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Engine Controls - Basic Diagnostic Procedures: Other Mazda 626 GF

Testing & Diagnostics 13 illustrations ~2658 words

Compression

Check engine mechanical condition with a compression gauge, vacuum gauge, or an engine analyzer. Ensure oil level and condition are okay. Ensure battery is fully charged. See engine analyzer manual for specific instructions.

WARNINGDO NOT use ignition switch during compression tests on fuel injected vehicles. Use a remote starter to crank engine. Fuel injectors on many models are triggered by ignition switch during cranking, which can create a fire hazard or contaminate the engine's oiling system.
ApplicationMinimum psi (kg/cm 2 ) @ RPMStandard psi (kg/cm 2 ) @ RPM
Miata146 (10.3) @ 300209 (14.7) @ 300
Millenia (1)
2.3L121 (8.5) @ 250164 (11.5) @ 250
2.5L132 (9.3) @ 300189 (13.3) @ 300
Protege (1)
1.6L146 (10.3) @ 300195 (13.7) @ 300
1.8L156 (11.0) @ 300199 (14.0) @ 300
626 (1)
2.0L119 (8.4) @ 300171 (12.0) @ 300
2.5L141 (9.9) @ 250203 (14.3) @ 250
(1) Difference between cylinders should not be more than 28 psi (2.0 kg/cm 2 ).
(1)Difference between cylinders should not be more than 28 psi (2.0 kg/cm 2 ).

COMPRESSION SPECIFICATIONS

Exhaust System Backpressure

Exhaust system can be checked with a vacuum or pressure gauge. Remove Heated Oxygen Sensor (HO2S) or air injection check valve (if equipped). Connect a 0-5 psi pressure gauge and run engine at 2500 RPM. If exhaust system backpressure is greater than 2 psi, exhaust system or catalytic converter is plugged.

If a vacuum gauge is used, connect vacuum gauge hose to intake manifold vacuum port and start engine. Observe vacuum gauge. Open throttle part way and hold steady. If vacuum gauge reading slowly drops after stabilizing, exhaust system should be checked for a restriction.

PRELIMINARY CHECKS

Ensure following systems and components are in good condition and operating properly before diagnosing problems in fuel injection system

  1. Check battery and charging system condition.
  2. Check all wiring and vacuum connections.
  3. Check air cleaner and ducting.
  4. Check state of tune.
  5. Check fuel delivery system.
  6. Check cooling system.
  7. Check inertia fuel shutoff switch.
  8. Check for blown head gasket (liquid in cylinder).
  9. Check fuel tank contents and fuel gauge accuracy.
  10. Check for dirt, water or other contamination in fuel.
  11. Check fuel lines and fittings for leaks.
  12. Check fuel delivery system for proper pressure and volume.
  13. Check for inoperative fuel injectors.
  14. Check for improperly installed electronic equipment such as anti-theft system, CB radio, cellular telephone or stereo.

Engine Does Not Crank

Check for enabled anti-theft system. Check starting and charging system for correct operation. Check for hydrostatic lock (liquid in cylinder). Repair as necessary.

Engine Cranks But Will Not Start

  1. Check fuel tank contents and fuel gauge accuracy. Check for dirt, water or contamination in fuel.
  2. Check fuel lines and fittings for leaks. If no leaks are found, check fuel delivery system for proper pressure and volumes. Reset Inertia Fuel Shutoff (IFS) switch (if necessary).
  3. Check for damaged or contaminated fuel injector wiring harness and connector. Ensure fuel injectors pulse when engine is cranked.
  4. Check ignition system for strong spark at spark plugs. If no spark exists or if spark is weak, proceed as follows: On all EEC-V models, go to step 1) of TEST JE in SELF-DIAGNOSTICS - B2500, B3000 & B4000 article. On all others, go to appropriate SELF-DIAGNOSTICS article.

All Models

Disconnect fuel pump relay. See FUEL PUMP RELAY LOCATIONS table. Start engine (if possible) and allow to die. Turn ignition off. Reconnect fuel pump relay.

