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Engine Control System [Mzr 2.3 Disi Turbo]: Removal & Installation Mazda 3 BM

Testing & Diagnostics 19 illustrations ~1669 words

VARIABLE SWIRL SHUTTER VALVE SWITCH REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. The variable swirl shutter valve switch cannot be removed as a single unit. When replacing the variable swirl shutter valve switch, replace it together with the intake manifold as a single unit.

  1. Remove the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000) .)

ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

WARNINGWhen the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing the ECT sensor.

Scheme 80

Scheme 80: ECT Sensor No.1
Scheme 80: ECT Sensor No.1
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI TURBO]»(ref-579402-S28000546112013100700000).)
  4. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  5. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  6. Remove the air duct. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  7. Disconnect the ECT sensor No.1 connector.
  8. Remove the ECT sensor No.1. (Scheme 80): Locating ECT Sensor No.1 With Torque Specifications
  9. Install in the reverse order of removal.
  10. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI TURBO]»(ref-579402-S28000546112013100700000).)

Scheme 81

Scheme 81: ECT Sensor No.2
Scheme 81: ECT Sensor No.2
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI TURBO]»(ref-579402-S28000546112013100700000).)
  4. Disconnect the ECT sensor No.2 connector.
  5. Remove the ECT sensor No.2 using the SST. (Scheme 81): Locating ECT Sensor No.2 With Torque Specifications NOTE: Wipe off any oil or engine coolant if it gets on the ECT sensor No.2 installation area.
  6. Install in the reverse order of removal.
  7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI TURBO]»(ref-579402-S28000546112013100700000).)

MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. Because the IAT sensor is integrated in the MAF sensor, replacing the IAT sensor includes replacement of the MAF/IAT sensor.

  1. Remove the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000) .)

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. Because the boost air temperature sensor is integrated in the MAP sensor, replacing the boost air temperature sensor includes replacement of the MAP sensor/boost air temperature sensor.

Scheme 82

Scheme 82: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 D
Scheme 82: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 D
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Remove the dipstick pipe. (See «OIL PAN REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579358-S28134022662013100700000).)
  4. Disconnect the MAP sensor/boost air temperature sensor connector.
  5. Remove the MAP sensor/boost air temperature sensor. (Scheme 82): Locating MAP Sensor/Boost Air Temperature Sensor With Torque Specifications
  6. Install in the reverse order of removal.

Scheme 83

Scheme 83: Voltage Inspection
Scheme 83: Voltage Inspection
  1. Connect the M-MDS to the DLC-2. (Scheme 83): Identifying DLC-2 Location
  2. Switch the ignition to ON.
  3. Verify that the MAP sensor output voltage (PID: MAP) is within the specification. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI TURBO]»(ref-579393-S40487792242013100700000).) (See «PCM INSPECTION [MZR 2.3 DISI TURBO]»(ref-579394-S08257791092013100700000).) If not as specified, replace the MAP sensor/boost air temperature sensor. (See «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579394-S34788313692013100700000).)

BAROMETRIC PRESSURE (BARO) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. Because the BARO sensor is integrated in the PCM, replacing the BARO sensor includes replacement of the PCM.

  1. Remove the PCM. (See «PCM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579394-S09139205922013100700000) .)

THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. The TP sensor cannot be removed as a single unit. When replacing the TP sensor, replace it together with the throttle body as a single unit.

  1. Remove the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000) .)

ACCELERATOR PEDAL POSITION (APP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. Because the APP sensor is integrated in the accelerator pedal, replacing the APP sensor includes replacement of the accelerator pedal.

  1. Remove the accelerator pedal. (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S42685552562013100700000) .)

FUEL PRESSURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

Note. If the fuel pressure sensor is removed, do not reuse the fuel pressure sensor and the fuel delivery pipe. When you replace the fuel pressure sensor, replace a new fuel delivery pipe with a new fuel pressure sensor.

  1. Remove the fuel delivery pipe. (See «FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579404-S38042114582013100700000) .)

AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

WARNINGA hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

Scheme 84

Scheme 84
Scheme 84
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Remove the charge air cooler. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  4. Remove the charge air cooler bracket. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  5. Disconnect the A/F sensor connector.
  6. Remove the A/F sensor using the SST. (Scheme 84): A/F Sensor And SST With Torque Specifications
  7. Install in the reverse order of removal.

Scheme 85

Scheme 85: A/F Sensor Inspection
Scheme 85: A/F Sensor Inspection

Scheme 86

Scheme 86
Scheme 86
  1. Connect the M-MDS to the DLC-2. (Scheme 85): Identifying DLC-2 Location
  2. Switch the ignition to ON.
  3. Warm up the engine to normal operating temperature.
  4. Access the following PIDs using the M-MDS. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI TURBO]»(ref-579393-S40487792242013100700000).) VSS (Vehicle speed) RPM (Engine speed) O2S11 (A/F sensor output current)
  5. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine speed is 3,000 rpm or more.
  6. Verify that the A/F sensor output current (PID: O2S11) is 0.25 mA or more while decelerating as shown in the figure. (Scheme 86): A/F Sensor Output Current Graph If not as specified, replace the A/F sensor. (See «AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579394-S33792319452013100700000).)

HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

WARNINGA hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

Scheme 87

Scheme 87
Scheme 87
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Disconnect the HO2S connector.
  4. Remove the HO2S using the SST. (Scheme 87): HO2S And SST With Torque Specifications
  5. Install in the reverse order of removal.

Scheme 88

Scheme 88: HO2S Inspection
Scheme 88: HO2S Inspection

Scheme 89

Scheme 89
Scheme 89
  1. Connect the M-MDS to the DLC-2. (Scheme 88): Identifying DLC-2 Location
  2. Switch the ignition to ON.
  3. Warm up the engine to normal operating temperature.
  4. Access the following PIDs using the M-MDS. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI TURBO]»(ref-579393-S40487792242013100700000).) VSS (Vehicle speed) RPM (Engine speed) O2S12 (HO2S output voltage)
  5. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine speed is 3,000 rpm or more
  6. Verify that the HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the HO2S voltage (PID: O2S12) is 0.3 V or less while decelerating as shown in the figure. (Scheme 89): HO2S Outputs Voltage Graph If not as specified, replace the HO2S. (See «HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579394-S08150444472013100700000).)

Removal

CAUTIONWhen foreign material such as an iron chip is on the CKP sensor, it can cause abnormal output from the sensor because of flux turbulence and adversely affect the engine control. Be sure there is no foreign material on the CKP sensor when replacing. Do not assemble the CKP sensor or change the installation position using any method other than the following. Otherwise, it could negatively affect engine controls, such as the ignition timing and fuel injection.

Scheme 90

Scheme 90
Scheme 90
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Perform the following procedure for easier access. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-579341-S33007366072013100700000).) Remove the front splash shield (RH). (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-579341-S13061542712013100700000).)
  4. Disconnect the CKP sensor connector.
  5. Remove the CKP sensor. (Scheme 90): Identifying CKP Sensor And Bolts

Installation

CAUTIONWhen foreign material such as an iron chip is on the CKP sensor, it can cause abnormal output from the sensor because of flux turbulence and adversely affect the engine control. Be sure there is no foreign material on the CKP sensor when replacing. Do not assemble the CKP sensor or change the installation position using any method other than the following. Otherwise, it could negatively affect engine controls, such as the ignition timing and fuel injection.

Scheme 91

Scheme 91
Scheme 91

Scheme 92

Scheme 92
Scheme 92

Scheme 93

Scheme 93
Scheme 93

Scheme 94

Scheme 94
Scheme 94
  1. Perform the following procedure so that piston No.1 is at TDC. Rotate the crankshaft in the direction of the engine rotation and remove the cylinder block lower blind plug when the No.1 cylinder is at the point prior to TDC of compression, then install the SST. (Scheme 91): Identifying SST 303-507 Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the crank weight contacts SST and stops.)
  2. Using a straight edge, draw a straight line directly in the center of the twentieth tooth of the crankshaft pulley pulse wheel (counting counterclockwise from the empty space). (Scheme 92): Adjusting CKP Sensor CAUTION: If the line is not accurately drawn, ignition timing, fuel injection and other engine control systems will be adversely effected. Draw the straight line carefully using a straight edge.
  3. Align the center line of the crankshaft position sensor and the line drawn in Step 2, then install the sensor.
  4. Install the CKP sensor fitting bolts. (Scheme 93): Identifying CKP Sensor And Fitting Bolts With Torque Specifications
  5. Remove the SST then install the cylinder block lower blind plug. (Scheme 94): Identifying Cylinder Block Lower Blind Plug And CKP Sensor With Torque Specifications

CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

CAUTIONWhen replacing the CMP sensor, make sure there is no foreign material on it such as metal shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting from fluctuation in magnetic flux and cause a deterioration in engine control.

Scheme 95

Scheme 95
Scheme 95
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Remove the charge air cooler cover. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  4. Disconnect the CMP sensor connector.
  5. Remove the CMP sensor. (Scheme 95): Identifying CMP Sensor And Bolt With Torque Specifications
  6. Install in the reverse order of removal.

KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

CAUTIONBe careful not to impact the sensor. Verify that there is no debris between the sensor and the cylinder block before installing.

Scheme 96

Scheme 96
Scheme 96
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Remove the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).)
  4. Disconnect the KS connector.
  5. Remove the KS. (Scheme 96): Knock Sensor And Bolt With Torque Specifications
  6. Install in the reverse order of removal.

FUEL TANK PRESSURE SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

CAUTIONDisconnecting/connecting the quick release connector without cleaning it may cause damage to the evaporative pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

Note. The fuel tank pressure sensor cannot be removed as a single unit. When replacing the fuel tank pressure sensor, replace it together with the evaporative hose component as a single unit.

Scheme 97

Scheme 97
Scheme 97

Scheme 98

Scheme 98
Scheme 98
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).)
  3. Disconnect the fuel tank pressure sensor connector.
  4. Remove the clip from the fuel tank pressure sensor bracket. (Scheme 97): Fuel Tank Pressure Sensor
  5. Disconnect the quick release connectors and remove the evaporative hose component. (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579419-S32441055942013100700000).) (Scheme 98): Evaporative Hose Components
  6. Install in the reverse order of removal.

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