Symptom Troubleshooting - Engine Controls [Mzr 1.5]: Diagnosis Mazda 2 II рестайлинг

SYMPTOM DIAGNOSTIC INDEX [MZR 1.5]

1. Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.

Diagnostic Index

Control System Device And Control Relationship Chart - MZR 1.5. Scheme 1

Quick Diagnostic Chart - MZR 1.5 (1 Of 4). Scheme 2

Quick Diagnostic Chart - MZR 1.5 (2 Of 4). Scheme 3

Quick Diagnostic Chart - MZR 1.5 (3 Of 4). Scheme 4

Quick Diagnostic Chart - MZR 1.5 (4 Of 4). Scheme 5

Diagnostic procedure

Inspection Method for Sensors

1. Connect the M-MDS to the DLC-2.
2. Switch the ignition to ON (engine off). NOTE: If engine starts and runs, perform the following steps at idle.
3. Access the PIDs for the switch you are inspecting.
4. Vibrate the sensor slightly with your finger. If the PID value is unstable or malfunction occurs, check for poor connection and/or poorly mounted sensor.

Scheme 6

1. Connect the M-MDS to the DLC-2.
2. Switch the ignition to ON (engine off). NOTE: If engine starts and runs, perform the following steps during idle.
3. Prepare the Output State Control for actuators or relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3 s as Output State Control is activated. If variable click sound is heard, inspect for poor connection and/or poorly mounted actuator or relay. see scheme 8: Inspecting Method For Actuators And Relays NOTE: Vibrating relays excessively may result in open relays.

Intake Manifold Vacuum Inspection

1. Verify the air intake hoses are installed properly.
2. Start the engine and idle it.
3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the purge solenoid valve side.
4. Connect a vacuum gauge to the vacuum hose and measure the intake manifold vacuum. (See «INTAKE MANIFOLD VACUUM INSPECTION [MZR 1.5]»(ref-517447-S01739688812012121200000) .) If not as specified, inspect the following: NOTE: Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring. Air suction at throttle body, intake manifold and PCV valve installation points Accelerator cable free play Fuel injector insulator Engine compression (See «COMPRESSION INSPECTION [MZR 1.5]»(ref-517441-S04356461842012121200000) .)

Engine coolant temperature compensation inspection

1. Connect the M-MDS to the DLC-2.
2. Access the following PIDs: (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) ECT1 IAT RPM
3. Verify that the engine is cold, then start the engine.
4. Verify that the engine speed decreases as the engine warms up. If the engine speed does not decrease or decreases slowly, inspect the following: ECT sensor No.1 and related wiring harness (See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 1.5]»(ref-517439-S23637998412012121200000) .) Throttle body and related wiring harness (See «THROTTLE BODY INSPECTION [MZR 1.5]»(ref-517447-S34062422092012121200000) .)

Load compensation inspection

1. Start the engine and idle it.
2. Connect the M-MDS to the DLC-2.
3. Verify that P0506:00 or P0507:00 is not displayed. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) If P0506:00 or P0507:00 are displayed, perform DTC inspection. (See «DTC P0507:00 [MZR 1.5]»(ref-517437-S12602341592012121200000) .)
4. Access the RPM PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) NOTE: Excludes temporary idle speed drop just after the loads are turned on.
5. Verify that the engine speed is within the specification under each load condition. If load condition is not as specified, inspect the following: A/C switch and related wiring harness Fan switch and related wiring harness

