DTC troubleshooting flow (on-board diagnostic)
- Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
- The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic function.
Diagnostic index
- The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely relating to the malfunction.
Quick diagnosis chart (If mentioned)
- The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction.
Symptom troubleshooting
- Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
Scheme 3
- Perform the basic inspection procedure before symptom troubleshooting.
- Perform each step in the order shown.
- The reference column lists the location of the detailed procedure for each basic inspection.
- Although inspections and adjustments are performed according to the reference column procedures, if the cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the action column.
Scheme 4
- DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC.
Using the diagnostic index
- Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
- The exact malfunction symptoms can be selected by following the index.
Typical Diagnostic Chart
| No. | TROUBLESHOOTING ITEM | DESCRIPTION | Reference | |
|---|---|---|---|---|
| 1 | Melting of main or other fuses | See MELT NO. 1 MAIN OR OTHER FUSE 01-03-6 ) | ||
| 2 | MIL Comes on | MIL is illuminated incorrectly. | See NO. 2 MIL COMES ON 01-03-7 ) | |
| 3 | Will not crank | Starter does not work | See NO. 3 WILL NOT CRANK 01-03-8 ) | |
| 4 | Hard start/long crank/erratic start/erratic crank | Starter cranks the engine at normal speed but the engine requires excessive cranking time before starting. | See NO. 4 HARD START/LONG CRANK/ERRATIC CRANK 01-03-9 ) | |
| 5 | Engine stalls | After start/at idle | Engine stops unexpectedly at idle or after start | See NO. 5 ENGINE STALLS AFTER START/AT IDLE 01-03-11 |
| 6 | Cranks normally but will not start | Starter cranks engine at normal speed but engine will not run. | See NO. 6 CRANKS NORMALLY BUT WILL NOT START 01-03-15 | |
| 7 | Slow return to idle | Engine takes more time than normal to return to idle speed. | See NO. 7 SLOW RETURN TO IDLE 01-03-19 | |
| 8 | Engine runs rough/rolling idle | Engine speed fluctuates between the specified idle speed and lower speed, and engine shakes excessively. | See NO. 8 ENGINE RUNS ROUGH/ROLLING IDLE 01-03-20 | |
| 9 | Fast idle/runs on | Engine speed continues at fast idle after warm-up. | See NO. 9 FAST IDLE/RUNS ON 01-03-23 | |
| 10 | Low idle/stalls during deceleration | Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. | See NO. 10 LOW IDLE/STALLS DURING DECELERATION 01-03-24 | |
Scheme 5
- The chart lists the relation between the symptom and the cause of the malfunction.
- The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies a range of common causes when multiple malfunction symptoms occur.
- The appropriate diagnostic inspection relating to a malfunction cause as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.
Scheme 6
- Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for each trouble symptom.
Malfunction Diagnosis System
- Use the Mazda Modular Diagnostic System (M-MDS) or equivalent for malfunction diagnosis.
Oil Leakage Inspection
- Use either of the following procedures to identify the type of oil that is leaking
Inspection During Removal, Disassembly
- When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.
Scheme 7
- All disassembled parts should be carefully arranged for reassembly.
- Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
Scheme 8
- All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
| WARNING | Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air. |
Scheme 9
- Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
- If removed, the following parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
- Depending on location: Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
Scheme 10
- Use suitable gauges and testers when making adjustments.
Scheme 11
- Prevent gasoline or oil from getting on rubber parts or tubing.
Scheme 12
- When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.
Scheme 13
- When using a torque wrench - SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.
| Torque Unit | Formula |
|---|---|
| N.m | N.m x [L/(L+A)] |
| Kgf.m | Kgf.m x [L/(L+A)] |
| Kgf.cm | Kgf.cm x [L/(L+A)] |
| Ft.lbf | Ft.lbf x [L/(L+A)] |
| In.lbf | In.lbf x [L/(L+A)] |
A
The length of the SST past the torque wrench drive.
L
The length of the torque wrench.
Scheme 14
- When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
Road test
INSPECT the following items
[] Brake operation
[] Operation of gauges
[] Engine general performance
[] Emergency locking retractors and automatic locking retractors
[] Cruise control system (if equipped)
[] Operation of meters and gauges, squeaks, rattles, and abnormal noises
After road test
INSPECT for necessary owner information materials, tools, and spare tire in vehicle The following items must be completed just before delivery to your customer.
[] Load test battery and charge if necessary (Load test result: Volts)
[] Adjust tire pressure to specification
[] Install fuses for accessories