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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Mazda 3 Workshop Manual –
Engine + Wiring Diagrams +
Diagnostic Trouble Codes
Contents
MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [Z6] ..... 25
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [LF] ... 248
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [Z6] .................. 451
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [Z6] ................ 514
NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [Z6] ............... 516
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [LF] .................. 550
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [LF] ................ 610
NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [LF] ............... 612
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [Z6] ................................. 671
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No.3 Engine Mount Rubber and No.3 Engine Mount Bracket Installation Note ....................... 704
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6] ..... 779
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [Z6] ............................. 781
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6] ........... 783
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [Z6] .................................... 785
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [LF] ............................. 797
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF] .................................... 798
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION ........................................ 853
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
IGNITION COIL WITH BUILT-IN POWER SWITCH INSPECTION ........................................... 886
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [Z6] ......................................... 936
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6] ........ 938
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [Z6] ................................. 939
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6] ............................ 943
CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [Z6] ................................ 946
THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION [Z6] ..................................... 948
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] ....................... 953
REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] .......................... 957
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
CONTROL SYSTEM WIRING DIAGRAM [Z6]
B3E010200102W12
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MONITORING SYSTEM AND CONTROL SYSTEM
DEVICE RELATIONSHIP CHART [Z6]
B3E010200102W13
×: Applicable
Component
Input
ECT sensor
IAT sensor
CKP sensor
CMP sensor
× × × × ×
× × × × ×
× × × × ×
× × × × ×
× × × × × TP sensor
MAF sensor
Front HO2S
× × × × ×
× × ×
Rear HO2S
BARO sensor
×
× ×
Vehicle speed signal ×
×
×
×
×
×
×
×
Output
Fuel injector
Purge solenoid valve
Front HO2S heater
× ×
×
Rear HO2S heater
MIL
×
× × × × ×
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD PENDING TROUBLE CODE [Z6]
B3E010200102W14
• These appear when a problem is detected in a monitored system. The code for a failed system is stored in the PCM memory in the first drive cycle. This code is called the pending code. If the problem is not found in a second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code (1DC). If the problem is not found in a second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code when the ignition switch is turned to the ON position in the next drive cycle
(2DC). If the problem is found in a second drive cycle too, the PCM judges that the system has failed, and the DTC is stored.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD FREEZE FRAME DATA [Z6]
B3E010200102W15
• This is the technical data which indicates the engine condition at the time of the first malfunction. This data will remain in the memory even if another emission-related DTC is stored, with the exception of fuel system or misfire DTCs. Once freeze frame data for a fuel system or misfire DTC is stored, it will overwrite any previous data and the freeze frame will not be overwritten again.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD ON-BOARD SYSTEM READINESS TEST [Z6]
B3E010200102W16
• This shows the OBD systems operating status. If any monitor function is incomplete, WDS or equivalent will identify which monitor function has not been completed. The fuel system, misfire and CCM are continuous monitoring-type functions. The HO2S and catalyst will be monitored under drive cycles. The
OBD diagnostic system is initialized by performing the DTC cancellation procedure or disconnecting the negative battery cable.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD READ/CLEAR DIAGNOSTIC TEST RESULT [Z6]
B3E010200102W17
• This retrieves all stored DTCs in the PCM and clears the on-board readiness test results, freeze frame data, DTC, diagnostic monitoring test results and pending trouble code.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD PARAMETER IDENTIFICATION (PID) ACCESS
[Z6]
B3E010200102W18
• The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since the PID values for output devices are the PCM internal data values, inspect each device to identify which output devices are malfunctioning.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ON-BOARD DIAGNOSTIC TEST [Z6]
B3E010200102W19
DTC Reading Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Retrieve the DTCs using the WDS or equivalent.
Pending Trouble Code Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Retrieve the pending trouble codes using the WDS or equivalent.
Freeze Frame PID Data Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Record the freeze frame PID data using the WDS or equivalent.
On-Board System Readiness Tests Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Monitor the OBD systems operating status using the WDS or equivalent.
PID/DATA Monitor and Record Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Access and monitor PIDs using the WDS or equivalent.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic Monitoring Test Results Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Access to the diagnostic monitoring test results and read the test results using the WDS or equivalent.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
AFTER REPAIR PROCEDURE [Z6]
B3E010200102W20
1. Connect the WDS or equivalent to the DLC-2.
2. Cycle the ignition switch off, then to the ON position (Engine off).
3. Record DTC if retrieved.
4. Clear all diagnostic data using the WDS or equivalent.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
OBD DRIVE MODE [Z6]
B3E010200102W21
• Performing the Drive Mode inspects the OBD system for proper operation and must be performed to ensure that no additional DTCs are present.
• During the Drive Mode, the following systems are inspected:
- HO2S heater
- HO2S
- TWC
- Fuel system and Misfire
Caution
• While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
• When the WDS or equivalent is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the WDS or equivalent using the
PID/DATA MONITOR AND RECORD function and inspect later.
Note
• Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer and tachometer. Use the WDS or equivalent to monitor vehicle speed.
• If the OBD system inspection is not completed during the Drive Mode, the following causes are considered:
- The OBD system detected a malfunction.
- The Drive Mode procedure was not completed correctly.
• Disconnecting the battery will reset the memory. Do not disconnect the battery during and after the Drive Mode.
• The WDS or equivalent can be used at anytime through the course of the Drive Mode to monitor the completion status. Monitoring can be done by viewing the ON BOARD SYSTEM READINESS menu.
PCM Adaptive Memory Produce Drive Mode
1. Start the engine and warm it up completely.
2. Verify the following conditions and correct if necessary:
• All accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
• Initial ignition timing and idle speed are within specification.
3. Idle the engine for more than 120 s .
4. Perform no load racing at the engine speed of 2,800-3,200 rpm for more than 30 s .
5. Idle the engine for more than 30 s after the cooling fan stopped.
6. Turn the ignition switch off.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
HO2S heater, HO2S, and TWC Repair Verification Drive Mode
1. Perform the "PCM Adaptive Memory Produce Drive Mode" first.
2. Verify that all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
3. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F. The driving condition before driving at constant speed is not specified.
For MTX
Zone Shift Position Vehicle Speed (km/h {mph}) Time (s)
O Neutral
A 2nd
B 3rd
C 2nd
D 3rd
E 4th
F 5th
0 {0}
40-50 {25-31}
65-75 {41-46}
60-75 {38-46}
75-100 {47-62}
50-75 {32-46}
75-95 {47-59}
T1: above 450
T2: above 30
T3: above 20
T4: above 120
For ATX
Zone Shift Position Vehicle Speed (km/h {mph}) Time (s)
O P or N 0 {0} T1: above 450
A M (3GR)
B M (3GR)
C M (2GR)
D M (3GR)
E M (4GR)
40-60 {25-37}
65-95 {41-59}
60-75 {38-46}
85-100 {53-62}
50-75 {32-46}
T2: above 30
T3: above 20
T4: above 120
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
F M (5GR) 75-100 {47-62}
4. Stop the vehicle and access the ON BOARD SYSTEM READINESS to inspect the Drive Mode completion status.
• If completed, RFC changes from No to Yes.
• If not completed, turn the ignition switch off, then go back to Step 3.
5. Verify that no DTCs are available.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC TABLE [Z6]
B3E010200102W22
×: Applicable
-: Not applicable
DTC
No.
Condition MIL DC
Monitor item
Memory function
Page
P0011 CMP-timing over-advanced
P0012 CMP-timing over-retarded
P0031
Front HO2S heater control circuit low
ON
P0032
Front HO2S heater control circuit high
ON
P0037
Rear HO2S heater control circuit low
P0038
Rear HO2S heater control circuit high
ON
ON
P0102 MAF sensor circuit low input
P0103 MAF sensor circuit high input
P0111
IAT sensor circuit range/performance problem
P0112 IAT sensor circuit low input
P0113 IAT sensor circuit high input
P0117 ECT sensor circuit low input
P0118 ECT sensor circuit high input
P0121
TP sensor circuit range/performance problem
P0122 TP sensor circuit low input
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
1 CCM
2 CCM
2
HO2S heater
2
HO2S heater
2
HO2S heater
2
HO2S heater
1 CCM
1 CCM
2 CCM
1 CCM
1 CCM
1 CCM
1 CCM
2 CCM
1 CCM
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
(See DTC P0011
[Z6] .)
(See DTC P0012
[Z6] .)
(See DTC P0031
[Z6] .)
(See DTC P0032
[Z6] .)
(See DTC P0037
[Z6] .)
(See DTC P0038
[Z6] .)
(See DTC P0102
[Z6] .)
(See DTC P0103
[Z6] .)
(See DTC P0111
[Z6] .)
(See DTC P0112
[Z6] .)
(See DTC P0113
[Z6] .)
(See DTC P0117
[Z6] .)
(See DTC P0118
[Z6] .)
(See DTC P0121
[Z6] .)
(See DTC P0122
[Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0123
P0301
P0302
P0303
P0304
P0327
P0328
P0335
P0340
P0403
TP sensor circuit high input
P0300 Random misfire detected
KS circuit low input
KS circuit high input
CKP sensor circuit problem
CMP sensor circuit problem
EGR control circuit problem
P0132 Front HO2S circuit high voltage
P0134
Front HO2S circuit no activity detected
P0138 Rear HO2S circuit high voltage
P0140
Rear HO2S circuit no activity detected
Cylinder No.1 misfire detected
Cylinder No.2 misfire detected
Cylinder No.3 misfire detected
Cylinder No.4 misfire detected
P0420
Catalyst system efficiency below threshold
ON
P0125
Insufficient coolant temperature for closed loop fuel control
ON
ON
P0133 Front HO2S circuit slow response ON
ON
ON
ON
Flash/ON
Flash/ON
Flash/ON
Flash/ON
Flash/ON
ON
ON
ON
ON
ON
ON
1
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
2
2
CCM
CCM
HO2S
HO2S
HO2S
HO2S
HO2S
Misfire
Misfire
Misfire
Misfire
Misfire
CCM
CCM
CCM
CCM
CCM
Catalyst
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
(See DTC P0123
[Z6] .)
(See DTC P0125
[Z6] .)
(See DTC P0132
[Z6] .)
(See DTC P0133
[Z6] .)
(See DTC P0134
[Z6] .)
(See DTC P0138
[Z6] .)
(See DTC P0140
[Z6] .)
(See DTC P0300
[Z6] .)
(See DTC P0301,
P0302, P0303,
P0304 [Z6] .)
(See DTC P0301,
P0302, P0303,
P0304 [Z6] .)
(See DTC P0301,
P0302, P0303,
P0304 [Z6] .)
(See DTC P0301,
P0302, P0303,
P0304 [Z6] .)
(See DTC P0327
[Z6] .)
(See DTC P0328
[Z6] .)
(See DTC P0335
[Z6] .)
(See DTC P0340
[Z6] .)
(See DTC P0403
[Z6] .)
(See DTC P0420
[Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0443
Purge solenoid valve circuit problem
ON
P0480 Cooling fan control circuit problem OFF
P0500
P0505
VSS circuit problem
IAC system problem
P0506
IAC system RPM lower than expected
P0507
IAC system RPM higher than expected
P0511 IAC circuit problem
P0550
P0602
P0610
PSP switch circuit problem
PCM programming error
PCM vehicle options error
ON
OFF
ON
ON
ON
ON
ON
ON
P0660
Variable intake-air control circuit/open
P0668
PCM temperature sensor circuit low input
OFF
P0669
PCM temperature sensor circuit high input
OFF
OFF
P0703 Brake switch input circuit problem ON
2
1
2
-
2
2
1
2
1
1
1
1
1
2
CCM
Other
CCM
-
CCM
CCM
CCM
CCM
CCM
CCM
Other
Other
Other
CCM
×
×
×
-
×
×
×
×
×
×
×
×
×
×
P0704 CPP switch input circuit problem ON 2 CCM ×
P0706
Transaxle range (TR) switch circuit range/performance
(See DTC TABLE [FN4A-EL] .)
P0707
Transaxle range (TR) switch circuit low input
(See DTC TABLE [FN4A-EL] .)
P0708
Transaxle range (TR) switch circuit high input
(See DTC TABLE [FN4A-EL] .)
P0711
Transaxle fluid temperature (TFT) sensor circuit range/performance
(stuck)
(See DTC TABLE [FN4A-EL] .)
(See DTC P0443
[Z6] .)
(See DTC P0480
[Z6] .)
(See DTC P0500
[Z6] .)
(See DTC P0505
[Z6] .)
(See DTC P0506
[Z6] .)
(See DTC P0507
[Z6] .)
(See DTC P0511
[Z6] .)
(See DTC P0550
[Z6] .)
(See DTC P0602
[Z6] .)
(See DTC P0610
[Z6] .)
(See DTC P0660
[Z6] .)
(See DTC P0668
[Z6] .)
(See DTC P0669
[Z6] .)
(See DTC P0703
[Z6] .)
(See DTC P0704
[Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0712
Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground)
(See DTC TABLE [FN4A-EL] .)
P0713
Transaxle fluid temperature (TFT) sensor circuit malfunction (open circuit)
(See DTC TABLE [FN4A-EL] .)
P0715
Input/turbine speed sensor circuit malfunction
(See DTC TABLE [FN4A-EL] .)
P0731
Gear 1 incorrect (incorrect gear ratio detected)
P0732
Gear 2 incorrect (incorrect gear ratio detected)
P0733
Gear 3 incorrect (incorrect gear ratio detected)
P0734
Gear 4 incorrect (incorrect gear ratio detected)
(See
(See
(See
(See
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
.)
.)
.)
.)
P0741
Torque converter clutch (TCC)
(stuck off)
P0742
Torque converter clutch (TCC)
(stuck on)
P0745
Pressure control solenoid malfunction
P0751 Shift solenoid A stuck off
P0752 Shift solenoid A stuck on
P0753
Shift solenoid A malfunction
(electrical)
P0756 Shift solenoid B stuck off
P0757 Shift solenoid B stuck on
P0758
Shift solenoid B malfunction
(electrical)
P0761 Shift solenoid C stuck off
P0762 Shift solenoid C stuck on
P0763
Shift solenoid C malfunction
(electrical)
P0766 Shift solenoid D stuck off
P0767 Shift solenoid D stuck on
(See
(See
(See
(See
(See
(See
(See
(See
(See
(See
(See
(See
(See
(See
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
.)
.)
.)
.)
.)
.)
.)
.)
.)
.)
.)
.)
.)
.)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0768
Shift solenoid D malfunction
(electrical)
P0771 Shift solenoid E stuck off
P0772 Shift solenoid E stuck on
P0773
Shift solenoid E malfunction
(electrical)
(See
(See
(See
(See
P0850 Neutral switch input circuit problem ON
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
DTC TABLE [FN4A-EL]
2 CCM ×
.)
.)
.)
.)
P0894 Forward clutch torque transmission (See DTC TABLE [FN4A-EL] .)
P1260 Immobilizer system problem OFF Other -
P2006
P2008
P2088
Variable valve timing control circuit low
ON
P2089
Variable valve timing control circuit high
ON
P2096
Target A/F feedback system too lean
P2097
Target A/F feedback system too rich
ON
ON
P2177 System too lean off idle
P2178
P2187
P2188
P2195
P2196
P2228
Variable tumble control stuck close
Variable tumble control circuit/open
System too rich off idle
System too lean at idle
System too rich at idle
Front HO2S signal stuck lean
Front HO2S signal stuck rich
BARO sensor circuit low input
ON
ON
ON
ON
ON
ON
ON
ON
ON
2
2
1
1
CCM
CCM
CCM
CCM
×
×
×
×
2
Fuel system
×
2
Fuel system
×
2
Fuel system
×
2
Fuel system
×
2
Fuel system
×
2
Fuel system
×
2 HO2S ×
2
1
HO2S
CCM
×
×
(See DTC P0850
[Z6] .)
(See DTC P1260
[Z6] .)
(See DTC P2006
[Z6] .)
(See DTC P2008
[Z6] .)
(See DTC P2088
[Z6] .)
(See DTC P2089
[Z6] .)
(See DTC P2096
[Z6] .)
(See DTC P2097
[Z6] .)
(See DTC P2177
[Z6] .)
(See DTC P2178
[Z6] .)
(See DTC P2187
[Z6] .)
(See DTC P2188
[Z6] .)
(See DTC P2195
[Z6] .)
(See DTC P2196
[Z6] .)
(See DTC P2228
[Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P2229
P2502
P2503
P2504
BARO sensor circuit high input
Charging system voltage low
Charging system voltage high
Charging system voltage problem
ON
OFF
OFF
OFF
1
1
1
1
CCM
-
-
-
×
-
-
-
(See DTC P2229
[Z6] .)
(See DTC P2502
[Z6] .)
(See DTC P2503
[Z6] .)
(See DTC P2504
[Z6] .)
P2507 PCM power input signal low ON 1 CCM ×
(See DTC P2507
[Z6] .)
U0073
Control module communication bus off
(See DTC TABLE [MULTIPLEX COMMUNICATION
SYSTEM] .)
U0121
Lost communication with anti-lock brake system (ABS) control module
(See DTC TABLE [MULTIPLEX COMMUNICATION
SYSTEM] .)
U0155
Lost communication with instrument panel cluster (IPC) control module
(See DTC TABLE [MULTIPLEX COMMUNICATION
SYSTEM] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0011 [Z6]
B3E010200001W01
DTC P0011 CMP-timing over-advanced
DETECTION
CONDITION
• The actual valve timing is over-advanced from the target valve timing when the
OCV is controlled within the maximum valve timing retard condition.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• OCV malfunction
• Spool valve in OCV is stuck in advance position.
POSSIBLE CAUSE
• Variable valve timing actuator is stuck in advance position.
• Loose timing chain or improper valve timing due to timing chain slippage
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes Go to the next step.
INSPECT OCV FOR MALFUNCTION
• Start the engine.
• Increase the engine speed.
• Stop the engine.
• Remove the OCV.
No
Replace the OCV, then go to Step 6.
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
• Inspect the position of the spool valve in the OCV.
(See OIL CONTROL VALVE (OCV)
INSPECTION [Z6] .)
• Is the spool valve located at valve retard position?
INSPECT STOPPER PIN MECHANISM
• Inspect the stopper pin.
(See VARIABLE VALVE TIMING
ACTUATOR INSPECTION [Z6] .)
• Is the stopper pin mechanism normal?
Yes Go to the next step.
No
Replace the variable valve timing actuator, then go to Step 6.
(See VARIABLE VALVE TIMING ACTUATOR
REMOVAL/INSTALLATION [Z6] .)
VARIABLE VALVE TIMING MECHANISM IS
NORMAL
Note
INSPECT ROTOR POSITION
• Remove the variable valve timing actuator.
Yes
• This DTC is detected by intermittent concern.
(See VARIABLE VALVE TIMING
ACTUATOR REMOVAL/INSTALLATION
[Z6] .)
• Is the rotor position at maximum valve timing retard?
• Intermittent concern might be removed by cleaning mode of variable valve timing control function.
Go to the next step.
No
Replace the variable valve timing actuator, go to the next step.
(See VARIABLE VALVE TIMING ACTUATOR
REMOVAL/INSTALLATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P0011 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
No Go to the next step.
• Access RPM PID using the WDS or equivalent.
• Turn off all electrical roads.
• Increase and keep the engine speed at 4,500 rpm or more for 5 s .
• Is the same DTC present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0012 [Z6]
B3E010200001W02
DTC P0012 CMP-timing over-retarded
DETECTION
CONDITION
POSSIBLE
CAUSE
• The actual valve timing is over-retarded from the target valve timing when the OCV system control is within feed-back range.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Low engine oil pressure
• OCV malfunction
• Spool valve in OCV is stuck in retard position.
• Variable valve timing actuator is stuck in retard position.
• Following oil runners are clogged or have leakage.
Oil runners
• Between oil pressure switch and OCV
• Between OCV and variable valve timing actuator
• In variable valve timing actuator
• Loose timing chain or improper valve timing due to timing chain slippage
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Verify related service repair information availability.
• Is any related repair information available?
VERIFY ENGINE OIL PRESSURE
• Start the engine.
• Does the oil pressure warning light illuminate?
No
Yes
No
Go to the next step.
Inspect engine oil pressure, then go to Step 7.
(See OIL PRESSURE INSPECTION [Z6]
Go to the next step.
.)
VERIFY TIMING CHAIN
INSTALLATION
• Is camshaft timing mark at correct point?
(See Timing Chain Installation Note .)
Yes
No
Go to the next step.
Reinstall the timing chain, then go to Step 7.
(See TIMING CHAIN REMOVAL/INSTALLATION
[Z6] .)
INSPECT OCV FOR MALFUNCTION
• Stop the engine.
• Remove the OCV.
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
• Inspect position of the spool valve in the OCV.
(See OIL CONTROL VALVE (OCV)
INSPECTION [Z6] .)
• Is the spool valve located at valve retard position?
VARIABLE VALVE TIMING MECHANISM IS
NORMAL
Yes
Note
• This DTC is detected by intermittent concern.
• Intermittent concern might be removed by cleaning mode of variable valve timing control function.
Go to the next step.
Replace the OCV, then go to Step 7.
No
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
INSPECT ENGINE OIL RUNNER
• Inspect following engine oil runners for clogging or leakage.
Yes
Repair or replace suspected runner, then go to the next step.
VARIABLE VALVE TIMING MECHANISM IS
NORMAL
- Between the oil pressure switch and the OCV
Note
- Between the OCV and the variable valve timing actuator
No
• This DTC is detected by intermittent concern.
- In the variable valve timing actuator
• Is there any clogging or leakage?
• Intermittent concern might be removed by cleaning mode of variable valve timing control function.
Go to the next step.
VERIFY TROUBLESHOOTING OF
DTC P0012 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the PCM memory using WDS or equivalent.
• Start the engine.
• Access RPM PID using the WDS or equivalent.
• Warm up the engine completely.
• Turn off all electrical roads.
• Increase and keep the engine speed 2,500 rpm or more for 10 s .
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR
PROCEDURE
• Perform "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0031 [Z6]
B3E010200001W03
DTC P0031 Front HO2S heater control circuit low
DETECTION
CONDITION
• The PCM monitors front HO2S heater control voltage at PCM terminal
2AM. If PCM turns front HO2S heater off but front HO2S heater circuit has low voltage, PCM determines that front HO2S heater circuit has malfunction.
Note
• Front HO2S heater is controlled by duty signal.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
POSSIBLE CAUSE
• Front HO2S heater malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between front HO2S terminal C and PCM terminal 2T
• Open circuit in wiring harness between front HO2S terminal D and PCM terminal 2AM
• Short to ground in wiring harness between front HO2S terminal D and PCM terminal 2AM
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT FRONT HO2S CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
INSPECT FRONT HO2S HEATER
• Inspect the front HO2S heater.
Replace the front HO2S, then go to Step 9.
Yes
(See FRONT HEATED OXYGEN
SENSOR (HO2S)
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT FRONT HO2S HEATER POWER
CIRCUIT FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for continuity between front HO2S terminal C (wiring harness-side) and PCM terminal 2T (wiring harness-side).
• Is there continuity?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
No
Yes
Go to the next step.
Repair or replace the wiring harness for a possible open circuit, then go to Step 9.
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT FRONT HO2S CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
• Inspect for continuity between front HO2S terminal D (wiring harness-side) and body GND.
No Go to the next step.
• Is there continuity?
INSPECT FRONT HO2S CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between front HO2S terminal D (wiring harness-side) and PCM terminal 2AM (wiring harness-side).
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC P0031
COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and TWC
Repair Verification Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0032 [Z6]
B3E010200001W04
DTC P0032 Front HO2S heater control circuit high
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the front HO2S heater control voltage at PCM terminal
2AM. If the PCM turns the front HO2S heater on but the front HO2S heater circuit has high voltage, the PCM determines that the front HO2S heater circuit has a malfunction.
Note
• Front HO2S heater is controlled by a duty signal.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Short to power supply in wiring harness between front HO2S terminal D and PCM terminal 2AM
• Short circuit in front HO2S or PCM terminal
• Front HO2S heater malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes
Repair or replace the terminal, then go to Step
7.
INSPECT FRONT HO2S CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT FRONT HO2S HEATER
No
Yes
Go to the next step.
Replace the front HO2S, then go to Step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
• Inspect the front HO2S heater.
(See FRONT HEATED OXYGEN
SENSOR (HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No
No
Yes
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Go to the next step.
Repair or replace the terminal, then go to Step
7.
Go to the next step.
INSPECT FRONT HO2S HEATER
CONTROL CIRCUIT FOR SHORT TO
POWER SUPPLY
• Turn the ignition switch to the ON position (Engine off).
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to the next step.
• Measure the voltage between front HO2S terminal D (wiring harness-side) and body
GND.
No Go to the next step.
• Is the voltage B+ ?
VERIFY TROUBLESHOOTING OF DTC
P0032 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0037 [Z6]
B3E010200001W05
DTC P0037 Rear HO2S heater control circuit low
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the rear HO2S heater control voltage at PCM terminal
2AT. If the PCM turns the rear HO2S heater off but the rear HO2S heater circuit has low voltage, the PCM determines that the rear HO2S heater circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Rear HO2S heater malfunction
• Open circuit in wiring harness between rear HO2S terminal C and PCM terminal 2T
• Open circuit in wiring harness between rear HO2S terminal D and PCM terminal 2AT
• Short to GND in wiring harness between rear HO2S terminal D and PCM terminal 2AT
• Connector or terminal malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 9.
INSPECT REAR HO2S CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the rear HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT REAR HO2S HEATER
• Inspect the rear HO2S heater.
Replace the rear HO2S, then go to Step 9.
Yes
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
(See REAR HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT REAR HO2S HEATER POWER
CIRCUIT FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for continuity between rear HO2S terminal C (wiring harness-side) and PCM terminal 2T (wiring harness-side).
• Is there continuity?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
No
Yes
Go to the next step.
Repair or replace the wiring harness for a possible open circuit, then go to Step 9.
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT REAR HO2S CIRCUIT FOR SHORT
TO GND
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
• Turn the ignition switch off.
• Inspect for continuity between rear HO2S terminal D (wiring harness-side) and body
GND.
• Is there continuity?
No Go to the next step.
INSPECT REAR HO2S CIRCUIT FOR OPEN
CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between rear HO2S terminal D (wiring harness-side) and PCM terminal 2AT (wiring harness-side).
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC P0037
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and TWC
Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0038 [Z6]
B3E010200001W06
DTC P0038 Rear HO2S heater control circuit high
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the rear HO2S heater control voltage at PCM terminal
2AT. If the PCM turns the rear HO2S heater on but the rear HO2S heater circuit has high voltage, the PCM determines that the rear HO2S heater circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Short to power supply in wiring harness between rear HO2S terminal D and
PCM terminal 2AT
• Short circuit in rear HO2S or PCM terminal
• Rear HO2S heater malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT REAR HO2S CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect rear HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to Step
7.
Go to the next step.
INSPECT REAR HO2S HEATER
• Inspect the rear HO2S heater.
(See REAR HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
Replace the rear HO2S, then go to Step 7.
Yes
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to Step
7.
Go to the next step.
INSPECT REAR HO2S HEATER
CONTROL CIRCUIT FOR SHORT TO
POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to the next step.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between rear HO2S terminal D (wiring harness-side) and body
GND.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
• Is the voltage B+ ?