IDLE-UP SPEED

Throttle position (TP) sweep inspection

1. Connect the M-MDS to the DLC-2.
2. Switch the ignition to ON.
3. Verify that none of the following DTCs are displayed: (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) P0122:00, P0123:00, P0222:00, P0223:00, P0638:00, P2101:00, P2107:00, P2108:00, P2109:00, P2112:00, P2119:00, P2122:00, P2123:00, P2127:00, P2128:00, P2135:00, P2138:00 If any one DTC is displayed, perform DTC inspection. (See «DTC TABLE [MZR 1.5]»(ref-517437-S01450735222012121200000) .)
4. Access the TP REL PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .)
5. Verify that the PID reading is within the CTP value. (See «PCM INSPECTION [MZR 1.5]»(ref-517439-S26329800452012121200000) .) If the PID reading is out of range, perform the following: Remove the air duct from the throttle body. Verify that the throttle valve opens when the accelerator pedal is depressed. If the throttle valve opens, inspect the TP sensor and related wiring harness. If the throttle valve does not open, inspect the throttle valve actuator control motor and related wiring harness.
6. Gradually depress the throttle pedal and verify that the PID reading increases accordingly. If the PID reading drops momentarily, inspect the following: TP sensor
7. Fully depress the throttle pedal and verify that the PID reading is within WOT value. (See «PCM INSPECTION [MZR 1.5]»(ref-517439-S26329800452012121200000) .) If the PID reading is out of range, perform the followings: Remove the air duct from throttle body. Verify that the throttle valve opens when throttle pedal is depressed. If the throttle valve opens, inspect the TP sensor and related wiring harness. If the throttle valve does not open, inspect the throttle valve actuator control motor and related wiring harness.

Fuel Cut Control System Inspection

1. Warm-up engine and idle it.
2. Turn off the electrical loads and A/C switch.
3. Connect the M-MDS to the DLC-2.
4. Access the RPM and FUELPW PIDs. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) CAUTION: While performing this step, always operate the vehicle in a safe and lawful manner. When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.
5. Monitor both PIDs while performing the following steps: Drive the vehicle with the engine speed is 4,000 rpm . Release the accelerator pedal (brake pedal is not depressed) and verify that the fuel injector duration time is 0 ms , and 2-5 ms when the engine speed drops 1,200 rpm or less . If not as specified, inspect the following: ECT sensor No.1 and related wiring harness (See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 1.5]»(ref-517439-S23637998412012121200000) .) CPP switch, Neutral switch and related wiring harness (MTX) (See «NEUTRAL SWITCH INSPECTION [MZR 1.5]»(ref-517439-S12606327872012121200000) .) TR switch and related wiring harness (ATX) (See «TRANSAXLE RANGE (TR) SWITCH INSPECTION [FN4A-EL]»(ref-517464-S32200048592012121200000) .)

Fuel Pump Control System Inspection

1. Connect the M-MDS to the DLC-2.
2. Switch the ignition to ON.
3. Access the FP PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .)
4. Turn the fuel pump relay from off to on and inspect if the operation sound of the fuel pump relay is heard. If no operation sound is heard, inspect the fuel pump relay. If the fuel pump relay is normal, inspect the following: Wiring harnesses and connectors (Main relay-Fuel pump relay-PCM terminal 1AQ)

Spark Test

1. Remove the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure. WARNING: High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. Verify that there is no ignitable material such as flammable gas in the area where the vehicle is being serviced. If ignition of flammable gas occurs it could cause death or serious injury, and damage to equipment.