ApplicationLocation
MiataAbove Accelerator Pedal
Millenia 2.3LIn Left Rear Of Engine Compartment, Mounted Near Cruise Actuator
Millenia 2.5L, Protege & 626Fuse/Relay Box In Left Side Of Engine Compartment

FUEL PUMP RELAY LOCATIONS

Scheme 1

Scheme 1: Fuel Pressure Hold
  1. Disconnect negative battery cable. Install fuel pressure gauge in fuel supply line. Reconnect negative battery cable.
  2. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on for 10 seconds to operate fuel pump. Turn ignition off and disconnect jumper wire. Wait 5 minutes and observe fuel pressure. Fuel pressure should be at least 21 psi (1.5 kg/cm 2 ).
  3. If fuel pressure is not as specified, check fuel pump hold pressure and fuel pressure regulator hold pressure. See «FUEL PUMP HOLD PRESSURE»(ref-91094-S31190704732001030200000) and «FUEL PRESSURE REGULATOR HOLD PRESSURE»(ref-91094-S40910003862001030200000). Also check for injector fuel leakage. See «INJECTOR FUEL LEAKAGE»(ref-91094-S06074670342001030200000).

Fuel Line Pressure (Except "B" Series Trucks)

  1. Disconnect negative battery cable. Install fuel pressure gauge in fuel supply line. Reconnect negative battery cable. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on and observe fuel line pressure. See «FUEL LINE PRESSURE»(ref-91094-S03207757172001030200000) table.
  2. If fuel line pressure is high, replace fuel pressure regulator. If fuel line pressure is low, check fuel pump maximum pressure. See «FUEL PUMP MAXIMUM PRESSURE»(ref-91094-S21448952062001030200000). If fuel pump maximum pressure is as specified, check for plugged or restricted fuel line or fuel filter. Repair as necessary. If no problems are found, check pressure regulator hold pressure. See «FUEL PRESSURE REGULATOR HOLD PRESSURE»(ref-91094-S40910003862001030200000).
ApplicationPressure psi (kg/cm 2 )
Miata53-61 (3.7-4.3)
Millenia
2.3L41-48 (2.8-3.4)
2.5L38-46 (2.7-3.2)
Protege41-46 (2.8-3.2)
62638-46 (2.7-3.2)

FUEL LINE PRESSURE

Fuel Line Pressure ("B" Series Trucks)

  1. Install Fuel Pressure Gauge (49 UN01 010) to fuel pressure relief valve (Schrader valve) located on fuel rail. Turn ignition on with engine off. Connect New Generation Star (NGS) scan tool to Data Link Connector (DLC). Connector is located under left side of instrument panel, right of steering column. Using scan tool, select ACTIVATE COMMAND MODES. Select OUTPUT TEST MODE. Press MODE to change to ALL ON mode. Press start to run fuel pump. Turn relay off. Observe fuel pressure.
  2. Fuel pressure should be 30-45 psi (2.0-3.1 kg/cm 2 ). If pressure is zero or low, check fuel pump. See FUEL PUMP. If fuel pump is okay, check for plugged or restricted fuel line or fuel filter. If pressure is high, check for high pressure in fuel pressure regulator. See FUEL PRESSURE REGULATOR HIGH PRESSURE.
  3. Wait one minute and observe fuel pressure. Fuel pressure should be within 5 psi (.35 kg/cm 2 ) of reading in step 2). If fuel pressure is not as specified, check fuel pressure regulator diaphragm. See FUEL PRESSURE REGULATOR DIAPHRAGM. Also, check for injector fuel leakage. See INJECTOR FUEL LEAKAGE. If fuel pressure is as specified, check fuel line pressure under load. See FUEL LINE PRESSURE UNDER LOAD.