VERIFY TROUBLESHOOTING OF DTC
P0038 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0102 [Z6]
B3E010200100W01
DTC P0102 MAF sensor circuit low input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the input voltage from the MAF sensor when the engine is running. If the input voltage at PCM terminal 2AU is less than 0.21 V , the
PCM determines that the MAF circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• MAF sensor malfunction
• Connector or terminal malfunction
• Short to ground in wiring harness between MAF/IAT sensor terminal A and
PCM terminal 2BG
• Open circuit in wiring harness between MAF/IAT sensor terminal A and
PCM terminal 2BG
• Short to ground in wiring harness between MAF/IAT sensor terminal C and
PCM terminal 2AU
• Open circuit in wiring harness between MAF/IAT sensor terminal C and
PCM terminal 2AU
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
3
INSPECTION
Yes Go to the next step.
ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT MAF/IAT SENSOR
CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
Yes
Repair or replace the terminal, then go to Step
8.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Is there any malfunction?
INSPECT MAF SENSOR CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
- MAF/IAT sensor terminal A
(wiring harness-side) and body
GND
- MAF/IAT sensor terminal C
(wiring harness-side) and body
GND
• Is there continuity?
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 8.
No Go to the next step.
INSPECT MAF SENSOR
• Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to Step 8.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to Step
8.
Go to the next step.
INSPECT MAF SENSOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- MAF/IAT sensor terminal A
(wiring harness-side) and PCM terminal 2BG (wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- MAF/IAT sensor terminal C
(wiring harness-side) and PCM terminal 2AU (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0102 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0103 [Z6]
B3E010200100W02
DTC P0103 MAF sensor circuit high input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the input voltage from the MAF sensor when the engine is running. If input the voltage at PCM terminal 2AU is more than 4.9 V , the
PCM determines that the MAF circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• MAF malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between MAF/IAT sensor terminal
C and PCM terminal 2AU
• Open circuit in wiring harness between MAF/IAT sensor terminal B and
PCM terminal 2BC
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION ACTION
Yes Go to the next step.
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
3
INSPECT MAF/IAT SENSOR CONNECTOR
FOR POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 8.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
INSPECT MAF SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between MAF/IAT sensor terminal C (wiring harness-side) and body GND.
• Is the voltage B+ ?
No Go to the next step.
INSPECT MAF SENSOR
• Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to Step
8.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 8.
No Go to the next step.
INSPECT MAF SENSOR GND CIRCUIT
FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between MAF/IAT sensor terminal B (wiring harness-side) and
PCM terminal 2BC (wiring harness-side).
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0103 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0111 [Z6]
B3E010200100W03
DTC P0111 IAT sensor circuit range/performance problem
DETECTION
CONDITION
• The PCM compares the IAT with the ECT when the engine is running. If the
IAT is higher than the ECT by 40 ° C {104 ° F} , the PCM determines that there is an IAT sensor circuit range/performance problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
POSSIBLE CAUSE
• IAT sensor malfunction
• Connector or terminal malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA
HAS BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
5
6
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
No
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE
OR STORED DTC
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
INSPECT MAF/IAT SENSOR
CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
Yes Repair or replace the terminal, then go to Step 7.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT IAT SENSOR
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE
(IAT) SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to Step 7.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
• Is there any malfunction?
VERIFY TROUBLESHOOTING OF
DTC P0111 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine and warm it up completely.
No Go to the next step.
• Is the PENDING CODE for this DTC present?
.)
VERIFY AFTER REPAIR
PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0112 [Z6]
B3E010200100W04
DTC P0112 IAT sensor circuit low input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the IAT sensor signal at PCM terminal 2AQ. If the PCM detects that the IAT sensor voltage is less than 0.16 V , the PCM determines that the IAT sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAT sensor malfunction
• Connector or terminal malfunction
• Short to ground in wiring harness between MAF/IAT sensor terminal D and
PCM terminal 2AQ
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes Repair or replace the terminal, then go to Step 7.
INSPECT MAF/IAT SENSOR
CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT IAT SENSOR SIGNAL
CIRCUIT FOR SHORT TO GND
• Turn the ignition switch off.
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 7.
• Inspect for continuity between MAF/IAT sensor terminal D (wiring harness-side) and body GND.
No Go to the next step.
• Is there continuity?
INSPECT IAT SENSOR Replace the MAF/IAT sensor, then go to Step 7.
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [Z6] .)
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0112 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
No Go to the next step.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0113 [Z6]
B3E010200100W05
DTC P0113 IAT sensor circuit high input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the input voltage from the IAT sensor. If the input voltage at PCM terminal 2AQ is more than 4.8 V , the PCM determines that the IAT sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAT sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between MAF/IAT sensor terminal D and
PCM terminal 2AQ
• Short to power supply in wiring harness between MAF/IAT sensor terminal
D and PCM terminal 2AQ
• Open circuit in wiring harness between MAF/IAT sensor terminal E and
PCM terminal 2AY
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
3
INSPECT MAF/IAT SENSOR
CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
Yes
Repair or replace the terminal, then go to Step
8.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT IAT SENSOR SIGNAL
CIRCUIT FOR SHORT TO POWER
SUPPLY
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between MAF/IAT sensor terminal D (wiring harness-side) and body GND.
• Is the voltage B+ ?
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to Step
8.
No Go to the next step.
INSPECT IAT SENSOR
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to Step 8.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to Step
8.
Go to the next step.
INSPECT IAT SENSOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- MAF/IAT sensor terminal D
(wiring harness-side) and PCM terminal 2AQ (wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- MAF/IAT sensor terminal E
(wiring harness-side) and PCM terminal 2AY (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0113 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0117 [Z6]
B3E010200100W06
DTC P0117 ECT sensor circuit low input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the ECT sensor signal at PCM terminal 2J. If the PCM detects that the ECT sensor voltage is less than 0.20 V , the PCM determines that the ECT sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• ECT sensor malfunction
• Connect or terminal malfunction
• Short to ground in wiring harness between ECT sensor terminal A and PCM connector terminal 2J
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
3
INSPECT ECT SENSOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the ECT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to Step
7.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
INSPECT ECT SENSOR SIGNAL
CIRCUIT FOR SHORT TO GND
• Turn the ignition switch off.
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 7.
• Inspect for continuity between ECT sensor terminal A (wiring harness-side) and body GND.
No Go to the next step.
• Is there continuity?
INSPECT ECT SENSOR Replace the ECT sensor, then go to Step 7.
• Inspect the ECT sensor.
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION [Z6] .)
Yes
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION
[Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0117 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0118 [Z6]
B3E010200100W07
DTC P0118 ECT sensor circuit high input
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the ECT sensor signal at PCM terminal 2J. If the PCM detects that the ECT sensor voltage is more than 4.9 V , the PCM determines that the ECT sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• ECT sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between ECT sensor terminal A and PCM terminal 2J
• Short to power supply in wiring harness between ECT sensor terminal A and PCM terminal 2J
• Open circuit in wiring harness between ECT sensor terminal B and PCM terminal 2AX
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Repair or replace the terminal, then go to Step
8.
INSPECT ECT SENSOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the ECT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT ECT SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between ECT sensor terminal A (wiring harness-side) and body
GND.
No Go to the next step.
• Is the voltage B+ ?
INSPECT ECT SENSOR Replace the ECT sensor, then go to Step 8.
• Inspect the ECT sensor.
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION [Z6] .)
Yes
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION
[Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to Step
8.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
• Is there any malfunction?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
INSPECT ECT SENSOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- ECT sensor terminal A (wiring harness-side) and PCM terminal 2J
(wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- ECT sensor terminal B (wiring harness-side) and PCM terminal
2AX (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0118 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P0121
DETECTION
CONDITION
DTC P0121 [Z6]
B3E010200100W08
TP sensor circuit range/performance problem
• If the PCM detects that the throttle valve opening angle is less than 12.5 % for 5 s after the following conditions are met, the PCM determines that there is a TP sensor circuit range/performance problem:
MONITORING CONDITION
- Engine coolant temperature is more than 70 ° C {158 ° F} .
- MAF sensor signal is more than 59.5 g/s {7.9 lb/min}.
• If the PCM detects that the throttle valve opening angle is more than 50% for 5 s after the following conditions are met, the PCM determines that there is a TP sensor circuit range/performance problem.
MONITORING CONDITION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
- MAF sensor signal is less than 3.3 g/s {0.4 lb/min} .
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• TP sensor malfunction
• Electrical corrosion in TP signal circuit
• MAF sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the available repair information.
Yes
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6]
• Verify the related PENDING CODE or stored
DTCs.
No Go to the next step.
• Are other DTC present?
.)
VERIFY CURRENT INPUT SIGNAL STATUS
: IS CONCERN INTERMITTENT OR
CONSTANT?
Yes Go to Step 7.
• Start the engine.
No Go to the next step.
• Access the ECT, TP and MAF PIDs using the WDS or equivalent.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Warm up the engine until ECT PID is more than 70 ° C {158 ° F}
• Drive the vehicle.
• Read the TP PID while MAF PID is more than 59.5 g/s {7.9 lb/min} .
• Is the TP PID less than 12.5 % ?
VERIFY TP PID
• Start the engine.
Yes Go to Step 11.
• Access the TP, MAF PIDs using the WDS or equivalent.
• Read the TP PID while MAF PID is less than
3.3 g/s {0.4 lb/min} .
No Go to the next step.
• Is the TP PID more than 50 % ?
Intermittent concern exists.
VERIFY CURRENT INPUT SIGNAL STATUS
: IS CONCERN INTERMITTENT OR
CONSTANT?
Yes
Perform the "INTERMITTENT CONCERNS
TROUBLESHOOTING".
(See INTERMITTENT CONCERN
TROUBLESHOOTING [Z6] .)
• Drive the vehicle and read the MAF PID.
Inspect the MAF sensor and related circuits and terminals.
• Does the MAF PID change in compliance with driving condition?
No
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
Repair or replace as necessary, then go to
Step 14.
INSPECT TP SENSOR TERMINAL FOR
ELECTRICAL CORROSION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to
Step 10.
• Disconnect the TP sensor connector.
• Inspect for electrical corrosion on TP sensor terminals.
No Go to the next step.
• Is any electrical corrosion found?
Yes Go to the next step.
VERIFY TP SENSOR
• Does TP sensor resistance smoothly change while gradually opening throttle valve?
No
Replace TP sensor, then go to Step 10.
(See THROTTLE POSITION (TP) SENSOR
REMOVAL/INSTALLATION [Z6] .)
Yes Repair terminal, then go to Step 10.
INSPECT PCM TERMINAL FOR
ELECTRICAL CORROSION
• Disconnect the PCM connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
• Inspect for electrical corrosion on PCM terminals.
• Is any electrical corrosion found?
VERIFY TROUBLESHOOTING OF DTC
P0121 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start the engine.
• Clear DTC from PCM memory using WDS or equivalent.
Replace the PCM, then go to Step 15.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Access ECT, TP and MAF PIDs using WDS or equivalent.
• Warm up the engine until ECT PID is reading more than 70 ° C {158 ° F} .
• Drive the vehicle and read TP and MAF
PIDs.
• Verify PIDs reading are within specifications.
No Go to Step 15.
- MAF PID: more than 59.5 g/s {7.9 lb/min}
- TP PID: 12.5 % or more
• Is the PENDING CODE for this DTC present?
INSPECT TP SENSOR TERMINAL FOR
ELECTRICAL CORROSION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to
Step 14.
• Disconnect the TP sensor connector.
• Inspect for electrical corrosion on TP sensor terminals.
No Go to the next step.
• Is any electrical corrosion found?
Yes Go to the next step.
VERIFY TP SENSOR
• Does resistance smoothly change while gradually opening throttle valve?
No
Replace the TP sensor, then go to Step 14.
(See THROTTLE POSITION (TP) SENSOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT PCM TERMINAL FOR
ELECTRICAL CORROSION
• Disconnect PCM connector.
• Inspect for electrical corrosion on PCM and
PCM connector male and female terminals.
• Is any electrical corrosion found?
Yes Repair terminal, then go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
15
VERIFY TROUBLESHOOTING OF DTC
P0121 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start engine.
• Clear DTC from PCM memory using the
WDS or equivalent.
• Access the TP and MAF PIDs using the
WDS or equivalent.
• Verify the TP PID is 50% or less while MAF
PID is less than 3.3 g/s {0.4 lb/min} .
• Is the PENDING CODE for this DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0122
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0122 [Z6]
B3E010200100W09
TP sensor circuit low input
• If the PCM detects that the TP sensor voltage at PCM terminal 2AA is less than 0.10 V while the engine is running, the PCM determines that the TP sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• TP sensor malfunction
• Connector or terminal malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Open circuit in wiring harness between TP sensor terminal A and PCM terminal 2W
• Short to GND in wiring harness between TP sensor terminal A and PCM terminal 2W
• Open circuit in wiring harness between TP sensor terminal C and PCM terminal 2AA
• Short to GND in wiring harness between TP sensor terminal C and PCM terminal 2AA
• PCM malfunction
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
ACTION
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Is any related repair information available?
No Go to the next step.
INSPECT TP SENSOR CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 8.
• Turn the ignition switch off.
• Disconnect the TP sensor connector.
No Go to the next step.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT TP SENSOR CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 8.
- TP sensor terminal A (wiring harness-side) and body GND
No Go to the next step.
- TP sensor terminal C (wiring harness-side) and body GND
• Is there continuity?
INSPECT TP SENSOR
• Inspect the TP sensor.
(See THROTTLE POSITION (TP) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the TP sensor, then go to Step 8.
Yes
(See THROTTLE POSITION (TP) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 8.
No Go to the next step.
INSPECT TP SENSOR CIRCUIT FOR
OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- TP sensor terminal A (wiring harness-side) and PCM terminal 2W
(wiring harness-side)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
- TP sensor terminal C (wiring harness-side) and PCM terminal
2AA (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0122 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0123
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0123 [Z6]
B3E010200100W10
TP sensor circuit high input
• If the PCM detects that the TP sensor voltage at PCM terminal 2AA is more than 4.9 V after the ignition switch is turned to the ON position, the PCM determines that the TP sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• TP sensor malfunction
• Connector or terminal malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Short to power supply in wiring harness between TP sensor terminal C and
PCM terminal 2AA
• Open circuit in wiring harness between TP sensor terminal B and PCM terminal 2AE
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT TP SENSOR CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 8.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Turn the ignition switch off.
• Disconnect the TP sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT TP SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between TP sensor terminal C (wiring harness-side) and body
GND.
• Is the voltage B+ ?
INSPECT TP SENSOR
• Inspect the TP sensor.
(See THROTTLE POSITION (TP) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
No
No
No
Go to the next step.
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 8.
Go to the next step.
Replace the TP sensor, then go to Step 8.
Yes
(See THROTTLE POSITION (TP)
SENSOR REMOVAL/INSTALLATION
[Z6] .)
Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 8.
Go to the next step.
INSPECT TP SENSOR GND CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between TP sensor terminal B (wiring harness-side) and PCM terminal 2AE (wiring harness-side).
• Is there continuity?
Yes
No
Go to the next step.
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0123 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
DTC P0125
DETECTION
CONDITION
POSSIBLE
CAUSE
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0125 [Z6]
B3E010200100W11
Insufficient coolant temperature for closed loop fuel control
• The PCM monitors the ECT after cold engine start. If the ECT does not reach the specification in a certain period, the PCM determines that the engine coolant temperature for closed loop fuel control is insufficient.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• ECT sensor malfunction
• MAF sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Is any related repair information available?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL Intermittent concern exists.
STATUS: IS CONCERN INTERMITTENT
OR CONSTANT?
Yes
Perform the "INTERMITTENT CONCERNS
TROUBLESHOOTING".
• Connect the WDS or equivalent to the
DLC-2.
(See INTERMITTENT CONCERN
TROUBLESHOOTING [Z6] .)
• Start the engine and warm it up completely.
• Access the ECT PID.
No Go to the next step.
• Is the ECT PID more than 70 ° C
{158 ° F} ?
INSPECT ECT SENSOR
• Inspect the ECT sensor.
(See ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the ECT sensor, then go to Step 6.
Yes
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
INSPECT MAF SENSOR
• Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to the next step.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0125 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Access the ECT PID.
• Wait until the ECT PID is less than
20 ° C {68 ° F} .
• Start the engine and warm it up completely.
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
DTC P0132
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0132 [Z6]
B3E010200100W12
Front HO2S circuit high voltage
• The PCM monitors the input voltage from the front HO2S when the engine is running. If the input voltage is more than 1.2 V , the PCM determines that the front HO2S circuit voltage is high.
Diagnostic support note
• This is a continuous monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between front HO2S terminal A and
PCM terminal 2AI
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
3
INSPECT FRONT HO2S CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes
Repair or replace the terminal, then go to Step
7.
No Go to the next step.
4
INSPECT FRONT HO2S CIRCUIT FOR
SHORT TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to Step
7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between front HO2S terminal A (wiring harness-side) and body
GND.
No Go to the next step.
• Is the voltage B+ ?
INSPECT FRONT HO2S
• Inspect the front HO2S.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
Replace the front HO2S, then go to Step 7.
Yes
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
No Go to the next step.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
VERIFY TROUBLESHOOTING OF DTC
P0132 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0133 [Z6]
B3E010200100W13
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0133
POSSIBLE
CAUSE
Front HO2S circuit slow response
DETECTION
CONDITION
• The PCM monitors the inversion cycle period, lean-to-rich response time and rich-tolean response time of the sensor. The PCM calculates the average of the inversion cycle period-specified inversion cycles, average response time from lean-to-rich, and from rich-to-lean when the following conditions are met. If any exceeds the threshold, the PCM determines that circuit has a malfunction.
MONITORING CONDITIONS
- HO2S heater, HO2S, and TWC repair verification drive mode
- Following conditions are met:
• Calculation load is 18.0-59.4 % (at 2,000 rpm ).
• Engine speed is 1,410- 4,000 rpm .
• Vehicle speed is more than 3.76 km/h {2.33 mph} .
• Engine coolant temperature is more than -10 ° C {14 ° F} .
• Front HO2S signal inversion cycle is more than 10 cycles .
Diagnostic support note
• This is a intermittent monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• DIAGNOSTIC MONITORING TEST RESULTS is available.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S deterioration
• Looseness front HO2S
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
• Clogged or restricted fuel filter (built-in fuel pump unit)
• Fuel leakage on fuel line from fuel distribution pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve malfunction
• Purge solenoid hoses improper connection
• Insufficient compression
• Engine malfunction (leakage engine coolant)
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Is DTC P0443 present?
No Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
Yes Go to the next step.
• Is DTC P0133 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up the engine.
• Access the O2S11 PID using the WDS or equivalent.
• Inspect the PID under following accelerator pedal conditions (in PARK
(ATX) or NEUTRAL (MTX)).
• Is the PID normal?
- More than 0.55 V when suddenly depressing the accelerator pedal (rich condition)
- Less than 0.55 V just after releasing the accelerator pedal
(lean condition)
Yes Go to step 8.
No Go to the next step.
Yes Go to the next step.
INSPECT INSTALLATION OF FRONT
HO2S
• Inspect if the front HO2S is loosely installed.
No Retighten the front HO2S, then go to Step 13.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
11
• Is the front HO2S installed securely?
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
INSPECT GAS LEAKAGE FROM
EXHAUST SYSTEM
• Visually inspect if there is any gas leakage between the exhaust manifold and front HO2S.
• Is there gas leakage?
Yes
No
Repair or replace any malfunctioning exhaust part, then go to Step 13.
Replace the front HO2S, then go to Step 13.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
INSPECT LONG TERM FUEL TRIM
• Access the LONGFT1 PID.
Yes
The engine is driven under rich condition. Go to the next step.
• Compare it with FREEZE FRAME DATA recorded at Step 1.
No
• Is it below FFD value?
The engine is driven under lean condition. Go to step 10.
Yes Go to Step 12.
INSPECT FUEL LINE PRESSURE
(EXCESSIVE FUEL LINE PRESSURE)
• Turn the ignition switch off.
• Inspect the fuel line pressure while the engine running.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
Inspect the fuel pump maximum pressure and fuel return pipe for clogging.
(See FUEL PUMP UNIT INSPECTION .)
No
• If there is any malfunction, repair or replace suspected parts.
• If all items above are normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Then go to Step 13.
INSPECT FUEL LINE PRESSURE (LOW
FUEL LINE PRESSURE)
Yes Go to step 12.
• Turn the ignition switch off.
• Inspect the fuel line pressure while the engine running.
No Go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
Yes Replace suspected fuel line, then go to Step 13.
INSPECT FUEL LINE FROM FUEL
PUMP TO FUEL DELIVERY PIPE Inspect the fuel filter for following:
• Visually inspect fuel line for any leakage.
No
• Is any fuel leakage found?
• Foreign materials or stain inside fuel filter (lowpressure side)
Perform following actions according to result.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
• If there is any foreign material or stain inside fuel filter (low-pressure side), clean the fuel tank and filter.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Then go to Step 13.
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
• Perform the "ENGINE COOLANT
LEAKAGE INSPECTION".
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
• Is there any malfunction?
No
Repair or replace malfunctioning part according
Yes to the inspection result. Then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0133 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0134
DETECTION
CONDITION
DTC P0134 [Z6]
B3E010200100W14
Front HO2S circuit no activity detected
• The PCM monitors the input voltage from the front HO2S when the following conditions are met. If the input voltage from sensor never exceeds
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
0.55 V for 120 s or more , the PCM determines that sensor circuit is not activated.
MONITORING CONDITIONS
- HO2S, HO2S heater and TWC repair verification drive mode
- Following conditions are met:
• Engine speed is 1,500 rpm or more .
• Engine coolant temperature is 70 ° C {158 ° F} or more .
• Within feed-back range
Diagnostic support note
• This is a continuous monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S deterioration
• Front HO2S heater malfunction
• Leakage in exhaust system
• Open circuit in wiring harness between front HO2S terminal A and PCM terminal 2AI
• Short to GND in wiring harness between front HO2S terminal A and PCM terminal 2AI
• Insufficient compression
• Engine malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING AND STORED
DTC
Yes
Go to appropriate DTC troubleshooting procedures.
Note (See DTC TABLE [Z6] .)
• If fuel monitor DTC, DTC P0132 is retrieved, ignore it until P0134 is fixed.
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify pending and stored DTCs using the
WDS or equivalent.
• Is other DTC present?
No Go to the next step.
Yes Go to step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up the engine.
• Access O2S11 PID using the WDS or equivalent.
• Verify PID while racing engine (in NEUTRAL
(MTX) or PARK (ATX)).
No Go to the next step.
• Is PID normal?
- More than 0.55 V when suddenly depressing the accelerator pedal (rich condition)
- Less than 0.55 V just after releasing the accelerator pedal (lean condition)
INSPECT INSTALLATION OF FRONT HO2S
Yes Go to the next step.
Install sensor securely, then go to Step 9.
• Inspect if the front HO2S is loosely installed.
• Is sensor installed securely?
No
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Yes
Repair or replace any malfunctioning exhaust part, then go to Step 9.
INSPECT GAS LEAKAGE FROM EXHAUST
SYSTEM
• Visually inspect if there is any gas leakage between the exhaust manifold and the front
HO2S.
• Is there gas leakage?
• Inspect the following wiring harnesses for open circuit or short to GND in wiring harness.
- Front HO2S terminal A (wiring harness-side) to PCM terminal 2AI
(wiring harness-side)
No
• Repair or replace wiring harness if necessary.
• If all items above are normal, replace the malfunctioning sensor.
Then go to Step 9.
INSPECT SEALING OF ENGINE COOLANT
PASSAGE
Warning
Air gets in from poor sealing on head gasket
Yes or other areas between combustion chamber and engine coolant passage.
• Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.
Repair or replace the malfunctioning part, then go to Step 9.
• When removing the radiator cap, wrap a thick cloth around and turn it slowly.
No Go to the next step.
• Remove the radiator cap.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
• Implement procedure to bleed air from engine coolant, then idle the engine.
• Is there any small bubble, which makes engine coolant white at filling opening?
Note
• Large bubbles are normal since they are remaining air coming out from engine coolant passage.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION [Z6] .)
• Is it normal?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
No
Perform engine overhaul for repairs, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0134 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No
Go to the next step.
DTC troubleshooting completed.
DTC P0138
DETECTION
CONDITION
DTC P0138 [Z6]
B3E010200100W15
Rear HO2S circuit high voltage
• The PCM monitors the input voltage from the rear HO2S when the engine is running. If the input voltage is more than 1.2 V , the PCM determines that the rear HO2S circuit voltage is high.
Diagnostic support note
• This is a continuous monitor (HO2S).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Rear HO2S malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between rear HO2S terminal A and
PCM terminal 2K
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
Perform repair or diagnosis according to the available repair information.
Yes
• If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Is any related repair information available?
INSPECT REAR HO2S CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the rear HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No
Yes
No
Go to the next step.
Repair or replace the terminal, then go to Step
7.
Go to the next step.
INSPECT REAR HO2S CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to Step
7.
• Measure the voltage between rear HO2S terminal A (wiring harness-side) and body
GND.
• Is the voltage B+ ?
No Go to the next step.
INSPECT REAR HO2S
• Inspect the rear HO2S.
(See REAR HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
Replace the rear HO2S, then go to Step 7.
Yes
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0138 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0140 [Z6]
B3E010200100W16
Rear HO2S circuit no activity detected DTC P0140
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the input voltage from the rear HO2S when the following conditions are met. If the input voltage from the sensor never exceeds 0.55
V for 30.4 s , the PCM determines that the sensor circuit is not activated.
MONITORING CONDITIONS
- HO2S, HO2S heater and TWC repair verification drive mode
- Following conditions are met:
• Engine speed is 1,500 rpm or more .
• Engine coolant temperature is 70 ° C {158 ° F} or more .
• Within feed-back range
Diagnostic support note
• This is a continuous monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Rear HO2S deterioration
• Rear HO2S heater malfunction
• Leakage exhaust system
• Open circuit in wiring harness between rear HO2S terminal A and PCM terminal 2K
• Short to GND in wiring harness between rear HO2S terminal A and PCM terminal 2K
• Insufficient compression
• Engine malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING AND
STORED DTC
Note
• If fuel monitor DTC, DTC P0132 is retrieved, ignore it until P0140 is fixed.
• Turn the ignition switch off, then the ON position (Engine off).
• Verify pending and stored DTCs using
WDS or equivalent.
• Is other DTC present?
Go to appropriate DTC troubleshooting
Yes procedures.
(See DTC TABLE [Z6] .)
No Go to the next step.
Yes Go to step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up engine.
• Access O2S12 PID using WDS or equivalent.
• Verify PID while racing engine at least 10 times (in NEUTRAL (MTX) or PARK (ATX)).
No Go to the next step.
• Is PID normal?
- More than 0.55 V at least once during engine racing
INSPECT INSTALLATION OF REAR HO2S
Yes Go to the next step.
• Inspect if rear HO2S is loosely installed.
Install sensor securely, then go to Step 9.
• Is sensor installed securely?
No
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Yes
Repair or replace any malfunctioning exhaust part, then go to Step 9.
