Mazda Protege 5. Manual — part 106
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]
01–03B–17
01–03B
End Of Sie
NO.5 ENGINE STALLS-AFTER START/AT IDLE [FS]
A3U010318881W10
16
•
Inspect engine condition while tapping EGR
valve housing.
•
Does engine condition improve?
Yes
Replace EGR valve.
No
Go to next step.
17
•
Inspect starting system.
(See 01–19–2 STARTER INSPECTION.)
•
Is starting system normal?
Yes
Inspect for loose connectors or poor terminal contact. If
okay, remove EGR valve and visually inspect for
mechanically stuck EGR valve.
No
Repair or replace components as required.
18
•
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
5
Engine stalls—After start/at idle
DESCRIPTION
•
Engine stops unexpectedly at idle and/or after start.
POSSIBLE CAUSE
•
A/C system improper operation
•
Air leakage from intake-air system parts
•
Purge solenoid valve malfunction
•
Improper operation of IAC valve
•
EGR valve malfunction
•
No signal from CKP sensor due to sensor, related wire or wrong installation
•
Vacuum leakage
•
Low engine compression
•
Spark leakage from high-tension leads
•
Poor fuel quality
•
PCV valve malfunction
•
Air cleaner restriction
•
Restriction in exhaust system
•
Electrical connector disconnection
•
Open or short circuit in fuel pump and related harness
•
No battery power supply to PCM or poor GND
•
Inadequate fuel pressure
•
Fuel pump mechanical malfunction
•
Fuel leakage from fuel injector
•
Fuel injector clogging
•
Immobilizer system and/or circuit malfunction
•
Pressure regulator control (PRC) 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.)
1712-1U-01G(01-03B).fm 17 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–18
Diagnostic procedure
STEP
INSPECTION
RESULTS
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.
2
•
Turn ignition key to ON.
•
Disconnect TP sensor connector.
•
Measure voltage at TP sensor connector
VREF terminal with ignition key on.
Voltage
4.5—5.5 V
•
Is voltage okay?
Yes
Go to next step.
No
Go to symptom troubleshooting “NO.30 REFERENCE
VOLTAGE [FS].”
3
•
Connect WDS or equivalent to DLC-2.
•
Retrieve any DTC.
•
Turn ignition key to ON.
•
Is “DTC” displayed?
Yes
DTC is displayed:
•
Go to appropriate DTC test.
Communication error message is displayed:
•
Inspect for following:
— Open circuit between main relay and PCM
terminal 71 or 97
— Open main relay GND circuit
— Main relay is stuck open.
— Open or poor GND circuit (PCM terminal 24, 51,
76, 77 or 103)
— Poor connection of vehicle body GND
No
No DTC is displayed:
•
Go to next step.
4
•
Attempt to start engine at part throttle.
•
Does engine run smoothly at part throttle?
Yes
Inspect IAC valve and wiring harness.
No
Go to next step.
5
•
Connect WDS or equivalent to DLC-2.
•
Access RPM PID.
•
Is RPM PID indicating engine speed during
cranking of engine?
Yes
Go to next step.
No
Inspect for following:
•
Open or short circuit in CKP sensor
•
Open or short circuit between CKP sensor and
PCM terminal 21 or 22
•
Open or short circuit in CKP sensor harnesses
If CKP sensor and harness are okay, go to next step.
6
•
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.
7
•
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.
8
•
Inspect for cracks on high-tension leads.
•
Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
9
•
Is strong blue spark visible at each
disconnected high-tension lead during
engine cranking?
Yes
Go to next step.
If symptom occurs with A/C on, go to Step 15.
No
Inspect for following:
•
Open or short circuit in ignition coil
•
Open circuit in high-tension leads
•
Open circuit between ignition coil connector GND
terminal and body GND
•
Open circuit between ignition key and ignition coil
•
Open circuit between ignition coil and PCM
terminal 26 or 52
1712-1U-01G(01-03B).fm 18 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–19
01–03B
End Of Sie
10
•
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 injector.
