Engine Controls - System & Component Testing: Diagnosis Mazda Millenia I рестайлинг

626 2.0L (Using New Generation Star (NGS) Scan Tool)

1. Warm engine to normal operating temperature. Connect NGS scan tool to DLC-2. DLC-2 is located under left side of instrument panel, right of steering column. Using scan tool, access DIAGNOSTIC DATA LINK menu, and select PCM. Highlight and select PID/DATA MONITOR AND RECORD.
2. Turn ignition on. Select O2S11 PID for front HO2S or O2S12 PID for rear HO2S. See PIN VOLTAGE/PID VALUE CHARTS article. If voltage is not as specified, check wiring harness between PCM and HO2S. Also check intake manifold system, fuel system and self-diagnostic system. Repair as necessary. If no problems are present, replace HO2S.
3. To test HO2S heating element, allow sensor to cool to room temperature. Disconnect HO2S connector. Using ohmmeter, measure resistance between appropriate HO2S 4-pin connector terminals "C" and "D". see scheme 18 Resistance should be about 6 ohms at 68°F (20° C). If resistance is not as specified, replace suspect HO2S.

EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER

Note. Perform this test using Mazda Special Service Tool (SST) - Evaporative Emission System Tester (MZ254AT3641).

Evaporative Emission System Tester Self Test

1. Verify gas cylinder valve is closed and control valve (located on tester) is in TEST position. All tester displays should be off at this time.
2. Connect long hose (part of SST ) to tester.
3. Connect manifold assembly (part of SST ) to long hose as shown.
4. Open gas cylinder valve and verify gas cylinder regulator left gauge reads 10 to 12 psi (preset at factory). If not, see tester operators manual to contact tester manufacturer.
5. Press ON/OFF switch to turn on SST and make sure left display reads 0.0. Turn control valve on tester to FILL position.
6. Verify left display reading is within 13.9 to 14.0 inches of water. If not, adjust pressure using regulator knob located on right side of tester.
7. Turn control valve to TEST position and press START switch.
8. After 2-minute countdown (left display) is completed, right display shows total pressure loss for that period. A 0.5 inch of water loss is acceptable on self-test. If loss is more than 0.5 inch of water, perform one or more self-test. If failed test repeats, check for leak using the ultrasonic leak detector (part of SST ).

Leak Inspection

1. Press RESET switch to set left display reading to 0.0.
2. Connect fuel cap test adapter (part of SST) to manifold assembly and fuel-filler cap from vehicle. If fuel-filler cap is not a Mazda part, replace it.
3. Connect threaded test adapter (part of SST) to manifold assembly and fuel-filler neck.
4. Connect scan tool to DLC-2.
5. Turn ignition switch on, engine off.
6. Close Canister Drain Cut Valve (CDCV) using ON BOARD DEVICE CONTROL function. NOTE: CDCV is closed for 10 minutes unless any of following action is done: Engine is started. Ignition switch is turned off. Fuel tank pressure sensor signal exceeds 1.9 in. Hg.
7. Turn control valve to FILL position.
8. Wait (maximum 40 seconds) until left display reads 13.5 to 14.0 inches of water. If reading is slightly below, adjust reading using regulator knob. If reading is far below, EVAP system has large leak. Check for leak using ultrasonic leak detector if necessary. Repair as necessary.
9. Turn control valve to TEST position and press START switch.
10. After 2-minute countdown (left display) is completed, check test result (FAILED/PASSED light on tester). If Green light turns on, EVAP system is OK. If Red light turns on, EVAP system has leakage.
11. Check for leak using ultrasonic leak detector and repair.
12. Close gas cylinder valve.
13. Turn control valve to FILL position.
14. Press ON/OFF switch to turn off tester.

FUEL-FILLER CAP INSPECTION

Note. Perform this test using Mazda Special Service Tool (SST) - Evaporative Emission System Tester (MZ254AT3641).

Perform evaporative emission system self test. See EVAPORATIVE EMISSION SYSTEM TESTER SELF TEST under EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER.

