Symptom Troubleshooting - Engine - [Mzr 2.5]: Other Mazda 6 GH рестайлинг

FOREWORD [MZR 2.5]

1. When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and diagnostic trouble code (DTC), then diagnose the malfunction according to the following flowchart

1. If a DTC exists, diagnose the applicable DTC inspection. (See «DTC TABLE [MZR 2.5]»(ref-448573-S03466771992012012000000) .)
2. If no DTC exists and the MIL does not illuminate or flash, diagnose the applicable symptom troubleshooting. (See «QUICK DIAGNOSTIC CHART [MZR 2.5]»(ref-448575-S33292970952012012000000) .)

Scheme 27

*: Malfunction indicator lamp (MIL), generator warning light, security light

NO. 1 MELTING OF MAIN OR OTHER FUSES [MZR 2.5]

SYMPTOM CHART (MELTING OF MAIN OR OTHER FUSES) 1 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. Damaged fuse Related wiring harness MAIN MAIN fuse BTN fuse ROOM fuse FAN fuse IG KEY 2 fuse Generator BTN BTN fuse ROOM fuse ROOM ROOM fuse DLC-2 FAN FAN fuse Fan control module relay IG KEY2 IG KEY2 fuse Starter relay FUEL PUMP FUEL PUMP fuse Fuel pump unit ST SIG ST SIG fuse Starter relay EGI INJ EGI INJ fuse Fuel injector No. 1 Fuel injector No. 2 Fuel injector No. 3 Fuel injector No. 4 PCM ENG+B ENG+B fuse PCM CV solenoid valve PCM PCM fuse PCM ENGINE IG ENGINE IG fuse Ignition coil No. 1 Ignition coil No. 2 Ignition coil No. 3 Ignition coil No. 4 PCM Fuel pump relay Diode Fan control module relay HO2S HO2S fuse HO2S (heater) 1 MELTING OF MAIN OR OTHER FUSES ENGINE ENGINE fuse Variable tumble solenoid valve Variable intake air solenoid valve EGR valve Purge solenoid valve A/F sensor MAF/IAT sensor

Scheme 28

NO. 2 MIL ILLUMINATES [MZR 2.5]

SYMPTOM CHART (MIL ILLUMINATES)

NO. 3 WILL NOT CRANK [MZR 2.5]

SYMPTOM CHART (WILL NOT CRANK)

Scheme 29

NO. 4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZR 2.5]

SYMPTOM CHART (HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK)

NO. 5 ENGINE STALLS-AFTER START/AT IDLE [MZR 2.5]

SYMPTOM CHART (ENGINE STALLS-AFTER START/AT IDLE)

NO. 6 CRANKS NORMALLY BUT WILL NOT START [MZR 2.5]

SYMPTOM CHART (CRANKS NORMALLY BUT WILL NOT START)

NO. 7 SLOW RETURN TO IDLE [MZR 2.5]

SYMPTOM CHART (SLOW RETURN TO IDLE)

NO. 8 ENGINE RUNS ROUGH/ROLLING IDLE [MZR 2.5]

SYMPTOM CHART (ENGINE RUNS ROUGH/ROLLING IDLE)

NO. 9 FAST IDLE/RUNS ON [MZR 2.5]

SYMPTOM CHART (FAST IDLE/RUNS ON)

NO. 10 LOW IDLE/STALLS DURING DECELERATION [MZR 2.5]

SYMPTOM CHART (LOW IDLE/STALLS DURING DECELERATION)

NO. 11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES [MZR 2.5]

SYMPTOM CHART (ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES)

NO. 12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [MZR 2.5]

SYMPTOM CHART (LACK/LOSS OF POWER-ACCELERATION/CRUISE)

NO. 13 KNOCKING/PINGING-ACCELERATION/CRUISE [MZR 2.5]

SYMPTOM CHART (KNOCKING/PINGING-ACCELERATION/CRUISE)

NO. 14 POOR FUEL ECONOMY [MZR 2.5]

SYMPTOM CHART (POOR FUEL ECONOMY)

NO. 15 EMISSION COMPLIANCE [MZR 2.5]

SYMPTOM CHART (EMISSION COMPLIANCE)

