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Engine Control System [Mzr 2.5]: Diagnosis Mazda 6 GJ

Testing & Diagnostics 8 illustrations ~1394 words

VARIABLE TUMBLE SHUTTER VALVE POSITION SENSOR INSPECTION [MZR 2.5]

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

Scheme 11

Scheme 11: VARIABLE TUMBLE SHUTTER VALVE POSITION SENSOR INSPECTION [MZR 2.5]
Scheme 11: VARIABLE TUMBLE SHUTTER VALVE POSITION SENSOR INSPECTION [MZR 2.5]
  1. Connect the M-MDS to the DLC-2. (Scheme 11): Identifying DLC-2
  2. Switch the ignition to ON.
  3. Verify that the variable tumble shutter valve position sensor output voltage (PID: IMRC_POS) within the specification. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-581633-S34331335932013101400000) ) (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000).) If not as specified, replace the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)

MASS AIR FLOW (MAF) SENSOR INSPECTION [MZR 2.5]

Note. The MAF sensor and IAT sensor cannot be removed as a single unit. When replacing the MAF sensor or IAT sensor, replace it together with the MAF/IAT sensor as a single unit.

Scheme 12

Scheme 12: MASS AIR FLOW (MAF) SENSOR INSPECTION [MZR 2.5]
Scheme 12: MASS AIR FLOW (MAF) SENSOR INSPECTION [MZR 2.5]
  1. Verify the connection condition of the MAF sensor/IAT sensor connector. If a connector has poor contact, install it correctly and then go to the next step. If the connector connection is normal, go to the next step.
  2. Verify the MAF sensor voltage under no airflow conditions using the following procedure: Connect the M-MDS to the DLC-2. CAUTION: Do not create suction in the exhaust pipe by cranking the engine and causing air to flow through the exhaust duct. It could cause a measurement error because the MAF sensor voltage is measured under no airflow conditions. Switch the ignition to ON (engine off) and wait for 30 s. Verify that the MAF/IAT sensor output voltage (PID: MAF). Specification 0.68 V If it is the specification or more, replace the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).) If it is less than the specification, go to the next step.
  3. Remove the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)
  4. Verify that there is no foreign matter in the MAF/IAT sensor. Shine light on the sensor (Direction A in figure below) in the flow path and verify visually. If there is visible, large foreign matter, replace the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).) If there is no foreign matter, go to the next step. (Scheme 12): Inspecting Sensor For Foreign Matter
  5. Verify that there is no damage, cracks, or dirt on the MAF sensor part of the MAD/IAT sensor. If a malfunction can be verified, repair or replace the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).) If a malfunction cannot be verified, go to the next step (MAF sensor is normal). NOTE: Install the removed MAF/IAT sensor because the MAF sensor is normal.
  6. Install the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)

INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR 2.5]

Note. The MAF sensor and IAT sensor cannot be removed as a single unit. When replacing the MAF sensor or IAT sensor, replace it together with the MAF/IAT sensor as a single unit.

Scheme 13

Scheme 13: INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR 2.5]
Scheme 13: INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR 2.5]
  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000).)
  2. Disconnect the MAF/IAT sensor connector.
  3. Measure the resistance between MAF/IAT sensor terminals D and E. (Scheme 13): Identifying MAF/IAT Sensor Connector Terminals If not as specified, replace the MAF/IAT sensor. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)

BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION [MZR 2.5]

Note. The BARO sensor cannot be removed as a single unit. When replacing the BARO sensor, replace it together with the PCM as a single unit.

Scheme 14

Scheme 14: BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION [MZR 2.5]
Scheme 14: BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION [MZR 2.5]
  1. Connect the M-MDS to the DLC-2. (Scheme 14): Identifying DLC-2
  2. Switch the ignition to ON.
  3. Verify that the BARO sensor output voltage (PID: BARO) within the specification. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-581633-S34331335932013101400000).) (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000).) If not as specified, replace the PCM. (See «PCM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S36222280212013101400000).)

THROTTLE POSITION (TP) SENSOR INSPECTION [MZR 2.5]

CAUTIONThe inspection cannot be performed with this method correctly if there is a malfunction of the APP sensor or throttle valve actuator. Verify that no DTCs related to the APP sensor or throttle valve actuator are stored before the inspection.

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

Scheme 15

Scheme 15
Scheme 15
  1. Connect the M-MDS to the DLC-2. (Scheme 15): Identifying DLC-2
  2. Switch the ignition to ON.
  3. Verify that the TP sensor output voltage (PID: TP1, TP2) is within the specification. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-581633-S34331335932013101400000).) (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000).) If not as specified, replace the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)

ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR 2.5]

Note. The APP sensor cannot be removed as a single unit. When replacing the APP sensor, replace it together with the accelerator pedal as a single unit.