Spark plug is grayish white:
•
Inspect for clogged fuel injector.
No
Install spark plugs on original cylinders.
Go to next step.
11
•
Remove and shake PCV valve.
•
Does PCV valve rattle?
Yes
Go to next step.
No
Replace PCV valve.
12
•
Inspect for a restriction in exhaust system.
•
Is there any restriction?
Yes
Inspect exhaust system.
No
Go to next step.
13
•
Install fuel pressure gauge between fuel filter
and fuel distributor.
•
Connect jumper wire between F/P terminal at
DLC in engine compartment and GND.
•
Turn ignition key to ON.
•
Is fuel line pressure correct with ignition key
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.
•
Inspect PRC solenoid valve and related vacuum
hose and harness.
High
•
Inspect pressure regulator for high pressure cause.
•
Inspect for clogged fuel return line.
14
•
Visually inspect for fuel leakage at fuel
injector O-ring and fuel line.
•
Service as necessary.
•
Does fuel line pressure hold after ignition key
is turned to LOCK?
(See 01–14–28 PRESSURE REGULATOR
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.
15
Note
•
The following test is for stall concerns with
A/C on. If other symptoms exist, go to
next step.
•
Connect pressure gauges to A/C low and
high pressure side lines.
•
Turn A/C on and measure low side and high
side pressures.
•
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 OR A/C COMPRESSOR
RUNS CONTINUOUSLY [FS].”
For other symptoms, inspect following:
•
Refrigerant charging amount
•
Condenser fan operation
16
•
Disconnect vacuum hose between purge
solenoid valve and intake manifold from
purge solenoid side.
•
Plug opening end of vacuum hose.
•
Start engine.
•
Is engine stall now eliminated?
Yes
Inspect if purge solenoid valve is stuck open.
Inspect evaporative emission control system.
No
Go to next step.
17
•
Is air leakage felt or heard at intake-air
system components while racing engine to
higher speed?
Yes
Repair or replace faulty part.
No
Go to next step.
18
•
Inspect engine condition while tapping EGR
valve housing
•
Does engine condition improve?
Yes
Replace EGR valve.
No
Go to next step.
19
•
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for cause.
20
•
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
1712-1U-01G(01-03B).fm 19 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–20
NO.6 CRANKS NORMALLY BUT WILL NOT START [FS]
A3U010318881W11
Diagnostic procedure
6
Cranks normally but will not start
DESCRIPTION
•
Starter cranks engine at normal speed but engine will not run.
•
Refer to “ENGINE STALLS” if this symptom appears after engine stall.
•
Fuel is in tank.
•
Battery is in normal condition.
POSSIBLE CAUSE
•
No battery power supply to PCM
•
Air leakage from intake-air system
•
Open PCM GND or vehicle body GND
•
Improper operation of IAC valve
•
EGR valve malfunction
•
No signal from CKP sensor due to sensor, related wire or incorrect installation
•
No signal from CMP sensor due to sensor, related wire or incorrect installation
•
Low engine compression
•
Vacuum leakage
•
Spark leakage from high-tension leads
•
Poor fuel quality
•
PCV valve malfunction
•
Air cleaner restriction
•
Restriction in exhaust system
•
Disconnected electrical connector
•
Open or short circuit in fuel pump and related harness
•
Inadequate fuel pressure
•
Fuel pump mechanical malfunction
•
Fuel leakage from injector
•
Fuel injector clogging
•
Purge solenoid valve malfunction
•
Pressure regulator solenoid (PRC) 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
•
Verify following:
— Vacuum connection
— External fuel shut off or accessory (kill
switch, alarm etc.)
— Fuel quality: proper octane,
contamination, winter/summer blend
— No air leakage from intake-air system
— Proper sealing of intake manifold and
components attached to intake manifold:
EGR valve, IAC valve
— Ignition wiring
— Electrical connections
— Fuses
— Smooth operation of throttle
•
Are all items okay?
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
1712-1U-01G(01-03B).fm 20 ページ 2001年6月29日 金曜日 午前9時33分
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