Part 2
Fuel Pump Control System Inspection1. Crank the engine and verify that fuel pump relay operation sound is heard.
2. If operation sound is not heard, inspect the following;
- Fuel pump relay
- Wiring harness and connectors (Main relay - fuel pump relay - PCM terminal 1 H)
Spark Test
1. Disconnect the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
Step 1-Step 8:
3. Inspect the ignition system in the following procedure.
EGR Control System Inspection
1. Verify that ERG valve operation (initial operation) sound is heard when the ignition switch is turned to ON position.
- If the operation sound is not heard, connect WDS or equivalent to the DLC-2 and verify that the DTC P0403 is shown. Perform DTC inspection. Diagnostic Trouble Code Descriptions
2. Start the engine and idle it.
3. Warm up the engine to normal operating temperature.
4. Select the following PIDs:
- ECT, RPM, SEGRP, APP1, APP2, TP_REL, VSS
5. Let the vehicle idle and verify that the SEGRP value is 0.
6. Put the vehicle in drive.
7. Depress the accelerator pedal and verify that the SEGRP value is increased.
- If the EGR valve will increase, inspect the following:
- EGR valve (stuck open or close)
- Wiring harness and connectors (Main relay - EGR valve - PCM)
- If the SEGRP value does not increase, inspect the VSS, APP1, APP2, TP_REL and ECT PIDs. PCM Inspection
8. Stop the vehicle and verify that the SEGRP value returns to 0.
Purge Control System Inspection
1. Start the engine.
2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold.
- If there is a vacuum, inspect the following:
- Wiring harness and connectors (Purge solenoid valve-PCM terminal 2C)
- Purge solenoid valve
4. Warm up the engine to the normal operating temperature.
5. Stop the engine.
6. Connect WDS or equivalent to the DLC-2 and verify that the DTC P0443 is shown. Perform DTC inspection. Diagnostic Trouble Code Descriptions
7. Turn the ignition switch to ON position.
8. Select ECT PID.
9. Verify that the engine coolant temperature is above 60 degrees C {140 degrees F}.
- If WDS or equivalent indicates below 60 degrees C {140 degrees F}, perform the ECT sensor inspection.
10. Set the vehicle on the dynamometer or chassis roller.
WARNING: When the dynamometer or chassis roller is operating, there is a possibility that the operator may come into contact with or be caught up in the rotating parts, leading to serious injuries or death. When performing work while the dynamometer or chassis roller is operating, be careful not to contact or be caught up in any of the rotating parts.
11. Drive vehicle at engine speed approx. 2000 rpm for 30 s or more.
12. Put a finger to the purge solenoid valve and verify that there is no vacuum applied while step 2.
- If there is no vacuum, inspect the following:
- Wiring harness and connector (Main relay - purge solenoid valve PCM terminal 2C)
- Purge solenoid valve
- MAF, APP1, APP2, TP_REL and LOAD PIDs
- If there is vacuum, inspect the following:
- Vacuum hose (Purge solenoid valve - charcoal canister)
A/C Cut-off Control System Inspection
1. Start the engine.
2. Turn the A/C switch and fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
- If it does not actuate, go to symptom troubleshooting "No.23 A/C does not. work sufficiently".
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2-5 seconds.
- If it actuates, inspect as follows:
- A/C relay
- Open or short to GND circuit in wiring harness and connectors (Ignition switch-A/C relay-PCM terminal 11)
- A/C related parts
- APP1, APP2 PIDs
Cooling fan control system inspection
Cooling Fan Control System Inspection:
1. Connect WDS or equivalent to DLC-2.
2. Verify that DTC P0480, P0481, and P0482 are not displayed.
- If DTC P0480, P0481 or P0482 are displayed, perform DTC inspection.
3. Verify that ECT PID is below cooling fan operating temperature.
4. Verify that the A/C switch and fan switch are off.
5. Start the engine and idle it.
6. Verify that the cooling fans are not operating.
- If cooling fan No.1 is operating, inspect whether cooling fan relay No.2 is stuck in the closed position.
- If the cooling fans are operating, inspect whether cooling fan relay No.1 is stuck in the closed position.
- If the cooling fans are operating at high speed, inspect DTC for ECT sensor (P0117, P0118).
- If cooling fan No.1 does not operate and cooling fan No.2 is operating, inspect whether cooling fan relay No.3 is stuck in the closed.
7. Start the engine.
8. Verify that the cooling fans are low speed when ECT PID is 100 degrees C {212 degrees F} or above.
- If cooling fan No.1 does not operate, verify that DTC P0480 is not detected.
