Engine Controls - System & Component Testing: Diagnosis Mazda MX-5 NB рестайлинг

IMCC System Inspection

1. Intake Manifold Communication Control (IMCC) actuator valve opens above 3750 RPM and closes again above 5500 RPM. Valve is normally closed. Using scan tool, check for DTCs. If DTC P0660 is present, see «DTC P0660: INTAKE MANIFOLD COMMUNICATION CONTROL»(ref-151881-S16421362202003010900000) testing procedure in SELF-DIAGNOSTICS - MPV article. If DTC P0660 is not present, check IMCC actuator operation. Remove IMCC actuator. Using fused jumper wires, connect battery voltage to IMCC actuator connector terminals. Ensure IMCC actuator operates properly. (Scheme 51) If IMCC actuator operates as specified, check for open or short circuit. Go to next step. If IMCC actuator does not operate as specified, replace IMCC actuator.
2. Open Circuit Inspection Disconnect PCM, IMCC actuator and main relay harness connectors. Check for continuity between following terminals: PCM 104-pin harness connector terminal No. 28 and IMCC actuator 2-pin harness connector terminal "B" (Red/Black wire). Main relay 4-pin harness connector terminal "D" (Yellow wire) and IMCC actuator harness connector terminal "A" (White/Red wire). If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: IMCC actuator harness connector terminal "A" (White/Red wire) and ground. IMCC actuator harness connector terminal "B" (Red/Black wire) and power. IMCC actuator harness connector terminal "B" (Red/Black wire) and ground. If continuity is present, repair short circuit in suspect wire or replace wire harness.

Scheme 51

Variable Air Duct (VAD) Shutter Valve Inspection - Mazda6

Remove air cleaner case. Disconnect vacuum hose from VAD shutter valve actuator. Connect vacuum pump to VAD shutter valve actuator. (Scheme 52) Apply vacuum and verify rod moves. See VAD SHUTTER VALVE ACTUATOR SPECIFICATIONS table. If rod does not move as specified, replace air cleaner. (Scheme 53)

VAD SHUTTER VALVE ACTUATOR SPECIFICATIONS

Scheme 52

Scheme 53

Variable Air Duct (VAD) Control Solenoid Valve Inspection - MAZDA6 (2.3L)

1. Remove VAD control solenoid valve. (Scheme 54) Blow air into port "A". Air should not flow through VAD valve. Connect battery to VAD control solenoid valve terminals "A" and "B". Blow air into port "A". Air should flow from port "B". If VAD control solenoid valve does not operate as specified, check for open or short circuit. Go to next step.
2. Open Circuit Inspection Check for continuity between following terminals: VAD control solenoid valve harness connector terminal "A" and main relay 4-pin harness connector terminal "C" (White wire). VAD control solenoid valve harness connector terminal "B" and PCM 30-pin harness connector terminal No. 4C (Green/White wire). If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: VAD control solenoid valve harness connector terminal "B" (Green/White wire) and ground. VAD control solenoid valve harness connector terminal "A" (White wire) and power supply. If continuity is present, repair short circuit in suspect wire or replace wire harness.

Scheme 54

Variable Air Duct (VAD) Control Solenoid Valve Inspection - MAZDA6 (3.0L)

1. Remove VAD control solenoid valve. (Scheme 54) Blow air into port "A". Air should not flow through VAD valve. Connect battery to VAD control solenoid valve terminals "A" and "B". Blow air into port "A". Air should flow from port "B". If VAD control solenoid valve does not operate as specified, check for open or short circuit. Go to next step.
2. Open Circuit Inspection Check for continuity between following terminals: VAD control solenoid valve harness connector terminal "A" and main relay 4-pin harness connector terminal "C" (White wire). VAD control solenoid valve harness connector terminal "B" and PCM 104-pin harness connector terminal No. 42 (Green/White wire). If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: VAD control solenoid valve harness connector terminal "B" (Green/White wire) and ground. VAD control solenoid valve harness connector terminal "A" (White wire) and power supply. If continuity is present, repair short circuit in suspect wire or replace wire harness.