NO. 16 HIGH OIL CONSUMPTION/LEAKAGE [MZR 2.5]

SYMPTOM CHART (HIGH OIL CONSUMPTION/LEAKAGE)

NO. 17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.5]

SYMPTOM CHART (COOLING SYSTEM CONCERNS-OVERHEATING)

NO. 18 COOLING SYSTEM CONCERNS-RUNS COLD [MZR 2.5]

SYMPTOM CHART (COOLING SYSTEM CONCERNS-RUNS COLD)

NO. 19 EXHAUST SMOKE [MZR 2.5]

SYMPTOM CHART (EXHAUST SMOKE)

NO. 20 FUEL ODOR (IN ENGINE COMPARTMENT) [MZR 2.5]

SYMPTOM CHART - FUEL ODOR (IN ENGINE COMPARTMENT)

NO. 23 A/C DOES NOT WORK SUFFICIENTLY [MZR 2.5]

SYMPTOM CHART (A/C DOES NOT WORK SUFFICIENTLY)

NO. 24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [MZR 2.5]

SYMPTOM CHART (A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY)

NO. 25 A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [MZR 2.5]

SYMPTOM CHART (A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS)

NO. 26 EXHAUST SULPHUR SMELL [MZR 2.5]

SYMPTOM CHART (EXHAUST SULPHUR SMELL)

NO. 28 FUEL FILLING SHUT OFF CONCERNS [MZR 2.5]

SYMPTOM CHART (FUEL FILLING SHUT OFF CONCERNS)

NO 29 SPARK PLUG CONDITION [MZR 2.5]

SYMPTOM CHART (SPARK PLUG CONDITION)

Water Sprinkling Method

1. If malfunction occurs only under high humidity or rainy/snowy weather, perform the following steps

1. Connect the M-MDS to the DLC-2 if you are inspecting sensors or switches.
2. Switch the ignition to ON (engine off). NOTE: If the engine starts and runs, perform the following steps at idle.
3. Access PIDs for sensor or switch if you are inspecting sensors or switches.
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a car wash.

1. If PID value is unstable or malfunction occurs, repair or replace part if necessary.

Scheme 30

If simulation function of M-MDS is used

FUEL INJECTOR OPERATION INSPECTION CHART

FUEL INJECTOR OPERATION INSPECTION CHART

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-PCM terminal 2C) Purge solenoid valve (stuck open) (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.5]»(ref-448581-S25756567752012012000000) .)
4. Verify that the DTC P0443:00 is displayed. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-448573-S30571243312012012000000) .) If the DTC P0443:00 is shown, perform the DTC inspection. (See «DTC P0443:00 [MZR 2.5]»(ref-448573-S20004910592012012000000) .)
5. Access the PCM PID EVAPCP using the M-MDS. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-448573-S30571243312012012000000) .)
6. Put a finger to the purge solenoid valve with Step 2 condition and verify that there is vacuum applied when set the present to 100 % duty value of the purge solenoid valve using the EVAPCP PID simulation function. If there is no vacuum, inspect the following: Increase the duty value of the purge solenoid valve to 50 % and inspect if the operation sound of the valve is heard. If the operation sound is heard, inspect for loose or damaged vacuum hoses. (Intake manifold-Purge solenoid valve-Charcoal canister) If the operation sound is not heard, inspect the purge solenoid valve. (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.5]»(ref-448581-S25756567752012012000000) .)
7. Warm up the engine to normal operating temperature.
8. Monitor the EVAPCP PID using the M-MDS, and drive the vehicle approx. 2000 RPM for 30 s or more.