- If DTC P0480 is detected, perform DTC inspection.
- If DTC P0480 is not detected, inspect for the following:
- Cooling fan relay No.2 is stuck in open position.
- Open circuit in wiring harnesses or connectors or both between cooling fan relay No.2 and cooling fan motor No.1.
- If the cooling fan No.2 does not operate, verify that DTC P0482 is not detected.
- If DTC P0482 is detected, perform DTC inspection.
- If DTC P0482 is not detected, inspect the following:
- Cooling fan relay No.3 is stuck in open position.
- Open circuit in wiring harnesses or connectors or both between cooling fan relay No.3 and cooling fan motor No.2
- If cooling fan No.1 or cooling fan No.2 or both are operating at high speed, verify that DTC P0481 is not detected.
- If DTC P0481 is detected, perform DTC inspection.
- If DTC P0481 is not detected, inspect the following:
- Cooling fan relay No.1 is stuck in closed position.
- Cooling fan relay No.4 is stuck in closed position.
9. Turn A/C switch and fan switch on.
10. Verify that A/C is operating.
- If A/C is not operating, inspect the following:
- A/C switch
- Fan switch
- Refrigerant pressure switch
11. Verify that cooling fan No.1 is operating at high speed and cooling fan No.2 is operating other than at low speed (high or middle speed).
- If the cooling fan relay does not operate high speed and cooling fan No.2 is operating low speed, inspect the following:
- Cooling fan relay No.1 is stuck in open position.
- Cooling fan relay No.4 is stuck in open position.
Variable Air Duct (VAD) Control System Operation Inspection
1. Connect WDS or equivalent to DLC-2.
2. Access ECT, TP_REL and RPM PIDs.
3. Start the engine.
4. Verify ECT PID is 70 degrees C {158 degrees F} or over.
5. Inspect shutter valve operation under the following conditions.
VAD Shutter Valve Operation:
- If the shutter valve operation is not as specified, inspect as follows:
1. Verify that DTC P2676 or P2677 is not displayed.
- If DTC P2676 or P2677 is shown, perform DTC inspection. Diagnostic Trouble Code Descriptions
2. Inspect VAD control solenoid valve.
- If the VAD control solenoid valve is not okay, replace VAD control solenoid valve.
- If the VAD control solenoid valve is okay, inspect the following:
- Vacuum hose looseness or damage
- Vacuum chamber cracks or damage
- Shutter valve actuator.
- Shutter valve is stuck open or closed.
Variable Valve Timing Control System Operation Inspection When idling cannot be continued
1. Remove the oil control valve (OCV) and verify that the spool valve is at maximum retard position.
2. Connect the oil control valve (OCV).
3. Turn the ignition switch to ON position.
4. Verify that the spool valve is at maximum retard position.
- If the spool valve is stuck in the advance direction, inspect for the following:
- Short circuit in harnesses or connectors between the oil control valve (OCV) and the PCM.
5. Inspect the variable timing actuator.
When idling can be continued
1. Disconnect oil control valve (OCV) connector.
2. Warm up the engine and idle it.
3. Apply battery voltage to the oil control valve (OCV) and verify that the engine idles roughly or stalls.
- If the engine idles roughly or stalls, inspect the timing chain component (valve timing deviation).
- If the engine does not idle roughly or stalls, go to the next step.
4. Remove the oil control valve (OCV) and perform spool valve operation inspection.
- If not as specified, inspect the following:
- Oil control valve (OCV)
- Harnesses and connectors between oil control valve (OCV) and PCM open or short.
- If as specified, inspect the following hydraulic passages for clogging or leakage or both:
- Oil pressure switch - oil control valve (OCV)
- Oil control valve (OCV) - camshaft
- Camshaft internal passage
5. If they are okay, replace the camshaft pulley (with built-in variable valve timing actuator).
Evaporative Emission (EVAP) System Leak Inspection
- To verify that the problem has been fixed properly after repairs, the run drive cycle or EVAP system leak inspection must be performed.
EVAP system leak inspection using the WDS or equivalent
NOTE: EVAP system test outline
- The EVAP system test, which can substituted for the run drive cycle as an EVAP control system repair confirmation method, can be done while operating the WDS in the KOEO (Key On Engine Off) condition instead of actually driving the vehicle.