EGR Control System Inspection

1. Crank the engine and verify that EGR valve operation (initial operation) sound is heard. If the operation sound is not heard, connect the M-MDS to the DLC-2 and verify that the DTC P0403:00 is shown. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) If DTC is displayed, perform the DTC inspection. (See «DTC P0403:00 [MZR 1.5]»(ref-517437-S41947498922012121200000) .)
2. Start the engine and idle it.
3. Increase the step value of EGR valve from 0 to 40 using SEGRP PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .)
4. Operate the EGR valve and inspect if the engine speed becomes unstable or the engine stalls. If the engine speed will not change, proceed to following. Stop the engine. Remove the EGR valve. (See «EGR VALVE REMOVAL/INSTALLATION [MZR 1.5]»(ref-517444-S39079364212012121200000) .) Connect the EGR valve connector. Switch the ignition to ON. Increase the step value of EGR valve from 0 to 40 using SEGRP PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) Inspect the EGR operation. (See «EGR VALVE INSPECTION [MZR 1.5]»(ref-517444-S40320765402012121200000) .) If the EGR valve is operated, clean the EGR valve and reinspect from Step 2. If the EGR valve will not operate, replace the EGR valve and reinspect from Step 2.
5. Start the engine and warm it up completely.
6. Access the following PIDs: (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .) ECT1 RPM SEGRP_DSD TP REL TP1 TP2 VSS
7. Idle the vehicle and verify that the SEGRP value is 0 . CAUTION: While performing this step, always operate the vehicle in a safe and lawful manner. When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.
8. Drive the vehicle.
9. Depress the accelerator pedal and verify that the SEGRP_DSD value is increased. If the SEGRP_DSD value will not increase, inspect the VSS, TP REL, TP1, TP2 and ECT1 PIDs. (See «PCM INSPECTION [MZR 1.5]»(ref-517439-S26329800452012121200000) .)
10. Stop the vehicle and verify that the SEGRP value is returned 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 terminal B-PCM terminal 2S) Purge solenoid valve (stuck open) (See «PURGE SOLENOID VALVE INSPECTION [MZR 1.5]»(ref-517444-S18358345742012121200000) .)
4. Warm up the engine to the normal operating temperature.
5. Stop the engine.
6. Connect the M-MDS to the DLC-2 and verify that the DTC P0443:00 is shown. Perform the DTC inspection. (See «DTC P0443:00 [MZR 1.5]»(ref-517437-S22078284242012121200000) .)
7. Switch the ignition to ON.
8. Access the ECT1 PID. (See «ON-BOARD DIAGNOSTIC TEST [MZR 1.5]»(ref-517437-S32972094912012121200000) .)
9. Verify that the engine coolant temperature is more than 60 °C {140 °F} . If the M-MDS indicates less than 60 °C {140 °F} , perform the ECT sensor No.1 inspection. (See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 1.5]»(ref-517439-S23637998412012121200000) .)
10. Put a finger to the purge solenoid valve and verify that there is vacuum applied with engine at idle and warmed up. If there is no vacuum, inspect the following: Wiring harness and connectors (Main relay-Purge solenoid valve terminal B-PCM terminal 2S) Purge solenoid valve (stuck close) (See «PURGE SOLENOID VALVE INSPECTION [MZR 1.5]»(ref-517444-S18358345742012121200000) .) MAF, APP1, APP2, TP REL and LOAD PIDs (See «PCM INSPECTION [MZR 1.5]»(ref-517439-S26329800452012121200000) .) If there is a vacuum, inspect the following: Wiring harness and connectors (Purge solenoid valve terminal B-PCM terminal 2S) 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". (See «NO.23 A/C DOES NOT WORK SUFFICIENTLY [MZR 1.5]»(ref-517438-S39826266742012121200000) .)
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2-5 s . If it actuates, inspect as follows: APP1 and APP2 PIDs (See «PCM INSPECTION [MZR 1.5]»(ref-517439-S26329800452012121200000) .) A/C relay (See «RELAY INSPECTION»(ref-517451-S07981145642012121200000) .) Open circuit or short to ground in wiring harness and connectors (Ignition switch-A/C relay-PCM terminal 1AN) A/C related parts