INSPECT GAS LEAKAGE FROM
EXHAUST SYSTEM
• Visually inspect if any gas leakage is found between exhaust pipe and rear HO2S.
No
• Is there gas leakage?
• Inspect the following wiring harnesses for open circuit or short to GND in wiring harness.
- Rear HO2S terminal A (wiring harness-side) to PCM terminal 2K
(wiring harness-side)
• Repair or replace wiring harness if necessary.
• If all items above are normal, replace the malfunctioning sensor.
Then go to Step 9.
INSPECT SEALING OF ENGINE COOLANT
PASSAGE
Warning
Air gets in from poor sealing on head gasket or other areas between combustion chamber
Yes and engine coolant passage.
• Removing radiator cap when
Repair or replace the malfunctioning part, then go to Step 9.
radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.
• When removing radiator cap, wrap a thick cloth around and turn it slowly.
No Go to the next step.
• Remove radiator cap.
• Implement procedure to bleed air from engine coolant, then run engine at idle.
• Is there any small bubble, which makes engine coolant white at filling opening?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
Note
• Large bubbles are normal since they are remaining air coming out from engine coolant passage.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION [Z6] .)
• Is it normal?
Yes
No
Go to the next step.
Implement engine overhaul for repairs, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0140 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
.)
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0300 [Z6]
B3E010200300W01
DTC P0300 Random misfire detected
DETECTION
CONDITION
• The PCM monitors the CKP sensor input signal interval time. the PCM calculates the change of interval time for each cylinder. If change of interval time exceeds the preprogrammed criteria, the PCM detects misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can damage the catalytic converter or affect emission performance, has occurred.
Diagnostic support note
• This is a continuous monitor (Misfire).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• The MIL flashes if the PCM detects misfire which can damage the catalytic converter during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• CKP sensor malfunction
• CMP sensor malfunction
• Ignition coil malfunction
• Erratic signal to ignition coil
• Spark plug malfunction
• MAF sensor contamination
• Excess air suction in intake air system (between MAF sensor and intake manifold)
• Fuel pump malfunction
• Fuel pressure regulator (built-in fuel pump unit) malfunction
• Fuel line clogged
• Fuel filter clogged
• Fuel leakage in fuel line
• Fuel runout
• Poor quality fuel
• Purge solenoid valve malfunction
• PCV valve malfunction
• EGR valve malfunction
• Vacuum hoses damages or improper connection
• Related connector and terminal malfunction
• Related wiring harness malfunction
• Insufficient compression
• Variable valve timing control system improper
Diagnostic procedure
STEP
1
INSPECTION
Yes Go to the next step.
ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO
ON/IDLE)
• Access the BOO, ECT, IAT, MAF, RPM,
TP, and VSS PIDs using the WDS or equivalent.
Inspect suspected circuit and/or part according to inspection results.
Yes
(See PCM INSPECTION [Z6] .)
Then go to Step 22.
(See PCM INSPECTION [Z6] .)
• Is there any signal that is far out of specification when ignition switch is the
ON position and engine runs at idle?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as in Step 4 while simulating FREEZE FRAME DATA condition.
Inspect suspected circuit and/or part according to inspection results.
Yes
(See PCM INSPECTION [Z6] .)
Then go to Step 22.
• Is there any signal which causes drastic changes?
No Go to the next step.
Yes Go to the next step.
INSPECT CMP SENSOR
• Inspect the CMP sensor.
(See CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [Z6] .)
• Is the CMP sensor normal?
Inspect installation condition and damages on the timing belt and gears, repair the malfunctioning part.
No
• If it is normal, replace the CMP sensor.
(See CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION [Z6] .)
Then go to Step 22.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
11
12
13
VERIFY CKP SENSOR INSTALLATION
CONDITION
• Inspect for the CKP sensor looseness.
• Is the CKP sensor loosen?
Retighten the CKP sensor, then go to Step 22.
Yes
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT IGNITION COIL HARNESS
• Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
• Are wiring harness conditions normal?
Yes Go to the next step.
No
Repair suspected wiring harnesses, then go to
Step 22.
INSPECT IGNITION SYSTEM
OPERATION
• Perform the spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
Yes
No
Go to the next step.
Repair or replace malfunctioning part according to spark test result. Then go to Step 22.
INSPECT POWER SUPPLY TERMINAL
AT IGNITION COIL CONNECTOR
• Disconnect the ignition coil connector.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between ignition coil terminal A (harness-side) and body ground.
• Is the voltage B+ ?
Yes Go to the next step.
No
Inspect for open circuit in wiring harness between ignition coil terminal A and PCM terminal 2A. Repair or replace wiring harness, then go to Step 22.
INSPECT IGNITION COIL RESISTANCE Yes Go to step 22.
• Inspect the ignition coil resistance.
• Is coil resistance normal?
(See IGNITION COIL INSPECTION [Z6] .)
Replace the ignition coil, then go to Step 22.
No
(See IGNITION COIL
REMOVAL/INSTALLATION [Z6] .)
INSPECT MAF PID Yes Go to the next step.
• Start the engine.
• Access the MAF PID using the WDS or equivalent.
• Verify that the MAF PID changes quickly according to race the engine RPM.
No
Replace the MAF/IAT sensor, then go to Step
22.
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
• Is the MAF PID response normal?
INSPECT EXCESSIVE AIR SUCTION IN
INTAKE AIR SYSTEM
Yes
Repair or replace suspected part, then go to
Step 22.
• Inspect for air leakage at following:
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
15
16
17
- Between MAF sensor and throttle body
- Between throttle body and intake manifold
• Is there any malfunction?
Yes Go to step 16.
INSPECT FUEL LINE PRESSURE
• Inspect the fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
INSPECT FUEL LINE FROM FUEL
PUMP TO FUEL DELIVERY PIPE
• Visually inspect for fuel leakage in fuel line for any leakage.
• Is any fuel leakage found?
If the fuel line pressure is too low, go to the next step.
No
If the fuel line pressure is excess high, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .) then go to Step 22.
Yes Replace the fuel line, then go to Step 22.
Inspect the fuel filter for following:
• Foreign materials or stain inside fuel filter (lowpressure side)
Perform following actions depending on the result above.
No
• If there is any foreign materials or stain inside fuel filter (low-pressure side), clean the fuel tank and filter (low-pressure side).
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Then, go to Step 22.
INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression.
(See COMPRESSION INSPECTION [Z6] .)
No
• Is it normal?
Perform the engine overhaul for repairs, then go to Step 22.
INSPECT VARIABLE VALVE TIMING
CONTROL SYSTEM OPERATION
• Inspect the variable valve timing control system operation.
(See Variable Valve Timing Control
System Operation Inspection .)
• Does the variable valve timing control system?
Yes Go to the next step.
No
Repair or replace malfunctioning part according to variable valve timing control system inspection results, then go to Step 22.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
18
19
20
21
INSPECT OPERATION OF PURGE
SOLENOID VALVE
• Turn the ignition switch off.
• Connect vacuum pump to the purge solenoid valve and apply vacuum to the purge solenoid valve.
• Verify that the purge solenoid valve holds vacuum.
Yes Go to the next step.
• Turn the ignition switch to the ON position (Engine off).
• Access the EVAPCP PID in
SIMULATION TEST using the WDS or equivalent.
• Set duty value to 100% for the EVAPCP
PID.
• Apply vacuum while turning the purge solenoid valve from Off to On and simulating EVAPCP PID with 100% duty value.
No
Replace the purge solenoid valve, then go to
Step 22.
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [Z6] .)
• Verify that the purge solenoid valve releases vacuum while the purge solenoid valve is turned ON.
• Is the purge solenoid valve operation normal?
Replace the PCV valve, then go to Step 22.
Yes
(See INTAKE-AIR SYSTEM HOSE ROUTING
DIAGRAM [Z6] .)
INSPECT PCV VALVE OPERATION
• Turn the ignition switch off.
• Remove the PCV valve and inspect valve operation.
(See INTAKE-AIR SYSTEM HOSE
ROUTING DIAGRAM [Z6] .)
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is the PCV valve operation normal?
No Go to the next step.
INSPECT OPERATION OF EGR VALVE
• Remove the EGR valve.
(See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
• Visually inspect for stuck to open.
Yes
Repair or replace the EGR valve, then go to
Step 22.
(See EGR VALVE REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
• Does EGR valve stuck to open?
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
Yes
Repair or replace malfunctioning part according to inspection result.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
22
• Perform "ENGINE COOLANT LEAKAGE
INSPECTION".
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
• Is there any malfunction?
Then go to the next step.
No Go to the next step.
VERIFY TROUBLESHOOTING OF
MISFIRE DTC COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
23
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0301, P0302, P0303, P0304 [Z6]
B3E010200300W02
DTC P0301
DTC P0302
DTC P0303
DTC P0304
DETECTION
CONDITION
Cylinder No.1 misfire detected
Cylinder No.2 misfire detected
Cylinder No.3 misfire detected
Cylinder No.4 misfire detected
• The PCM monitors the CKP sensor input signal interval time. The PCM calculates the change of interval time for each cylinder. If the change of interval time exceeds the preprogrammed criteria, the PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can damage the catalytic converter or affect emission performance, has occurred.
Diagnostic support note
• This is a continuous monitor (Misfire).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• The MIL flashes if the PCM detects the misfire which can damage the catalytic converter during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Spark plug malfunction
• Erratic signal to ignition coil
• Fuel injector malfunction
• Air suction in intake air system (between dynamic chamber and cylinder head)
• Inadequate engine compression due to engine internal malfunction
• Related connector or terminal malfunction
• Related wiring harness malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO ON
/IDLE)
Yes
Inspect suspected circuit and/or part according to inspection results. Then go to Step 13.
(See PCM INSPECTION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Access BOO, ECT, IAT, MAF, RPM, TP and VSS PIDs using WDS or equivalent.
(See PCM INSPECTION [Z6] .)
• Is there any signal that is far out of specification when ignition switch is ON and engine runs at idle?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect the same PIDs as in Step 4 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected circuit and/or part according to inspection results. Then go to Step 13.
(See PCM INSPECTION [Z6] .)
• Is there any signal which causes drastic changes?
No Go to the next step.
INSPECT SPARK PLUG CONDITION
• Turn the ignition switch off.
• Remove the spark plug from suspected cylinder.
(See SPARK PLUG
REMOVAL/INSTALLATION [Z6] .)
• Inspect the spark plug condition:
- Cracks
- Excess wear
- Gap
- Wet
• Is any problem found on spark plug?
• If the spark plug is wet, fuel flooding is suspected. Go to step 13.
• If the spark plug has a cracks, excessive
Yes wear or improper gap, replace the malfunctioning spark plug. Then go to Step 13.
(See SPARK PLUG
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT IGNITION COIL HARNESS
• Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
• Are wiring harness conditions normal?
Yes Go to the next step.
No
Repair suspected wiring harnesses, then go to
Step 13.
INSPECT FOR AIR SUCTION AT
INTAKE-AIR SYSTEM
• Inspect for air leakage at following:
- Around connection of dynamic chamber and intake manifold
- Around connection of intake manifold and cylinder head
• Is air leakage found?
Yes
No
Repair or replace suspected part, then go to
Step 13.
Go to the next step.
INSPECT FUEL INJECTOR HARNESS Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
• Remove the intake air system parts.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
• Disconnect the fuel injector connector on suspected cylinder.
• Connect noid light to the fuel injector connector terminals.
• Inspect dim of light during cranking.
• Does noid light illuminate?
Inspect for fuel injector wiring harnesses.
No
Repair or replace it if necessary, then go to
Step 13.
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
• Perform the "ENGINE COOLANT
LEAKAGE INSPECTION".
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
• Is there any malfunction?
Yes
No
Repair or replace malfunctioning part according to inspection result.
Then go to Step 13.
Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect the engine compression.
Yes Go to the next step.
(See COMPRESSION INSPECTION [Z6] .)
No Overhaul the engine, then go to Step 13.
• Is the engine compression normal?
INSPECT FUEL INJECTOR OPERATION
• Remove the fuel injector from suspected cylinder.
Replace fuel injector, then go to the next step.
Yes
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
• Switch injector with injector on other cylinder.
• Start the engine and run it at idle.
• Is misfire DTC for cylinder which has a suspected fuel injector?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0301, P0302, P0303, P0304
COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
(See OBD DRIVE MODE [Z6] .)
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0327
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0327 [Z6]
B3E010200300W03
KS circuit low input
• The PCM monitors the input signal from the KS when the engine is running.
If the input voltage at PCM terminal 2BA is less than 1.25 V , the PCM determines that the KS circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• KS malfunction
• Connector or terminal malfunction
• Short to GND in wiring harness between KS terminal A and PCM terminal
2BA
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
ACTION
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
3
4
INSPECT KS CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the KS connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to Step
7.
No Go to the next step.
INSPECT KS SIGNAL CIRCUIT FOR
SHORT TO GND
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
• Turn the ignition switch off.
• Inspect for continuity between KS terminal
A (wiring harness-side) and body GND.
No Go to the next step.
• Is there continuity?
INSPECT KS
• Inspect the KS.
(See KNOCK SENSOR (KS) INSPECTION
[Z6] .)
Replace the KS, then go to Step 7.
Yes
(See KNOCK SENSOR (KS)
REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
No Go to the next step.
6
7
8
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0327 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P0328
DETECTION
CONDITION
DTC P0328 [Z6]
B3E010200300W04
KS circuit high input
• The PCM monitors the input signal from the KS when the engine is running.
If the input voltage at PCM terminal 2BA is more than 3.75 V , the PCM determines that the KS circuit has a malfunction.
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• KS malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between KS terminal A and PCM terminal
2BA
• Short to power supply in wiring harness between KS terminal A and PCM terminal 2BA
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT KS CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the KS connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 8.
Go to the next step.
INSPECT KS SIGNAL CIRCUIT FOR SHORT
TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between KS terminal A
(wiring harness-side) and body GND.
No Go to the next step.
• Is the voltage B+ ?
INSPECT KS
• Inspect the KS.
(See KNOCK SENSOR (KS) INSPECTION
[Z6] .)
• Is there any malfunction?
Replace the KS, then go to Step 8.
Yes
(See KNOCK SENSOR (KS)
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 8.
Go to the next step.
INSPECT KS SIGNAL CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between KS terminal A
(wiring harness-side) and PCM terminal 2BA
(wiring harness-side).
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
• Is there continuity?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
VERIFY TROUBLESHOOTING OF DTC
P0328 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0335
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0335 [Z6]
B3E010200300W05
CKP sensor circuit problem
• If the PCM does not receive the input voltage from the CKP sensor for 4.2 s or more while the MAF is 1.43 g/s {0.189 lb/min} or more , the PCM determines that there is a CKP sensor circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• CKP sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between CKP sensor terminal A and PCM terminal 2T
• Short to GND in wiring harness between CKP sensor terminal A and PCM terminal 2T
• Open circuit in wiring harness between CKP sensor terminal B and PCM terminal 2P
• Short to power supply in wiring harness between CKP sensor terminal B and PCM terminal 2P
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Short to GND in wiring harness between CKP sensor terminal B and PCM terminal 2P
• Open circuit in wiring harness between CKP sensor terminal C and PCM terminal 2BF
• Short to power supply in wiring harness between CKP sensor terminal C and PCM terminal 2BF
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
INSPECT CKP SENSOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the CKP sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT CKP SENSOR CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
- CKP sensor terminal A (wiring harness-side) and body GND
No Go to the next step.
- CKP sensor terminal B (wiring harness-side) and body GND
• Is there continuity?
INSPECT CKP SENSOR CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following terminals:
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
- CKP sensor terminal B (wiring harness-side) and body GND
- CKP sensor terminal C (wiring harness-side) and body GND
• Is the voltage B+ ?
No Go to the next step.
INSPECT CKP SENSOR
• Inspect the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Replace the CKP sensor, then go to Step 9.
Yes
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
INSPECT CKP SENSOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- CKP sensor terminal A (wiring harness-side) and PCM terminal 2T
(wiring harness-side)
- CKP sensor terminal B (wiring harness-side) and PCM terminal 2P
(wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- CKP sensor terminal C (wiring harness-side) and PCM terminal
2BF (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0335 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Start the engine.
• Run the engine for 4.2 s or more when the
MAF PID is 1.43 g/s {0.189 lb/min} or more .
No Go to the next step.
• Is the same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0340
DETECTION
CONDITION
DTC P0340 [Z6]
B3E010200300W06
CMP sensor circuit problem
• The PCM monitors the input voltage from the CMP sensor when the engine is running. If the PCM does not receive the input voltage from the CMP sensor for 12 consecutive engine rotations, the PCM determines that there is a CKP sensor circuit problem.
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• CMP sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between CMP sensor terminal A and PCM terminal 2T
• Short to GND in wiring harness between CMP sensor terminal A and PCM terminal 2T
• Open circuit in wiring harness between CMP sensor terminal B and PCM terminal 2BB
• Short to power supply in wiring harness between CMP sensor terminal B and PCM terminal 2BB
• Short to GND in wiring harness between CMP sensor terminal B and PCM terminal 2BB
• Open circuit in wiring harness between CMP sensor terminal C and PCM terminal 2BF
• Short to power supply in wiring harness between CMP sensor terminal C and PCM terminal 2BF
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 9.
INSPECT CMP SENSOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the CMP sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
INSPECT CMP SENSOR CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
- CMP sensor terminal A (wiring harness-side) and body GND
- CMP sensor terminal B (wiring harness-side) and body GND
• Is there continuity?
No Go to the next step.
INSPECT CMP SENSOR CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following terminals:
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
- CMP sensor terminal B (wiring harness-side) and body GND
- CMP sensor terminal C (wiring harness-side) and body GND
• Is the voltage B+ ?
No Go to the next step.
INSPECT CMP SENSOR
• Inspect the CMP sensor.
(See CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Replace the CMP sensor, then go to Step 9.
Yes
(See CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
INSPECT CMP SENSOR CIRCUIT FOR
OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
- CMP sensor terminal A (wiring harness-side) and PCM terminal 2T
(wiring harness-side)
- CMP sensor terminal B (wiring harness-side) and PCM terminal
2BB (wiring harness-side)
- CMP sensor terminal C (wiring harness-side) and PCM terminal
2BF (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0340 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Start the engine.
• Run the engine when the MAF PID is more than 1.43 g/s {0.189 lb/min} .
No Go to the next step.
• Is the same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0403
DETECTION
CONDITION
DTC P0403 [Z6]
B3E010200400W01
EGR control circuit problem
• The PCM monitors the input voltage from the EGR valve. If the voltages at
PCM terminals 2Z, 2V, 2R and/or 2N remain low or high, the PCM determines that the there is a EGR control circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• EGR valve malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between EGR valve terminal C and PCM terminal 2BG
• Short to GND in wiring harness between EGR valve terminal C and PCM terminal 2BG
• Open circuit in wiring harness between EGR valve terminal D and PCM terminal 2BG
• Short to GND in wiring harness between EGR valve terminal D and PCM terminal 2BG
• Open circuit in wiring harness between EGR valve terminal E and PCM terminal 2Z
• Short to power supply in wiring harness between EGR valve terminal E and
PCM terminal 2Z
• Short to GND in wiring harness between EGR valve terminal E and PCM terminal 2Z
• Open circuit in wiring harness between EGR valve terminal A and PCM terminal 2V
• Short to power supply in wiring harness between EGR valve terminal A and
PCM terminal 2V
• Short to GND in wiring harness between EGR valve terminal A and PCM terminal 2V
• Open circuit in wiring harness between EGR valve terminal B and PCM terminal 2R
• Short to power supply in wiring harness between EGR valve terminal B and
PCM terminal 2R
• Short to GND in wiring harness between EGR valve terminal B and PCM terminal 2R
• Open circuit in wiring harness between EGR valve terminal F and PCM terminal 2N
• Short to power supply in wiring harness between EGR valve terminal F and
PCM terminal 2N
• Short to GND in wiring harness between EGR valve terminal F and PCM terminal 2N
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT EGR VALVE CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to
Step 9.
• Disconnect the EGR valve connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
• Is there any malfunction?
INSPECT EGR VALVE CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes
Repair or replace wiring harness for short to
GND, then go to Step 9.
- EGR valve terminal C (wiring harness-side) and body GND
- EGR valve terminal D (wiring harness-side) and body GND
- EGR valve terminal E (wiring harness-side) and body GND
- EGR valve terminal A (wiring harness-side) and body GND
- EGR valve terminal B (wiring harness-side) and body GND
- EGR valve terminal F (wiring harness-side) and body GND
• Is there continuity?
No Go to the next step.
INSPECT EGR VALVE CONTROL CIRCUIT
FOR SHORT TO POWER SUPPLY
Yes
Repair or replace wiring harness for short to power supply, then go to Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following terminals:
- EGR valve terminal E (wiring harness-side) and body GND
- EGR valve terminal A (wiring harness-side) and body GND
- EGR valve terminal B (wiring harness-side) and body GND
No Go to the next step.
- EGR valve terminal F (wiring harness-side) and body GND
• Is the voltage B+ ?
INSPECT EGR VALVE
• Inspect the EGR valve.
(See EGR VALVE INSPECTION .)
• Is there any malfunction?
Replace the EGR valve, then go to Step 9.
Yes
(See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to
Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT EGR VALVE CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- EGR valve terminal C (wiring harness-side) and PCM terminal
2BG (wiring harness-side)
- EGR valve terminal D (wiring harness-side) and PCM terminal
2BG (wiring harness-side)
- EGR valve terminal E (wiring harness-side) and PCM terminal 2Z
(wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- EGR valve terminal A (wiring harness-side) and PCM terminal 2V
(wiring harness-side)
- EGR valve terminal B (wiring harness-side) and PCM terminal 2R
(wiring harness-side)
- EGR valve terminal F (wiring harness-side) and PCM terminal 2N
(wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0403 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the PENDING CODE for this DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Are any DTCs present?
DTC P0420 [Z6]
B3E010200400W02
DTC P0420
POSSIBLE
CAUSE
Catalyst system efficiency below threshold
DETECTION
CONDITION
• The PCM compares the number of the front HO2S and rear HO2S inversions for a predetermined time. The PCM monitors the number of inversions the rear side performs while the front side inverts for a specified number of times when the following monitoring conditions are met. The PCM detects the inversion ratio. If inversion ratio is below the threshold, the PCM determines that the catalyst system has deteriorated.
MONITORING CONDITION
- HO2S, HO2S heater and TWC repair verification drive mode
- Engine speed is 1,500- 3,000 rpm .
- Calculated TWC temperature in PCM is more than 600 ° C
{1112 ° F} (MTX), more than 620 ° C {1148 ° F} (ATX).
- Calculated load is 17- 48 % .* 1
* 1 : Maximum calculated load value varies depending on engine speed.
Diagnostic support note
• This is a intermittent monitor (Catalyst).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• DIAGNOSTIC MONITORING TEST RESULTS and PENDING CODE are available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• TWC deterioration or malfunction
• Exhaust gas leakage
• Loose front HO2S
• Loose rear HO2S
• Front HO2S malfunction
Diagnostic procedure
STEP
1
INSPECTION
Yes Go to the next step.
ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
INSPECT GAS LEAKAGE OF EXHAUST
SYSTEM
Yes
Repair or replace the malfunctioning exhaust parts, then go to Step 7.
• Visually inspect exhaust gas leakage in exhaust system.
• Is there gas leakage?
No Go to the next step.
INSPECT INSTALLATION OF FRONT
HO2S AND REAR HO2S
• Inspect the front HO2S and rear HO2S for looseness.
• Is it normal?
Yes Go to the next step.
Retighten the sensor, then go to Step 7.
No
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
INSPECT TWC
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Turn the ignition switch off then to the
ON position.
• Inspect the TWC.
• Is it normal?
Replace the HO2S, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
Yes (HO2S) REMOVAL/INSTALLATION [Z6] .)
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Replace the TWC, then go to the next step.
No
(See EXHAUST SYSTEM
REMOVAL/INSTALLATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P0420 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0443
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0443 [Z6]
B3E010200400W03
Purge solenoid valve circuit problem
• The PCM monitors the purge solenoid valve control signal. If the voltage at
PCM terminal 2AV remains low or high, the PCM determines that there is a purge solenoid valve circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Purge solenoid valve malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between purge solenoid valve terminal A and
PCM terminal 2T
• Short to GND in wiring harness between purge solenoid valve terminal A and PCM terminal 2T
• Open circuit in wiring harness between purge solenoid valve terminal B and
PCM terminal 2AV
• Short to power supply in wiring harness between purge solenoid valve terminal B and PCM terminal 2AV
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Short to GND in wiring harness between purge solenoid valve terminal B and PCM terminal 2AV
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT PURGE SOLENOID VALVE
CONNECTOR FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the purge solenoid valve connector.
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT PURGE SOLENOID VALVE
CIRCUIT FOR SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
- Purge solenoid valve terminal A
(wiring harness-side) and body GND
- Purge solenoid valve terminal B
(wiring harness-side) and body GND
• Is there continuity?
Yes
Repair or replace wiring harness for short to
GND, then go to Step 9.
No Go to the next step.
INSPECT PURGE SOLENOID VALVE
CONTROL CIRCUIT FOR SHORT TO
POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
Yes
Repair or replace wiring harness for short to power supply, then go to Step 9.
• Measure the voltage between purge solenoid
No Go to the next step.
valve terminal B (wiring harness-side) and body GND.
• Is the voltage B+ ?
INSPECT PURGE SOLENOID VALVE
• Inspect the purge solenoid valve.
(See PURGE SOLENOID VALVE
INSPECTION .)
• Is there any malfunction?
No
Replace the purge solenoid valve, then go
Yes to Step 9.
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [Z6] .)
Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT PURGE SOLENOID VALVE
CIRCUIT FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
- Purge solenoid valve terminal A
(wiring harness-side) and PCM terminal 2T (wiring harness-side)
- Purge solenoid valve terminal B
(wiring harness-side) and PCM terminal 2AV (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0443 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the PENDING CODE for this DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0480
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0480 [Z6]
B3E010200400W04
Cooling fan control circuit problem
• The PCM monitors input voltage from the fan control module. If the voltage at PCM terminal 1AP remains low or high, the PCM determines that there is a cooling fan control circuit problem.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• Fan control module malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between fan control module terminal C and
PCM terminal 1AP
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Short to power supply in wiring harness between fan control module terminal C and PCM terminal 1AP
• Short to GND in wiring harness between fan control module terminal C and
PCM terminal 1AP
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT FAN CONTROL MODULE
CONNECTOR FOR POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 9.
• Turn the ignition switch off.
• Disconnect the fan control module connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR SHORT TO GND
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
• Turn the ignition switch off.
• Inspect for continuity between fan control module terminal C (wiring harness-side) and body GND.
• Is there continuity?
No Go to the next step.
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR SHORT TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fan control module terminal C (wiring harness-side) and body GND.
No Go to the next step.
• Is the voltage B+ ?
INSPECT FAN CONTROL MODULE
• Inspect the fan control module.
(See COOLING FAN MOTOR COMPONENT
INSPECTION .)
• Is there any malfunction?
Replace the cooling fan component, then
Yes go to Step 9.
(See RADIATOR
REMOVAL/INSTALLATION .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between fan control module terminal C (wiring harness-side) and
PCM terminal 1AP (wiring harness-side).