Fuel Pump

  1. Fuel pump is located inside fuel tank. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Remove fuel filler cap. Turn ignition on. Listen for fuel pump operation at fuel filler. Install fuel filler cap.
  2. If fuel pump does not operate, using DVOM, measure voltage between fuel pump connector power terminal and chassis ground. If battery voltage is present, go to next step. If battery voltage is not present, repair power circuit to fuel pump. See appropriate wiring diagram in WIRING DIAGRAMS article.
  3. Using DVOM, check for continuity between fuel pump connector ground terminal and chassis ground. If continuity exists, replace fuel pump. If continuity does not exist, repair ground circuit.

Fuel Pump Hold Pressure

  1. Disconnect negative battery cable. Disconnect fuel inlet hose at fuel rail. Install fuel pressure gauge to fuel inlet hose and plug fuel pressure gauge outlet hose. Reconnect negative battery cable.
  2. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on for 10 seconds to operate fuel pump. Turn ignition off and disconnect jumper wire. Wait 5 minutes and observe fuel pressure. On Miata and 626, fuel pressure should be more than 50 psi (3.5 kg/cm 2 ). On Millenia and Protege, fuel pressure should be at least 21 psi (1.5 kg/cm 2 ). On all models, if fuel pressure is not as specified, replace fuel pump.

Fuel Pump Maximum Pressure

  1. Disconnect negative battery cable. Disconnect fuel inlet hose at fuel rail. Install fuel pressure gauge to fuel inlet hose and plug fuel pressure gauge outlet hose. Reconnect negative battery cable.
  2. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on for 10 seconds to operate fuel pump and observe fuel pressure. See «FUEL PUMP MAXIMUM PRESSURE»(ref-91094-S27112973392001030200000) table. Turn ignition off and disconnect jumper wire. If fuel pressure is not as specified, replace fuel pump.
ApplicationPressure psi (kg/cm 2 )
Miata92 (6.5)
Millenia71-92 (5.0-6.5)
62671-92 (5.0-6.5)
Protege64-92 (4.5-6.5)

FUEL PUMP MAXIMUM PRESSURE

Fuel Pump Relay

  1. Locate fuel pump relay. See «FUEL PUMP RELAY LOCATIONS»(ref-91094-S03733219232001030200000) table under FUEL PRESSURE RELEASE. Using jumper wires, connect battery voltage to fuel pump relay terminal "A" (positive) and terminal "B" (negative). (Scheme 2)or (Scheme 3).
  2. On Miata and Protege, check continuity between fuel pump relay terminals "C" and "E". On Millenia and 626, check continuity between fuel pump relay terminals "C" and "D". On all models, with battery voltage connected, continuity should exist. With battery voltage disconnected, continuity should not exist. If continuity is not as specified, replace fuel pump relay.

Scheme 2

Scheme 2

Scheme 3

Scheme 3

Fuel Pressure Regulator

  1. Disconnect negative battery cable. Install fuel pressure gauge in fuel supply line. Reconnect negative battery cable.
  2. Start and operate engine at idle. Ensure vacuum is available to pressure regulator. Observe fuel pressure with vacuum hose connected and disconnected at fuel pressure regulator. See «REGULATED FUEL PRESSURE»(ref-91094-S01829061782001030200000) table. If fuel pressure is not as specified, check fuel pressure regulator hold pressure. See «FUEL PRESSURE REGULATOR HOLD PRESSURE»(ref-91094-S40910003862001030200000) .
ApplicationAt Idle W/ Vacuum psi (kg/cm 2 )At Idle W/O Vacuum psi (kg/cm 2 )
Miata30-37 (2.1-2.6)38-46 (2.7-3.2)
62630-37 (2.1-2.6)38-46 (2.7-3.2)
Protege28-34 (2.0-2.4)40-46 (2.8-3.2)

REGULATED FUEL PRESSURE

Fuel Pressure Regulator Hold Pressure

  1. Disconnect negative battery cable. Install fuel pressure gauge in fuel supply line. Reconnect negative battery cable.
  2. Locate data link connector in left side of engine compartment. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on for 10 seconds to operate fuel pump. Turn ignition off and disconnect jumper wire. Carefully pinch fuel return hose closed. Wait 5 minutes and observe fuel pressure.
  3. Fuel pressure should be more than 21 psi (1.5 kg/cm 2 ). If fuel pressure is not as specified, replace fuel pressure regulator.