Leakage Inspection

1. Press RESET switch to set left display reading to 0.0.
2. Connect fuel cap receiver assembly (part of SST ) to manifold assembly and fuel-filler cap from vehicle. If fuel-filler cap is not a Mazda part, replace it.
3. Turn control valve to FILL position.
4. Wait (maximum 20 seconds) until left display reads 13.9-14 inches of water. If reading is slightly below, adjust it using regulator knob. If reading is far below, fuel-filler cap has leak. Replace fuel-filler cap.
5. Turn valve to EST position and press START switch.
6. After 2-minute countdown (left display) is completed, check test result (FAILED/PASSED light on tester). If Green light turns on, fuel-filler cap is OK. If the Red light turns on, fuel-filler cap has leakage. Replace fuel-filler cap.
7. Close gas cylinder valve.
8. Turn control valve to FILL position.
9. Press ON/OFF switch to turn off tester.

System Inspection

Purge system operation takes place when vehicle is accelerating in gear (off idle), engine is at operating temperature and HO2S is functioning normally. Ensure all vapor lines are connected and in acceptable condition. (Scheme 64)or (Scheme 65).

Note. Evaporative emission system schematic for Protege and 626 is not available from manufacturer.

Scheme 64

Scheme 65

Purge system operation takes place when vehicle is accelerating in gear (off idle), engine is at operating temperature and HO2S is functioning normally. Ensure all vapor lines are connected and in acceptable condition. (Scheme 66)

Scheme 66

EVAP System Test

Note. This can be used as an alternative to Drive mode 4.

Scheme 67

Scheme 68

1. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. Select PID/DATA MONITOR AND RECORD function. Check PIDs. Ensure BARO (72.2 kPa or more), ECT (-7.5-78°C), FLT V (.5-1.9 volts) and IAT (0-60°C) are as specified. Ensure IAT and ECT are less than 10°C.
2. Start engine. Run engine at 3500 RPM for 200 seconds. Select DIAGNOSTIC SUPPORT PROCEDURE and press TRIGGER. Select SINGLE TEST and press TRIGGER. Select EVAP LEAK TEST and press TRIGGER. Press TRIGGER again to start EVAP system test. Engine speed should raise to 2000 RPM. After one minute, depress accelerator to end test. Check and record FTP1SV and FTP2SV PIDs. Check FTP1SV/BARO PID value. (Scheme 67) If FTP1SV/BARO PID is okay, go to next step. If FTP1SV/BARO PID is not within specification, a large leak is present. See DTC P0455.
3. Check FTP2SP/BARO PID value. (Scheme 68) If FTP2SP/BARO PID value is okay, test is complete. If FTP2SP/BARO PID value is not within specification, a small leak is present. See DTC P0442.

Whole System Test

Note. Test must be performed within 10 minutes and without starting engine. Do not exceed 6.4 kPa pressure in EVAP system.

Disconnect vacuum hose from catch tank to purge solenoid valve at valve. (Scheme 66) Connect hose to vacuum pump. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. (Scheme 69) Select ON BOARD DEVICE CONTROL function. Press CANCEL twice. Select PID/DATA MONITOR AND RECORD function. Select FTP PID. Press START to view PID. Apply 1.7 kPa vacuum. Vacuum should hold for at least two minutes. If vacuum does not hold, check FTP sensor. If FTP sensor is okay, go to CHARCOAL CANISTER-TO-PURGE SOLENOID TEST.

Scheme 69

Charcoal Canister-To-Purge Solenoid Test

Note. Test must be performed within 10 minutes and without starting engine. Do not exceed 6.4 kPa pressure in EVAP system.

Check hose condition and routing between charcoal canister and purge solenoid valve. (Scheme 66) Repair as necessary. Disconnect fuel tank side of charcoal canister. Connect hose from vacuum pump to charcoal canister. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. (Scheme 69) Select ON BOARD DEVICE CONTROL and press TRIGGER. Press CANCEL twice. Select PID/DATA MONITOR AND RECORD function. Select FTP PID. Press start to view PID. Apply 1.7 kPa vacuum. Vacuum should hold for at least two minutes. If vacuum does not hold, check FTP sensor, purge solenoid valve, catch tank, charcoal canister, CDCV and connecting hoses. Repair or replace as necessary. If vacuum holds, reconnect hose and go to CHARCOAL CANISTER-TO-FUEL TANK TEST.

Charcoal Canister-To-Fuel Tank Test

Note. Test must be performed within 10 minutes and without starting engine. Do not exceed 6.4 kPa pressure in EVAP system.