• Is there continuity?
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
Yes Replace the PCM, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
VERIFY TROUBLESHOOTING OF DTC
P0480 COMPLETED
• Make sure to reconnect all disconnected connectors.
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Turn the A/C switch on to operate the cooling fan motor.
No Go to the next step.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P0500
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P0500 [Z6]
B3E010200500W01
VSS circuit problem
• The PCM monitors the vehicle speed from the ABS HU/CM or DSC HU/CM. If the
PCM does not receive the input vehicle speed signal, the PCM determines that there is a VSS circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• VSS circuit malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
Yes Go to the next step.
ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY STORED DTC IN ABS HU/CM
OR DSC HU/CM
• Turn the ignition switch to the ON position (Engine off).
• Verify stored DTCs in ABS HU/CM or
DSC HU/CM.
(See ON-BOARD DIAGNOSIS [ABS] .)
(See ON-BOARD DIAGNOSIS [DSC
(DYNAMIC STABILITY CONTROL)] )
• Are DTCs stored?
Go to the appropriate DTC inspection.
Yes (See DTC Table )
(See DTC Table .)
No Go to the next step.
MTX
VERIFY TROUBLESHOOTING OF DTC
P0500 COMPLETED
• Start the engine.
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
Yes
• Clear the DTC from the PCM memory using the WDS or equivalent.
ATX
Note
• Possible VSS circuit problem related to ATX control.
Go to DTC inspection for ATX control.
• Is the PENDING CODE for this DTC present?
(See DTC P0500 [FN4A-EL] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0505 [Z6]
B3E010200500W02
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0505
DETECTION
CONDITION
POSSIBLE CAUSE
IAC system problem
• The PCM cannot control idle speed toward target idle speed while KOER self test.
• IAC valve circuit malfunction
• Air cleaner element clogged
• Air intake passage clogged
• A/C relay control circuit malfunction
• Generator control circuit malfunction
• Low engine compression (Over capacity of blow-by gas)
• PCM malfunction
Diagnostic procedure
STEP
1
2
3
INSPECTION ACTION
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
Yes Go to the next step.
VERIFY RELATED PENDING OR
STORED DTC
• Turn the ignition switch off, then to the
ON position. (Engine OFF)
Yes
Perform the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
• Verify pending code or stored DTCs using the WDS or equivalent.
• Does DTC P0511,P2502, P2503 or
P2504 present?
No Go to the next step.
INSPECT IAC VALVE
MALFUNCTION
• Start engine.
• Disconnect IAC valve connector.
• Is engine speed decreased?
No
Repair the IAC valve, then go to Step 9.
(See IDLE AIR CONTROL (IAC) VALVE
REMOVAL/INSTALLATION [Z6] .)
4
INSPECT A/C MAGNETIC CLUTCH
OPERATION
Note
• The following test should be performed for A/C. Go to the
Go to "A/C ALWAYS ON / A/C COMPRESSOR
Yes
RUNS CONTINUOUSLY." of ENGINE SYMPTOM
TROUBLESHOOTING, then go to step 9.
(See ENGINE SYMPTOM TROUBLESHOOTING
[Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
10 next step for vehicles without
A/C.
• Turn the A/C switch off.
• Is magnetic clutch still on?
INSPECT GENERATOR CONTROL
CIRCUIT MALFUNCTION
• Apply electrical load.
• Is engine speed increased?
Yes Go to the next step.
No
Repair short to power supply in generator control circuit, then go to Step 9.
INSPECT AIR CLEANER ELEMENT
• Remove the air cleaner element with the engine running.
• Is the engine speed increased?
Yes
Clean or replace the air cleaner element, then go to
Step 9.
No Go to the next step.
INSPECT THROTTLE BODY
PASSAGE
• Is throttle body clogged?
Yes
Clean the throttle body passage or replace the throttle body, then go to Step 9.
No Go to the next step.
Yes Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION
[Z6] .)
• Is engine compression normal?
No Overhaul engine, then go to the next step.
VERIFY TROUBLESHOOTING OF
DTC P0505 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC using the WDS or equivalent.
• Perform KOER self-test.
• Is the same DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR
PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P0506 [Z6]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0506
DETECTION
CONDITION
POSSIBLE
CAUSE
B3E010200500W03
IAC system RPM lower than expected
• The PCM compares the actual idle speed with the target idle speed when the engine is running. If the actual idle speed is lower than the targeted by 100 rpm for 14 s , the
PCM determines that the IAC system RPM is lower than expected.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAC valve malfunction
• A/C cut-off control malfunction
• Generator control system malfunction
• Intake-air line clogged
- Clogged air cleaner
- Clogged throttle body
• Purge solenoid valve malfunction
• IAT sensor malfunction
• ECT sensor malfunction
• CKP sensor malfunction
• Insufficient compression
- Engine oil malfunction
- Oil pressure decrease
- Oil pump malfunction
- Oil pump control malfunction
- Engine malfunction
• Fuel line pressure malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related Service Information availability.
• Is any related repair Information available?
No
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
INSPECT IAC VALVE
• Inspect the IAC valve.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
• Is there any malfunction?
Repair IAC valve, then go to Step 19.
Yes
(See IDLE AIR CONTROL (IAC) VALVE
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT A/C MAGNETIC CLUTCH
OPERATION
Note
• The following test should be performed for A/C. Go to the next step for vehicles without A/C.
• Turn the A/C switch off.
• Is magnetic clutch still on?
Go to the "NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY.".
Yes
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
No Go to the next step.
Yes Go to the next step.
INSPECT GENERATOR CONTROL
SYSTEM OPERATION
• Apply the electrical load during idle.
• Is the engine speed increased?
No
Repair or replace the wiring harness for a possible short to power supply, then go to Step
19.
INSPECT AIR CLEANER ELEMENT
• Remove the air cleaner element with the engine running.
• Is the engine speed increased?
Clean or replace the air cleaner element, then
Yes go to Step 18.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
INSPECT THROTTLE BODY PASSAGE
• Remove the throttle body.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
• Is throttle body clogged?
INSPECT PURGE SOLENOID VALVE
• Inspect the purge solenoid valve.
(See PURGE SOLENOID VALVE
INSPECTION .)
• Is there any malfunction?
Clean the throttle body passage or replace the
Yes throttle body, then go to Step 19.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
Replace the purge solenoid valve, then go to
Yes
Step 19.
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
10
11
12
13
14
15
INSPECT IAT SENSOR
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to Step
19.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT ECT SENSOR Replace the ECT sensor, then go to Step 19.
• Inspect the ECT sensor.
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION [Z6] .)
Yes
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION
[Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT CKP SENSOR
• Inspect the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
No Go to the next step.
Replace the CKP sensor, then go to Step 19.
Yes
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect the engine compression.
Yes Go to the next step.
(See COMPRESSION INSPECTION [Z6] .)
• Is there any malfunction?
No Go to Step 16.
INSPECT OIL PUMP
(See
• Inspect the oil pump.
OIL PUMP INSPECTION [Z6]
• Is there any malfunction?
.)
INSPECT ENGINE OIL CONDITION
Repair or replace the malfunctioning part according to the inspection results.
Yes
Overhaul or replace the engine.
Then go to Step 19.
No Go to the next step.
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
16
17
18
19
20
• Inspect the engine oil condition.
• Is the engine oil condition normal?
Replace the engine oil.
Inspect the ECT sensor and related wiring harnesses.
No (See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION [Z6] .)
Overhaul or replace the engine.
Then go to Step 19.
INSPECT OIL PRESSURE
• Inspect the oil pressure.
(See OIL PRESSURE INSPECTION [Z6] .)
• Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Overhaul or replace the engine.
Then go to Step 19.
No Go to the next step.
INSPECT OIL PASSAGE
• Inspect the oil passage.
• Is there any malfunction?
Inspect for leakage and/or clogging in oil passage of engine and repair if necessary.
Yes
Overhaul or replace the engine.
Then go to Step 19.
No
Overhaul or replace the engine.
Then go to the next step.
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No
Replace the fuel pump unit, then go to the next
Yes step.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0506 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0507 [Z6]
B3E010200500W04
DTC P0507 IAC system RPM higher than expected
DETECTION
CONDITION
• The PCM compares the actual idle speed with the target idle speed when the engine is running. If the actual idle speed is higher than the targeted by 200 rpm for 14 s , the
PCM determines that the IAC system RPM is higher than expected.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
POSSIBLE
CAUSE
• Vacuum hoses improper connection
• IAC valve malfunction
• Accelerator cable misadjustment
• Throttle valve malfunction
• IAT sensor malfunction
• ECT sensor malfunction
• CKP sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
ACTION
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair Information available?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
8
9
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
No Go to the next step.
• Are other DTCs present?
INSPECT VACUUM HOSE FOR POOR
CONNECTION
• Are the vacuum hoses connected completely?
(See INTAKE-AIR SYSTEM HOSE
ROUTING DIAGRAM [Z6] .)
Yes Go to the next step.
Connect the vacuum hose completely, then go to
Step 11.
No
(See INTAKE-AIR SYSTEM HOSE ROUTING
DIAGRAM [Z6] .)
INSPECT IAC VALVE
• Inspect the IAC valve.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
• Is there any malfunction?
Repair IAC valve, then go to Step 11.
Yes
(See IDLE AIR CONTROL (IAC) VALVE
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT ACCELERATOR CABLE
FREE PLAY
• Inspect the accelerator cable free play.
Yes
Adjust the accelerator cable free play, then go to
Step 11.
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [Z6] .)
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT THROTTLE VALVE
• Remove the throttle body.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
Yes
No
Clean or repair the throttle body, then go to Step
11.
(See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6]
Go to the next step.
.)
INSPECT IAT SENSOR Replace the MAF/IAT sensor, then go to Step 11.
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [Z6] .)
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT ECT SENSOR
• Inspect the ECT sensor.
Replace the ECT sensor, then go to Step 11.
Yes
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION
[Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
(See ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
INSPECT CKP SENSOR
• Inspect the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
No
Yes
No
Go to the next step.
Replace the CKP sensor, then go to the next step.
(See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [Z6]
Go to the next step.
.)
VERIFY TROUBLESHOOTING OF DTC
P0507 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the PENDING CODE for this DTC present?
No Go to the next step.
12
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P0511
DETECTION
CONDITION
DTC P0511 [Z6]
B3E010200500W05
IAC circuit problem
• If the PCM detects that the IAC signal voltage is above or below the threshold * when the IAC control duty target is within 19-50% , the PCM determines that the IAC circuit problem.
*: Detected threshold value depends on the battery voltage and the IAC control signal duty value.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAC valve malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between IAC valve terminal A and PCM terminal 2X
• Short to power supply in wiring harness between IAC valve terminal A and
PCM terminal 2X
• Short to GND in wiring harness between IAC valve terminal A and PCM terminal 2X
• Open circuit in wiring harness between IAC valve terminal B and PCM terminal 2AB
• Short to power supply in wiring harness between IAC valve terminal B and
PCM terminal 2AB
• Short to GND in wiring harness between IAC valve terminal B and PCM terminal 2AB
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT IAC VALVE CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the IAC valve connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to Step
9.
No Go to the next step.
INSPECT IAC VALVE CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
- IAC valve terminal A (wiring harness-side) and body GND
No Go to the next step.
- IAC valve terminal B (wiring harness-side) and body GND
• Is there continuity?
INSPECT IAC VALVE CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following circuits:
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
- IAC valve terminal A (wiring harness-side) and body GND
- IAC valve terminal B (wiring harness-side) and body GND
• Is the voltage B+ ?
No Go to the next step.
INSPECT IAC VALVE Yes Replace the IAC valve, then go to Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
• Inspect the IAC valve.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
• Is there any malfunction?
(See IDLE AIR CONTROL (IAC) VALVE
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to Step
9.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT IAC VALVE CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
- IAC valve terminal A (wiring harness-side) and PCM terminal 2X
(wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- IAC valve terminal B (wiring harness-side) and PCM terminal
2AB (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0511 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P0550 [Z6]
B3E010200500W06
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0550
DETECTION
CONDITION
POSSIBLE CAUSE
PSP switch circuit problem
• The PCM monitors the input signal from the PSP switch. If the input signal does not change for 1 min , the PCM determines that the PSP switch circuit problem.
• The PCM monitors the input voltage from the PSP switch when the following conditions are met. If the input voltage is low for 1 min , the PCM determines that the PSP switch circuit problem.
MONITORING CONDITION
- Vehicle speed is more than 60 km/h {37.3 mph} .
- ECT is more than 60 ° C {140 ° F} .
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• PSP switch malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between PSP switch terminal A and PCM terminal 2AC
• Short to power supply in wiring harness between PSP switch terminal A and PCM terminal 2AC
• Short to GND in wiring harness between PSP switch terminal A and PCM terminal 2AC
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT PSP SWITCH CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to
Step 9.
• Disconnect the PSP switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
INSPECT PSP SWITCH SIGNAL CIRCUIT
FOR SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between PSP switch terminal A (wiring harness-side) and body
GND.
• Is there continuity?
Yes
No
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
Go to the next step.
INSPECT PSP SWITCH SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between PSP switch terminal A (wiring harness-side) and body
GND.
• Is the voltage B+ ?
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
No Go to the next step.
INSPECT PSP SWITCH Replace the PSP switch, then go to Step 9.
• Inspect the PSP switch.
(See POWER STEERING PRESSURE (PSP)
SWITCH INSPECTION [Z6] .)
Yes
(See POWER STEERING OIL PUMP (Z6)
DISASSEMBLY/ASSEMBLY .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT PSP SWITCH SIGNAL CIRCUIT
FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between PSP switch terminal A (wiring harness-side) and PCM terminal 2AC (wiring harness-side).
• Is there continuity?
Yes
No
Go to the next step.
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0550 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
• Start the engine.
• Access the ECT PID.
• Warm up the engine until the ECT PID is more than 60 ° C {140 ° F} .
• Drive the vehicle more than 60 km/h {37.3 mph} for 1 min .
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0602
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0602 [Z6]
B3E010200600W01
PCM programming error
• No configuration data in the PCM.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Complete configuration has not been completed
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No
Perform the "PCM CONFIGURATION", then go to the next step.
(See PCM CONFIGURATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P0602 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P0610
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0610 [Z6]
B3E010200600W02
PCM vehicle options error
• PCM data configuration error.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Configuration procedure has not been completed
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No
Perform the "PCM CONFIGURATION", then go to the next step.
(See PCM CONFIGURATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P0610 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P0660
DETECTION
CONDITION
DTC P0660 [Z6]
B3E010200600W03
Variable intake-air control circuit/open
• The PCM monitors the variable intake-air control signal at PCM terminals
2AS and 2AO. If the PCM turns the variable intake-air shutter valve actuator to open or close but the voltages at PCM terminals 2AS and 2AO do not coincide with the PCM signal voltages, the PCM determines that the variable intake-air control circuit has a malfunction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• The PCM could not perform the self-test for the variable intake-air control circuit.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• Variable intake-air shutter valve actuator malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between variable intake-air shutter valve actuator terminal A and PCM terminal 2AO
• Short to power supply in wiring harness between variable intake-air shutter valve actuator terminal A and PCM terminal 2AO
• Short to GND in wiring harness between variable intake-air shutter valve actuator terminal A and PCM terminal 2AO
• Open circuit in wiring harness between variable intake-air shutter valve actuator terminal B and PCM terminal 2AS
• Short to power supply in wiring harness between variable intake-air shutter valve actuator terminal B and PCM terminal 2AS
• Short to GND in wiring harness between variable intake-air shutter valve actuator terminal B and PCM terminal 2AS
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
3
INSPECT VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 9.
• Turn the ignition switch off.
• Disconnect the variable intake-air shutter valve actuator connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
• Inspect for poor connection (such as damaged/pulled-out pins, and corrosion).
• Is there any malfunction?
INSPECT VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR CIRCUIT FOR SHORT
TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following circuits:
- Variable intake-air shutter valve actuator terminal A (wiring harnessside) and body GND
- Variable intake-air shutter valve actuator terminal B (wiring harnessside) and body GND
• Is the voltage B+ ?
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR CIRCUIT FOR SHORT
TO GND
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
- Variable intake-air shutter valve actuator terminal A (wiring harnessside) and body GND
- Variable intake-air shutter valve actuator terminal B (wiring harnessside) and body GND
• Is there continuity?
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR
• Inspect the variable intake-air shutter valve actuator.
Replace the variable intake-air shutter valve actuator, then go to Step 9.
Yes
(See VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR
REMOVAL/INSTALLATION [Z6] .)
(See VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR INSPECTION [Z6] .)
• Is there any malfunction?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
• Inspect for poor connection (such as damaged/pulled-out pins, and corrosion).
• Is there any malfunction?
INSPECT VARIABLE INTAKE-AIR SHUTTER
VALVE ACTUATOR CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
- Variable intake-air shutter valve actuator terminal A (wiring harnessside) and PCM terminal 2AO (wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- Variable intake-air shutter valve actuator terminal B (wiring harnessside) and PCM terminal 2AS (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0660 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Access the RPM PID.
• Increase the engine speed 4,100 rpm or more .
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform "AFTER REPAIR PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
No Troubleshooting completed.
DTC P0668 [Z6]
PCM temperature sensor circuit low input
B3E010200600W04
DTC P0668
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
• The PCM monitors the PCM temperature sensor (integrated in the PCM) signal. If the PCM detects that the PCM temperature sensor voltage is 0.10 V or less , the
PCM determines that the PCM temperature sensor has a malfunction.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• PCM temperature sensor malfunction POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0668 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Are any DTCs present?
DTC P0669
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P0669 [Z6]
PCM temperature sensor circuit high input
B3E010200600W05
• The PCM monitors the PCM temperature sensor (integrated the PCM) signal. If the
PCM detects that the PCM temperature sensor voltage is 4.98 V or more , the PCM determines that the PCM temperature sensor has a malfunction.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• PCM temperature sensor malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0669 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Turn the ignition switch to the ON position (Engine off).
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No Troubleshooting completed.
DTC P0703
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0703 [Z6]
B3E010200700W01
Brake switch input circuit problem
• The PCM monitors the input signal from the brake switch. If the input signal does not change while following decelerating 8 times , the PCM determines that there is a brake switch input circuit problem.
MONITORING CONDITION
- Vehicle speed is from above 30 km/h {19 mph} to 30 km/h {19 mph} or less
- Deceleration rate exceeds 3.8 km/h {2.4 mph} per 0.1 s
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Brake switch malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between brake switch terminal A and battery positive terminal
• Short to GND in wiring harness between brake switch terminal A and battery positive terminal
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Open circuit in wiring harness between brake switch terminal D and PCM terminal 1V
• Short to power supply in wiring harness between brake switch terminal D and PCM terminal 1V
• Short to GND in wiring harness between brake switch terminal D and PCM terminal 1V
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT BRAKE SWITCH CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the brake switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 10.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
INSPECT BRAKE SWITCH CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
- Brake switch terminal A (wiring harness-side) and body GND
- Brake switch terminal D (wiring harness-side) and body GND
• Is there continuity?
INSPECT BRAKE SWITCH CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between brake switch terminal D (wiring harness-side) and body
GND.
• Is the voltage B+ ?
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 10.
No Go to the next step.
Yes
Repair or replace harness for short to power supply, then go to Step 10.
No Go to the next step.
INSPECT BRAKE SWITCH
• Inspect the brake switch.
(See
• Is there any malfunction?
BRAKE SWITCH INSPECTION .)
Replace the brake switch, then go to Step
10.
Yes
(See BRAKE PEDAL
REMOVAL/INSTALLATION .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 10.
Go to the next step.
INSPECT BRAKE SWITCH POWER CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Measure the voltage between brake switch terminal A (wiring harness-side) and body
GND.
• Is the voltage B+ ?
No
Repair or replace the wiring harness for a possible open circuit, then go to Step 10.
INSPECT BRAKE SWITCH SIGNAL CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
• Inspect for continuity between brake switch terminal D (wiring harness-side) and PCM terminal 1V (wiring harness-side).
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0703 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Drive the vehicle.
• Repeat deceleration 8 times under both of the following conditions:
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
- Vehicle speed: from above 30 km/h
{19 mph} to 30 km/h {19 mph} or less
No Go to the next step.
- Deceleration rate should exceed 3.8 km/h {2.4 mph} per 0.1 s
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0704
DETECTION
CONDITION
DTC P0704 [Z6]
B3E010200700W02
CPP switch input circuit problem
• The PCM monitors the input signal from the CPP switch. If the input signal does not change while following decelerating 8 times , the PCM determines that there is a CPP switch input circuit problem.
MONITORING CONDITION
- Vehicle speed: from above 30 km/h {19 mph} to 30 km/h {19 mph} or less
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• CPP switch malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between CPP switch terminal A and PCM terminal 1P
• Short to GND in wiring harness between CPP switch terminal A and PCM terminal 1P
• Open circuit in wiring harness between CPP switch terminal B and GND
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the available repair information.
Yes
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
8
INSPECT CPP SWITCH CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the CPP switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
INSPECT CPP SWITCH GND CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between CPP switch terminal B (wiring harness-side) and body
GND.
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to Step 9.
INSPECT CPP SWITCH SIGNAL CIRCUIT
FOR SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between CPP switch terminal A (wiring harness-side) and body
GND.
• Is there continuity?
INSPECT CPP SWITCH
• Inspect the CPP switch.
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [Z6] .)
• Is there any malfunction?
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
No
No
Go to the next step.
Replace the CPP switch, then go to Step 9.
Yes
(See CLUTCH PEDAL
REMOVAL/INSTALLATION .)
Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT CPP SWITCH SIGNAL CIRCUIT
FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between CPP switch terminal A (wiring harness-side) and PCM terminal 1P (wiring harness-side).
Yes
Repair or replace the terminal, then go to
Step 9.
No
Yes
No
Go to the next step.
Go to the next step.
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Is there continuity?
9
10
VERIFY TROUBLESHOOTING OF DTC
P0704 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Drive the vehicle.
• Repeat deceleration 8 times under the following conditions:
- Vehicle speed: from above 30 km/h
{19 mph} to 30 km/h {19 mph} or less
• Is the PENDING CODE for this DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P0850
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0850 [Z6]
B3E010200800W01
Neutral switch input circuit problem
• The PCM monitors changes in input voltage from neutral switch. If the PCM does not detect PCM terminal 1AB voltage changes while running vehicle with vehicle speed 30 km/h {19 mph} or more and clutch pedal turns press and depress 10 times repeatedly, the PCM determines that there is a neutral switch circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Neutral switch malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Connector or terminal malfunction
• Open circuit in wiring harness between neutral switch terminal A and PCM terminal 1AB
• Short to GND in wiring harness between neutral switch terminal A and PCM terminal 1AB
• Open circuit in wiring harness between neutral switch terminal B and GND
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related Service Information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT NEUTRAL SWITCH CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the neutral switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
INSPECT NEUTRAL SWITCH GND CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between neutral switch terminal B (wiring harness-side) and body GND.
No
Repair or replace the wiring harness for a possible open circuit, then go to Step 9.
• Is there continuity?
INSPECT NEUTRAL SWITCH SIGNAL
CIRCUIT FOR SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between neutral switch terminal A (wiring harness-side) and body GND.
No Go to the next step.
• Is there continuity?
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 9.
INSPECT NEUTRAL SWITCH
• Inspect the neutral switch.
(See NEUTRAL SWITCH INSPECTION [Z6] .)
• Is there any malfunction?
Replace the neutral switch, then go to
Yes
Step 9.
(See NEUTRAL SWITCH
REMOVAL/INSTALLATION [F35M-R] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT NEUTRAL SWITCH SIGNAL
CIRCUIT FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between neutral switch terminal A (wiring harness-side) and PCM terminal 1AB (wiring harness-side).
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC P0850
COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Depress and release clutch pedal more than
10 times repeatedly under the following condition:
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Vehicle speed: 30 km/h {19 mph} or more
• Is the PENDING CODE for this DTC present?
10
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P1260
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P1260 [Z6]
B3E010201200W02
Immobilizer system problem
• The instrument cluster detects an immobilizer system problem.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is not stored in the PCM memory.
• Immobilizer system malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes Go to the appropriate DTC inspection.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
VERIFY STORED DTC IN INSTRUMENT
CLUSTER
• Turn the ignition switch to the ON position (Engine off).
• Verify stored DTCs in instrument cluster.
(See DTC TABLE [IMMOBILIZER SYSTEM]
No Go to the next step.
.)
(See DTC INSPECTION [IMMOBILIZER
SYSTEM] .)
• Are DTCs stored?
VERIFY TROUBLESHOOTING OF DTC
P1260 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P2006
DETECTION
CONDITION
DTC P2006 [Z6]
B3E010202000W06
Variable tumble control stuck close
• The PCM monitors the mass air amount. If the actual air flow amount is below the estimated air flow amount when the following monitoring conditions are met. The
PCM determines that the variable tumble control is stuck closed.
MONITORING CONDITION
- Engine coolant temperature is 70 ° C {158 ° F} or more .
- Throttle valve opening angle is more than 75 % .
- Engine speed is 3,500 rpm or more .
Diagnostic support note
• This is a continuous monitor (CCM).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• MAF sensor malfunction
• Excessive air suction of intake-air system (from MAF sensor onward)
• Improper intake-air system hose routing
• Variable tumble shutter valve stuck closed
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No Go to the next step.
INSPECT MAF SENSOR
• Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the MAF/IAT sensor, then go to
Step 6.
Yes
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
INSPECT FOR EXCESSIVE AIR SUCTION
OF INTAKE-AIR SYSTEM OR IMPROPER
ROUTING OF INTAKE-AIR SYSTEM HOSE
Yes
Repair or replace source of air suction, then go to the next step.
• Visually inspect hoses on intake air system for looseness, cracks or damages.
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2006 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Perform no load racing at the engine speed of 3,500 rpm or more with the throttle valve opening angle more than 75 % .
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Access the ECT PID.
• Warm up the engine until the ECT PID is 70 ° C {158 ° F} or more .
No Go to the next step.
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P2008
DETECTION
CONDITION
DTC P2008 [Z6]
B3E010202000W07
Variable tumble control circuit/open
• The PCM monitors the variable tumble control signal at PCM terminals 2AF and 2AJ. If the PCM turns the variable tumble shutter valve actuator to open or close but voltages at PCM terminals 2AF and 2AJ do not coincide with the
PCM signal voltages the PCM determines that the variable tumble control circuit has a malfunction.
• Variable tumble control IC error.
Diagnostic support note
• This is a continuous monitor (CCM).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Variable tumble shutter valve actuator malfunction
• Short to power supply in wiring harness between variable tumble shutter valve actuator terminal A and PCM terminal 2AJ
• Short to ground in wiring harness between variable tumble shutter valve actuator terminal A and PCM terminal 2AJ
• Open circuit in wiring harness between variable tumble shutter valve actuator terminal A and PCM terminal 2AJ
• Short to power supply in wiring harness between variable tumble shutter valve actuator terminal B and PCM terminal 2AF
• Short to ground in wiring harness between variable tumble shutter valve actuator terminal B and PCM terminal 2AF
• Open circuit in wiring harness between variable tumble shutter valve actuator terminal B and PCM terminal 2AF
• Poor connection at variable tumble shutter valve actuator or PCM
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the variable tumble shutter valve actuator connector.