Variable Inertia Charge System (VICS) Shutter Valve Actuator Inspection

Carry out VICS Operation Inspection. See VICS OPERATION INSPECTION. If operation is not as specified, disconnect vacuum hose from VICS shutter valve actuator. see scheme 5 Connect vacuum pump to VICS shutter valve actuator. Slowly apply vacuum and inspect rod movement of VICS shutter valve actuator. See VICS SHUTTER VALVE VACUUM APPLICATION (PROTEGE & PROTEGE5) table. If VICS shutter valve actuator operates as specified, inspect vacuum hoses for proper routing, kinks or leakage. If VICS shutter valve actuator does not operate as specified, replace VICS shutter valve actuator. After repair, return vehicle to original condition.

VICS SHUTTER VALVE VACUUM APPLICATION (PROTEGE & PROTEGE5)

Variable Inertia Charge System (VICS) Solenoid Valve Inspection - Protege & Protege5

1. Airflow Inspection Carry out VICS Operation Inspection. See «VICS OPERATION INSPECTION»(ref-151892-S29088087082003010900000). If operation is not as specified, disconnect negative battery cable. Remove VICS solenoid valve. Apply air pressure to port "B". (Scheme 55) Air should flow from port "C". Using fused jumper wires, apply battery voltage to VICS solenoid valve terminals. Apply air pressure to port "B". Air should flow from port "A". If airflow is as specified, check for open or short circuit. Go to next step. If airflow is not as specified, replace VICS solenoid valve.
2. Open Circuit Inspection Disconnect PCM 104-pin harness connector. Connect 104-Pin Breakout Box (49-UN01-130) to PCM harness connector only. see scheme 19 Using DVOM, check continuity of following circuits: Power circuit (White/Red wire) between VICS solenoid valve 2-pin harness connector terminal "A" and main relay 4-pin harness connector terminal "D". Control circuit (Blue/Red wire) between VICS solenoid valve harness connector terminal "B" and breakout box terminal No. 19. If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: Power circuit (White/Red wire) between VICS solenoid valve 2-pin harness connector terminal "A" and main relay 4-pin harness connector terminal "D" to ground. Control circuit (Blue/Red wire) between VICS solenoid valve harness connector terminal "B" and breakout box terminal No. 19 to ground. If continuity is present, repair open circuit in suspect wire or replace wire harness. After repair, return vehicle to original condition.

Scheme 55

Variable Intake-Air System (VIS) Inspection

1. Start engine.
2. Inspect rod operation. See «VIS SHUTTER VALVE ROD OPERATION - MAZDA6 (2.3L)»(ref-151892-S32701722132003050700000) table. If shutter valve actuator rod operation is not as specified, inspect as follows: Stop engine. Connect scan tool to DLC-2. Ensure DTC P0661 or P0662 is not displayed. If DTC P0661 or P0662 is displayed, see appropriate DTC testing procedure under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - MAZDA6 2.3L article. Check VIS control solenoid valve. See «VARIABLE INTAKE-AIR SYSTEM CONTROL SOLENOID VALVE INSPECTION»(ref-151892-S22195747112003050700000) . If VIS control solenoid valve is faulty, replace VIS control solenoid valve. If VIS control solenoid valve is okay, check following: Vacuum hose and vacuum chamber for looseness or damage. VIS shutter valve actuator. See «VARIABLE INTAKE-AIR SYSTEM (VIS) SHUTTER VALVE ACTUATOR INSPECTION»(ref-151892-S02081208222003050700000) . Check if VIS shutter valve is stuck open or closed. Repair as necessary.

VIS SHUTTER VALVE ROD OPERATION - MAZDA6 (2.3L)

Variable Intake-Air System (VIS) Shutter Valve Actuator Inspection

Remove intake-air hose. Disconnect vacuum hose from Variable Intake-Air System (VIS) control solenoid valve. Connect a vacuum pump to VIS shutter valve actuator. Apply vacuum and verify VIS shutter valve actuator rod moves. See VIS SHUTTER VALVE VACUUM APPLICATION - MAZDA6 (2.3L) table.