Injector Fuel Leakage

  1. Using mechanics wire, secure each fuel injector to fuel rail. Disconnect fuel injector connectors. Remove fuel rail assembly from intake manifold. See REMOVAL, OVERHAUL & INSTALLATION article. Reconnect fuel lines to fuel rail. Locate data link connector in left side of engine compartment.
  2. Connect a jumper wire between data link connector terminals F/P and GND. (Scheme 1) Turn ignition on. Tilt injectors about 60 degrees and check injector nozzles for fuel leaks. Fuel leakage should be less than one drop every 2 minutes. If fuel leakage exists, replace injector.

IGNITION CHECKS

CAUTIONWhile performing diagnostics, DO NOT connect Powertrain Control Module (PCM) to breakout box unless directed to do so.

Note. Perform following tests in sequence shown, unless test procedures indicate otherwise. For the following test, the term Electronic Ignition (EI) may be used to describe the ignition system.

Spark Check

Remove spark plug. Connect spark plug to high-tension lead and hold about 1/4" from ground. Crank engine and verify a strong Blue spark is discharged. If spark is not present, measure spark plug wire resistance on suspect wire. Resistance should be less than 16,000 ohms per 3.28 feet. Replace spark plug wire and spark plug as necessary.

Ignition Coil Power Source

Turn ignition on. Using voltmeter, check for 12 volts between ignition coil positive (+) terminal and ground. If voltage is not present, check battery feed, main fuse, ignition switch and fusible links. See appropriate wiring diagram in WIRING DIAGRAMS article.

Ignition Coil Resistance (Miata)

  1. Disconnect 4-pin connector. Using ohmmeter, measure primary resistance between terminals "A" and "D". (Scheme 8) Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace coil.
  2. Using an ohmmeter, measure secondary resistance between terminal "A" and coil tower. (Scheme 9) Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace coil.

Ignition Coil Resistance (Millenia 2.3L)

Ignition coil and ignition control module are integrated as a coil-on-plug unit. Ignition coil testing procedure and resistance specifications are not available from manufacturer. If misfire DTC is present (DTC's P0300-P0306), refer to appropriate Self-Diagnostics article to retrieve codes and diagnose misfire. Misfire diagnostic procedure includes switching ignition coil with a known good ignition coil from another cylinder.

Ignition Coil Resistance (Millenia 2.5L)

  1. Disconnect 3-pin harness connector. Using ohmmeter, measure primary resistance between terminals "A" and "B". (Scheme 4) Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace distributor.
  2. Using an ohmmeter, measure secondary resistance between terminal "A" and coil tower. (Scheme 5) Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace distributor.

Scheme 4

Scheme 4

Scheme 5

Scheme 5

Ignition Coil Resistance (626 2.0L & 2.5L)

  1. Disconnect ignition coil harness connector. Using ohmmeter, on 2.0L, measure primary resistance between ignition coil terminals "A" and "B" and terminals "B" and "C". On 2.5L, measure between terminals "A" and "D", terminals "B" and "D" and terminals "C" and "D". (Scheme 6)or (Scheme 7). Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace ignition coil.
  2. Disconnect high tension leads. Using an ohmmeter, on 2.0L, measure secondary resistance between coil towers No. 1 and 4 and towers No. 2 and 3. On 2.5L, measure secondary resistance between coil towers No. 1 and 4, towers No. 2 and 5 and towers No. 3 and 6. (Scheme 6)or (Scheme 7). Resistance should be as specified. See «IGNITION COIL RESISTANCE»(ref-91094-S14755129822001030200000) table. If resistance is not as specified, replace ignition coil.
  3. Measure resistance between terminal "D" and coil case. Resistance should be greater than 10-megohms. If resistance is not as specified, replace coil.