Yes
Repair or replace the terminal, then go to
Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
• Inspect for poor connection (such as damaged, pulled-out pins, and corrosion).
• Is there any malfunction?
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR MALFUNCTION
• Perform the variable tumble shutter valve actuator inspection.
(See VARIABLE TUMBLE SHUTTER VALVE
ACTUATOR INSPECTION [Z6] .)
• Is the variable tumble shutter valve actuator normal?
Yes
No
Go to the next step.
Replace the variable tumble shutter valve actuator, then go to Step 9.
(See VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair terminal, then go to Step 9.
Go to the next step.
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR CONTROL CIRCUIT FOR
OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between followings;
- Between variable tumble shutter valve actuator terminal A (wiring harnessside) and PCM terminal 2AJ (wiring harness-side) No
Repair or replace wiring harness for open circuit, then go to Step 9.
- Between variable tumble shutter valve actuator terminal B (wiring harnessside) and PCM terminal 2AF (wiring harness-side)
• Is there continuity?
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR CONTROL CIRCUIT FOR
SHORT TO GROUND
Yes
Repair or replace for short to ground, then go to Step 9.
• Inspect for continuity between followings;
- Between variable tumble shutter valve actuator terminal A (wiring harnessside) and body ground
No Go to the next step.
- Between variable tumble shutter valve actuator terminal B (wiring harnessside) and body ground
• Is there continuity?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR CONTROL CIRCUIT FOR
SHORT TO POWER
Yes
Repair or replace for short to power supply, then go to the next step.
• Turn the ignition switch to the ON position.
(Engine off).
• Measure the voltage following wiring harnessside terminals:
- Variable tumble shutter valve actuator terminal A
No Go to the next step.
- Variable tumble shutter valve actuator terminal B
• Are each terminal voltage B+ ?
9
10
VERIFY TROUBLESHOOTING OF DTC P2008
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform "AFTER REPAIR PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
No Troubleshooting completed.
DTC P2088
DETECTION
CONDITION
DTC P2088 [Z6]
B3E010202000W08
Variable valve timing control circuit low
• If the PCM detects that the OCV drive current is less than the specification * when the OCV control duty target is approx. 100 % , the PCM determines that the variable valve timing control circuit low.
*: Detected specification value depends on the battery voltage.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• OCV malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between OCV terminal A and PCM terminal
2AK
• Short to GND in wiring harness between OCV terminal A and PCM terminal
2AK
• Open circuit in wiring harness between OCV terminal B and PCM terminal
2AG
• Short to GND in wiring harness between OCV terminal B and PCM terminal
2AG
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT OCV CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to Step
8.
• Turn the ignition switch off.
• Disconnect the OCV connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT OCV CIRCUIT FOR SHORT TO
GND
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 8.
- OCV terminal A (wiring harnessside) and body GND
- OCV terminal B (wiring harnessside) and body GND
• Is there continuity?
No Go to the next step.
INSPECT OCV
• Inspect the OCV.
(See OIL CONTROL VALVE (OCV)
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the OCV, then go to Step 8.
Yes
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to Step
8.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT OCV CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following circuits:
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
- OCV terminal A (wiring harnessside) and PCM terminal 2AK (wiring harness-side)
- OCV terminal B (wiring harnessside) and PCM terminal 2AG (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P2088 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P2089
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2089 [Z6]
B3E010202000W09
Variable valve timing control circuit high
• If the PCM detects that the OCV drive current is as specified or more when the OCV control duty target is 3 % or less , the PCM determines that the variable valve timing control circuit high.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• OCV circuit malfunction
• Connector or terminal malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Short to power supply in wiring harness between OCV terminal B and PCM terminal 2AG
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT OCV CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the OCV connector.
Yes
Repair or replace the terminal, then go to Step
7.
No Go to the next step.
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4
5
6
7
8
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Inspect for poor connection (such as damaged/pulled-out pins, and corrosion).
• Is there any malfunction?
INSPECT OCV CONTROL CIRCUIT FOR
SHORT TO POWER SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to Step
7.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between OCV terminal B (wiring harness-side) and body
GND.
No Go to the next step.
• Is the voltage B+ ?
INSPECT OCV
• Inspect the OCV.
(See OIL CONTROL VALVE (OCV)
INSPECTION [Z6] .)
• Is there any malfunction?
Replace the OCV, then go to Step 7.
Yes
(See OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, and corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to the next step.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2089 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P2096 [Z6]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2096
DETECTION
CONDITION
POSSIBLE
CAUSE
B3E010202000W10
Target A/F feedback system too lean
• The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is more than the specification, the PCM determines that the target A/F feedback system is too lean.
Diagnostic support note
• This is a continuous monitor (Fuel system).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Leakage exhaust gas
• Rear HO2S malfunction
• IAT sensor malfunction
• ECT sensor malfunction
• Air suction in intake-air system
• Front HO2S malfunction
• MAF sensor malfunction
• Insufficient fuel line pressure
• Fuel pump unit malfunction
• Leakage fuel
• Improper operation ignition system
• Insufficient engine compression
• Fuel injector malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
VERIFY REPAIR INFORMATION
AVAILABILITY
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
Yes
Perform repair or diagnosis according to the available repair information.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
• Verify related service repair information availability.
• Is any related repair information available?
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
• Turn the ignition switch off, then ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2177 or P2187 also present?
No Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
Yes Go to the next step.
• Is DTC P2096 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY CURRENT INPUT SIGNAL
STATUS OF REAR HO2S
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine and warm it up completely.
Yes Go to the next step.
• Access the O2S12 PID.
Visually inspect for gas leakage between the
TWC and rear HO2S.
• Read the O2S12 PID under following accelerator pedal condition (in PARK or
NEUTRAL).
- More than 0.45 V when suddenly depressing accelerator pedal (rich condition)
No
• If there is no leakage, replace the rear HO2S.
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Then go to Step 17.
- Less than 0.45 V just after releasing accelerator pedal (lean condition)
• Is the PID normal?
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs.
(See PCM INSPECTION [Z6] .)
- ECT
- MAF
Yes Go to the next step.
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 17.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
- TP
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME
DATA CONDITION
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs under the
FREEZE FRAME DATA condition.
(See PCM INSPECTION [Z6] .)
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
Yes Go to the next step.
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 17.
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Connect the WDS or equivalent to the
DLC-2.
Yes Go to the next step.
• Start the engine and warm it up completely.
• Access O2S11 PID.
Visually inspect for exhaust gas leakage between exhaust manifold and front HO2S.
• Read O2S11 PID under following accelerator pedal condition (in PARK or
NEUTRAL).
- More than 0.45 V when suddenly depressing accelerator pedal (rich condition)
No
• If there is no leakage, replace front HO2S.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Then go to Step 17.
- Less than 0.45 V just after releasing accelerator pedal (lean condition)
• Is the PID normal?
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
Yes Go to the next step.
• Connect the WDS or equivalent to the
DLC-2.
Replace MAF/IAT sensor, then go to Step 17.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
No
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
14
15
16
• Is the PID normal?
INSPECT INTAKE-AIR SYSTEM FOR
EXCESSIVE AIR SUCTION
Yes
Repair or replace the malfunctioning part, then go to Step 17.
• Visually inspect hoses in intake-air system for looseness, cracks or damages
.
No Go to the next step.
• Is there any malfunction?
Yes Go to the next step.
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No Go to Step 13.
INSPECT FUEL SYSTEM FOR FUEL
LEAKAGE
• Visually inspect fuel leakage in the fuel system.
• Is there fuel leakage?
Yes
Repair or replace the malfunctioning part, then go to Step 17.
Replace the fuel pump unit, then go to Step 17.
No
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
INSPECT IGNITION COIL HARNESS Yes Go to the next step.
• Inspect the ignition coil related harness condition (intermittent open or short circuit) for all cylinders.
• Are harness conditions normal?
No
Repair suspected wiring harnesses, then go to
Step 17.
Yes Go to the next step.
INSPECT IGNITION SYSTEM
OPERATION
• Perform the spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
No
Repair or replace malfunctioning part according to spark test result.
Then go to Step 17.
INSPECT ENGINE COMPRESSION
• Inspect the engine compression.
(See COMPRESSION INSPECTION
[Z6] .)
• Is there any malfunction?
Yes Go to the next step.
No Overhaul engine, then go to Step 17.
INSPECT FUEL INJECTOR
• Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
Yes
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
17
18
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2096 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P2097
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P2097 [Z6]
B3E010202000W11
Target A/F feedback system too rich
• The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is less than the specification, the PCM determines that the target A/F feedback system is too rich.
Diagnostic support note
• This is a continuous monitor (Fuel system).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Leakage exhaust gas
• Rear HO2S malfunction
• IAT sensor malfunction
• ECT sensor malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Front HO2S malfunction
• Excessive fuel line pressure
• Fuel pump unit malfunction
• Purge solenoid valve malfunction
• Insufficient engine compression
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2178 or P2188 also present?
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2097 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6]
Yes Go to the next step.
.)
VERIFY CURRENT INPUT SIGNAL
STATUS OF REAR HO2S
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine and warm it up completely.
• Access the O2S12 PID.
Visually inspect for exhaust gas leakage between the TWC and rear HO2S.
No
• If there is no leakage, replace the rear HO2S.
(See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
Then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
• Read the O2S12 PID under following accelerator pedal condition (in PARK or
NEUTRAL).
- More than 0.45 V when suddenly depressing accelerator pedal (rich condition)
- Less than 0.45 V just after releasing accelerator pedal (lean condition)
• Is the PID normal?
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs.
(See PCM INSPECTION [Z6] .)
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
Yes
No
Go to the next step.
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME DATA
CONDITION
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs under the
FREEZE FRAME DATA condition.
Yes Go to the next step.
(See PCM INSPECTION [Z6]
- ECT
- MAF
.)
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
- TP
- VSS
• Are the PIDs normal?
Yes Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine and warm it up completely.
No
Visually inspect for exhaust gas leakage between the exhaust manifold and front
HO2S.
• If there is no leakage, replace front HO2S.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
11
12
• Access the O2S11 PID.
• Read the O2S11 PID under following accelerator pedal condition (in PARK or
NEUTRAL).
- More than 0.45 V when accelerator pedal is suddenly depressed (rich condition)
- Less than 0.45 V just after release of accelerator pedal (lean condition)
• Is the PID normal?
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6]
Then go to Step 11.
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No
Replace the fuel pump unit, then go to Step
Yes
11.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the purge solenoid valve.
INSPECT LONG TERM FUEL TRIM
• Connect the WDS or equivalent to the
DLC-2.
(See PURGE SOLENOID VALVE
INSPECTION .)
• Access the LONGFT1 PID.
• Compare the LONGFT1 PID with recorded
FREEZE FRAME DATA at Step 1.
Yes
• If there is any malfunction, replace the purge solenoid valve.
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [Z6] .)
• Is the LONGFT1 PID above FREEZE
FRAME DATA?
Then go to Step 17.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2097 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
DTC P2177 [Z6]
B3E010202100W07
DTC P2177
DETECTION
CONDITION
System too lean off idle
• The PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control during off-idle. If the LONGFT or the sum total of these fuel trims exceed preprogrammed criteria, PCM determines that fuel system is too lean during off-idle.
Diagnostic support note
• This is a continuous monitor. (Fuel system)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
POSSIBLE
CAUSE
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
• Fuel filter clogged or restricted
• Fuel leakage on fuel line from fuel delivery pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
• Purge solenoid hoses improper connection
• Air suction in intake-air system
• Insufficient engine compression
• Variable valve timing control system improper operation
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
7
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
• If misfire DTC is present, go to Step 8.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
• If other DTC is present, go to the appropriate
DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No
• If drive ability concern is present, go to Step
8.
• If other, go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2177 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO
ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using the WDS or equivalent.
• Is there any signal that is far out of specification when KOER?
Yes
No
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Repair or if necessary.
Then go to Step 17.
Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 4 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected sensor and related wiring harnesses repair or replace it.
Then go to Step 17.
• Is there any signal which causes drastic changes?
No Go to the next step.
Yes Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using the
WDS or equivalent.
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
• Verify PID under following accelerator pedal condition (in PARK (ATX) or
NEUTRAL (MTX)).
• Is PID normal?
- Above 0.45 V when suddenly depressing accelerator pedal (rich condition)
- Below 0.45 V just after releasing accelerator pedal (lean condition)
INSPECT MAF PID
• Start engine.
• Access MAF PID using WDS or equivalent.
• Verify that MAF PID changes quickly according to race engine RPM.
• Is MAF PID response normal?
Then go to Step 17.
Yes Go to the next step.
Replace the MAF/IAT sensor, then go to Step
17.
No
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT FOR EXCESSIVE AIR
SUCTION OF INTAKE-AIR SYSTEM
Yes
Repair or replace source of air suction, then go to Step 17.
• Visually inspect hoses on intake-air system for looseness, cracks or damages .
No Go to the next step.
• Is there any malfunction?
Yes Go to the next step.
INSPECT PURGE SOLENOID
OPERATION
• Perform the Purge Control System
Inspection.
(See Purge Control System Inspection .)
• Does the purge control system function properly?
No
Repair or replace malfunctioning part according to inspection result, then go to Step 17.
INSPECT FUEL LINE PRESSURE
• Turn the ignition switch off.
Yes Go to Step 13.
Note
• If engine will not start, inspect the fuel line pressure with ignition switch to the ON position.
No
• Inspect fuel line pressure while engine running.
If fuel pressure is too high, replace fuel pump unit, then go to Step 17.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
If fuel line pressure is low, go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
17
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
Yes
Replace suspected fuel line, then go to Step
17.
Inspect for foreign materials or stain inside fuel filter (low pressure).
• Is any fuel leakage found?
No If for foreign materials or stain inside fuel filter
(low pressure), clean the fuel tank and filter.
Then go to Step 17.
INSPECT IGNITION SYSTEM
• Perform the spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
Yes Go to the next step.
No
Repair or replace malfunctioning part according to spark test results, then go to Step 17.
INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression.
(See COMPRESSION INSPECTION [Z6] .)
No
• Is it normal?
Perform engine overhaul for repairs, then go to
Step 17.
INSPECT VARIABLE VALVE TIMING
CONTROL SYSTEM OPERATION
Yes Go to the next step.
• Inspect variable valve timing control system operation.
(See Variable Valve Timing Control System
Operation Inspection .)
No
• Does the variable valve timing control system work properly?
Repair or replace malfunctioning part according to inspection results, then go to Step 17.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove the fuel injector.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
• Inspect the fuel injector (resistance, injection amount).
(See FUEL INJECTOR INSPECTION .)
• Is the fuel injector normal?
No
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P2177 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
18
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P2178 [Z6]
B3E010202100W08
DTC P2178
DETECTION
CONDITION
POSSIBLE
CAUSE
System too rich off idle
• The PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control at off-idle. If the LONGFT or the sum total of these fuel trims exceed preprogrammed criteria, PCM determines that fuel system is too rich at off-idle.
Diagnostic support note
• This is a continuous monitor. (Fuel system)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
• EGR valve improper operation
• Variable tumble shutter valve actuator improper operation
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Purge solenoid hoses improper connection
• Variable valve timing control system improper operation
• PCV valve malfunction
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
Yes Go to the next step.
ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the
ON position (Engine off).
• If misfire DTC is present, go to Step 8.
Yes
• If other DTC is present, go to the appropriate
DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No
• If drive ability concern is present, go to Step 8.
• If other, go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
Yes Go to the next step.
• Is DTC P2178 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
5
6
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO
ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.
• Is there any signal that is far out of specification when KOER?
Yes
No
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Repair or if necessary.
Then go to Step 16.
Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
Yes
Inspect suspected sensor and related wiring harnesses repair or replace it.
• Inspect same PIDs as Step 4 while simulating FREEZE FRAME DATA condition.
No
Then go to Step 16.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
11
• Is there any signal which causes drastic changes?
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using
WDS or equivalent.
Yes Go to the next step.
• Verify PID under following accelerator pedal condition (in PARK (ATX) or
NEUTRAL (MTX)).
• Is PID normal?
- Above 0.45 V when suddenly depressing accelerator pedal (rich condition)
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 16.
- Below 0.45 V just after releasing accelerator pedal (lean condition)
INSPECT MAF PID
• Start engine.
• Access MAF PID using WDS or equivalent.
• Verify that MAF PID changes quickly according to race engine RPM.
• Is MAF PID response normal?
Yes Go to the next step.
No
Replace the MAF/IAT sensor, then go to Step
16.
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
Yes Go to the next step.
INSPECT PURGE SOLENOID
OPERATION
• Perform the "Purge Control System
Inspection".
(See Purge Control System Inspection .)
• Does purge control system work properly?
INSPECT PCV VALVE OPERATION
• Inspect the PCV valve operation.
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is the PCV valve normal?
No
Yes
No
Repair or replace malfunctioning part according to inspection result, then go to Step 16.
Go to the next step.
Replace the PCV valve, then go to Step 16.
(See INTAKE-AIR SYSTEM HOSE ROUTING
DIAGRAM [Z6] .)
INSPECT EGR VALVE OPERATION
• Perform the "EGR Control System
Inspection".
(See EGR Control System Inspection .)
Yes Go to the next step.
No
Repair or replace malfunctioning part according to inspection result, then go to Step 16.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
• Does the EGR control system work properly?
INSPECT VARIABLE TUMBLE
SHUTTER VALVE ACTUATOR
OPERATION
• Perform the "Variable Tumble Control
Operation Inspection".
(See Variable Tumble Control Operation
Inspection .)
• Does the variable tumble control work properly?
Yes Go to the next step.
No
Repair or replace malfunctioning part according to inspection results, then go to Step 16.
INSPECT FUEL LINE PRESSURE
• Turn the ignition switch off.
Yes Go to the next step.
Note
• If the engine will not start, inspect the fuel line pressure with the ignition switch to the ON position.
• Inspect the fuel line pressure while the engine running.
If the fuel pressure is too high, replace the fuel pump unit, then go to Step 16.
No
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
If the fuel line pressure is low, go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
Yes Replace suspected fuel line, then go to Step 16.
INSPECT FUEL LINE FROM FUEL
PUMP TO FUEL DELIVERY PIPE
• Visually inspect fuel line for leakage.
• Is any fuel leakage found?
Inspect inside fuel filter (low pressure) for foreign materials or stain.
No
If there is foreign materials or stain inside fuel filter (low pressure), clean the fuel tank and filter.
Then go to Step 16.
INSPECT VARIABLE VALVE TIMING
CONTROL SYSTEM OPERATION
• Inspect the variable valve timing control system operation.
Yes Go to the next step.
(See Variable Valve Timing Control
System Operation Inspection .)
• Does the variable valve timing control system work properly?
No
Repair or replace malfunctioning part according to inspection results, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2178 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
17
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P2187 [Z6]
B3E010202100W09
DTC P2187
DETECTION
CONDITION
POSSIBLE
CAUSE
System too lean at idle
• The PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control during idle. If the LONGFT or the sum total of these fuel trims and correction exceed preprogrammed criteria, PCM determines that fuel system is too lean during idle.
Diagnostic support note
• This is a continuous monitor. (Fuel system)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel filter clogged or restricted
• Fuel leakage on fuel line from fuel delivery pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve malfunction
• Purge solenoid hoses improper connection
• Air suction in intake-air system
• Insufficient engine compression
• Variable valve timing control system improper operation
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
• If misfire DTC is present, go to Step 8.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
• If other DTC is present, go to the appropriate
DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No
• If drive ability concern is present, go to Step
8.
• If other, go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2187 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Yes
Repair or if necessary.
Then go to Step 17.
• Is there any signal that is far out of specification when KOER?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 4 while simulating FREEZE FRAME DATA condition.
• Is there any signal which causes drastic changes?
Yes
Inspect suspected sensor and related wiring harnesses repair or replace it.
Then go to Step 17.
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2187 PID using WDS or equivalent.
Yes Go to the next step.
• Verify PID under following accelerator pedal condition (in PARK (ATX) or
NEUTRAL (MTX)).
• Is PID normal?
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 17.
- Above 0.45 V when suddenly depressing accelerator pedal (rich condition)
- Below 0.45 V just after releasing accelerator pedal (lean condition)
INSPECT MAF PID
• Start the engine.
• Access MAF PID using the WDS or equivalent.
• Verify that the MAF PID changes quickly according to the engine speed.
• Is the MAF PID response normal?
Yes Go to the next step.
No
Replace the MAF/IAT sensor, then go to Step
17.
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
9
INSPECT FOR EXCESSIVE AIR SUCTION
OF INTAKE AIR SYSTEM
Yes
Repair or replace source of air suction, then go to Step 17.
• Visually inspect hoses in the intake-air system for looseness, cracks or damages.
• Is there any malfunction?
No Go to the next step.
10
INSPECT PURGE SOLENOID VALVE
STUCK OPEN
• Turn the ignition switch off.
Replace the purge solenoid valve.
Yes
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [Z6] .)
• Disconnect the both hoses from the purge solenoid valve.
Then go to Step 17.
• Blow air through the purge solenoid valve.
No Go to the next step.
• Does air blow through?
11 INSPECT FUEL LINE PRESSURE Yes Go to Step 13.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
• Turn the ignition switch off.
Note
• If the engine will not start, inspect the fuel line pressure with the ignition switch to the ON position.
• Inspect the fuel line pressure while the engine running.
If the fuel pressure is too high, replace the fuel pump unit, then go to Step 17.
No
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
If the fuel line pressure is low, go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect the fuel line for any leakage.
• Is the any fuel leakage?
Yes
Replace suspected fuel line, then go to Step
17.
No
Inspect for foreign materials or stain inside fuel filter (low pressure).
If for foreign materials or stain inside fuel filter
(low pressure), clean the fuel tank and filter.
Then go to Step 17.
Yes Go to the next step.
INSPECT IGNITION SYSTEM
• Perform the spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
No
Repair or replace malfunctioning part according to the spark test results, then go to
Step 17.
INSPECT ENGINE COMPRESSION
• Inspect the engine compression.
(See COMPRESSION INSPECTION [Z6] .)
• Is it normal?
Yes Go to the next step.
No
Perform the engine overhaul for repairs, then go to Step 17.
INSPECT VARIABLE VALVE TIMING
CONTROL SYSTEM OPERATION
Yes Go to the next step.
• Inspect the variable valve timing control system operation.
(See Variable Valve Timing Control System
Operation Inspection .)
No
Repair or replace malfunctioning part according to inspection results, then go to
Step 17.
• Does the variable valve timing control system function properly?
INSPECT FUEL INJECTOR OPERATION
• Remove the fuel injector.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
Yes Go to the next step.
No
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
17
18
• Inspect the fuel injector (resistance, injection amount).
(See FUEL INJECTOR INSPECTION .)
• Is the fuel injector normal?
VERIFY TROUBLESHOOTING OF DTC
P2187 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P2188
DETECTION
CONDITION
DTC P2188 [Z6]
B3E010202100W10
System too rich at idle
• The PCM monitors the short term fuel trim (SHRTFT) and long term fuel trim
(LONGFT) during the closed loop fuel control at idle. If the LONGFT or the sum total of these fuel terms exceed the preprogrammed criteria, PCM determines that fuel system is too rich at idle.
Diagnostic support note
• This is a continuous monitor. (Fuel system)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Misfire POSSIBLE
CAUSE
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
• EGR valve stuck open
• Variable tumble shutter valve actuator improper operation
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
• Purge solenoid hoses improper connection
• Variable valve timing control system improper operation
• PCV valve malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
• If misfire DTC is present, go to Step 8.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
Yes
• If other DTC is present, go to the appropriate
DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Are other DTCs present?
No
• If drive ability concern is present, go to Step
8.
• If other, go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2188 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
VERIFY CURRENT INPUT SIGNAL
STATUS (IGNITION SWITCH TO ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using the WDS or equivalent.
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Yes
Repair or if necessary.
Then go to Step 16.
• Is there any signal that is far out of specification when KOER?
No Go to the next step.
6
7
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 4 while simulating FREEZE FRAME DATA condition.
• Is there any signal which causes drastic changes?
Yes
Inspect suspected sensor and related wiring harnesses repair or replace it.
Then go to Step 16.
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2188 PID using the
WDS or equivalent.
• Verify PID under following accelerator pedal condition (in PARK (ATX) or
NEUTRAL (MTX)).
• Is PID normal?
- Above 0.45 V when suddenly depressing accelerator pedal (rich condition)
- Below 0.45 V just after releasing accelerator pedal (lean condition)
Yes Go to the next step.
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 16.
8
INSPECT MAF PID
• Start the engine.
• Access the MAF PID using the WDS or equivalent.
• Verify that the MAF PID changes quickly according to race engine RPM.
• Is the MAF PID response normal?
Yes Go to the next step.
Replace the MAF/IAT sensor, then go to Step
16.
No
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
Yes Go to the next step.
9
INSPECT PURGE SOLENOID
OPERATION
• Perform the "Purge Control System
Inspection".
(See Purge Control System Inspection .)
• Does the purge control system work properly?
10 INSPECT PCV VALVE OPERATION
No
Yes
Repair or replace malfunctioning part according to inspection result, then go to Step
16.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11
12
• Inspect the PCV valve operation.
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is the PCV valve normal?
No
Replace the PCV valve, then go to Step 16.
(See INTAKE-AIR SYSTEM HOSE ROUTING
DIAGRAM [Z6] .)
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR OPERATION
Yes Go to the next step.
• Perform the "Variable Tumble Control
Operation Inspection".
(See Variable Tumble Control Operation
Inspection .)
No
Repair or replace malfunctioning part according to inspection results, then go to
Step 16.
• Does the variable tumble control work properly?
INSPECT FUEL LINE PRESSURE
• Turn the ignition switch off.
Yes Go to the next step.
Note
• If the engine will not start, inspect the fuel line pressure with the ignition switch to the ON position.
• Inspect the fuel line pressure while the engine running.
If the fuel pressure is too high, replace the fuel pump unit, then go to Step 16.
No
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
If the fuel line pressure is low, go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
13
14
15
Yes
Replace suspected fuel line, then go to Step
16.
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
• Is any fuel leakage found?
Inspect for foreign materials or stain inside fuel filter (low pressure).
No If for foreign materials or stain inside fuel filter
(low pressure), clean of fuel tank and filter.
Then go to Step 16.
INSPECT VARIABLE VALVE TIMING
CONTROL SYSTEM OPERATION
Yes Go to the next step.
• Inspect the variable valve timing control system operation.
(See Variable Valve Timing Control System
Operation Inspection .)
No
Repair or replace malfunctioning part according to inspection results, then go to
Step 16.
• Does the variable valve timing control system work properly?
INSPECT EGR VALVE STUCK OPEN Yes
Clean or replace the EGR valve, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
16
17
• Remove the EGR valve.
(See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
• Does the EGR valve stuck open?
No
(See EGR VALVE REMOVAL/INSTALLATION
[Z6] .)
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2188 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "PCM Adaptive Memory
Produce Drive Mode".
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
.)
DTC P2195
DETECTION
CONDITION
DTC P2195 [Z6]
B3E010202100W11
Front HO2S signal stuck lean
• The PCM monitors the front HO2S output voltage when the following conditions are met. If the output voltage is less than 0.45 V for 46 s , the PCM determines that the front HO2S signal remains lean.