VIS SHUTTER VALVE VACUUM APPLICATION - MAZDA6 (2.3L)

Variable Intake-Air System Control Solenoid Valve Inspection

1. Airflow Inspection Disconnect negative battery cable. Remove Variable Intake-Air System (VIS) control solenoid valve. Apply air pressure to port "B". (Scheme 56) Air should flow from port "C". Using fused jumper wires, apply battery voltage to VIS control solenoid valve terminals. Apply air pressure to port "B". Air should flow from port "A". If airflow is as specified, check for open or short circuit. Go to next step. If airflow is not as specified, replace VIS control solenoid valve.
2. Open Circuit Inspection Using DVOM, check continuity between following terminals: VIS control solenoid valve harness connector terminal "B" and PCM 30-pin harness connector terminal No. 4R (Green/Red wire). VIS control solenoid valve terminal "A" and main relay 4-pin harness connector terminal "C" (White wire). If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: VIS control solenoid valve harness connector terminal "B" (Green/Red wire) and body GND. VIS control solenoid valve harness connector terminal "A" (White wire) and power supply. If continuity is present, repair short circuit in suspect wire or replace wire harness.

Scheme 56

Variable Tumble Control System (VTCS) Solenoid Valve Inspection

1. Airflow Inspection Disconnect negative battery cable. Remove VTCS solenoid valve. Apply air pressure to port "B". (Scheme 56) Air should flow from port "C". Using fused jumper wires, apply battery voltage to VTCS solenoid valve terminals. Apply air pressure to port "B". Air should flow from port "A". If airflow is as specified, check for open or short circuit. Go to next step. If airflow is not as specified, replace VTCS solenoid valve.
2. Open Circuit Inspection Disconnect PCM and VTCS solenoid valve harness connectors. Using DVOM, check continuity between following terminals: VTCS solenoid valve harness connector terminal "B" and PCM 30-pin harness connector terminal No. 4T (Blue/Orange wire). VTCS solenoid valve terminal "A" and main relay 4-pin harness connector terminal "C" (White wire). If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
3. Short Circuit Inspection Check for continuity between following: VTCS solenoid valve harness connector terminal "B" (Blue/Orange wire) and body GND. VTCS solenoid valve harness connector terminal "A" (White wire) and power supply. If continuity is present, repair short circuit in suspect wire or replace wire harness.

Variable Tumble Control System (VTCS) Shutter Valve Actuator Inspection

Remove intake-air hose. Disconnect vacuum hose from variable tumble control solenoid valve. Connect a vacuum pump to VTCS shutter valve actuator. Apply vacuum and verify VTCS shutter valve actuator rod moves. See VTCS SHUTTER VALVE VACUUM APPLICATION - MAZDA6 (2.3L) .

VTCS SHUTTER VALVE VACUUM APPLICATION - MAZDA6 (2.3L)

Variable Tumble Control System (VTCS) Shutter Valve Actuator Switch Inspection

1. Turn ignition on, engine off. Verify PCM 30-pin harness connector teriminal "1N" voltage is as shown in «VTCS SHUTTER VALVE ACTUATOR SWITCH SPECIFICATIONS - MAZDA6 (2.3L)»(ref-151892-S02394532562003100100000) table when VTCS shutter valve actuator rod is depressed and released by hand. If not as specified, perform Circuit Open/Short Inspection. Go to next step. If there is no open or short circuit, replace intake manifold. VTCS SHUTTER VALVE ACTUATOR SWITCH SPECIFICATIONS - MAZDA6 (2.3L) Condition PCM Terminal "1N" Released (Open Position) About 5.0 volts Depressed (Closed Position) Less Than 0.4 volt
2. Open Circuit Inspection Check for continuity between following terminals: VTCS shutter valve switch 3-pin harness connector terminal "A" and PCM 30-pin harness connector terminal "2K" (Red/Black wire) VTCS shutter valve switch 3-pin harness connector terminal "B" and PCM 30-pin harness connector terminal "2H" (Brown wire). VTCS shutter valve switch 3-pin harness connector terminal "C" and PCM 30-pin harness connector terminal "1N" (Orange/Blue wire). If continuity is present, check for short circuit in wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Go to next step. If continuity is not present, repair open circuit in suspected wire or replace wire harness.
3. Short Circuit Inspection Check for continuity between following: VTCS shutter valve switch 3-pin harness connector terminal "A" (Red/Black wire) and power supply. VTC shutter valve switch 3-pin harness connector terminal "A" (Red/Black wire) and body GND. VTCS shutter valve switch 3-pin harness connector terminal "B" (Brown wire) and power supply. VTCS shutter valve switch 3-pin harness connector terminal "C" (Orange/Blue wire) and power supply. VTCS shutter valve switch 3-pin harness connector terminal "C" (Orange/Blue wire) and body GND. If continuity is present, repair short circuit in suspected wire or replace wire harness.

