Emission System (L3): Other Mazda 5 I

Exhaust System

EXHAUST SYSTEM COMPONENTS

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test: NOTE: If the tester does not work correctly during self-test, refer to the tester operator's manual for more detailed procedures. Verify the gas cylinder valve is closed and the control valve located on the tester is in the TEST position. All tester display should be off at this time. Connect the long hose (part of SST ) to the tester. Connect the manifold assembly (part of SST ) to the long hose as shown. Open the gas cylinder valve and verify the gas cylinder regulator left gauge reads 10 to 12 psi (preset at factory). If not, refer to the tester operator's manual to contact tester manufacturer. Press the ON/OFF switch to turn on the SST and make sure the left display reads 0.0. Turn the control valve on the tester to the FILL position. Verify the left display reading is within 13.9 to 14.0 in of water. If not, adjust the pressure using the regulator knob located on the right side of the tester. Turn the control valve to TEST position and press the START switch. After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that period. A 0.5 in of water loss is acceptable on the self-test. If the loss is more than 0.5 in of water , do one or more self-test. If the failed test repeats, check for leak using the ultrasonic leak detector (part of SST ).
2. Press the RESET switch to set the left display reading to 0.0.
3. Connect the fuel cap receiver assembly (part of SST ) to the manifold assembly and fuel-filler cap from the vehicle. If the fuel-filler cap is not a genuine part, replace it.
4. Turn the control valve to the FILL position.
5. Wait ( maximum 20 s ) until the left display reads 13.9 to 14 in of water. If the reading is slightly below, adjust it using the regulator knob. If the reading is far below, the fuel-filler cap has leak. Replace it.
6. Turn the control valve to the TEST position and press the START switch.
7. After the 2-min countdown (left display) is completed, check the test result (the failed/passed light on the tester). If the green light turns on, the fuel-filler cap is OK. If the red light turns on, the fuel-filler cap has leakage. Replace it.
8. Close the gas cylinder valve.
9. Turn the control valve to the FILL position.
10. Press the ON/OFF switch to turn off the tester.

Scheme 22

1. Remove the air filter. (See «AIR FILTER REMOVAL/INSTALLATION [L3]»(ref-244343-S38673191942006092100000) ).
2. Blow from port A and verify that there is airflow from port B. If not as specified, replace the air filter.
3. Blow from port B and verify that there is airflow from port A. If not as specified, replace the air filter. (See «AIR FILTER REMOVAL/INSTALLATION [L3]»(ref-244343-S38673191942006092100000) ).

Scheme 23

1. Remove the rear tire (RH).
2. Remove the fuel-filler cap.
3. Remove the splash shield.
4. Remove the Air filter.
5. Install in the reverse order of removal.

Open circuit

1. If there is no continuity, there is an open circuit. Repair or replace the wiring harness. EVAP system leak detection pump terminal A and main relay terminal C EVAP system leak detection pump terminal B and the body ground EVAP system leak detection pump terminal C and PCM terminal 1AJ EVAP system leak detection pump terminal D and PCM terminal 1AF

Scheme 24

1. If there is continuity, there is a short circuit. Repair or replace the wiring harness. EVAP system leak detection pump terminal A and the body ground EVAP system leak detection pump terminal B and power supply EVAP system leak detection pump terminal C and power supply EVAP system leak detection pump terminal C and body ground EVAP system leak detection pump terminal D and power supply EVAP system leak detection pump terminal D and body ground

Scheme 25

Scheme 26

1. Remove the plug hole plate.
2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
3. Disconnect the negative battery cable.
4. Remove using the following procedure: CAUTION: Do not disconnect the purge solenoid valve and evaporative hose except when replacing the purge solenoid valve because it may cause evaporative gas leakage. When it is necessary to remove the purge solenoid valve for removing/installing other parts, disconnect the valve at the quick release connector. Disconnect the evaporative hose at the charcoal canister side. (See «EVAPORATIVE HOSE INSTALLATION NOTE»(ref-244343-S28695924802006092100000) ). Turn the evaporative hose (intake manifold side) approx. 30° from the dot line to the solid line. Disconnect the quick release connector (Type A). (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3]»(ref-244329-S37413676872006092100000) ).
5. Install in the reverse order of removal.

