Mazda Protege 5. Manual - part 113

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–45

01–03B

End Of Sie

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

A3U010318881W29

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

24

A/C is always on or 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

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

•

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

•

Disconnect 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 reading 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 reading 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 if A/C switch is stuck closed.

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.

1712-1U-01G(01-03B).fm  45 ページ  ２００１年６月２９日 金曜日 午前９時３３分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–46

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

A3U010318881W30

Diagnostic procedure

End Of Sie

NO.26 EXHAUST SULPHUR SMELL [FS]

A3U010318881W31

Diagnostic procedure

25

A/C is 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

RESULTS

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 OR A/C COMPRESSOR RUNS 
CONTINUOUSLY [FS].”

2

•

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:

•

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 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

•

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 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.

1712-1U-01G(01-03B).fm  46 ページ  ２００１年６月２９日 金曜日 午前９時３３分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–47

01–03B

End Of Sie

NO.27 FUEL REFILL CONCERNS [FS]

A3U010318881W32

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

RESULTS

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 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

•

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 non return 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.

1712-1U-01G(01-03B).fm  47 ページ  ２００１年６月２９日 金曜日 午前９時３３分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–48

NO.28 FUEL FILLING SHUT OFF ISSUES [FS]

A3U010318881W33

Diagnostic procedure

End Of Sie

NO.29 INTERMITTENT CONCERNS [FS]

A3U010318881W34

Diagnostic procedure

28

Fuel filling shut off issues

DESCRIPTION

•

Fuel does not shut off properly.

POSSIBLE CAUSE

•

Clogged evaporative emission pipes

•

Nonreturn valve malfunction

•

Fuel shut-off valve malfunction

•

Fuel nozzle malfunction

•

Fuel nozzle is not inserted correctly.

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

•

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 for following:

•

Improper use of fuel nozzle

•

Fuel nozzle is not inserted correctly.

•

Inspect fuel shut-off valve

No

If nonreturn valve 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.

29

Intermittent concerns

DESCRIPTION

•

Symptom occurs randomly and is difficult to diagnose.

STEP

INSPECTION

RESULTS

ACTION

1

•

Talk to customer.

•

Retrieve vehicle service history.

•

Does vehicle have a number of previous 
repairs and components replaced for a 
certain symptom?

Yes

Go to next step.

No

Go to Symptom Index.

2

•

Connect WDS or equivalent to DLC-2.

•

If input is switch-type component, turn on 
manually.

•

Turn ignition key to ON.

•

Access PIDs for suspect component.

•

Lightly tap on suspect component, wiggle 
and pull each wire/connector at suspect 
component or PCM.

•

Are any PID values out of range, or do they 
suddenly change and go back into range?

Yes

Inspect each wire for corrosion, bent or loose terminal 
crimps.

No

Go to next step.

1712-1U-01G(01-03B).fm  48 ページ  ２００１年６月２９日 金曜日 午前９時３３分