Variable Tumble Control System (VTCS) Delay Valve Inspection

Remove delay valve from VTCS shutter valve actuator vacuum hose. Blow air into port "A" air should flow out of port "B". Blow air into port "B" air should not flow out of port "A". If airflow is not as specified, replace VTCS delay valve.

Disconnect vacuum hose from actuator. Connect a vacuum pump to actuator. (Scheme 57)or (Scheme 58). Watch actuator rod and slowly apply vacuum to actuator. See SHUTTER VALVE ACTUATOR VACUUM APPLICATION table. If actuator does not operate as specified, replace actuator. If system is not working properly but actuator is okay, check vacuum lines.

SHUTTER VALVE ACTUATOR VACUUM APPLICATION

Scheme 57

Scheme 58

Note. Perform VTCS solenoid check only when directed by SELF-DIAGNOSTICS testing.

Variable Tumble Control System (VTCS) Vacuum Switch Inspection (Miata)

1. Disconnect vacuum hose and 2-pin harness connector from VTCS vacuum switch. Connect vacuum pump to port on VTCS vacuum switch and DVOM to VTCS connector terminals. Slowly apply vacuum to VTCS vacuum switch. See «VTCS VACUUM SWITCH VACUUM APPLICATION»(ref-151892-S41430674052003050800000) table. If VTCS vacuum switch is okay but PID value is out of specification, check for short or open circuit. Go to next step. If continuity is not as specified, replace VTCS vacuum switch.
2. Open Circuit Inspection Disconnect PCM harness connectors. Using DVOM, check for continuity in following circuits: Power circuit (Orange wire) between VTCS vacuum switch harness connector terminal "A" and PCM 31-pin harness connector terminal No. 4J. GND circuit (Black wire) between VTCS vacuum switch harness connector terminal "B" and ground through common connector. If continuity is present, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. After repair, return vehicle to original condition.
3. Short Circuit Inspection Check for continuity to ground in Orange wire between VTCS vacuum switch harness connector terminal "A" and PCM 31-pin harness connector terminal No. 4J through common connector.

If continuity is present, repair short circuit to ground in Orange wire between VTCS vacuum switch harness connector terminal "A" and PCM 31-pin harness connector terminal No. 4J through common connector or replace wire harness.

VTCS VACUUM SWITCH VACUUM APPLICATION (MIATA)

Inspection (MAZDA6 - 2.3L)

1. Ensure no DTCs related to Accelerator Pedal Position (APP) sensor are present. If no DTCS related to APP sensor are present, go to next step. If any DTCs related to APP sensor are present, perform diagnostic procedure for those DTCs first. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-151885-S34958757572003010900000) in SELF-DIAGNOSTICS - MAZDA6 2.3L article.
2. Turn ignition on, engine off. Go to next step.
3. Using DVOM, verify PCM 27-pin harness connector terminal "3M" (Brown/Yellow wire) and terminal "3J" (Brown/Black wire) voltage readings change smoothly while throttle valve is gradually opened. If as verified, go to next step. If not as verified, check for open or short circuit. Go to step 5 . If open or short circuits are not present, replace throttle body.
4. Verify PCM 27-pin harness connector terminal "3M" (Brown/Yellow wire) and terminal "3J" (Brown/Black wire) output voltages are as specified in «THROTTLE POSITION SENSOR VOLTAGE SPECIFICATIONS»(ref-151892-S33464352562003090800000) table. If output voltage readings are not as specified, go to step 5 . If open or short circuits are not present, replace throttle body.
5. Open Circuit Inspection Check for continuity between following terminals: Throttle body 6-pin harness connector terminal "A" and PCM 27-pin harness connector terminal "3M". Throttle body 6-pin harness connector terminal "B" and PCM 27-pin harness connector terminal "3N". Throttle body 6-pin harness connector terminal "C" and PCM 27-pin harness connector terminal "3J". Throttle body 6-pin harness connector terminal "D" and PCM 27-pin harness connector terminal "3K". If continuity is present between all terminals, go to next step. If no continuity is present, repair open circuit in suspect wire or replace wire harness.
6. Short Circuit Inspection Check for continuity between following: Throttle body 6-pin harness connector terminal "A" and power supply. Throttle body 6-pin harness connector terminal "A" and body ground. Throttle body 6-pin harness connector terminal "B" and power supply. Throttle body 6-pin harness connector terminal "B" and body ground. Throttle body 6-pin harness connector terminal "C" and power supply. Throttle body 6-pin harness connector terminal "C" and body ground. Throttle body 6-pin harness connector terminal "D" and power supply. If continuity is present, repair short circuit in suspect wire or replace wire harness.