Scheme 27

1. Install the evaporative hose and clamp as shown in the figure.

Scheme 28

1. Warm up the engine and idle it.
2. Disconnect the vacuum hose which is connected to the charcoal canister from purge solenoid valve.
3. Place your finger onto the evaporative hose as shown in the figure and verify that vacuum is applied. If vacuum is not applied, inspect the following: PCM output signal circuit (wiring harness, connector) Evaporative purge control signal Purge solenoid valve
4. Run the vehicle on the chassis dynamometer and maintain the engine speed at approx. 2,000 RPM.
5. Verify that vacuum is applied after approx. 30 s. If the vacuum is not verified, inspect the following: PCM input signal circuit (sensor, switch, wiring harness) Intake air temperature signal (IAT sensor) Evaporative purge control signal (purge solenoid valve) Throttle opening signal (TP sensor) Load/no load identification signal Neutral switch/CPP switch (MTX)/TR switch (ATX) Purge solenoid valve

Scheme 29

1. Connect the WDS or equivalent to the DLC-2.
2. Warm up the engine and idle it.
3. Using the "EVAPCP" simulation function, set the present 0% duty value of the purge solenoid valve to the 100% duty value and verify that the engine idles roughly or stalls. If the idle status does not change, inspect the following: Turn the ignition switch to the ON position. Using the "EVAPCP" simulation function, set the present 0% duty value of the purge solenoid valve to the 50% duty value and verify purge solenoid valve operation sound. If the operation sound is verified, inspect the following: Purge solenoid valve airflow Disconnection and damage of the vacuum hose (intake manifold-purge solenoid valve-charcoal canister) If the operation sound is not verified, inspect the following: Purge solenoid valve airflow Wiring harness and connector open circuit (main relay-purge solenoid valve-PCM)

Scheme 30

1. Remove the purge solenoid valve without disconnecting the evaporative hose. (See «PURGE SOLENOID VALVE REMOVAL/INSTALLATION [L3]»(ref-244343-S02276159152006092100000) ).
2. Verify that the airflow is as indicated in the table. If as specified in the table, perform the "Circuit Open/Short Inspection". If not as specified in the table, inspect the purge solenoid valve. (See «PURGE SOLENOID VALVE REMOVAL/INSTALLATION [L3]»(ref-244343-S02276159152006092100000) ). CONTINUITY REFERENCE Measured condition Continuity between A-B When voltage is not applied between terminals A and B No airflow When voltage is applied between terminals A and B Airflow detected

Scheme 31

1. Disconnect the PCM connector. (See «PCM REMOVAL/INSTALLATION [L3]»(ref-244330-S07461751642006092100000) ).
2. Inspect the following wiring harnesses for open or short circuit (continuity check).

1. If there is no continuity, there is an open circuit. Repair or replace the wiring harness. Purge solenoid valve terminal A and PCM terminal 2AN Purge solenoid valve terminal B and main relay terminal C

Short circuit

1. If there is continuity, there is a short circuit. Repair or replace the wiring harness. Purge solenoid valve terminal A and body ground Purge solenoid valve terminal A and power supply Purge solenoid valve terminal B and body ground

Without using WDS or equivalent

1. Inspect the following: EGR pipe clogging PCM terminal voltage EGR valve signal Vehicle speed signal Throttle opening signal Engine coolant temperature signal EGR valve (If it is stuck or not moving smoothly, replace it with a new one).

Using WDS or equivalent

1. Connect the WDS or equivalent to the DLC-2.
2. Start the engine.
3. Using the "SEGRP" simulation function, operate with Steps 0 (idling) to 52 and verify that the engine speed becomes unstable or the engine stalls. If the engine speed does not change, perform the following procedure: Stop the engine. Remove the EGR valve. (See «EGR VALVE REMOVAL/INSTALLATION [L3]»(ref-244343-S33251781692006092100000) ). Connect the EGR valve connector. Turn the ignition switch to the ON position. Using the "SEGRP" simulation function, verify that it operates with Steps 0 (idling) to 52. If the EGR valve operates, inspect the following: EGR pipe clogging If the EGR valve does not operate, inspect the following: PCM terminal voltage EGR valve signal EGR valve (If it is stuck or not moving smoothly, replace it with a new one).
4. Warm up the engine to normal operating temperature.
5. Place the vehicle on the chassis dynamometer.
6. Monitor the following signals using the PID/data monitor. EGR valve step number (SEGRP) Engine speed (RPM) Vehicle speed (VSS) Throttle position (TP) Engine coolant temperature (ECT)
7. Verify that the EGR valve step number is 0 during idle.
8. Verify that the EGR valve step number increases when the accelerator pedal is depressed to increase the vehicle speed. If it does not increase, inspect the following using the PID/data monitor. Vehicle speed (VSS) Throttle position (TP) Engine coolant temperature (ECT)
9. Stop the vehicle and verify that the EGR valve step number is 0 during idle.

1. If there is continuity, there is a short circuit. Repair or replace the wiring harness. EGR valve terminal A and body ground EGR valve terminal A and power supply EGR valve terminal B and body ground EGR valve terminal B and power supply EGR valve terminal C and body ground EGR valve terminal D and body ground EGR valve terminal E and body ground EGR valve terminal E and power supply EGR valve terminal F and body ground EGR valve terminal F and power supply

Scheme 32

1. Remove the intake manifold.
2. Remove the PCV valve.
3. Verify that there is no airflow when pressure is applied to port A. If there is airflow, replace the PCV valve.
4. Verify that there is airflow when vacuum is applied to port A. If there is no airflow, replace the PCV valve.