MONITORING CONDITION
- Fuel injection control system status: feedback zone
- ECT is more than 70 ° C {158 ° F}.
- Engine speed is more than 1,500 rpm .
Diagnostic support note
• This is a continuous monitor. (HO2S)
• The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S malfunction
• Fuel injector malfunction
• Insufficient fuel line pressure
• Leakage exhaust gas
• Air suction at intake-air system
• Leakage fuel
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
5
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE
OR STORED DTC
• Turn the ignition switch off, then to the
ON position (Engine off).
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2177 or P2187 also present?
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR
FREEZE FRAME DATA
• Is DTC P2195 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6]
Yes Go to the next step.
.)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs.
(See PCM INSPECTION [Z6] .)
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 13.
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME
DATA CONDITION
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs under the
FREEZE FRAME DATA condition.
Yes Go to the next step.
(See PCM INSPECTION [Z6]
- ECT
- MAF
.)
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 13.
- TP
- VSS
• Are the PIDs normal?
INSPECT INTAKE-AIR SYSTEM FOR
EXCESSIVE AIR SUCTION
• Visually inspect the hose in the intakeair system for looseness, cracks or damages.
• Is there any malfunction?
Yes
Repair or replace the malfunctioning part, then go to Step 13.
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
Replace the MAF/IAT sensor, then go to Step 13.
No
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
11
12
13
14
INSPECT FRONT HO2S
• Inspect the front HO2S.
(See FRONT HEATED OXYGEN
SENSOR (HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
Replace the front HO2S, then go to Step 13.
Yes
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT FUEL INJECTOR
• Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• Is there any malfunction?
Yes
Replace suspected fuel injector, then go to Step
13.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
Yes Go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No Go to Step 13.
INSPECT FUEL SYSTEM FOR FUEL
LEAKAGE
Yes
Repair or replace the malfunctioning part, then go to the next step.
• Visually inspect the fuel system for fuel leakage.
No
• Is there fuel leakage?
Replace the fuel pump unit, then go to the next step.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
VERIFY TROUBLESHOOTING OF DTC
P2195 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2196 [Z6]
B3E010202100W12
DTC P2196 Front HO2S signal stuck rich
DETECTION
CONDITION
POSSIBLE
CAUSE
• The PCM monitors the front HO2S output voltage when the following conditions are met. If output voltage is more than 0.45 V for 46 s , the PCM determines that the front HO2S signal remains rich.
MONITORING CONDITION
- Fuel injection control system status: feedback zone
- ECT: more than 70 ° C {158 ° F}
- Engine speed: more than 1,500 rpm
Diagnostic support note
• This is a continuous monitor. (HO2S)
• The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S malfunction
• Fuel injector malfunction
• Excessive fuel pressure
• Restriction in intake-air system
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
• Verify related service repair information availability.
No Go to the next step.
• Is any related repair information available?
VERIFY RELATED PENDING CODE
OR STORED DTC
• Turn the ignition switch off, then to the
ON position (Engine off).
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2177 or P2187 also present?
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR
FREEZE FRAME DATA
• Is DTC P2196 on FREEZE FRAME
DATA?
No
Go to the FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [Z6] .)
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs.
(See PCM INSPECTION [Z6] .)
- ECT
- MAF
Yes Go to the next step.
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
- TP
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME
DATA CONDITION
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs under the
FREEZE FRAME DATA condition.
(See PCM INSPECTION [Z6]
- ECT
- MAF
.)
Yes Go to the next step.
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
- TP
- VSS
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
Replace the MAF/IAT sensor, then go to Step 11.
No
(See MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
INSPECT FRONT HO2S
• Inspect the front HO2S.
(See FRONT HEATED OXYGEN
SENSOR (HO2S) INSPECTION [Z6] .)
• Is there any malfunction?
Replace the front HO2S, then go to Step 11.
Yes
(See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
9
10
11
INSPECT FUEL INJECTOR
• Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• Is there any malfunction?
Replace the fuel injector, then go to Step 11.
Yes
(See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
Yes
Replace the fuel pump unit, then go to the next step.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2196 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the "HO2S heater, HO2S, and
TWC Repair Verification Drive Mode".
No Go to the next step.
(See OBD DRIVE MODE [Z6] .)
• Is the PENDING CODE for this DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
DTC P2228
DETECTION
CONDITION
POSSIBLE CAUSE
No DTC troubleshooting completed.
DTC P2228 [Z6]
B3E010202200W01
BARO sensor circuit low input
• The PCM monitors input voltage from the BARO sensor. If the input voltage at PCM terminal 2S is less than 1.7 V , the PCM determines that the BARO sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• BARO sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between BARO sensor terminal C and PCM terminal 2W
• Short to GND in wiring harness between BARO sensor terminal C and PCM terminal 2W
• Open circuit in wiring harness between BARO sensor terminal B and PCM terminal 2S
• Short to GND in wiring harness between BARO sensor terminal B and PCM terminal 2S
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 8.
INSPECT BARO SENSOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the BARO sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT BARO SENSOR CIRCUIT FOR
SHORT TO GND
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 8.
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
- BARO sensor terminal C (wiring harness-side) and body GND
- BARO sensor terminal B (wiring harness-side) and body GND
• Is there continuity?
INSPECT BARO SENSOR
• Inspect the BARO sensor.
(See BAROMETRIC PRESSURE (BARO)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Yes
No
Replace the BARO sensor, then go to Step
8.
Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 8.
No Go to the next step.
INSPECT BARO SENSOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between the following terminals:
Yes Go to the next step.
- BARO sensor terminal C (wiring harness-side) and PCM terminal 2W
(wiring harness-side)
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- BARO sensor terminal B (wiring harness-side) and PCM terminal 2S
(wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P2228 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
DTC P2229
DETECTION
CONDITION
POSSIBLE CAUSE
No DTC troubleshooting completed.
DTC P2229 [Z6]
B3E010202200W02
BARO sensor circuit high input
• The PCM monitors input voltage from the BARO sensor. If the input voltage at PCM terminal 2S is 2.9 V or more , PCM determines that the BARO sensor circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• BARO sensor malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between BARO sensor terminal B and PCM terminal 2S
• Open circuit in wiring harness between BARO sensor terminal A and PCM terminal 2AX
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT BARO SENSOR CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 8.
• Turn the ignition switch off.
• Disconnect the BARO sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
• Is there any malfunction?
INSPECT BARO SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to
Step 8.
No Go to the next step.
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5
6
7
8
9
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Measure the voltage between BARO sensor terminal B (wiring harness-side) and body
GND.
• Is the voltage B+ ?
INSPECT BARO SENSOR
• Inspect the BARO sensor.
(See BAROMETRIC PRESSURE (BARO)
SENSOR INSPECTION [Z6] .)
• Is there any malfunction?
Yes
Replace the BARO sensor, then go to Step
8.
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 8.
Go to the next step.
INSPECT BARO SENSOR GND CIRCUIT
FOR OPEN CIRCUIT
• Turn the ignition switch off.
• Inspect for continuity between BARO sensor terminal A (wiring harness-side) and PCM terminal 2AX (wiring harness-side).
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2229 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P2502 [Z6]
B3E010202500W01
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2502
DETECTION
CONDITION
POSSIBLE CAUSE
Charging system voltage problem
• The PCM determines that the generator output voltage is more than 17
V or the battery voltage is less than 11 V while the engine running.
• Generator malfunction
• Battery malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between generator terminal B and battery positive terminal
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
INSPECT BATTERY
• Turn the ignition switch off.
• Inspect the battery.
(See BATTERY INSPECTION .)
• Is the battery normal?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No
Yes
No
Go to the next step.
Go to the next step.
Replace the battery, then go to Step 7.
(See BATTERY REMOVAL/INSTALLATION [Z6] .)
INSPECT POOR INSTALLATION OF
GENERATOR TERMINAL
• Turn the ignition switch off.
• Inspect the generator terminal B installation nut for looseness.
• Is the nut loose?
Yes
Tighten the generator terminal B installation nut, then go to Step 7.
No Go to the next step.
INSPECT POOR INSTALLATION OF
BATTERY POSITIVE TERMINAL
Yes
Connect the battery positive terminal correctly, then go to Step 7.
• Inspect the battery positive terminal for looseness.
No Go to the next step.
• Is the terminal loose?
INSPECT BATTERY CHARGING
CIRCUIT
• Disconnect the generator terminal B.
• Measure the voltage between generator terminal B (wiring harnessside) and body GND.
• Is the voltage B+ ?
Yes Go to the next step.
No
Repair or replace wiring harness between generator terminal B and battery positive terminal, then go to the next step.
VERIFY TROUBLESHOOTING OF
DTC P2502 COMPLETED
• Make sure to reconnect all connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
• Clear DTC from memory using the
WDS or equivalent.
• Start the engine.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Is same DTC present?
8
VERIFY AFTER REPAIR
PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE
[Z6] .)
• Are any DTCs present?
DTC P2503
DETECTION
CONDITION
POSSIBLE CAUSE
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P2503 [Z6]
B3E010202500W02
Charging system voltage low
• The PCM needs more than 20 A from the generator, and determines that the generator output voltage is less than 8.5 V while the engine running.
• Generator malfunction
• Drive belt misadjustment
• Connector or terminal malfunction
• Open circuit in wiring harness between generator terminal D and PCM terminal 2AN
• Short to GND in wiring harness between generator terminal D and PCM terminal 2AN
• Open circuit in wiring harness between generator terminal P and PCM terminal 2AR
• Short to GND in wiring harness between generator terminal P and PCM terminal 2AR
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
INSPECT DRIVE BELT CONDITION
• Verify that the drive belt auto tensioner indicator mark does not exceed the limit.
(See DRIVE BELT INSPECTION [Z6] .)
• Is the drive belt normal?
INSPECT GENERATOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the generator connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 8.
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 8.
No
Go to the next step.
Replace and/or adjust the drive belt, then go to Step 8.
(See DRIVE BELT REPLACEMENT [Z6]
Go to the next step.
.)
INSPECT GENERAOR CIRCUIT FOR
SHORT TO GND
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between the following terminals:
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 8.
- Generator terminal D (wiring harness-side) and body GND
- Generator terminal P (wiring harness-side) and body GND
• Is there continuity?
No Go to the next step.
INSPECT GENERATOR CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch off.
Yes Go to the next step.
• Inspect for continuity between the following terminals:
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
- Generator terminal D (wiring harness-side) and PCM terminal
2AN (wiring harness-side)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
- Generator terminal P (wiring harness-side) and PCM terminal
2AR (wiring harness-side)
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P2503 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is same DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
DTC P2504
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2504 [Z6]
B3E010202500W03
Charging system voltage high
• The PCM determines that the generator output voltage is more than 18.5
V or battery voltage is more than 16.0 V while the engine running.
• Short to power supply in wiring harness between generator connector terminal D and PCM connector terminal 2AN
• Generator malfunction
• PCM and/or generator are poorly connected.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
8
INSPECT GENERATOR CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the generator connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to Step
7.
Go to the next step.
INSPECT GENERATOR CONTROL
TERMINAL FOR SHORT TO POWER
SUPPLY
Repair or replace the wiring harness for a
Yes possible short to power supply, then go to Step
7.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between generator terminal D (wiring harness-side) and body
GND.
• Is the voltage B+ ?
No Go to the next step.
INSPECT GENERATOR
• Inspect the generator.
(See GENERATOR INSPECTION .)
• Is there any malfunction?
Replace the generator, then go to Step 7.
Yes
(See GENERATOR
REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2504 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is same DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
(See AFTER REPAIR PROCEDURE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Are any DTCs present?
DTC P2507
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2507 [Z6]
B3E010202500W04
PCM power input signal low
• The PCM monitors the voltage of the backup battery positive at PCM terminal 1AX. If the PCM detects that the battery positive terminal voltage is 2.5 V or less for 2 s , the PCM determines that the backup voltage circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if PCM detects the above malfunction condition during the first drive cycle.
• The PENDING CODE is available if the PCM detects the above malfunction condition.
• The FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Connector or terminal malfunction
• Open circuit in wiring harness between the battery positive terminal and
PCM terminal 1AX
• Short to GND in wiring harness between the battery positive terminal and
PCM terminal 1AX
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT PCM POWER MONITOR
CIRCUIT FOR SHORT TO GND
• Turn the ignition switch off.
• Inspect for continuity between battery positive terminal (wiring harness-side) and body GND.
• Is there continuity?
Yes
Repair or replace the wiring harness for a possible short to GND, then go to Step 6.
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes
Repair or replace the terminal, then go to Step
6.
• Turn the ignition switch off.
• Disconnect the PCM connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT PCM POWER MONITOR
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Measure the voltage between PCM terminal 1AX (wiring harness-side) and body
GND.
No
Repair or replace the wiring harness for a possible open circuit, then go to the next step.
• Is the voltage B+ ?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [Z6] .)
VERIFY TROUBLESHOOTING OF DTC
P2507 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE [Z6] .)
• Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [Z6] .)
No DTC troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ON-BOARD DIAGNOSTIC[ENGINE
CONTROL SYSTEM (LF)]
CONTROL SYSTEM WIRING DIAGRAM [LF]
B3E010200102W01
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MONITORING SYSTEM AND CONTROL SYSTEM
DEVICE RELATIONSHIP CHART [LF]
B3E010200102W02 x: Applicable
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Component
Input
A/C switch, refrigerant pressure switch (high, low pressure)
TP sensor x
ECT sensor
IAT sensor
MAF sensor
HO2S (front)
HO2S (rear) x x x x x x x x x x x x x x x x x x x
BARO sensor
MAP sensor
CMP sensor x x x x x x x x x x x x x x x x x x x x x x CKP sensor
Output
Fuel injector x
EGR valve
Purge solenoid valve
MIL
DLC-2 x x x x x x x x x x
OBD PENDING TROUBLE CODE [LF]
B3E010200102W03
• These appear when a problem is detected in a monitored system. The code for a failed system is stored in the PCM memory in the first drive cycle. This code is called the pending code. If the problem is not found in a second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code (1DC). If the problem is not found in a second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code when the ignition switch is turned to the ON position in the next drive cycle
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(2DC). If the problem is found in a second drive cycle too, the PCM judges that the system has failed, and the DTC is stored.
OBD FREEZE FRAME DATA [LF]
B3E010200102W04
• This is the technical data which indicates the engine condition at the time of the first malfunction. This data will remain in the memory even if another emission-related DTC is stored, with the exception of Fuel system or Misfire DTCs. Once freeze frame data for Fuel system or Misfire DTC is stored, it will overwrite any previous data and the freeze frame will not be overwritten again.
OBD ON-BOARD SYSTEM READINESS TEST [LF]
B3E010200102W05
• This shows the OBD systems operating status. If any monitor function is incomplete, WDS or equivalent will identify which monitor function has not been completed. The Fuel system, Misfire and CCM are continuous monitoring-type functions. The HO2S, EGR system and Catalyst will be monitored under drive cycles. The OBD diagnostic system is initialized by performing the DTC cancellation procedure or disconnecting the negative battery cable.
OBD READ/CLEAR DIAGNOSTIC TEST RESULT [LF]
B3E010200102W06
• This retrieves all stored DTCs in the PCM and clears the on-board readiness test results, freeze frame data, DTC and pending trouble code.
OBD PARAMETER IDENTIFICATION (PID) ACCESS
[LF]
B3E010200102W07
• The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since the PID values for output devices are the PCM internal data values, inspect each device to identify which output devices are malfunctioning.
ON-BOARD DIAGNOSTIC TEST [LF]
B3E010200102W08
DTC Reading Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Retrieve the DTCs using the WDS or equivalent.
Pending Trouble Code Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Retrieve the pending trouble codes using the WDS or equivalent.
Freeze Frame PID Data Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Record the freeze frame PID data using the WDS or equivalent.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
On-Board System Readiness Tests Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Monitor the OBD-II systems operating status using the WDS or equivalent.
PID/DATA Monitor and Record Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Access and monitor the PIDs using the WDS or equivalent.
Diagnostic Monitoring Test Results Access Procedure
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Access to the diagnostic monitoring test results and read the test results using the WDS or equivalent.
AFTER REPAIR PROCEDURE [LF]
B3E010200102W09
1. Connect the WDS or equivalent to the DLC-2.
2. Cycle the ignition switch off, then to the ON position (Engine off).
3. Record the DTC if retrieved.
4. Clear all diagnostic data using the WDS or equivalent.
OBD DRIVE MODE [LF]
B3E010200102W10
• Performing the Drive Mode inspects the OBD system for proper operation and must be performed to ensure that no additional DTCs are present.
• During the Drive Mode, the following systems are inspected:
- HO2S heater
- HO2S
- TWC
- Fuel system and Misfire
Caution
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
• When the WDS or equivalent is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the WDS or equivalent using the
PID/DATA MONITOR AND RECORD function and inspect later.
Note
• Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer and tachometer. Use the WDS or equivalent to monitor vehicle speed.
• If the OBD system inspection is not completed during the Drive Mode, the following causes are considered:
- The OBD system detected a malfunction.
- The Drive Mode procedure was not completed correctly.
• Disconnecting the battery will reset the memory. Do not disconnect the battery during and after the Drive Mode.
• The WDS or equivalent can be used at anytime through the course of the Drive Mode to monitor the completion status. Monitoring can be done by viewing the ON BOARD SYSTEM READINESS menu.
Mode 1 (PCM Adaptive Memory Produce Drive Mode)
1. Start the engine and warm it up completely.
2. Verify the following conditions and correct if necessary:
• All accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
• Initial ignition timing and idle speed are within specification.
3. Perform no load racing at the engine speed of 2,800-3,200 rpm for more than 30 s .
4. Idle the engine for more than 30 s after the cooling fan stopped.
5. Turn the ignition switch off.
Mode 3 (HO2S heater, HO2S, and TWC Repair Verification Drive Mode)
1. Perform the Mode 1 first.
2. Verify that all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
3. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F. The driving condition before driving at constant speed is not specified.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Zone Shift Position Vehicle Speed (km/h {mph}) Time (s)
O Neutral
A 2nd
B 3rd
C 2nd
D 3rd
E 4th
F 5th
0 {0}
40-50 {25-31}
65-75 {41-46}
60-75 {38-46}
75-100 {47-62}
50-75 {32-46}
70-95 {44-59}
T1: above 455
T2: above 30
T3: above 20
T4: above 120
4. Stop the vehicle and access the ON BOARD SYSTEM READINESS to inspect the Drive Mode completion status.
• If completed, RFC changes from No to Yes.
• If not completed, turn the ignition switch off, then go back to Step 3.
5. Verify that no DTCs are available.
DTC TABLE [LF]
B3E010200102W11
×: Applicable
-: Not applicable
DTC
No.
Condition MIL DC
Monitor item
Memory function
Page
P0031
Front HO2S heater circuit low input
ON 2
HO2S heater
× (See DTC P0031 [LF] )
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0032
Front HO2S heater circuit high input
ON
P0037
Rear HO2S heater circuit low input
ON
P0038
Rear HO2S heater circuit high input
ON
P0101
MAF sensor circuit range/performance problem
ON
P0102 MAF sensor circuit low input ON
P0103 MAF sensor circuit high input ON
P0107 MAP sensor circuit low input ON
P0108 MAP sensor circuit high input ON
P0111
IAT sensor circuit range/performance problem
ON
P0112 IAT sensor circuit low input ON
P0113 IAT sensor circuit high input ON
P0117 ECT sensor circuit low input ON
P0118 ECT sensor circuit high input ON
P0121 TP sensor stuck closed ON
P0122 TP sensor circuit low input ON
P0123 TP sensor circuit high input ON
P0125
Excessive time to enter closed loop fuel control
ON
P0132 Front HO2S circuit high input ON
P0133 Front HO2S circuit problem ON
2
2
2
2
1
1
1
1
2
1
1
1
2
HO2S heater
HO2S heater
HO2S heater
CCM
CCM
CCM
CCM
CCM
CCM
CCM
CCM
CCM
1 CCM
2 CCM
1 CCM
1 CCM
CCM
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
2 HO2S ×
2 HO2S ×
P0134
Front HO2S no activity detected
ON
P0138 Rear HO2S circuit high input ON
P0140
Rear HO2S no activity detected
ON
2
2
2
HO2S
HO2S
HO2S
×
×
×
P0300 Random misfire detected Flash/ON
1 or
2
Misfire ×
P0301 Cylinder No.1 misfire detected Flash/ON
1 or
2
Misfire ×
(See
(See
(See
(See
DTC P0032 [LF]
DTC P0037 [LF]
DTC P0038 [LF]
DTC P0300 [LF]
)
)
)
)
(See DTC P0101 [LF] )
(See DTC P0102 [LF] )
(See DTC P0103 [LF] )
(See DTC P0107 [LF] )
(See DTC P0108 [LF] )
(See DTC P0111 [LF] )
(See DTC P0112 [LF] )
(See DTC P0113 [LF] )
(See DTC P0117 [LF] )
(See DTC P0118 [LF] )
(See DTC P0121 [LF] )
(See DTC P0122 [LF] )
(See DTC P0123 [LF] )
(See DTC P0125 [LF] )
(See DTC P0132 [LF] )
(See DTC P0133 [LF] )
(See DTC P0134 [LF] )
(See DTC P0138 [LF] )
(See DTC P0140 [LF] )
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0302 Cylinder No.2 misfire detected Flash/ON
1 or
2
Misfire ×
P0303 Cylinder No.3 misfire detected Flash/ON
1 or
2
Misfire ×
P0304 Cylinder No.4 misfire detected Flash/ON
1 or
2
Misfire ×
P0327
P0328
KS circuit low input
KS circuit high input
ON
ON
1
1
CCM
CCM
×
×
P0335
P0340
CKP sensor circuit problem
CMP sensor circuit problem
ON
ON
1
1
CCM
CCM
×
×
P0403
EGR valve (stepper motor) circuit problem
P0420
Catalyst system efficiency below threshold
P0443
Purge solenoid valve circuit problem
ON
ON
ON
P0480
Cooling fan control circuit problem
P0500
P0505
VSS circuit problem
IAC system problem
OFF
ON
OFF
P0506
Idle control system RPM lower than expected
ON
2
2
2
1
2
-
2
CCM
Catalyst
CCM
Other
CCM
Other
CCM
×
×
×
×
×
×
-
P0507
Idle control system RPM higher than expected
P0511 IAC valve circuit problem
P0602 PCM programming error
P0610 PCM vehicle options error
P0661
Variable intake-air solenoid valve circuit low input
P0662
Variable intake-air solenoid valve circuit high input
P0703
Brake switch input circuit problem
P0704
CPP switch input circuit problem
ON
ON
ON
ON
OFF
OFF
ON
ON
2
1
1
1
2
2
CCM
CCM
1 CCM
1 CCM
Other
Other
CCM
CCM
×
×
×
×
×
×
×
×
(See DTC P0301,
P0302, P0303, P0304
[LF] )
(See DTC P0327 [LF] )
(See DTC P0328 [LF] )
(See DTC P0335 [LF] )
(See DTC P0340 [LF] )
(See
(See
(See
(See
DTC P0403 [LF]
DTC P0420 [LF]
DTC P0443 [LF]
DTC P0480 [LF]
)
)
)
)
(See DTC P0500 [LF] )
(See DTC P0505 [LF] )
(See
(See
(See
(See
(See
(See
DTC P0506 [LF]
DTC P0507 [LF]
)
(See DTC P0511 [LF] )
(See DTC P0602 [LF] )
(See DTC P0610 [LF] )
DTC P0661 [LF]
DTC P0662 [LF]
DTC P0703 [LF]
DTC P0704 [LF]
)
)
)
)
)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
P0850
Neutral switch input circuit problem
ON
P1260 Immobilizer system problem OFF
P2006
Variable tumble shutter valve stuck closed
ON
2
1
2
CCM
Other
CCM
×
×
×
(See
(See
(See
DTC P0850 [LF]
DTC P1260 [LF]
DTC P2006 [LF]
)
)
)
P2009
Variable tumble solenoid valve circuit low input
ON
P2010
Variable tumble solenoid valve circuit high input
ON
P2096
P2097
P2177
P2178
P2187
P2188
Target A/F feedback system too lean
Target A/F feedback system too rich
Fuel system too lean at off idle
Fuel system too rich at off idle
Fuel system too lean at idle
Fuel system too rich at idle
ON
ON
ON
ON
ON
ON
2
2
CCM
CCM
×
×
2
2
2
2
Fuel system
Fuel system
Fuel system
Fuel system
×
×
×
×
2
Fuel system
×
2
Fuel system
×
2 HO2S ×
2 HO2S ×
1 CCM ×
(See
(See
(See
(See
(See
(See
(See
(See
DTC P2009 [LF]
DTC P2010 [LF]
DTC P2096 [LF]
DTC P2097 [LF]
DTC P2177 [LF]
DTC P2178 [LF]
DTC P2187 [LF]
DTC P2188 [LF]
)
)
)
)
)
)
)
)
P2195 Front HO2S signal stuck lean ON
P2196 Front HO2S signal stuck rich ON
P2228 BARO sensor circuit low input ON
P2229
BARO sensor circuit high input
ON 1 CCM ×
(See
(See
DTC P2195 [LF]
DTC P2229 [LF]
)
(See DTC P2196 [LF] )
(See DTC P2228 [LF] )
)
P2502
Charging system voltage problem
OFF
P2503 Charging system voltage low OFF
P2504 Charging system voltage high OFF
P2507 PCM B+ voltage low ON
1 Other
1 Other
1 Other
1 CCM
×
×
×
×
(See DTC P2502 [LF] )
(See DTC P2503 [LF] )
(See DTC P2504 [LF] )
(See DTC P2507 [LF] )
U0073
CAN system communication error
(See DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM] )
U0121
Communication error to ABS
HU/CM
(See DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM] )
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
U0155
Communication error to instrument cluster
DTC P0031
DETECTION
CONDITION
POSSIBLE CAUSE
(See DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM] )
DTC P0031 [LF]
B3E010201084W01
Front HO2S heater circuit low input
• The PCM monitors the front HO2S heater control signal at PCM terminal
2G. If the PCM turns the front HO2S heater off but the front HO2S heater circuit has low voltage, the PCM determines that the front HO2S heater circuit has malfunction.
Note
• The front HO2S heater is controlled by duty signal.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Front HO2S malfunction
• Open circuit in wiring harness between main relay and front HO2S terminal
C
• Open circuit in wiring harness between front HO2S terminal D and PCM terminal 2G
• Short to ground in wiring harness between front HO2S terminal D and PCM terminal 2G
• Poor connection at front HO2S or the PCM connector
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 9.
INSPECT POOR CONNECTION OF FRONT
HO2S CONNECTOR
• Turn the ignition switch off.
• Disconnect front HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT FRONT HO2S HEATER
No
Yes
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Inspect the front HO2S heater.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is the front HO2S heater normal?
No Replace the front HO2S, then go to Step 9.
INSPECT POWER CIRCUIT OF FRONT HO2S
HEATER FOR OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between front HO2S terminal
C (harness-side) and body ground.
No
Repair or replace the wiring harness for open circuit, then go to Step 9.
• Is the voltage B+ ?