THROTTLE POSITION SENSOR VOLTAGE SPECIFICATIONS

Inspection (MAZDA6 - 3.0L)

1. Ensure no DTCs related to Accelerator Pedal Position (APP) sensor are present. If no DTCS related to APP sensor are present, go to next step. If any DTCs related to APP sensor are present, perform diagnostic procedure for those DTCs first. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-151886-S37188811592003010900000) in SELF-DIAGNOSTICS - MAZDA6 3.0L article.
2. Connect WDS to DLC-2. Go to next step.
3. Turn ignition on, engine off. Go to next step.
4. Select TP1 or TP2 PID on WDS. Go to next step.
5. Verify TP1 or TP2 PID changes smoothly while throttle valve is gradually opened. If as verified, go to next step. If not as verified, check for open or short circuit. Go to step 7 .
6. Verify TP1 or TP2 PID are as specified in «THROTTLE POSITION SENSOR PID SPECIFICATIONS»(ref-151892-S39117858762003090800000) table. If PID values are as specified, check for open or short circuit in wire harness. Go to next step. If PID values are not as specified, replace throttle body.
7. Open Circuit Inspection Check for continuity between following terminals: Throttle body 6-pin harness connector terminal "C" and PCM 104-pin harness connector terminal No. 63. Throttle body 6-pin harness connector terminal "D" and PCM 104-pin harness connector terminal No. 20. Throttle body 6-pin harness connector terminal "E" and PCM 104-pin harness connector terminal No. 36. Throttle body 6-pin harness connector terminal "F" and PCM 104-pin harness connector terminal No. 89. If continuity is present between all terminals, go to next step. If continuity is not present, repair open circuit in suspect wire or replace wire harness.
8. Short Circuit Inspection Check for continuity between following: Throttle body 6-pin harness connector terminal "C" and power supply. Throttle body 6-pin harness connector terminal "C" and body ground. Throttle body 6-pin harness connector terminal "D" and power supply. Throttle body 6-pin harness connector terminal "D" and body ground. Throttle body 6-pin harness connector terminal "E" and power supply. Throttle body 6-pin harness connector terminal "F" and power supply. Throttle body 6-pin harness connector terminal "F" and body ground. If continuity is present, repair short circuit in suspect wire or replace wire harness.

THROTTLE POSITION SENSOR PID SPECIFICATIONS

Resistance Inspection (Miata)

1. Disconnect TP sensor 3-pin harness connector. (Scheme 59) Using DVOM, measure resistance between following TP sensor terminals: Terminals "A" and "B" - 2500-5000 ohms. Terminals "B" and "C" - 200-1100 ohms. If resistance readings are not as specified, replace TP sensor.

Resistance Inspection (MPV, Protege & Protege5)

Disconnect TP sensor connector. Using DVOM, measure resistance between TP sensor terminals "A" and "C". (Scheme 59) If resistance reading is not as specified, replace TP sensor. See TP SENSOR RESISTANCE (MPV, PROTEGE & PROTEGE5) table.

Scheme 59

TP SENSOR RESISTANCE (MPV, PROTEGE & PROTEGE5)

Fuel Pump Relay Inspection - MAZDA6 & MPV

Remove fuel pump relay. See FUEL PUMP RELAY LOCATIONS table. Using ohmmeter, check for continuity between fuel pump relay terminals "C" and "D". (Scheme 60) Continuity should not be present. Using fused jumper wires apply battery voltage to terminal "A" and ground terminal "E". Continuity should be present between fuel pump relay terminals "C" and "D" with battery voltage applied. If continuity is not as specified, replace fuel pump relay.