Evaporative Emission (EVAP) System Leak Inspection

1. 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 M-MDS

EVAP system test out line

Scheme 7

Scheme 8

Scheme 9

1. The EVAP system test, which can substituted for the run drive cycle as an EVAP control system repair confirmation method, can detect the small/large leak or blockage without run-drive cycle. NOTE: M-MDS can not detect "VERY SMALL LEAK". To identify the leak point, please use the leak tester or ultrasonic leak detector. EVAP system test description
2. The EVAP system test finds gas leaks or blockage of EVAP system using the changes of the fuel tank pressure. This test starts after sending an on-demand test signal from the M-MDS to the PCM. This test consists of three stages, and each stage is performed automatically as follows: Stage 1 test. (Test for large leak or blockage) M-MDS send the stage 1 test start signal to the PCM. (Scheme 6): Testing Fuel Tank Pressure (Large Leak Or Blockage) PCM controls the CV solenoid valve and purge solenoid valve to control the tank pressure to the targeted value. M-MDS detect the large leak or the purge line blockage if the tank pressure does not arrive at the target vacuum in specified period. Stage 2 test. (Test for small leak) When fuel tank pressure arrived at the targeted pressure at stage 1 test, M-MDS sends the stage 2 test signal to the PCM to turn off the purge solenoid to keep the tank pressure. see scheme 11: Testing Fuel Tank Pressure (Small Leak) M-MDS detects the small leak if the tank pressure can not be kept within the target of specified period. Stage 3 test. (Test for blockage) M-MDS sends the stage 3 test signal to the PCM to turn off the CV solenoid to check the blockage of EVAP system. (Scheme 7): Testing Fuel Tank Pressure (Blockage) M-MDS detects blockage of the CV solenoid valve or air filter if the tank pressure does not arrive at the target (atmosphere). EVAP system malfunction judgment
3. M-MDS detects the small/large leak or blockage based on fuel tank pressure at the end of EVAP Test. The EVAP Test could not obtain the target vacuum. A Large leak or blockage is This judgment means tank pressure could not arrive at target pressure at stage 1 Check for the large leakage or inspect the purge solenold valve operation and re Repair or replace any malfunctioning parts. The EVAP Test could not maintain the target vacuum. A small leak is suspect. This judgment means tank pressure could not stay in target pressure at stage 2 te Run the EVAP Test again after retightening the fuel filler cap. If small leak is suspected again, use the leak tester or ultrasonic leak detector to Repair or replace any malfunctioning parts. Blockage in EVAP system. This judgment means tank pressure could not return to atmosphere at stage 3 test Inspect the CV solenoid, air filter, charcoal canister and related hoses for blockage. No large leaks or blockage have been detected in the EVAP system at this time. M-MDS can not detect "VERY SMALL LEAK". To identify the leak point, please use the leak tester or ultrasonic leak detector. A small leak in the purge solenold valve is suspect. This judgment means tank pressure goes to minus side at stage 2 test. Check the purge solenoid valve. Refer to the workshop manual. Evaporative system test procedure
4. Verify that all PIDs are within the following specifications. SPECIFICATION PID PID Range BARO 74.9 kPa {562 mmHg, 22.1 in Hg} or more FLI 15 - 85% ECT ECT minus IAT - 10 - 25 °C {-5.6 - 13.9 °F} IAT NOTE: To successfully perform this procedure, all PIDs must be within the specifications before proceeding to the next step.
5. Select the following items from the initialization screen of the M-MDS. Select "Powertrain". Select "Fuel". Select "EVAP Test". Verify that ECT1 and IAT are within specifications at the confirmation screen. To successfully perform this procedure, ECT1 and IAT must be within the spec before proceeding to the next step. Fuel Level must be maintained within 15%-85%. PCM will cancel the EVAP Test If the Fuel Level is lower than 15% or higher than 85%.
6. Verify the test results described on the M-MDS and follow the instructions.

Scheme 10

Scheme 11

1. Perform the following SST (EVAP System Tester 134-01049A) self-test: NOTE: If the tester does not work correctly during the self-test, refer to the tester operators manual for a more detailed self-test procedure. Verify that the control valve on the panel is in the HOLD position, then open the nitrogen bottle valve. (Scheme 8): Connecting Vehicle Interface Hose To Self-Test Port On Control Panel 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.) Turn the control valve to the TEST position. 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. Turn the control valve to the HOLD position. 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 tester operators manual.
2. Connect the SST to the vehicle. Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve. Remove the fuel-filler cap from the vehicle. If the fuel-filler cap is not a MAZDA part or equivalent, replace it. NOTE: INSPECT FUEL FILLER CAP AND FILLER NECK Visually inspect for damage, insufficient sealing, rust, cracks or warps of filler cap and filler neck. Repair or replace if necessary. Connect the receiver assembly ( SST: 134-01059) to the vehicle cap test hose assembly (part of the SST ) and the fuel-filler cap from the vehicle. (Scheme 9): Connecting Receiver Assembly To Vehicle Cap Test Hose Assembly And Fuel-Filler Cap Connect the cap adaptor ( SST: 134-01058) to the vehicle cap test hose assembly (part of the SST ) and to the fuel-filler neck. 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 M-MDS to the DLC-2.
4. Switch the ignition to ON (engine off).
5. Using the M-MDS request the PCM on-board device control (Mode 08) to close the canister vent value. NOTE: The canister vent value is closed for 10 min unless any of the following actions are done: The engine is started. The ignition is switched to off.
6. Make sure the control valve on the 134-01049A 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 min, then refer to the Mazda Workshop Manual to verify that the canister vent valve is properly closed. If canister vent valve is properly closed, the EVAP system has large leakage. Check for leakage and repair as necessary.
9. Verify 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 preset 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 .