Scheme 6

Scheme 6

Scheme 7

Scheme 7

Ignition Coil Resistance (Protege)

Ignition coil is integrated into distributor. Disconnect distributor 7-pin connector. Remove distributor cap. Using an ohmmeter, measure secondary resistance between terminal "G" and coil tower. (Scheme 10) If resistance is not as specified, replace distributor. See IGNITION COIL RESISTANCE table.

ApplicationPrimarySecondary
Miata(1)8240-12,360
Millenia
2.3L(2)(2)
2.5L.49-.73(3) 20,000-31,000
Protege(1)(3) 20,000-31,000
626.45-.5511,500-15,500
(1) Information is not available from manufacturer. (2) Refer to IGNITION COIL RESISTANCE (MILLENIA 2.3L) . (3) Remove distributor cap to measure secondary coil resistance.
(1)Information is not available from manufacturer.
(2)Refer to IGNITION COIL RESISTANCE (MILLENIA 2.3L) .
(3)Remove distributor cap to measure secondary coil resistance.

IGNITION COIL RESISTANCE - Ohms @ 68°F (20°C)

Scheme 8

Scheme 8

Scheme 9

Scheme 9

Scheme 10

Scheme 10

Crankshaft Position Sensor Resistance

Disconnect crankshaft position sensor connector. Using ohmmeter, measure resistance between terminals "A" and "B". (Scheme 11) Resistance should be as specified. See CRANKSHAFT POSITION SENSOR RESISTANCE table. If resistance is not as specified, replace crankshaft position sensor.

ApplicationOhms @ 68°F (20°C)
Miata(1)
Millenia
2.3L950-1250
2.5L520-580
Protege500-600
626520-580
(1) Information is not available from manufacturer.
(1)Information is not available from manufacturer.

CRANKSHAFT POSITION SENSOR RESISTANCE

Scheme 11

Scheme 11

Crankshaft Position Sensor Air Gap

Using a feeler gauge, measure air gap between crankshaft pulley and crankshaft position sensor. (Scheme 12) Air gap should be as specified. See CRANKSHAFT POSITION SENSOR AIR GAP table. If air gap is not as specified, replace crankshaft pulley or crankshaft position sensor.

ApplicationIn. (mm)
Miata, Protege & 626.020-.059 (.5-1.5)
Millenia
2.3L.040-.080 (1.0-2.0)
2.5L.020-.059 (.5-1.5)

CRANKSHAFT POSITION SENSOR AIR GAP

Scheme 12

Scheme 12

Camshaft Position Sensor Resistance (626 - 2.0L & 2.5L)

Disconnect camshaft position sensor. Using DVOM, measure resistance between terminals "A" and "B". If resistance reading is about 950-1250 ohms (550 ohms on 2.5L), check related wiring harness and connectors. If resistance is not as specified, replace camshaft position sensor.

Camshaft Position Sensor Voltage (Millenia 2.3L)

  1. Remove camshaft position sensor and reconnect connector. Disconnect ignition control module connector. Disconnect fuel injector connector. Turn ignition on. Connect Harness Adapter (49 T018 902) and Signal Monitor (49 9200 162A) to ECM. (Scheme 13)
  2. Set signal monitor to specified ECM terminal. Rotate camshaft position sensor by hand and measure output voltage. See «CAMSHAFT POSITION SENSOR VOLTAGE»(ref-91094-S41667643802001030200000) table. If voltage is not as specified, check wiring harness and connectors. If harness and connectors are okay, replace camshaft position sensor.