Scheme 60

Fuel Pump Relay Inspection - Miata

Note. The fuel pump relay housing is easily broken when relay is removed. Test relay in place and remove relay only for replacement.

Disconnect negative battery cable. Disconnect fuel pump relay 6-pin harness connector. FUEL PUMP RELAY LOCATIONS table. Check continuity between fuel pump relay terminals "C" and "E". (Scheme 61) Continuity should not be present between fuel pump relay terminals "C" and "E". Using fused jumper wires, connect positive battery terminal to fuel pump relay terminal "A". Connect negative battery terminal to fuel pump relay terminal "B". Continuity should be present between fuel pump relay terminals "C" and "E". If continuity is not as specified, replace fuel pump relay.

Scheme 61

Fuel Pump Relay Inspection - Protege & Protege5

Remove fuel pump relay. See FUEL PUMP RELAY LOCATIONS table. Using ohmmeter, check for continuity between relay terminals "C" and "E". (Scheme 62) Continuity should not be present. Using fused jumper wires, connect positive battery terminal to fuel pump relay terminal "A". Connect negative battery terminal to fuel pump relay terminal "B". Continuity should be present between fuel pump relay terminals "C" and "E". If continuity is not as specified, replace fuel pump relay.

FUEL PUMP RELAY LOCATIONS

Scheme 62

EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER

Note. Perform this test using Evaporative Emission System Tester (MZ254AT3641).

Scheme 63

Scheme 64

Scheme 65

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 emission system tester) to tester. (Scheme 63)
3. Connect manifold assembly (part of emission system tester) to long hose. (Scheme 64)
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 emission system tester 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 emission system tester).
9. Press RESET switch to set left display reading to 0.0.
10. Connect fuel cap test adapter (part of emission system tester) to manifold assembly and fuel-filler cap from vehicle. (Scheme 65) If fuel-filler cap is not a Mazda part, replace it.
11. Connect threaded test adapter (part of emission system tester) to manifold assembly and fuel-filler neck.
12. Connect scan tool to DLC-2.
13. Turn ignition on, engine off.
14. Request PCM for on-board device control (Mode 08) using scan tool to close change over valve (COV) in EVAP system leak detection pump NOTE: COV is closed for 10 minutes unless any of following action is done: Engine is started. Ignition is turned off.
15. Turn control valve to FILL position.
16. Wait (maximum 40 seconds) until left display reads 13.5 to 14.0 inches of water. If reading is slightly less than specified, adjust reading using regulator knob. If reading is far less than specified, EVAP system has large leak. Check for leak using ultrasonic leak detector. Repair as necessary.
17. Turn control valve to TEST position and press START switch.
18. 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.
19. Check for leak using ultrasonic leak detector and repair.
20. Close gas cylinder valve.
21. Turn control valve to FILL position.
22. Press ON/OFF switch to turn off tester.

Evaporative Emission System Tester Self Test - Protege & Protege5

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 emission system tester) to tester. (Scheme 63)
3. Connect manifold assembly (part of emission system tester) to long hose. (Scheme 64)
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 emission system tester 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 emission system tester).
9. Press RESET switch to set left display reading to 0.0.
10. Connect fuel cap test adapter (part of emission system tester) to manifold assembly and fuel-filler cap from vehicle. (Scheme 65) If fuel-filler cap is not a Mazda part, replace it.
11. Connect threaded test adapter (part of emission system tester) to manifold assembly and fuel-filler neck.
12. Connect scan tool to DLC-2.
13. Turn ignition on, engine off.
14. 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 is turned off. Fuel Tank Pressure (FTP) sensor signal exceeds 1.9 in. Hg.
15. Turn control valve to FILL position.
16. Wait (maximum 40 seconds) until left display reads 13.5 to 14.0 inches of water. If reading is slightly less than specified, adjust reading using regulator knob. If reading is far less than specified, EVAP system has large leak. Check for leak using ultrasonic leak detector. Repair as necessary.
17. Turn control valve to TEST position and press START switch.
18. 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.
19. Check for leak using ultrasonic leak detector and repair.
20. Close gas cylinder valve.
21. Turn control valve to FILL position.
22. 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 66)- (Scheme 75).