Scheme 16

Scheme 16: ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR 2.5]
Scheme 16: ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR 2.5]
  1. Connect the M-MDS to the DLC-2. (Scheme 16): Identifying DLC-2
  2. Switch the ignition to ON.
  3. Verify that the APP sensor output voltage (PID: APP1, APP2) increases according to the increase in the accelerator opening angle when the accelerator opening angle is gradually increased. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-581633-S34331335932013101400000).) If verified, go to the next step. If not as verified, replace the accelerator pedal. (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S05648032372013101400000).)
  4. Verify that the APP sensor output voltage (PID: APP1, APP2) is within the specification when the accelerator pedal is depressed and not depressed. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.5]»(ref-581633-S34331335932013101400000).) (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000).) If not as specified, replace the accelerator pedal. (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S05648032372013101400000).)

Air Gap Inspection

  1. Verify that the CKP sensor is securely installed.
  2. Using a thickness gauge, measure the air gap between the plate projections at the back of crankshaft pulley and the CKP sensor. If not within the specification, inspect the plate projections for cracks or bending. If there is any malfunction, replace the crankshaft pulley. (See «FRONT OIL SEAL REPLACEMENT [MZR 2.5]»(ref-581643-S29010730612013101400000) .) Air gap 0.5-1.5 mm {0.02-0.05 in}

Visual Inspection

  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000) .)
  2. Perform the following procedure for easier access. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-581657-S19487724012013101400000) .) Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-581657-S33349810032013101400000) .)
  3. Disconnect the CKP sensor connector.
  4. Remove the CKP sensor. (See «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S14515451062013101400000) .)
  5. Verify that there are no metal shavings on the sensor. If there is a malfunction, remove any metal shavings that are adhering.

Voltage Inspection

CAUTIONWater penetrating the connector will cause sensor malfunction. To prevent this, be careful not to damage the wiring harnesses or the waterproof connector so as to cause water penetration.
  1. Idle the engine.
  2. Measure the crankshaft position signal and verify that rectangular waves are produced. (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000) .) If not as specified, replace the CKP sensor. (See «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S14515451062013101400000) .)
  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000) .)
  2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-581643-S18902301812013101400000) .)
  3. Disconnect the CMP sensor connector.
  4. Remove the CMP sensor. (See «CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S42651684492013101400000) .)
  5. Verify that there are no metal shavings on the sensor. If there is a malfunction, remove any metal shavings that are adhering.
CAUTIONWater penetrating the connector will cause sensor malfunction. To prevent this, be careful not to damage the wiring harnesses or the waterproof connector so as to cause water penetration.
  1. Idle the engine.
  2. Measure the camshaft position signal and verify that rectangular waves are produced. (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000) .) If not as specified, replace the CMP sensor. (See «CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S42651684492013101400000) .)

Scheme 17

Scheme 17: KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZR 2.5]
Scheme 17: KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZR 2.5]
  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000).)
  2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-581643-S18902301812013101400000).)
  3. Remove the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)
  4. Disconnect the KS connector.
  5. Remove the KS. (Scheme 17): Identifying Knock Sensor And Bolt With Torque Specification
  6. Install in the reverse order of removal.

Scheme 18

Scheme 18: KNOCK SENSOR (KS) INSPECTION [MZR 2.5]
Scheme 18: KNOCK SENSOR (KS) INSPECTION [MZR 2.5]
  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000).)
  2. Disconnect the KS connector.
  3. Measure the resistance between KS terminals A and B. (Scheme 18): Identifying Knock Sensor Connector Terminals If not as specified, replace the KS. (See «KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZR 2.5]»(ref-581641-S22704965432013101400000).) KS specification Approx. 4.87 megohms [ECT: 25 °C {77 °F}]

FUEL TANK PRESSURE SENSOR INSPECTION [MZR 2.5]

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.

  1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000) .)
  2. Remove the evaporative hose component. (See «FUEL TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581648-S31560925882013101400000) .)
  3. Reconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.5]»(ref-581638-S19258420632013101400000) .)
  4. Switch the ignition to ON.
  5. Plug one end of the evaporative hose component and verify that the output voltage from the fuel tank pressure sensor changes when pressure is applied from the other hose end. If not as verified, replace the evaporative hose component. (See «FUEL TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581648-S31560925882013101400000) .)

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