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Mazda Protege 5. Manual - part 105

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–13

01–03B

NO.1 MELTING OF MAIN OR OTHER FUSES [FS]

A3U010318881W06

End Of Sie

Melting of main or other fuses

[TROUBLESHOOTING HINTS]
Inspection condition of fuse.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–14

NO.2 MIL ILLUMINATES [FS]

A3U010318881W07

Diagnostic procedure

End Of Sie

NO.3 WILL NOT CRANK [FS]

A3U010318881W08

Diagnostic procedure

MIL illuminates

DESCRIPTION

MIL is illuminated incorrectly.

POSSIBLE CAUSE

•

PCM illuminates for emission-related concern (DTC is stored in PCM)

•

Short to ground circuit between MIL (located on instrument cluster) and PCM

Note

•

If MIL blinks at steady rate, misfire condition could possibly exist.

STEP

INSPECTION

RESULTS

ACTION

•

Connect WDS or equivalent to DLC-2.

•

Retrieve any DTC.

•

Turn ignition key to ON.

•

Is “DTC” displayed?

Yes

No DTC is displayed:

•

Inspect for short to ground circuit between MIL
(located on instrument cluster) and PCM terminal 2.

DTC is displayed:

•

Go to appropriate DTC test.

•

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 completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

Will not crank

DESCRIPTION

•

Starter does not work.

POSSIBLE CAUSE

•

Open starter circuit between ignition key and starter

•

Transaxle range switch malfunction (ATX)

•

Transaxle range switch misadjustment (ATX)

•

Starter interlock switch malfunction (MTX)

•

Starter malfunction

•

Seized/hydrolocked engine, flywheel (MTX) or drive plate (ATX)

STEP

INSPECTION

RESULTS

ACTION

•

Inspect for following:
— Battery connection
— Battery condition
— Transaxle is in Park or Neutral. (ATX)
— Clutch is fully depressed. (MTX)
— Fuses

•

Are all items okay?

Yes

Go to next step.

Service as necessary.
Repeat Step 1.

•

Is clicking sound heard from starter when
ignition key is turned to START?

Yes

Go to next step.

Go to Step 4.

•

Inspect starting system.
(See 01–19–2 STARTER INSPECTION.)

•

Is starting system okay?

Yes

Inspect for seized/hydrolocked engine, flywheel (MTX)
or drive plate (ATX).

Repair or replace components as required.

•

Do any other electrical accessories work?

Yes

Go to next step.

Inspect charging system.
(See 01–17–1 BATTERY INSPECTION.)
(See 01–17–3 GENERATOR INSPECTION.)

Note

•

Following test should be performed on
ATX only. For MTX, go to next step.

•

Inspect adjustment of transaxle range
switch.

•

Is transaxle range switch adjusted properly?

Yes

Go to next step.

Inspect for open circuit between transaxle range switch
and PCM terminal 64 or starter.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–15

01–03B

End Of Sie

NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [FS]

A3U010318881W09

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

No DTC displayed:

•

Inspect following:
— START circuit in ignition key
— Open circuit between ignition key and starter
— Starter interlock switch (MTX)

DTC displayed:

•

Go to appropriate DTC test.

Communication error message 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

•

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.

Hard to start/long crank/erratic start/erratic crank

DESCRIPTION

•

Starter cranks engine at normal speed but engine requires excessive cranking time before starting.

•

Battery is in normal condition.

POSSIBLE CAUSE

•

Spark leakage from high-tension leads

•

Vacuum leakage

•

Poor fuel quality

•

Starting system malfunction

•

Spark plug malfunction

•

Air leakage from intake-air system

•

Erratic signal from CKP sensor

•

Erratic signal from CMP sensor

•

Air cleaner restriction

•

IAC valve malfunction

•

PCV valve malfunction

•

Inadequate fuel pressure

•

Purge solenoid valve malfunction

•

MAF sensor contamination

•

Restriction in exhaust system

•

EGR valve 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.)

STEP

INSPECTION

RESULTS

ACTION

•

Inspect for following:
— Vacuum leakage
— Fuel quality (e.g. proper octane,

contamination, winter/summer blend)

— Loose bands on intake-air system
— Cracks on intake-air system parts
— Air cleaner restriction

•

Are all items okay?

Yes

Go to next step.

Service as necessary.

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SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (FS)]

01–03B–16

•

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 DTC displayed:

•

Go to next step.

•

Is engine overheating?

Yes

Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS - OVERHEATING [FS].”

Go to next step.

•

Inspect for cracks on high-tension leads.

•

Are there any cracks on high-tension leads?

Yes

Repair suspected high-tension leads.

Go to next step.

•

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 fuel injector.

Spark plug is grayish white:

•

Inspect for clogged fuel injector.

Install spark plugs on original cylinders.
Go to next step.

•

Visually inspect CKP sensor and teeth of
crankshaft pulley.

•

Are CKP sensor and teeth of crankshaft
pulley okay?

Yes

Go to next step.

Replace malfunctioning parts.

•

Measure gap between CKP sensor and teeth
of crankshaft pulley.

Specification
0.5—1.5 mm {0.020—0.59 in}

•

Is gap within specification?

Yes

Go to next step.

Adjust CKP sensor.

•

Remove and inspect PCV valve.

•

Does PCV valve rattle?

Yes

Go to next step.

Replace PCV valve.

•

Install fuel pressure gauge between fuel filter
and fuel distributor.

•

Connect jumper wire between F/P terminal at
DLC in engine compartment and GND.
(See 01–14–5 AFTER REPAIR
PROCEDURE.)

•

Turn ignition key to ON.

•

Is fuel line pressure correct?

Fuel line pressure
270—310 kPa {2.7—3.2 kgf/cm

, 39—45 psi}

Yes

Go to next step.

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.

•

Is fuel line pressure held after ignition key is
turned to LOCK?
(See 01–14–28 Operation Inspection.)

Yes

Go to next step.

Inspect pressure regulator diaphragm condition.
If condition is okay, inspect fuel injector.
If condition is not okay, replace pressure regulator.

•

Disconnect vacuum hose from pressure
regulator and plug the hose.

•

Start engine.

•

Does fuel line pressure remain within

±±±±

kPa {0.21 kgf/cm

, 3 psi} while driving

vehicle?

Yes

Go to next step.

Inspect for clogged fuel filter.

•

Connect vacuum hose to pressure regulator.

•

Install vacuum gauge to intake manifold.

•

Start engine.

•

Does fuel pressure gauge reading increase
as vacuum gauge reading decreases and/or
fuel pressure gauge reading decrease as
vacuum gauge reading increases?

Yes

Go to next step.

Connect vacuum pump to pressure regulator.
Start engine.
Verify that fuel pressure gauge reading changes as
vacuum changes.
If changes, inspect vacuum line.
If does not change, replace pressure regulator.

•

Disconnect vacuum hose from purge
solenoid valve and plug opening end of
vacuum hose.

•

Attempt to start engine.

•

Is starting condition improved?

Yes

Inspect if purge solenoid valve is stuck open.

Go to next step.

•

Inspect MAF sensor for contamination.

•

Is there any contamination?

Yes

Replace MAF sensor.

Go to next step.

•

Is there a restriction in exhaust system?

Yes

Inspect exhaust system.

Go to next step.

STEP

INSPECTION

RESULTS

ACTION

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Content .. 103 104 105 106 ..