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

EVAP System Test

Note. The EVAP system test, which can be substituted for run Drive Cycle as an EVAP control system repair confirmation method, can be done while operating scan tool at idle instead of actually driving vehicle.

Scheme 76

Scheme 77

1. Connect scan tool to DLC-2. DLC-2 is located under left side of instrument panel, left of steering column. Select EVAP test from TOOLBOX on scan tool display and follow instructions. Check PIDs. Ensure BARO (21.3 in. Hg or more), FLT V (1.3-3.7 volts) and IAT (14-140°F) readings are within specification at pretest confirmation screen.
2. Start engine and run at 3500 RPM for 200 seconds to warm up completely. Select Tick icon to start test. (Scheme 76) Ensure each result is within specification, using FTL_V PID recorded in step 1). If scan tool values are not within specification, diagnose problem using «DTC/SYSTEM TROUBLESHOOTING»(ref-151892-S28462167472003010900000) table. DTC/SYSTEM TROUBLESHOOTING Failure Troubleshoot Small Leak (A) DTC P0442 Very Small Leak (mA) DTC P0456 IMO (1) COV (2) (1) Inspect for open circuit or short to ground between PCM and EVAP system leak detection pump. (2) Inspect Change Over Valve (COV) to ensure valve is not stuck closed.
3. Check LDP_SLDV PID value. If LDP_SLDV PID value is lower than specified in (Scheme 76) and (Scheme 77), perform appropriate test: Small Leak See «DTC P0442: EVAP SYSTEM LEAK DETECTED - SMALL LEAK DETECTED»(ref-151881-S11635126182003010900000) in SELF-DIAGNOSTICS - MPV article. Very Small Leak See «DTC P0456: EVAP SYSTEM LEAK DETECTED - VERY SMALL LEAK DETECTED»(ref-151881-S15521747922003010900000) in SELF-DIAGNOSTICS - MPV article. IMO (Air Pump Operation) If LDP_REF PID value stay at zero volts during test. EVAP system leak detection pump circuit has electrical malfunction. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair or replace wiring harness as necessary. Change Over Valve (COV) Status If LDP_REF/LDP_IDL PID value is lower than 0.002 A, COV is stuck closed. See «DTC P0446: EVAP SYSTEM VENT CONTROL - MALFUNCTION»(ref-151881-S40370274222003010900000) in SELF-DIAGNOSTICS - MPV article.

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 78)- (Scheme 80).

Scheme 78

Scheme 79

Scheme 80

System Leak Inspection - Using Vacuum Pump

Whole System Inspection

1. Disconnect vacuum hose between purge solenoid valve and catch tank from purge solenoid valve. (Scheme 79)
2. Connect hose on vacuum pump.
3. Connect scan tool to DLC-2.
4. Turn ignition on, engine off.
5. Using scan tool, close Canister Drain Cut Valve (CDCV) using ON BOARD DEVICE CONTROL function. NOTE: CDCV is closed for 10 minutes unless any of following actions is done: Engine is started. Ignition is turned off. Fuel Tank Pressure (FTP) sensor signal exceeds 1.9 in. Hg (6.43 kPa).
6. Apply 1.7 kPa vacuum and monitor FTP output voltage.
7. Verify voltage holds at specified readings for a minimum of 2 minutes. If voltage does not hold, inspect fuel tank pressure sensor. If FTP sensor is okay, perform "Inspection From Charcoal Canister To Fuel Tank".

Inspection From Charcoal Canister To Fuel Tank

1. Check for loose and incorrectly installed hoses between charcoal canister and fuel tank. (Scheme 66), (Scheme 67) & (Scheme 79).
2. Disconnect vacuum hose between charcoal canister and fuel tank from charcoal canister.
3. Connect hose to vacuum pump.
4. Apply 1.7 kPa vacuum.
5. Verify that vacuum holds at specified readings for a minimum of 2 minutes. If vacuum does not hold, check fuel tank, related vacuum hoses and fuel-filler cap. If fuel tank, related vacuum hoses and fuel-filler cap are okay, perform "Inspection From Charcoal Canister To Purge Solenoid Valve".