Check hose condition and routing between charcoal canister and fuel tank. Repair as necessary. Disconnect vacuum hose from fuel tank to charcoal canister at canister. (Scheme 66) Connect hose to vacuum pump. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. (Scheme 69) Select ON BOARD DEVICE CONTROL function. Press CANCEL twice. Select PID/DATA MONITOR AND RECORD function. Select FTP PID. Press START to view PID. Apply 1.7 kPa vacuum. Vacuum should hold for at least two minutes. If vacuum does not hold, check fuel filler cap, fuel filler pipe, fuel tank and connecting hoses. Repair or replace as necessary.

Purge Control Test

1. Start engine. Disconnect vacuum hose from catch tank to purge solenoid valve at valve. Check that there is no vacuum at purge solenoid valve fitting when engine is cold. If no vacuum is present, go to next step. If vacuum is present, check purge solenoid valve and wiring between purge solenoid valve and PCM terminal No. 18. Repair as necessary.
2. Warm engine to operating temperature. Turn ignition off. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. (Scheme 69) Turn ignition on. Select PID/DATA MONITOR AND RECORD. Select ECT PID. Ensure ECT is more than 140°F (60°C). If ECT is as specified, go to next step. If ECT PID is 140°F (60°C) or less, check ECT sensor. Repair as necessary.
3. Select SIMULATION TEST. Select PRG V PID. Press start. Using scan tool, increase purge solenoid valve duty cycle to 50 percent. If valve operation is heard, check vacuum hoses between intake manifold, purge solenoid valve, catch tank and charcoal canister. If valve operation is not heard, check purge solenoid valve. Repair as necessary.

System Inspection - Except MPV

Remove Positive Crankcase Ventilation (PCV) valve, with hose attached, from valve cover. Block PCV valve opening and check for vacuum. If no vacuum is felt, check for collapsed or blocked PCV valve hose. Repair as necessary. If hose is okay, replace PCV valve.

System Inspection - MPV

Remove PCV valve from valve cover. Blow air into port "A". (Scheme 70) Air should flow from port "C". Blow air into port "B". Air should flow from port "C". Blow air into ports "B" or "C". Air should not flow from port "A". Repair as necessary. If hose is okay, replace PCV valve.

Scheme 70

Inspection

Note. Ensure no HO2S DTC has been detected. If detected, this inspection cannot be used.

Using scan tool, access O2S11 (front HO2S) and O2S12 (rear HO2S) PIDs. Drive vehicle for 10 minutes at 40-60 MPH to ensure Warm Up Three-Way Catalytic Converter (WU-TWC) reaches operating temperature. Let engine idle and record PIDs for one minute. Scan tool should display graphs for O2S11 and O2S12. (Scheme 71)and (Scheme 72). Count number of times graphline crosses below.5V line (inversion) for both front and rear HO2Ss. Divide number of inversions for front HO2S by number of inversions for rear HO2S for ratio data. If ratio is 2 or more or no rear HO2S inversions, WU-TWC converter is functioning properly. (Scheme 71)and (Scheme 72). If ratio is less than 2, WU-TWC converter has deteriorated. (Scheme 71)and (Scheme 73). Replace WU-TWC converter.

Scheme 71

Scheme 72

Scheme 73

VACUUM LINE INSPECTION (MILLENIA S)

Remove the clamps and the hose. Apply both suction and pressure to the engine-side of the hose, and verify that air flows only toward that side. (Scheme 74) If air flows in both directions or not at all, replace the vacuum hose.

Scheme 74

VACUUM PUMP INSPECTION (MILLENIA S)

1. Disconnect the vacuum hose from the power brake unit side of the vacuum pump and plug them.
2. Disconnect the vacuum hose from the solenoid valve side of the vacuum pump and connect a vacuum gauge as shown in illustration. (Scheme 75)
3. Under the conditions specified in the «VACUUM PUMP SPECIFICATIONS»(ref-12154-S23573536162004120600000) table, measure the vacuum using a vacuum gauge. If not as specified, replace the pump. VACUUM PUMP SPECIFICATIONS Condition Vacuum In Hg. (KPa) After Running Engine At 900 RPM For 20 Seconds 17.3 (58.7) After Running Engine At 1800 RPM For 20 Seconds 22.8 (77.3)

Scheme 75