Yes Repair terminal, then go to Step 9.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
Yes
Repair or replace the wiring harness for short to ground, then go to Step 9.
INSPECT CONTROL CIRCUIT OF FRONT
HO2S HEATER FOR SHORT TO GROUND
• Inspect for continuity between front HO2S terminal D (wiring harness-side) and body ground.
• Is there continuity?
INSPECT CONTROL CIRCUIT OF FRONT
HO2S HEATER FOR OPEN CIRCUIT
• Inspect for continuity between front HO2S terminal D (wiring harness-side) and PCM terminal 2G.
• Is there continuity?
No
Yes
No
Go to the next step.
Go to the next step.
Repair or replace the wiring harness for open circuit, then go to Step 9.
VERIFY TROUBLESHOOTING OF DTC P0031
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
DTC P0032
DETECTION
CONDITION
POSSIBLE CAUSE
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0032 [LF]
B3E010201084W02
Front HO2S heater circuit high input
• The PCM monitors the front HO2S heater control signal at PCM terminal
2G. If the PCM turns the front HO2S heater on but the front HO2S heater circuit has high voltage, PCM determines that front HO2S heater circuit has malfunction.
Note
• Front HO2S heater is controlled by a duty signal.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Short to power supply in wiring harness between front HO2S terminal D and PCM terminal 2G
• Short circuit in front HO2S or PCM terminal
• Front HO2S heater malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT FRONT HO2S TERMINALS
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 7.
Go to the next step.
INSPECT FRONT HO2S HEATER
• Inspect the front HO2S heater.
Yes Go to the next step.
No Replace the front HO2S, then go to Step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is the front HO2S heater normal?
INSPECT PCM TERMINAL
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes Repair the terminal, then go to Step 7.
No Go to the next step.
6
7
8
INSPECT FRONT HO2S HEATER CONTROL
CIRCUIT FOR SHORT TO POWER SUPPLY
Repair or replace the wiring harness for
Yes shot to power circuit, then go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between front HO2S terminal D (wiring harness-side) and body ground.
No Go to the next step.
• Is the voltage B+ ?
VERIFY TROUBLESHOOTING OF DTC
P0032 COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0037
DETECTION
CONDITION
DTC P0037 [LF]
B3E010201084W03
Rear HO2S heater circuit low input
• The PCM monitors the rear HO2S heater control signal at PCM terminal
2C. If the PCM turns the rear HO2S heater off but the rear HO2S heater circuit has low voltage, the PCM determines that the rear HO2S heater circuit has malfunction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Rear HO2S malfunction
• Open circuit in wiring harness between the main relay and rear HO2S terminal C
• Open circuit in wiring harness between rear HO2S terminal D and PCM terminal 2C
• Short to ground in wiring harness between rear HO2S terminal D and PCM terminal 2C
• Poor connection at the rear HO2S or the PCM connector
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform the repair or diagnosis according
Yes to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF REAR
HO2S CONNECTOR
• Turn the ignition switch off.
• Disconnect the rear HO2S connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT REAR HO2S HEATER
• Inspect the rear HO2S heater.
(See REAR HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is rear HO2S heater normal?
Yes
No
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
Go to the next step.
Replace the rear HO2S, then go to Step 9.
INSPECT REAR HO2S HEATER POWER
CIRCUIT FOR OPEN CIRCUIT
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between rear HO2S terminal C (wiring harness-side) and body ground.
• Is the voltage B+ ?
Yes
No
Go to the next step.
Repair or replace the wiring harness for open circuit, then go to Step 9.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair terminal, then go to Step 9.
Go to the next step.
INSPECT REAR HO2S HEATER CONTROL
CIRCUIT FOR SHORT TO GROUND
Yes
Repair or replace the wiring harness for short to ground, then go to Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Inspect for continuity between rear HO2S terminal D (wiring harness-side) and body ground.
• Is there continuity?
INSPECT HREAR HO2S HEATER CONTROL
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between rear HO2S terminal D (wiring harness-side) and PCM terminal 2C.
• Is there continuity?
No
Repair or replace the wiring harness for open circuit, then go to Step 9.
9
VERIFY TROUBLESHOOTING OF DTC P0037
COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
10
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
DTC P0038
DETECTION
CONDITION
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0038 [LF]
Rear HO2S heater circuit high input
B3E010201084W04
• The PCM monitors the rear HO2S heater control signal at PCM terminal
2C. If the PCM turns the rear HO2S heater on but the rear HO2S heater circuit has high voltage, the PCM determines that the rear HO2S heater circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Short to power supply in wiring harness between rear HO2S terminal D and
PCM terminal 2C
• Short circuit in rear HO2S or PCM
• Rear HO2S heater malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform the repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
8
INSPECT REAR HO2S TERMINAL
• Turn the ignition switch off.
• Disconnect the rear HO2S connector.
• Inspect for poor connection (such as damaged/pulled out pins, corrosion).
• Is there any malfunction?
INSPECT REAR HO2S HEATER
• Inspect rear HO2S heater.
(See REAR HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is rear HO2S heater normal?
INSPECT PCM TERMINAL
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Yes
No
Yes
No
Repair or replace the terminal, then go to
Step 7.
Go to the next step.
Go to the next step.
Go to the next step.
Replace the rear HO2S, then go to Step 7.
Repair the terminal, then go to Step 7.
INSPECT REAR HO2S HEATER CONTROL
CIRCUIT FOR SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
Repair or replace the wiring harness for
Yes shot to power circuit, then go to the next step.
• Measure the voltage between rear HO2S terminal D (wiring harness-side) and body ground.
• Is the voltage B+ ?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0038 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0101 [LF]
B3E010201084W05
DTC P0101 MAF sensor circuit range/performance problem
DETECTION
CONDITION
• The PCM compares actual MAF amount with expected MAF amount when the engine is running.
- If the mass intake air flow amount is below 5.0 g/s {0.66 lb/min} for 5 s and throttle opening angle is above 50% with engine running, the PCM determines that detected mass intake air flow amount is too low.
- If the mass intake air flow amount is above 96.0 g/s {12.7 lb/min} for 5 s and the engine speed is below 2,000 rpm with the engine running, the
PCM determines that detected mass intake air flow amount is too high.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
POSSIBLE
CAUSE
• MAF sensor malfunction
• TP sensor malfunction
• Electrical corrosion in MAF signal circuit
• Electrical corrosion in MAF RETURN circuit
• Voltage drop in MAF signal circuit
• Voltage drop in ground circuit
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
ACTION
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Perform repair or diagnosis according to the
Yes available repair information.
• If vehicle is not repaired, go to the next step.
• Verify related service repair information availability.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
• Is any related repair information available?
VERIFY CURRENT INPUT SIGNAL
STATUS: IS CONCERN
INTERMITTENT OR CONSTANT?
• Connect the WDS or equivalent to DLC-
2.
Make sure that the throttle position sensor resistance changes smoothly while gradually opening the throttle valve.
Yes
• If not, replace the throttle position sensor and go to Step 7.
• Start the engine.
• For others, go to the next step.
• Access ECT, TP and MAF PIDs.
• Warm up the engine until ECT PID is above 80 ° C {176 ° F} .
• Drive the vehicle.
• Read MAF PID when the TP PID is above 50% .
• Is MAF PID below 5.0 g/s {0.66 lb/min} ?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS: IS CONCERN
INTERMITTENT OR CONSTANT?
• Connect the WDS or equivalent to DLC-
2.
Yes Go to Step 8.
• Start the engine.
• Access ECT, MAF and RPM PIDs.
• Warm up the engine until ECT PID is above 80 ° C {176 ° F} .
• Read MAF PID when the RPM PID is below 2,000 rpm .
• Is MAF PID above 96.0 g/s {12.7 lb/min} ?
No
Intermittent concern exists. Go to
INTERMITTENT CONCERNS
TROUBLESHOOTING procedure.
(See INTERMITTENT CONCERN
TROUBLESHOOTING [LF] .)
INSPECT POOR CONNECTION OF
MAF SENSOR CONNECTOR
• Turn the ignition switch off.
• Disconnect MAF/IAT sensor connector.
Yes
Repair or replace the terminal or the MAF/IAT sensor, then go to Step 7.
No Go to the next step.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is there any malfunction?
Yes Repair the terminal, then go to the next step.
INSPECT POOR CONNECTION OF
PCM CONNECTOR
• Disconnect the PCM connector.
No
Replace MAF/IAT sensor, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
• Inspect for poor connection
(damaged/pulled-out pins, corrosion, etc.).
• Is there any malfunction?
VERIFY TROUBLESHOOTING OF DTC
P0101 COMPLETED
Yes Replace the PCM, then go to Step 11.
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from memory using the
WDS or equivalent.
• Start the engine.
• Access ECT, TP and RPM PIDs.
• Warm up the engine until ECT PID is reading above 80 ° C {176 ° F} .
• Drive the vehicle while TP PID above
50% for 50 s .
• Is the PENDING CODE for this DTC present?
No Go to Step 11.
INSPECT MAF SENSOR TERMINALS
FOR ELECTRICAL CORROSION
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is There corrosion?
Yes
Repair or replace the terminal or the MAF/IAT sensor, then go to Step 10.
No Go to the next step.
INSPECT POOR CONNECTION OF
PCM CONNECTOR
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is there any malfunction?
Yes
No
Repair the terminal, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0101 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position (Engine off).
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11
• Clear the DTC from the memory using the WDS or equivalent.
• Start the engine.
• Warm up the engine until ECT PID is above 80 ° C {176 ° F} .
• Drive the vehicle while RPM PID 2,000 rpm for 50 s .
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0102
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0102 [LF]
B3E010201084W06
MAF sensor circuit low input
• The PCM monitors input voltage from the MAF sensor when the engine running. If the input voltage at PCM terminal 1AC is below 0.21 V , the PCM determines that the MAF circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• MAF sensor malfunction
• Connector or terminal malfunction
• Short to ground in wiring harness between MAF/IAT sensor terminal C and
PCM terminal 1AC
• Open circuit in wiring harness between MAF/IAT sensor terminal C and
PCM terminal 1AC
• Open circuit in wiring harness between main relay and MAF/IAT sensor terminal A
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT POOR CONNECTION OF MAF
SENSOR CONNECTOR
• Turn the ignition switch off.
Yes
Repair or replace the terminals, then go to
Step 8.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is there any malfunction?
No Go to the next step.
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
INSPECT POWER SUPPLY CIRCUIT FOR
OPEN CIRCUIT
• Turn the ignition switch to the ON position
(Engine off).
• Inspect voltage at the MAF/IAT sensor terminal A (wiring harness-side).
No
Inspect for open circuit in wiring harness between MAF/IAT sensor terminal A (wiring harness-side) and main relay.
Repair or replace wiring harness, then go to
Step 8.
• Is the voltage B+ ?
Yes Repair the terminal, then go to Step 8.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is there any malfunction?
No Go to the next step.
INSPECT MAF SENSOR SIGNAL CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between MAF/IAT sensor terminal C (wiring harness-side) and
PCM terminal 1AC (wiring harness-side).
No
Repair or replace the wiring harness, then go to Step 8.
• Is there continuity?
INSPECT MAF SENSOR SIGNAL CIRCUIT
FOR SHORTS
Yes
Repair or the wiring harness, then go to the next step.
• Inspect for continuity between following terminals:
- MAF/IAT sensor terminal C (wiring harness-side) and body ground
- MAF/IAT sensor connector terminal C (wiring harness-side) and
B (wiring harness-side)
No
Replace the MAF/IAT sensor, then go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0102 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the memory using the
WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
No Go to the next step.
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0103
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0103 [LF]
B3E010201084W07
MAF sensor circuit high input
• The PCM monitors the input voltage from the MAF sensor when the engine running. If the input voltage at PCM terminal 1AC is above 4.9 V , the PCM determines that the MAF circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• MAF sensor malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between MAF/IAT sensor terminal
C and PCM terminal 1AC
• Open circuit in MAF/IAT sensor ground circuit
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF MAF
SENSOR CONNECTOR
• Turn the ignition switch to off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion.)
• Is there any malfunction?
Yes
Repair or replace the terminals, then go to
Step 7.
No Go to the next step.
Yes Go to the next step.
INSPECT MAF SIGNAL CIRCUIT FOR
SHORT TO POWER CIRCUIT
• Turn the ignition switch to the ON position
(Engine off).
No
Repair or replace the wiring harness, then go to Step 7.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
• Measure the voltage between MAF/IAT sensor terminal C (wiring harness-side) and body ground.
• Is the voltage 0 V ?
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes Repair the terminal, then go to Step 7.
No Go to the next step.
6
7
8
INSPECT MAF SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
Yes
Replace MAF/IAT sensor, then go to the next step.
• Inspect for continuity between MAF/IAT sensor terminal B (wiring harness-side) and body ground.
• Is there continuity?
No
Repair or replace the wiring harness, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0103 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the memory using the
WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0107
DETECTION
CONDITION
DTC P0107 [LF]
B3E010201084W08
MAP sensor circuit low input
• The PCM monitors the input voltage from the MAP sensor when the intake air temperature is above 10 ° C {50 ° F} . If the input voltage at PCM terminal
2AL is below 0.1V
, the PCM determines that the MAP sensor circuit has a malfunction.
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• MAP sensor malfunction
• Connector or terminal malfunction
• Short to ground in wiring harness between MAP sensor terminal D and
PCM terminal 2AL
• Open circuit in wiring harness between MAP sensor terminal C and PCM terminal 2W
• MAP sensor signal circuit and MAP sensor ground circuit are shorted each other
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
Yes Go to the next step.
ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY MAP PID WHEN MAP SENSOR
CONNECTOR IS DISCONNECTED
Yes Go to the next step.
• Disconnect the MAP sensor connector.
• Connect the WDS or equivalent to DLC-
2.
No Go to Step 5.
• Access MAP PID.
• Is the voltage above 4.9 V ?
INSPECT POWER SUPPLY CIRCUIT
VOLTAGE AT MAP SENSOR
CONNECTOR
Note
• If DTC P0122 and P2228 are also retrieved with P0107, go to
CONSTANT VOLTAGE troubleshooting procedure.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between MAP sensor terminal C (wiring harness-side) and body ground.
• Is the voltage within 4.5- 5.5 V?
Inspect for poor connection at MAP sensor terminal C (wiring harness-side).
Yes
• Repair or replace the terminal if necessary.
• If there is no malfunction, replace the MAP sensor.
Then go to Step 7.
No
Inspect for open circuit in wiring harness between PCM terminal 2W (wiring harness-side) and MAP sensor terminal C (wiring harnessside).
Repair or replace suspected wiring harness, then go to Step 7.
INSPECT MAP SENSOR SIGNAL
CIRCUIT FOR SHORT TO GROUND
• Turn the ignition switch off.
• Disconnect the PCM connector.
Yes
Repair or replace the wiring harness, then go to
Step 7.
• Inspect continuity between MAP sensor terminal D (wiring harness-side) and body ground.
No Go to the next step.
• Is there continuity?
Yes
Repair or replace the wiring harness, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
INSPECT MAP SENSOR SIGNAL AND
GROUND CIRCUIT FOR SHORT EACH
OTHER
• Inspect for continuity between MAP sensor terminals D and A (wiring harnessside).
No Go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0107 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0108
DETECTION
CONDITION
DTC P0108 [LF]
B3E010201084W09
MAP sensor circuit high input
• The PCM monitors the input voltage from the MAP sensor when the intake air temperature is above 10 ° C {50 ° F} . If input the voltage at PCM terminal
2AL is above 4.9V
, the PCM determines that the MAP sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• MAP sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between MAP sensor terminal A and PCM terminal 2AA
• Open circuit in wiring harness between MAP sensor terminal D and PCM terminal 2AL
• MAP sensor signal circuit shorts to constant voltage supply circuit
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA
HAS BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
8
9
INSPECT CONNECTION OF MAP
SENSOR CONNECTOR
• Turn the ignition switch off.
• Verify that the MAP sensor connector is connected securely.
• Is connection normal?
Yes
No
Go to the next step.
Reconnect the connector, then go to Step 9.
INSPECT POOR CONNECTION OF
MAP SENSOR CONNECTOR
Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the MAP sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
• Is there any malfunction?
VERIFY MAP SENSOR GROUND
CIRCUIT FOR OPEN CIRCUIT
• Inspect for continuity between the
MAP sensor terminal A (wiring harness-side) and body ground.
• Is there continuity?
INSPECT PCM CONNECTOR
• Disconnect the PCM connector.
• Inspect for poor connection at terminals (such as damaged/pulledout pins, corrosion).
• Is there any malfunction?
Yes
No
Go to the next step.
Inspect for open circuit in wiring harness between
PCM terminal 2AA (wiring harness-side) and MAP sensor terminal A (wiring harness-side). Repair or replace suspected harness, then go to Step 9.
Yes Repair the terminal, then go to Step 9.
No Go to the next step.
VERIFY MAP SENSOR SIGNAL
CIRCUIT FOR SHORT TO
CONSTANT VOLTAGE CIRCUIT
Yes
Repair or replace the wiring harness, then go to Step
9.
• Inspect for continuity between MAP sensor terminal D and C (wiring harness-side).
No Go to the next step.
• Is there continuity?
VERIFY MAP SENSOR SIGNAL
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between MAP sensor terminal D (wiring harnessside) and PCM terminal 2AL (wiring harness-side).
No
Repair or replace the wiring harness, then go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF
DTC P0108 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
No Go to the next step.
10
VERIFY AFTER REPAIR
PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .) No Troubleshooting completed.
• Are any DTC present?
DTC P0111
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P0111 [LF]
B3E010201084W10
IAT circuit range/performance problem
• If the intake air temperature is higher than the engine coolant temperature by 40 ° C
{104 ° F} with key on, the PCM determines that there is a IAT sensor performance problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in PCM memory.
• IAT sensor malfunction
• Poor connection at MAF/IAT sensor or PCM connector
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify for related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Repair or replace the terminal, then go to Step
6.
INSPECT POOR CONNECTION OF
MAF/IAT SENSOR CONNECTOR
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT IAT SENSOR
• Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [LF] )
• Is the IAT sensor normal?
No
Yes
No
Go to the next step.
Replace the MAF/IAT sensor, then go to Step
6.
Go to the next step.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to Step
6.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0111 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine and run the engine under
FREEZE FRAME DATA condition.
No Go to the next step.
.)
• Is THE PENDING code for this DTC present?
VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0112
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0112 [LF]
B3E010201084W11
IAT sensor circuit low input
• The PCM monitors the IAT sensor signal at PCM terminal 1AH. If the PCM detects the IAT sensor voltage below 0.16 V , the PCM determines that the
IAT sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• IAT sensor malfunction
• Short to ground in wiring harness between MAF/IAT sensor terminal D and
PCM terminal 1AH
• Short each wiring harness IAT signal circuit and IAT ground circuit
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT IAT SENSOR TERMINAL
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for bent terminal of MAF/IAT sensor terminals D and E (part-side).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 7.
No Go to the next step.
CLASSIFY IAT SENSOR MALFUNCTION OR
WIRING HARNESS MALFUNCTION
Yes
Replace the MAF/IAT sensor, then go to
Step 7.
• Connect the WDS or equivalent to DLC-2.
• Access IAT PID.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Verify IAT value when disconnecting the
MAF/IAT sensor connector.
• Does IAT value change?
5
INSPECT IAT SIGNAL CIRCUIT FOR
SHORT TO GROUND
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for continuity between MAF/IAT sensor terminal D (wiring harness-side) and body ground.
• Is there continuity?
Yes
Repair or replace the wiring harness for short to ground, then go to Step 7.
No Go to the next step.
6
7
8
INSPECT IAT CIRCUITS FOR SHORT
• Inspect for continuity between MAF/IAT sensor terminals D and E (wiring harnessside).
• Is there continuity?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
No
Repair or replace the wiring harness for short, then go to Step 7.
VERIFY TROUBLESHOOTING OF DTC
P0112 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No
Go to the next step.
Troubleshooting completed.
DTC P0113
DETECTION
CONDITION
DTC P0113 [LF]
B3E010201084W12
IAT sensor circuit high input
• The PCM monitors the input voltage from the IAT sensor if input voltage at
PCM terminal 1AH is above 4.8 V , the PCM determines that IAT sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAT sensor malfunction
• Open circuit in wiring harness between MAF/IAT sensor terminal D and
PCM terminal 1AH
• Short to power supply in wiring harness between MAF/IAT sensor terminal
D and PCM terminal 1AH
• Open circuit in wiring harness between MAF/IAT sensor terminal E and
PCM terminal 1AA
• Poor connection at MAF/IAT sensor or PCM connector
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF IAT
SENSOR CONNECTOR
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
No
Repair or replace the replace the wiring terminal, then go to Step 9.
Go to the next step.
Go to the next step.
CLASSIFY IAT SENSOR MALFUNCTION OR
WIRING HARNESS MALFUNCTION
Yes
Replace the MAF/IAT sensor, then go to
Step 9.
• Connect the WDS or equivalent to DLC-2.
• Access IAT PID.
• Connect a jumper wire between MAF/IAT sensor terminals D and E.
• Verify IAT value
• Is the voltage below 4.8 V ?
No Go to the next step.
INSPECT IAT SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between MAF/IAT sensor terminal D (wiring harness-side) and body ground.
• Is the voltage B+ ?
Yes
Repair or replace the wiring harness for short to power supply, then go to Step 9.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect PCM terminals 1AH and 1AA (wiring harness-side) for tightness using feeler tool.
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to
Step 10.
No Go to the next step.
Yes Go to the next step.
INSPECT IAT SENSOR SIGNAL CIRCUIT
FOR OPEN CIRCUIT
No
Repair or replace the wiring harness for open circuit, then go to Step 10.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
• Inspect for continuity between MAF/IAT sensor terminal D (wiring harness-side) and
PCM terminal 1AH.
• Is there continuity?
INSPECT IAT SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
• Inspect for continuity between MAF/IAT sensor terminal E (harness-side) and PCM terminal 1AA.
• Is there continuity?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
No
Repair or replace the wiring harness for open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0113 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No
Go to the next step.
Troubleshooting completed.
DTC P0117
DETECTION
CONDITION
DTC P0117 [LF]
B3E010201084W13
ECT sensor circuit low input
• The PCM monitors the ECT sensor signal at PCM terminal 2AK. If the PCM detects the ECT sensor voltage below 0.2 V , the PCM determines that the
ECT sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• ECT sensor malfunction
• Connect or terminal malfunction
• Short to ground in wiring harness between ECT sensor terminal A and PCM connector terminal 2AK
• Short each wiring harness ECT signal circuit and ECT ground circuit
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
INSPECT TERMINAL BENT
• Turn the ignition switch off.
• Disconnect the ECT sensor connector.
Yes
No
Repair or replace the terminal, then go to
Step 7.
Go to the next step.
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4
5
6
7
8
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Inspect for bent of ECT sensor terminals A and B (part-side).
• Is there any malfunction?
CLASSIFY ECT SENSOR MALFUNCTION
OR WIRING HARNESS MALFUNCTION
• Connect the WDS or equivalent to DLC-2.
• Access ECT PID.
• Verify ECT value when disconnecting ECT sensor connector.
• Does the ECT value change?
Yes Replace the ECT sensor, then go to Step 7.
No Go to the next step.
INSPECT ECT SIGNAL CIRCUIT FOR
SHORT TO GROUND
• Turn the ignition switch off.
• Inspect continuity between ECT sensor terminal A (wiring harness-side) and body ground.
• Is there continuity?
Yes
Repair or replace the wiring harness for short to ground, then go to Step 7.
No Go to the next step.
INSPECT IAT CIRCUIT FOR SHORT
WIRING HARNESSES
• Inspect for continuity between ECT sensor terminal A and B (wiring harness-side).
• Is there continuity?
Yes
Repair or replace the wiring harness for short, then go to the next step.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0117 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0118 [LF]
B3E010201084W14
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0118
DETECTION
CONDITION
POSSIBLE CAUSE
ECT sensor circuit high input
• The PCM monitors the ECT sensor signal at PCM terminal 2AK. If the PCM detects the ECT sensor voltage is above 4.6 V , the PCM determines that the
ECT sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• ECT sensor malfunction
• Open circuit in wiring harness between ECT sensor terminal A and PCM terminal 2AK
• Short to power supply in wiring harness between ECT sensor terminal A and PCM terminal 2AK
• Open circuit in wiring harness between ECT sensor terminal B and PCM terminal 2AA
• Poor connection of ECT sensor or PCM connectors
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
5
6
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF ECT
SENSOR CONNECTOR
• Turn the ignition switch off.
• Disconnect ECT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
CLASSIFY ECT SENSOR MALFUNCTION
OR WIRING HARNESS MALFUNCTION
• Verify the ECT value.
• Is the voltage 4.6 V or below ?
Yes Replace the ECT sensor, then go to Step 9.
• Connect the WDS or equivalent to the DLC-
2.
• Access ECT PID.
• Connect a jumper wire between ECT sensor terminals A and B.
No Go to the next step.
Yes
Repair or replace the wiring harness for short to power supply, then go to Step 9.
INSPECT ECT SENSOR SIGNAL CIRCUIT
FOR SHORT TO POWER
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between ECT sensor terminal A (wiring harness-side) and body ground.
• Is the voltage B+ ?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No
Yes
No
Go to the next step.
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
INSPECT ECT SENSOR SIGNAL CIRCUIT
FOR OPEN CIRCUIT
• Inspect the continuity between ECT sensor terminal A (wiring harness-side) and PCM terminal 2AK.
• Is there continuity?
Yes Go to the next step.
No
Repair or replace the wiring harness for open circuit, then go to Step 9.
INSPECT ECT SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between ECT sensor terminal B (wiring harness-side) and PCM terminal 2AA.
• Is there continuity?
No
Repair or replace the wiring harness for open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0118 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
10
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
DTC P0121
DETECTION
CONDITION
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0121 [LF]
B3E010201084W15
TP sensor stuck closed
• If the PCM detects that the throttle valve opening angle is below 12.5% for 5 s after following conditions are met, the PCM determines that the TP is stuck closed:
MONITORING CONDITION
- Engine coolant temperature is above 70 ° C {158 ° F} .
- MAF sensor signal is above 32.0 g/s {4.2 lb/min.} .
• If PCM detects that throttle valve opening angle is above 50% for 5 s after following conditions are met, the PCM determines that TP is stuck open:
MONITORING CONDITION
- Engine speed above 500 rpm
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
- MAF sensor signal below 5 g/s {0.7 lb/min.}
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• TP sensor malfunction
• Electrical corrosion in TP signal circuit
• Voltage drop in constant voltage supply circuit
• Voltage drop in ground circuit
• MAF sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
4
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch to the ON position
(Engine off).
Yes
Go to DTC P0101 troubleshooting procedure.
• Retrieve the pending or stored DTC using the
WDS or equivalent.
No Go to the next step.
• Is DTC P0101 also retrieved?
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL STATUS:
IS CONCERN INTERMITTENT OR
CONSTANT?
Yes Go to Step 7.
No Go to the next step.
• Start the engine.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Access ECT, TP and MAF PIDs using the
WDS or equivalent.
• Warm up the engine until ECT PID is above
70 ° C {158 ° F}
• Drive the vehicle.
• Read TP PID while MAF PID is above 32.0 g/s {4.2 lb/min.} .