EVAP system test description
- The EVAP system test finds gas leaks in the system using the PCM to monitor changes in the air pump load current of the EVAP system leak detection pump. This test starts after sending an on-demand test signal from the WDS to the PCM. The PCM controls the air pump and change-over-valve operation and also stores the load current of the air pump as follows:
i. The PCM commands turn the air pump on and retrieve the air pump load current value (LDP_MON PID) as a reference current (LDP_REF PID).
ii. After retrieving a reference current value, the PCM commands the change-over-valve to open, then captures the air pump load current value (LDP_MON PID) as idle current (LDP_IDL PID). The EVAP system will be pressurized from this phase.
iii. The PCM continues to monitor the air pump load current value (LDP_MON PID) until the end of the test.
- You can confirm whether any EVAP gas leak occurred or not by reading the test results.
EVAP system malfunction judgment
DTC No.P0442-P2407:
- The PCM calculates the stored air pump load current value and send the results to the WDS as DTCs:
Evaporative system test procedure
1. Select the EVAP system test from the Toolbox on the WDS display and follow the instructions.
2. Verify that all of the following PIDs are within the specifications at the pre-test confirmation screen.
NOTE:
- To successfully perform this procedure, all PIDs must be within the following specifications before proceeding to the next step.
- The PCM will cancel the EVAP system test if the VPWR PID value falls lower than 11.0 V during the test.
Specification:
3. Start the engine.
4. Drive the vehicle or let the engine idle more than 20 minutes.
5. Turn ignition switch off, then turn it to the ON position again (Key On Engine Off).
6. Press the tick icon to start the test.
7. Verify that no DTCs present after the completion of the test.
- If any test result is indicated with red, diagnose the problem using the following DTC troubleshooting procedure or component inspection procedure.
- If any DTCs are detected, diagnose the problem using the appropriate DTC troubleshooting procedure.
EVAP system leak inspection using leak tester
1. Perform the following SST (EVAP System Tester 134-01049) self-test:
NOTE: If the tester does not work correctly during the self-test, refer to the tester operators manual for more detailed self-test procedure.
1. Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve.
2. Connect the vehicle interface hose (part of the SST) to the SELF TEST port located on the control panel. Hand tighten the fitting. (Do not overtighten.)
3. Turn the control valve to the TEST position.
4. The gauge should read 331-381 mm {13- 15 in} of water.
- If the gauge is not reading in this range, adjust the pressure by turning the black knob on the low pressure regulator at the nitrogen bottle.
5. Turn the control valve to the HOLD position.
6. Verify that the gauge holds pressure and that the flow meter reads no flow.
- If there is no drop in pressure and no flow, the tester passes the self-test.
- If the gauge leaks down, refer to the operators manual.
2. Connect the SST to the vehicle.
1. Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve.
2. Remove the fuel-filler cap from the vehicle.
- If the fuel-filler cap is not a MA2DA part or equivalent, replace it.
3. Connect the receiver assembly (SST: 134-01059) to the vehicle cap test hose assembly (part of SST) and the fuel-filler cap from the vehicle.
4. Connect the cap adaptor (SST: 134-01058) to the vehicle cap test hose assembly (part of the SST) and to the fuel-filler neck.
5. Connect the vehicle interface hose (part of the SST) to the center fitting of the vehicle cap test hose assembly (part of the SST).
3. Connect the WDS or equivalent to the DLC-2.
4. Turn the ignition switch to the ON position (Engine off).
5. Request the PCM on-board device control (Mod 08) using the WDS or equivalent to close the change-over valve (COV) in the EVAP system leak detection pump.
NOTE:
- The COV is closed for 10 minutes unless the following any actions are done:
- The engine is started.
- The ignition switch is turned off position.
6. Make sure the control valve on the 134-01049 is in the HOLD position and that the valve on the cylinder of nitrogen gas is open.
7. Turn the control valve to the open position and let the system fill. You should note a drop in the gauge pressure along with the flow meter being pegged at maximum flow for several minutes depending on how full or empty the fuel tank is, and how long it takes to completely fill and pressurize the evaporative emissions system hoses.
8. If the gauge and the flow meter do not settle to a measurable level after 2-3 minutes, then refer to the Mazda Workshop Manual to verify that the cut or vent valve is properly closed.
9. Verify the pressure gauge and flow meter reading to determine if there is an evaporative emissions leak:
NO EVAPORATIVE LEAK:
- The flow meter registers "zero flow" and the pressure gauge returns to the pre-set pressure of 356 mm {14 in} of water (H2O).
EVAPORATIVE LEAK:
- The pressure does not return to the preset level of 356 mm {14 in} of water (H2O) when measuring the flow. See "SETTING LEAK STANDARD FOR TESTING" (.020 to. 040 inch H2O) of the Evaporative Emissions Tester operators manual (134-01067).
NOTE: Turn the control valve to the HOLD position then disconnect the SST.