1. If the EVAPCP PID is 0 %, inspect the following

1. MAF, APP1, APP2, TP REL and LOAD PIDs (See «PCM INSPECTION [MZR 2.5]»(ref-448574-S07437731972012012000000) .)

If simulation function of M-MDS is not used

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-PCM terminal 2C) Purge solenoid valve (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.5]»(ref-448581-S25756567752012012000000) .)
4. Warm up the engine to the normal operating temperature.
5. Stop the engine.
6. Verify that the DTC P0443:00 is displayed. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-448573-S30571243312012012000000) .) If the DTC P0443:00 is shown, perform the DTC inspection. (See «DTC P0443:00 [MZR 2.5]»(ref-448573-S20004910592012012000000) .)
7. Switch the ignition to ON.
8. Access the PCM PID ECT. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-448573-S30571243312012012000000) .)
9. Verify that the engine coolant temperature is more than 78 °C {172 °F}. If the M-MDS indicates less than 78 °C {172 °F} , perform the ECT sensor inspection. (See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 2.5]»(ref-448574-S19104746962012012000000) .)
10. Set the vehicle on the dynamometer or chassis roller. WARNING: When the dynamometer or chassis roller is operating, there is a possibility that the operator may come into contact with or be caught up in the rotating parts, leading to serious injuries or death. When performing work while the dynamometer or chassis roller is operating, be careful not to come into contact with or be caught up in any of the rotating parts.
11. Drive vehicle at engine speed approx. 2,000 RPM for 30 s or more.
12. Put a finger to the purge solenoid valve and verify that there is no vacuum applied while step 2.

1. If there is no vacuum, inspect the following: Wiring harness and connector (Main relay-Purge solenoid valve-PCM terminal 2C) Purge solenoid valve (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.5]»(ref-448581-S25756567752012012000000) .) MAF, APP1, APP2, TP REL and LOAD PIDs (See «PCM INSPECTION [MZR 2.5]»(ref-448574-S07437731972012012000000) .)
2. If there is vacuum, inspect the following

1. Vacuum hose (Purge solenoid valve-Charcoal canister)

Cooling fans do not operate

1. Inspect for followings

1. Open circuit between fan control module relay and battery positive terminal
2. Open circuit between fan control module relay and BCM
3. Open circuit between fan control module relay and fan control module
4. Open circuit between fan control module and ground
5. Poor connection of the fan control module connector
6. Fan control module relay malfunction (See «RELAY INSPECTION»(ref-448587-S07835372662012012000000) .)

1. If there is no malfunction, replace the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S07120384462012012000000) .)

Cooling fan motor No. 1 does not operate

1. Inspect for followings

1. Open or short to ground circuit between the fan control module and cooling fan motor No. 1
2. Poor connection of the fan control module connector or cooling fan motor No. 1 connector

1. If there is no malfunction, replace the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S07120384462012012000000) .)

Cooling fan motor No. 2 does not operate

1. Inspect for followings

1. Open or short to ground circuit between the fan control module and the cooling fan motor No. 2
2. Poor connection of the fan control module connector or the cooling fan motor No. 1 connector

1. If there is no malfunction, replace the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S07120384462012012000000) .)

EVAP system malfunction judgment

1. M-MDS detect the small/large leak or blockage based on fuel tank pressure at the end of EVAP Test.

Scheme 31

A small leak in the purge solenoid valve is suspect.

1. This judgment means tank pressure goes to minus side at stage 2 test.

1. Check the purge solenoid valve. Refer to the «PURGE SOLENOID VALVE INSPECTION [MZR 2.5]»(ref-448581-S25756567752012012000000) .

Scheme 32

1. Verify that all PIDs within the following specifications. NOTE: To successfully perform this procedure, all PIDs must be within the specifications before proceeding to the next step.
2. Select the following items from the initialization screen of the M-MDS. Select the "Powertrain". Select the "Fuel". Select the "EVAP Test". Verify that ECT and IAT are within the specifications at the confirmation screen. To successfully perform this procedure, ECT 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 % .
3. Verify the test results described on the M-MDS and follow the instructions.

Scheme 33

Scheme 34

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 . Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve. 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 {13.1-15.0 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 for 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. 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. Request the PCM on-board device control (Mode 08) using the M-MDS to close the canister vent value. NOTE: The canister vent value is closed for 10 min unless the following any actions are done: The engine is started. The ignition switch is turned off position.
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 EVAP 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 testers operators 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 the pressure gauge and flow meter reading to determine if there is an EVAP leak

NO EVAPORATIVE LEAK

1. The flow meter registers "zero flow" and the pressure gauge returns to the pre-set pressure of 356 mm {14.0 in} of water (H2O).

EVAPORATIVE LEAK

1. The pressure does not return to the preset level of 356 mm {14.0 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 .