manual 
to contact tester manufacturer.

(5) Press the ON/OFF switch to turn on the SST 

and make sure the left display reads 0.0.

(6) Turn the control valve on the tester to the 

FILL position.

(7) Verify the left display reading is within 13.9 to 

14.0 inches of water.

If not, adjust the pressure using the 
regulator knob located on the right side of the tester.

(8) Turn the control valve to TEST position and press the START switch.
(9) After the 2-minute countdown (left display) is completed, the right display shows the total pressure loss

for that period. A 0.5 inch of water loss is acceptable on the self-test.

If the loss is more than 0.5 inch of water, do one or more self-test. If the failed test repeats, check for 
leak using the ultrasonic leak detector (part of SST).

2. Press the RESET switch to set the left display reading to 0.0.
3. Connect the fuel cap test adapter (part of SST) to the manifold assembly and fuel-filler cap from the vehicle.

If the fuel-filler cap is not a genuine part, replace it.

4. Connect the threaded test adapter (part of SST

to the manifold assembly and fuel-filler neck.

5. Connect the WDS or equivalent to DLC-2.
6. Turn the ignition key to ON (engine OFF).
7. Close the canister drain cut valve (CDCV) using 

ON BOARD DEVICE CONTROL function (mode 
08).

Note

The CDCV is closed for 10 minutes unless 
the following any action is done:
— The engine is started.
— The ignition key is turned to OFF.
— The fuel tank pressure sensor signal 

exceeds 6.43 kPa {48.3 mmHg, 1.9 inHg}.

8. Turn the control valve to the FILL position.
9. Wait (maximum 40 seconds) until the left display reads 13.5 to 14 inches of water.

If the reading is slightly below, adjust it using the regulator knob.

If the reading is far below, the EVAP system has large leak. Check for leak (using the ultrasonic leak 
detector if necessary) and repair.

10. Turn the control valve to the TEST position and press the START switch.
11. After the 2-minute countdown (left display) is completed, check the test result (the failed/passed light on the 

tester).

If the green light turns on, the EVAP system is OK.

If the red light turns on, the EVAP system has leakage. Check for leak using the ultrasonic leak detector 
and repair.

12. Close the gas cylinder valve.
13. Turn the control valve to the FILL position.
14. Press the ON/OFF switch to turn off the tester.

YMU103WZ2

YMU103WZ3

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–56

Evaporative System Leak Inspection Using Vacuum Pump
Whole system inspection

1. Disconnect the vacuum hose between the purge solenoid valve and the catch tank from the purge solenoid 

valve.

2. Insert hose on the vacuum pump.
3. Connect WDS or equivalent to DLC-2.
4. Turn ignition key to ON (Engine OFF).
5. Close the canister drain cut valve (CDCV) using ON BOARD DEVICE CONTROL function.

Note

The CDCV is closed for 10 minutes unless the following any action is done:
— The engine is started.
— The ignition key is turned to OFF.
— The fuel tank pressure sensor signal exceeds 6.43 kPa {48.3 mmHg, 1.9 inHg}.

6. Apply 1.7 kPa vacuum and monitor FTP output voltage.
7. Verify that the voltage holds at the specified readings for a minimum of 2 minites.

If the voltage does not hold, inspect the fuel tank pressure sensor.

If the fuel tank pressure sensor is okay, carry out the “Inspection from charcoal canister to fuel tank”.

Inspection from charcoal canister to fuel tank

1. Inspect for loose and wrongly connected hoses between the charcoal canister and the fuel tank. (See 01–16–2 

EMISSION SYSTEM LOCATION INDEX.)

2. Disconnect the vacuum hose between the charcoal canister and the fuel tank from the charcoal canister.
3. Insert hose on the vacuum pump.
4. Apply 1.7 kPa vacuum.
5. Verify that the vacuum holds at the specified readings for a minimum of 2 minites.

If the vacuum does not hold, inspect the fuel tank, related vacuum hoses and fuel-filler cap.

If the the fuel tank, related vacuum hoses and fuel-filler cap are okay, carry out the “Inspection from 
charcoal canister to fuel tank”.

Inspection from charcoal canister to purge solenoid valve

1. Inspect for loose and wrongly connected hoses between the charcoal canister and the purge solenoid valve. 

(See 01–16–2 EMISSION SYSTEM LOCATION INDEX.)

2. Disconnect the vacuum hose between the charcoal canister and the catch tank from the charcoal canister.
3. Insert hose on the vacuum pump.
4. Apply 3.3 kPa {25 mmHg, 1.0 inHg} vacuum. Vacuum should hold at the specified readings for a minimum of 

2 minutes.

If the vacuum does not hold, inspect the following:
— Catch tank for plugging, damages and pinhole using vacuum pump
— Purge solenoid valve (See 01–16–12 PURGE SOLENOID VALVE INSPECTION.)
— Charcoal canister for damage and pinhole (See 01–16–9 CHARCOAL CANISTER INSPECTION.)
— CDCV for damage and leakage (See 01–16–10 CANISTER DRAIN CUT VALVE (CDCV) 

INSPECTION .)

— Detached, incorrectly installed or cracked hose from charcoal canister to CDCV

Main Relay Operation Inspection

1. Verify that the main relay clicks when the ignition switch is turned to on and off.

If there is no operation sound, inspect the following:
— Main relay
— Harness and connector between ignition switch and main relay

X3U101WCV

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