Mazda Protege 5. Manual - part 112

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–41

01–03B

NO.19 EXHAUST SMOKE [FS]

A3U010318881W24

Diagnostic procedure

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 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

RESULTS

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 key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

No DTC displayed:

•

Go to next step.

No

DTC displayed:

•

Go to appropriate DTC test.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–42

End Of Sie

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

A3U010318881W25

Diagnostic procedure

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.

STEP

INSPECTION

RESULTS

ACTION

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 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

RESULTS

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 key is 
turned to LOCK?
(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 key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

No DTC displayed:

•

Inspect charcoal canister for fuel saturation.
— If excess amount of liquid fuel is present, replace 

charcoal canister.

No

DTC displayed:

•

Go to appropriate DTC test.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–43

01–03B

End Of Sie

NO.21 ENGINE NOISE [FS]

A3U010318881W26

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

RESULTS

ACTION

21

Engine noise

DESCRIPTION

•

Engine noise from under hood or driveline

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

RESULTS

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 belts.

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 [FS].”

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.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–44

NO.22 VIBRATION CONCERNS (ENGINE) [FS]

A3U010318881W27

Diagnostic procedure

End Of Sie

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

A3U010318881W28

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

RESULTS

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

RESULTS

ACTION

1

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC displayed:

•

Go to appropriate DTC test.

No

No DTC displayed:

•

Go to next step.

2

•

Disconnect A/C compressor connector.

•

Start engine and turn A/C switch to 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 key to 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 resistor 
(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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