Camshaft Position Sensor Voltage (Except Millenia 2.3L & 626)

  1. Remove distributor and reconnect connector. Disconnect ignition control module connector. Disconnect fuel injector connector. Turn ignition on. Connect Harness Adapter (49 T018 902) and Signal Monitor (49 9200 162A) to ECM/PCM. (Scheme 13)
  2. Set signal monitor to specified ECM/PCM terminal. Rotate distributor drive by hand and measure output voltage. See «CAMSHAFT POSITION SENSOR VOLTAGE»(ref-91094-S41667643802001030200000) table. If voltage is not as specified, check wiring harness and connectors. If harness and connectors are okay, replace distributor.
ECM/PCM Terminal (1)(2) Volts
Miata
4G (SGC Signal)5 (1 pulse/rev)
Millenia
4F (SGC Signal)5 (1 pulse/rev)
Protege
1.5L
3A (SGT Signal)5 (4 pulses/rev)
1.8L
4F (SGT Signal)5 (4 pulses/rev)
(1) See PIN VOLTAGE CHARTS article for terminal identification. (2) Rotate sensor/distributor by hand while measuring output voltage.
(1)See PIN VOLTAGE CHARTS article for terminal identification.
(2)Rotate sensor/distributor by hand while measuring output voltage.

CAMSHAFT POSITION SENSOR VOLTAGE

Scheme 13

Scheme 13

Ignition Control Module (Miata & Protege)

Check ignition coil, ECM/PCM and high-tension lead connections. Check secondary coil winding and high-tension lead resistance. Measure voltage between ground and appropriate ECM/PCM terminals. See ECM/PCM TERMINAL IDENTIFICATION table. If all measurements are within specification, and misfire still occurs, replace distributor or ignition coil.

Ignition Control Module (Millenia)

Testing information is not available from manufacturer. Check for diagnostic trouble codes. See appropriate SELF-DIAGNOSTICS article.

Wire Color To Ground (1)KOEO VoltsKOER (Idle) Volts
Miata
Brown/Yellow(3G)Less Than 1.2
Brown (3H)Less Than 1.2
Protege
1.5L
Violet/Green (3A)0 Or 52
Yellow/Black (4N)Less Than 1.3
1.8L
Violet/Green (4F)0 Or 52
Yellow/Black (4N)Less Than 1.3
(1) ECM/PCM terminal number in parentheses. See PIN VOLTAGE CHARTS article for terminal identification.
(1)ECM/PCM terminal number in parentheses. See PIN VOLTAGE CHARTS article for terminal identification.

ECM/PCM TERMINAL IDENTIFICATION

IDLE SPEED & IGNITION TIMING

Ensure idle speed and base ignition timing are set to specification. See IDLE SPEED SPECIFICATIONS and IGNITION TIMING SPECIFICATIONS (Degrees BTDC @ RPM) tables. If adjustment is necessary, see ON-VEHICLE ADJUSTMENTS article.

ApplicationMan. Trans. RPM(1) Auto. Trans. RPM
Miata750-850750-850
MilleniaN/A600-700
Protege (2)650-750700-800
626
2.0L550-850500-800
2.5L550-750550-750
(1) Place automatic transmission in Park. (2) Connect a jumper wire between terminals TEN and GND at data link connector. (Scheme 1)
(1)Place automatic transmission in Park.
(2)Connect a jumper wire between terminals TEN and GND at data link connector. (Scheme 1)

IDLE SPEED SPECIFICATIONS

ApplicationMan. Trans.(1) Auto. Trans.
Miata9-11@ 8009-11@ 800
Millenia (2)N/A6-8 @ 650
Protege (2)9-11 @ 7509-11 @ 750
626
2.0L6-18 @ 550-8506-18 @ 500-800
2.5L4-16 @ 550-7504-16 @ 550-750
(1) Place automatic transmission in Park. (2) Connect a jumper wire between terminals TEN and GND of data link connector. (Scheme 1)
(1)Place automatic transmission in Park.
(2)Connect a jumper wire between terminals TEN and GND of data link connector. (Scheme 1)

IGNITION TIMING SPECIFICATIONS (Degrees BTDC @ RPM)

SUMMARY

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to appropriate SELF-DIAGNOSTICS article. If no hard codes are found in self-diagnostics, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.