Inspection From Charcoal Canister To Purge Solenoid Valve

1. Check for loose and incorrectly installed hoses between charcoal canister and purge solenoid valve. (Scheme 78)- (Scheme 80).
2. Disconnect vacuum hose between charcoal canister and catch tank from charcoal canister.
3. Connect hose to vacuum pump.
4. Apply 1.0 in. Hg vacuum. Vacuum should hold at specified reading for a minimum of 2 minutes. If vacuum does not hold, inspect following: Catch tank for plugging, damage and pinhole using vacuum pump. Purge solenoid valve. See «PURGE SOLENOID VALVE»(ref-151892-S06723237912003010900000). Charcoal canister for damage and pinhole. See «CHARCOAL CANISTER»(ref-151892-S39481580092003010900000). CDCV for damage and leakage. See «CANISTER DRAIN CUT VALVE (CDCV)»(ref-151892-S34245146942003010900000). Disconnect incorrectly installed or cracked hose from charcoal canister to CDCV.

Valve Inspection - Except Mazda6 (3.0L) & MPV

Remove PCV valve from valve cover. For location (Scheme 69), (Scheme 71) or (Scheme 80). Blow air into port "A". (Scheme 81)or (Scheme 82). Air should flow from port "B". Blow air into port "B". Air should not flow from port "A". If airflow is not as specified, replace PCV valve.

Scheme 81

Scheme 82

Valve Inspection - Mazda6 (3.0L) & MPV

Remove intake manifold (MPV only). Remove PCV valve. (Scheme 70)or (Scheme 75). Blow air into port "A". (Scheme 83) Air should flow from port "B". Blow air into port "B". Air should not flow from port "A". If airflow is not as specified, replace PCV valve.

Scheme 83

PCV VALVE INSPECTION [L3]

1. Disconnect the negative battery cable.
2. Remove the intake manifold. (see «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-177913-S07169903802005060800000) ).
3. Remove the PCV valve.
4. Blow through the valve and verify that air flows as specified. If not as specified, replace the PCV valve.

Scheme 84

Scheme 85

Inspection

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

1. Using scan tool, access O2S11 (front HO2S) and O2S12 (rear HO2S) PIDs.
2. Monitor appropriate PIDs.
3. Drive vehicle for 10 minutes at 40-60 MPH to ensure Warm Up Three-Way Catalytic Converter (WU-TWC) reaches operating temperature.
4. Stop vehicle, let engine idle and record PIDs for one minute.
5. Select appropriate PIDs and read graph. (Scheme 86)or (Scheme 87).
6. Count number of times graphline actually crosses.5V line (inversion) for both front and rear HO2Ss.
7. Divide number of front HO2S inversions by number of rear HO2S inversions for ratio data. If ratio is 2 (1.5 on Mazda6) or more or no rear HO2S inversions, WU-TWC converter is functioning properly. If ratio is less than 2 (1.5 on Mazda6), WU-TWC converter has deteriorated. (Scheme 88) Replace faulty WU-TWC converter.

Scheme 86

Scheme 87

Scheme 88

Coil Resistance Inspection

1. Disconnect Oil Control Valve (OCV) 2-pin harness connector. See «OCV LOCATION»(ref-151892-S05162117722003050600000) table.
2. Using DVOM, measure resistance between OCV terminals. See «OCV RESISTANCE SPECIFICATIONS»(ref-151892-S36219826692003050600000) table.
3. If resistance reading is not as specified, replace OCV.

OCV LOCATION

OCV RESISTANCE SPECIFICATIONS

Miata (Extreme Spark Retard Position Inspection)

1. Disconnect negative battery cable.
2. Remove variable valve timing actuator. Refer to «VARIABLE VALVE TIMING ACTUATOR»(ref-151901-S38245530762003010900000) under VARIABLE VALVE TIMING SYSTEM in REMOVAL, OVERHAUL & INSTALLATION article. CAUTION: If engine oil gets on parts, they may not function properly. When removing variable valve timing actuator, be sure to cover other parts with a cloth to protect them from oil.
3. Ensure camshaft dowel pin hole on variable valve timing actuator is aligned with top of third tooth, by counting back 3 teeth to sprocket gap which is aligned with alignment mark. (Scheme 89) If not as specified, stopper pin in variable valve timing actuator is not engaged at position of maximum valve timing retard. Replace variable valve timing actuator.
4. Return vehicle to original condition.

Scheme 89