• Is TP PID above 12.5% ?
VERIFY TP PID
• Start the engine.
Yes Go to Step 12.
• Access TP, MAF and RPM PIDs using the
WDS or equivalent.
• Read TP PID while MAF PID is below 5 g/s
{0.7 lb/min} and RPM PID is above 500 rpm .
No Go to the next step.
• Is TP PID above 50% ?
VERIFY CURRENT INPUT SIGNAL STATUS:
IS CONCERN INTERMITTENT OR
CONSTANT?
• Drive the vehicle and read MAF PID.
Intermittent concern exists. Go to
Yes INTERMITTENT CONCERNS troubleshooting procedure.
Inspect the mass airflow sensor, elated circuits and terminals.
• Does MAF PID change according to driving condition?
No
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [LF] .)
Repair or replace if necessary, then go to
Step 16.
INSPECT TP SENSOR TERMINALS FOR
ELECTRICAL CORROSION
• Turn the ignition switch off.
• Disconnect the TP sensor connector.
• Inspect male and female the TP sensor terminals for electrical corrosion.
• Is any electrical corrosion found?
Yes
No
Repair or replace the terminal or TP sensor, then go to Step 11.
Go to the next step.
VERIFY TP SENSOR Yes Go to the next step.
• Does the TP sensor resistance smoothly change while gradually opening throttle valve?
No Replace the TP sensor, then go to Step 11.
INSPECT PCM TERMINALS FOR
ELECTRICAL CORROSION
• Disconnect the PCM connector.
• Inspect the PCM male and female terminals for electrical corrosion on.
Yes Repair the terminal, then go to Step 11.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
• Is any electrical corrosion?
INSPECT CONSTANT VOLTAGE SUPPLY
AND TP SIGNAL CIRCUITS FOR VOLTAGE
DROP
Yes Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect the voltage between following terminals:
- TP sensor terminal C (wiring harness-side) and PCM terminal 2W
No
Inspect the PCM terminals 2I and 2W
(wiring harness-side) for rust or corrosion on.
• Repair or replace the terminal then go to the next step.
- TP sensor terminal B (wiring harness-side) and PCM terminal 2I
• Is the voltage approx. 0 V ?
VERIFY TROUBLESHOOTING OF DTC
P0121 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start the engine.
Yes Replace the PCM, then go to Step 17.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Access ECT, TP and MAF PIDs using WDS or equivalent.
• Warm up the engine until ECT PID is above
70 ° C {158 ° F} .
• Drive the vehicle and read TP and MAF PIDs.
• Verify PID readings are within specifications
No Go to Step 17.
MAF PID: above 32.0 g/s {4.2 lb/min}
TP PID: above 12.5% above 5 s
• Is the PENDING CODE for this DTC present?
INSPECT TP SENSOR TERMINALS FOR
ELECTRICAL CORROSION
• Turn the ignition switch off.
• Disconnect TP sensor connector.
• Inspect for electrical corrosion on male and female TP sensor terminals.
• Is any electrical corrosion found?
Yes
Repair or replace the terminal or TP sensor, then go to Step 16.
No Go to the next step.
Yes Go to the next step.
INSPECT GROUND CIRCUIT FOR
VOLTAGE DROP
No
Inspect the PCM terminal 2AA (wiring harness-side) for rust or corrosion.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
• Inspect the resistance between TP sensor terminal A (wiring harness-side) and body ground.
• Is the resistance approx. 0 ohm ?
VERIFY TP SENSOR
• Does resistance smoothly change while gradually opening throttle valve?
• Repair or replace the terminal.
Go to Step 16.
Yes Go to the next step.
No Replace the TP sensor, then go to Step 16.
15
16
17
INSPECT PCM TERMINALS FOR
ELECTRICAL CORROSION
• Disconnect the PCM connector.
• Inspect the PCM and PCM connector male and female terminals for electrical corrosion.
• Is any electrical corrosion found?
Yes
No
Repair the terminal, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0121 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Verify TP PID reading is below 50% while
MAF PID is below 4.8 g/s {0.6 lb/min} and
RPM PID is above 500 rpm .
• Is the PENDING CODE for this DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Start the engine.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Access RPM, TP and MAF PIDs using WDS or equivalent.
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0122
DETECTION
CONDITION
DTC P0122 [LF]
B3E010201084W16
TP sensor circuit low input
• If the PCM detects the TP sensor voltage at PCM terminal 2I is below 0.1
V while the engine running to on, the PCM determines that the TP circuit has malfunction.
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction conditions in first drive cycles.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• TP sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between TP sensor terminal B and PCM terminal 2I
• Short to ground in wiring harness between TP sensor terminal B and PCM terminal 2I
• Open circuit in wiring harness between TP sensor terminal C and PCM terminal 2W
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
CLASSIFY TP SENSOR OR WIRING
HARNESS MALFUNCTION
• Connect the WDS or equivalent.
• Access the TP PID.
Yes Go to the next step.
• Disconnect the TP sensor connector.
• Connect a jumper wire between TP sensor terminals B and C (wiring harnessside).
• Is the voltage above 4.9 V ?
No Go to step 5.
INSPECT TP SENSOR
• Perform TP sensor inspection.
(See THROTTLE POSITION (TP)
SENSOR INSPECTION [LF] .)
• Is TP sensor normal?
Inspect TP sensor terminal C for poor
Yes connection. Repair or replace if necessary, then go to Step 7.
No Replace the TP sensor, then go to Step 7.
INSPECT POWER SUPPLY CIRCUIT
VOLTAGE AT TP SENSOR
CONNECTOR
Yes Go to the next step.
Note
• If DTC P0107 and P2228 are also retrieved with P0122, go to
CONSTANT VOLTAGE troubleshooting procedure.
• Turn the ignition switch to the ON position (Engine off).
• Inspect the voltage at TP sensor terminal
C (wiring harness-side).
• Is the voltage within 4.5- 5.5 V ?
No
Repair or replace open circuit in wiring harness between TP sensor connector terminal C and
PCM terminal 2W (wiring harness-side).
Then, go to Step 7.
VERIFY TP SIGNAL CIRCUIT FOR
SHORT TO GROUND
Yes
Repair or replace the wiring harness, then go to
Step 7.
• Inspect for continuity between TP sensor terminal B (harness-side) and body ground.
No Go to the next step.
• Is there continuity?
Yes Replace the PCM, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VERIFY TROUBLESHOOTING OF DTC
P0122 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
(See PCM REMOVAL/INSTALLATION [LF]
No Go to the next step.
.)
• Start the engine.
• Is the same DTC present?
8
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0123
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0123 [LF]
B3E010201084W17
TP sensor circuit high input
• If the PCM detects the TP sensor voltage at PCM terminal 2I is above 4.9
V while the engine is running, the PCM determines that the TP circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition in first drive cycles.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• TP sensor malfunction
• Connector or terminal malfunction
• Open circuit in wiring harness between TP sensor terminal A and PCM terminal 2AA
• Short to constant voltage supply circuit in wiring harness between TP sensor terminal B and PCM terminal 2I
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA
HAS BEEN RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
No
Perform repair or diagnosis according to the available
Yes repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
INSPECT TP SENSOR
CONNECTOR
• Turn the ignition switch off.
Yes Go to the next step.
• Verify that the TP sensor connector is connected securely.
No Connect the connector securely, then go to Step 11.
• Is connector normal?
INSPECT POOR CONNECTION OF
TP SENSOR CONNECTOR
Yes Repair or replace the terminal, then go to Step 11.
• Disconnect the TP sensor connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
10
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT TP SENSOR
• Perform TP sensor inspection.
(See THROTTLE POSITION (TP)
SENSOR INSPECTION [LF] )
• Is TP sensor normal?
Yes Go to the next step.
No Replace the TP sensor, then go to Step 11.
INSPECT TP SENSOR SIGNAL
CIRCUIT FOR SHORT TO POWER
SUPPLY
Yes
Repair or replace short to power supply. Then, go to
Step 11.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between terminal B and body ground.
• Is the voltage above 4.9 V ?
No Go to the next step.
VERIFY TP SIGNAL CIRCUIT FOR
OPEN CIRCUIT
Yes Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between TP sensor terminal B (wiring harnessside) and PCM terminal 2I.
• Is there continuity?
No
Repair or replace the wiring harness, then go to Step
11.
VERIFY TP SENSOR GROUND
CIRCUIT FOR OPEN CIRCUIT
• Inspect for continuity between TP sensor terminal A and body ground.
Repair or replace open circuit in wiring harness
Yes between TP sensor terminal A (wiring harness-side) and PCM terminal 2AA (wiring harness-side). Then, go to Step 11.
• Is there continuity?
No Go to the next step.
INSPECT PCM CONNECTOR
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes Repair terminal, then go to Step 11.
No Go to Step 11.
VERIFY TP SIGNAL CIRCUIT FOR
SHORT TO CONSTANT VOLTAGE
CIRCUIT
Yes
Repair or replace the wiring harness, then go to the next step.
• Inspect the continuity between TP sensor terminals B and C.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11
• Is there continuity?
VERIFY TROUBLESHOOTING OF
DTC P0123 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is same DTC present?
No Go to the next step.
12
VERIFY AFTER REPAIR
PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .) No Troubleshooting completed.
• Are any DTC present?
DTC P0125 [LF]
B3E010201084W18
DTC P0125
DETECTION
CONDITION
POSSIBLE
CAUSE
Excessive time to enter closed loop fuel control
• The PCM monitors the ECT sensor signal at PCM terminal 2AK after engine is started while the engine is cold. If the engine coolant temperature does not reach the expected temperature for specified period, the PCM determines that it has taken an excessive amount of time for the engine coolant temperature to reach the temperature necessary to start closed-loop fuel control.
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• ECT sensor malfunction
• Poor connection of connectors
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
7
Yes Go to the next step.
ACTION
No
Record FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS: IS CONCERN INTERMITTENT
OR CONSTANT
• Start the engine.
• Warm up the engine completely.
• Access ECT PID using the WDS or equivalent.
• Is ECT PID above 60 ° C {140 ° F} ?
Intermittent concern exists. Go to
INTERMITTENT CONCERNS
Yes
TROUBLESHOOTING procedure.
(See INTERMITTENT CONCERN
TROUBLESHOOTING [LF] .)
No Go to the next step.
INSPECT POOR CONNECTION OF ECT
SENSOR CONNECTOR
• Turn the ignition switch off.
• Disconnect the ECT sensor connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
Repair or replace the terminal, then go to Step
7.
No Go to the next step.
INSPECT ECT SENSOR
• Inspect the ECT sensor.
Yes Go to the next step.
(See ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION [LF] .)
No Replace the ECT sensor, then go to Step 7.
• Is it normal?
INSPECT POOR CONNECTION OF PCM
CONNECTOR
Yes
Repair or replace the terminal, then go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
Yes Replace the PCM, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
VERIFY TROUBLESHOOTING OF DTC
P0125 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
(See PCM REMOVAL/INSTALLATION [LF]
• Turn the ignition switch to the ON position
(Engine off).
No Go to the next step.
• Access ECT PID using the WDS or equivalent.
• Wait until ECT PID below 20 ° C {68 ° F} .
.)
• Start the engine and warm it up completely.
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0132
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0132 [LF]
B3E010201084W19
Front HO2S circuit high input
• The PCM monitors the input voltage from the front HO2S. If the input voltage from the front HO2S sensor is above 1.2 V for 0.8 s , the PCM determines that circuit input is high.
Diagnostic support note
• This is a continuous monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Front HO2S malfunction
• Short to power in wiring harness between front HO2S terminal A and PCM terminal 2AG
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Front HO2S or PCM terminal shorted
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING OR STORED
DTC
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify pending code or stored DTCs using the WDS or equivalent.
• Is other DTC present?
Yes
Go to the appropriate DTC troubleshooting procedures.
(See DTC TABLE [LF] .)
No Go to the next step.
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P0132 on FREEZE FRAME DATA?
No
Go to troubleshooting procedures for DTC on FREEZE FRAME DATA.
(See DTC TABLE [LF] .)
INSPECT FRONT HO2S SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between front HO2S terminal A (wiring harness-side) and body ground.
• Is any voltage reading?
Yes
No
Replace the wiring harness short to power supply, then go to Step 7.
Go to the next step.
VERIFY CURRENT INPUT SIGNAL STATUS
• Start the engine.
Yes
Repair or replace the sensor, then go to the next step.
• Access O2S12 PID using the WDS or equivalent.
• Verify PID while racing the engine at least 10 times in NEUTRAL.
No Go to the next step.
• Does PID remain above 0.45 V ?
VERIFY TROUBLESHOOTING OF DTC
P0132 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using the
WDS or equivalent.
• Run HO2S heater, HO2S, and TWC Repair
Verification Drive Mode.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0133 [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E010201084W20
DTC P0133
DETECTION
CONDITION
POSSIBLE
CAUSE
Front HO2S circuit problem
• The PCM monitors inversion cycle period, lean-to-rich response time and rich-to-lean response time of the sensor. The PCM calculates the average of the inversion cycle period-specified inversion cycles, average response time from lean-to-rich, and from rich-to-lean when following conditions are met. If any exceeds threshold, the PCM determines that circuit has malfunction.
MONITORING CONDITIONS
- HO2S heater, HO2S, and TWC Repair Verification Drive Mode
- Following conditions are met:
• Calculation load is 14.8-59.4 % (at 2,000 rpm ).
• Engine speed is 1,410- 4,000 rpm .
• Vehicle speed is above 3.76 km/h {2.33 mph} .
• Engine coolant temperature is above -10 ° C {14 ° F} .
• Front HO2S signal inversion cycle is above 10 cycles .
Diagnostic support note
• This is an intermittent monitor. (OXYGEN SENSOR)
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• DIAGNOSTIC MONITORING TEST RESULTS is available.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Front HO2S deterioration
• Front HO2S malfunction
• Looseness front HO2S
• Pressure regulator (built-in fuel pump unit) malfunction
• Fuel pump malfunction
• Fuel filter (built-in fuel pump unit) clogged or restricted
• Fuel leakage on fuel line from fuel distribution pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve malfunction
• Purge solenoid hoses improper connection
• Insufficient compression
• Engine malfunction (Leakage engine coolant)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
ACTION
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
• If vehicle is not repaired, go to the next step.
• Verify related service repair information availability.
• Is any related repair information available?
No Go to the next step.
3
4
5
6
VERIFY RELATED PENDING AND
STORED DTC
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify pending and /or stored DTCs using the WDS or equivalent.
Yes
Go to DTC P0443 troubleshooting procedures, then go to Step 13.
No Go to the next step.
• Is DTC P0443 also present?
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P0133 on FREEZE FRAME DATA?
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
(See DTC TABLE [LF] .)
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up the engine.
• Access O2S11 PID using WDS or equivalent.
• Inspect PID under following accelerator pedal conditions in NEUTRAL.
• Is PID normal?
- More than 0.55 V when suddenly depress accelerator pedal (rich condition).
- Less than 0.55 V just after release of accelerator pedal (lean condition).
Yes Go to step 8.
No Go to the next step.
Yes Go to the next step.
INSPECT INSTALLATION OF FRONT
HO2S
• Inspect if the front HO2S is loosely installed.
No Retighten the sensor, then go to Step 13.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
11
• Is the sensor installed securely?
INSPECT GAS LEAKAGE FROM
EXHAUST SYSTEM
Yes
Repair or replace malfunctioning faulty exhaust part, then go to Step 13.
• Visually inspect if there is any gas leakage is found between the exhaust manifold and front HO2S.
No Replace sensor, then go to Step 13.
• Is there gas leakage?
INSPECT LONG TERM FUEL TRIM
• Access LONGFT1 PIDs
• Compare it with FREEZE FRAME DATA recorded at Step 1.
• Is it below FFD value?
Yes
No
Engine is driven under rich condition. Go to the next step.
Engine is driven under lean condition. Go to step 10.
Yes Go to step 12.
INSPECT FUEL LINE PRESSURE
(Excessive fuel line pressure)
• Turn the ignition switch off.
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is the fuel line pressure normal?
Inspect fuel pump maximum pressure and fuel return pipe for clogging.
(See FUEL PUMP UNIT INSPECTION
Then go to Step 13.
.)
No
• If there is any problem, repair or replace the parts.
• If all items above are normal, replace fuel pump unit.
INSPECT FUEL LINE PRESSURE (Low fuel line pressure)
• Turn the ignition switch off.
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
Yes
No
Go to step 12.
Go to the next step.
Yes Replace the fuel line, then go to Step 13.
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect the fuel line for any leakage.
• Is there any fuel leakage?
Inspect the fuel filters for the following:
• Foreign materials or stain inside fuel filter
(low-pressure side)
No
Perform the following actions according to the result.
• If foreign material or stain is found inside fuel filter (low-pressure side), clean the fuel tank and filter.
• If normal, replace fuel pump unit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
Then go to Step 13.
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
Yes Go to the next step.
• Perform inspection engine coolant leakage.
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
No
Repair or replace the malfunctioning part according to inspection result.
Then go to the next step.
• Is there any malfunction?
VERIFY TROUBLESHOOTING OF DTC
P0133 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using
WDS or equivalent.
• Perform the HO2S heater, HO2S, and
TWC Repair Verification Drive Mode.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
14
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0134
DETECTION
CONDITION
DTC P0134 [LF]
B3E010201084W21
Front HO2S no activity detected
• The PCM monitors the input voltage from the front HO2S when the following conditions are met. If the input voltage from the sensor never exceeds 0.55 V for 83.2 s , the PCM determines that sensor circuit is not activated.
MONITORING CONDITIONS
- HO2S, HO2S heater and TWC Repair Verification Drive Mode
- Following conditions are met
• Engine speed is above 1,500 rpm .
• Engine coolant temperature is above 70 ° C {158 ° F} .
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (HO2S).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Front HO2S deterioration
• Front HO2S heater malfunction
• Leakage exhaust system
• Open circuit or short to ground in wiring harness t between front HO2S terminal A and PCM terminal 2AG
• Insufficient compression
• Engine malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
No
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING AND
STORED DTC
Yes
Go to the appropriate DTC troubleshooting procedures.
Note
• If fuel monitor DTC, DTC P0132 is retrieved, ignore it until P0134 is fixed.
• Turn the ignition switch off, then to the ON position (Engine off).
No Go to the next step.
• Verify pending and stored DTCs using the
WDS or equivalent.
• Is other DTC present?
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P0134 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
(See DTC TABLE [LF] .)
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up engine.
• Access O2S11 PID using WDS or equivalent.
• Verify PID while racing engine in
NEUTRAL.
• Is PID normal?
- More than 0.55 V when suddenly depressing accelerator pedal (rich condition)
- Less than 0.55 V just after releasing the of accelerator pedal
(lean condition)
Yes Go to step 8.
No Go to the next step.
Yes Go to the next step.
INSPECT INSTALLATION OF FRONT
HO2S
• Inspect if the front HO2S is loosely installed.
• Is the sensor installed securely?
No Install sensor securely, then go to Step 10.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
11
Yes
Repair or replace any malfunctioning exhaust part, then go to Step 10.
INSPECT GAS LEAKAGE FROM
EXHAUST SYSTEM
• Inspect the following harnesses for open circuit or short to ground, repair or replace wiring harness if necessary.
• Visually inspect if the re is any gas leakage between the exhaust manifold and front HO2S.
No
• Is there gas leakage?
- Front HO2S terminal A (wiring harness-side) to PCM terminal 2AG
(wiring harness-side)
• Repair or replace wiring harness if necessary.
• If all items above are normal, replace malfunctioning sensor.
Then go to Step 10.
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
• Perform the ENGINE COOLANT
LEAKAGE INSPECTION. (See ENGINE
COOLANT LEAKAGE INSPECTION .)
• Is there any malfunction?
Repair or replace the malfunctioning part
Yes according to inspection results, then go to Step
10.
No Go to the next step.
INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect engine compression.
(See COMPRESSION INSPECTION [LF] .)
No
Perform engine overhaul for repairs, then go to the next step.
• Is it normal?
VERIFY TROUBLESHOOTING OF DTC
P0134 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear the DTC from memory using the
WDS or equivalent.
• Perform the HO2S heater, HO2S, and
TWC Repair Verification Drive Mode.
No Go to the next step.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0138 [LF]
B3E010201084W22
DTC P0138 Rear HO2S circuit high input
DETECTION
CONDITION
• The PCM monitors input voltage from rear HO2S. If the input voltage from the rear HO2S sensor is above 1.2 V for 0.8 s , the PCM determines that circuit input is high.
Diagnostic support note
• This is a continuous monitor (HO2S).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
POSSIBLE CAUSE
• Rear HO2S malfunction
• Short to power supply in wiring harness between rear HO2S terminal A and
PCM terminal 2AH
• Rear HO2S or PCM terminal shorted
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
4
5
6
7
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING OR STORED
DTC
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify pending code or stored DTCs using
WDS or equivalent.
• Is other DTC present?
Yes
Go to the appropriate DTC troubleshooting procedures.
(See DTC TABLE [LF] .)
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P0138 on FREEZE FRAME DATA?
No
Go to troubleshooting procedures for DTC on FREEZE FRAME DATA.
(See DTC TABLE [LF] .)
INSPECT REAR HO2S SIGNAL CIRCUIT
FOR SHORT TO POWER SUPPLY
• Turn the ignition switch off.
• Disconnect rear HO2S connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between rear HO2S terminal A (wiring harness-side) and body ground.
• Is any voltage reading?
Yes
No
Replace short to power supply, then go to
Step 7.
Go to the next step.
VERIFY CURRENT INPUT SIGNAL STATUS
• Start engine.
Yes
Repair or replace sensor, then go to the next step.
• Access O2S12 PID using WDS or equivalent.
No Go to the next step.
• Verify PID while racing engine at least 10 times in NEUTRAL.
• Does PID stay above 0.55 V ?
Yes Replace the PCM, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VERIFY TROUBLESHOOTING OF DTC
P0138 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using the
WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
8
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
DTC P0140
DETECTION
CONDITION
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0140 [LF]
B3E010201084W23
Rear HO2S no activity detected
• The PCM monitors the input voltage from the rear HO2S when the following conditions are met. If the input voltage from the sensor never exceeds 0.55
V for 30.4 s , the PCM determines that the sensor circuit is not activated.
MONITORING CONDITIONS
- HO2S, HO2S heater and TWC Repair Verification Drive Mode
- Following conditions are met:
• Engine speed is above 1,500 rpm .
• Engine coolant temperature is above 70 ° C {158 ° F} .
Diagnostic support note
• This is a continuous monitor (HO2S).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• Rear HO2S deterioration
• Rear HO2S heater malfunction
• Leakage exhaust system
• Open circuit or short to ground in wiring harness between rear HO2S terminal A and PCM terminal 2AH
• Insufficient compression
• Engine malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING AND STORED
DTC
Go to the appropriate DTC troubleshooting
Yes procedures.
(See DTC TABLE [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
Note
• If fuel monitor DTC, DTC P0132 is retrieved, ignore it until P0140 is fixed.
• Turn the ignition switch off, then to the ON position (Engine off).
• Verify pending and stored DTCs using WDS or equivalent.
• Is other DTC present?
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P0140 on FREEZE FRAME DATA?
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
(See DTC TABLE [LF] .)
Yes Go to step 8.
VERIFY CURRENT INPUT SIGNAL
STATUS
• Warm up the engine.
• Access O2S12 for P0140 PID using the
WDS or equivalent.
• Verify PID while racing the engine at least 10 times in NEUTRAL.
• Is PID reading normal?
- More than 0.55 V at least once during engine racing
No Go to the next step.
INSPECT INSTALLATION OF REAR HO2S Yes Go to the next step.
• Check if rear HO2S is loosely installed.
• Is sensor installed securely?
No Install sensor securely, then go to Step 10.
Yes
Repair or replace any malfunctioning exhaust part, then go to Step 10.
INSPECT GAS LEAKAGE FROM EXHAUST
SYSTEM
• Visually check if any gas leakage is found between exhaust pipe and rear HO2S.
• Is there any gas leakage?
No
• Inspect the following wiring harnesses for open or short to ground circuit, repair or replace wiring harness if necessary.
- Rear HO2S terminal A (wiring harness-side) to PCM terminal 2AH
(wiring harness-side)
• Repair or replace wiring harness if necessary.
• If all items above are normal, replace malfunctioning sensor.
Then go to Step 10.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
INSPECT SEALING OF ENGINE COOLANT
PASSAGE
Warning
Air gets in from poor sealing on head gasket or other areas between combustion chamber
Yes and engine coolant passage.
• Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.
Repair or replace the malfunctioning part, then go to Step 10.
• When removing the radiator cap, wrap a thick cloth around and turn it slowly.
• Remove radiator cap.
• Perform procedure to bleed air from the engine coolant, then run the engine at idle.
• Is there any small bubble, which makes the engine coolant white at filling opening?
No Go to the next step.
Note
• Large bubbles are normal since they are remaining air coming out from the engine coolant passage.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION [LF] .)
• Is it normal?
Yes Go to the next step.
No
Perform engine overhaul for repairs, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0140 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using the
WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode.
No Go to the next step.
.)
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0300 [LF]
B3E010201085W01
DTC P0300 Random misfire detected
DETECTION
CONDITION
• The PCM monitors CKP sensor input signal interval time. The PCM calculates change of interval time for each cylinder. If change of interval time exceeds preprogrammed criteria, the PCM detects misfire in the corresponding cylinder. While the engine is running, the PCM counts number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions and calculates misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the PCM determines that a misfire, which can damage catalytic converter or affect emission performance, has occurred.
Diagnostic support note
• This is a continuous monitor (MISFIRE).
• MIL illuminates if the PCM detects the misfire which affects emission performance in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• The MIL flashes if the PCM detects the misfire which can damage the catalytic converter during first drive cycle. Therefore, PENDING CODE is not available while the
MIL flashes.
• PENDING CODE is available if the PCM detects the misfire which affects emission performance during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
POSSIBLE
CAUSE
• CKP sensor malfunction
• CMP sensor malfunction
• Ignition coil malfunction
• Erratic signal to ignition coil
• Spark plug malfunction
• MAF sensor contamination
• Excess air suction in intake air system (between MAF sensor and intake manifold)
• Fuel pump malfunction
• Fuel pressure regulator (built-in fuel pump unit) malfunction
• Fuel line clogged
• Fuel filter clogged
• Fuel leakage in fuel line
• Fuel runout
• Poor quality fuel
• Purge control solenoid valve malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• PCV valve malfunction
• EGR valve malfunction
• Vacuum hoses damages or improper connection
• Related connector and terminal malfunction
• Related wiring harness malfunction
• Insufficient compression
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
4
5
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE
OR STORED DTC
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Are other DTCs present?
Yes
Go to the appropriate DTC troubleshooting.
(See DTC TABLE [LF] .)
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON/IDLE)
• Access BOO, ECT, IAT, MAF, RPM,
TP, and VSS PIDs using WDS or equivalent.
Yes
Inspect suspected circuit and/or part according to inspection results.
(See PCM INSPECTION [LF] .)
Then go to Step 21.
(See PCM INSPECTION [LF] .)
• Is there any signal that is far out of specification when the ignition switch is turned to the ON position and the engine idles?
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE
CONDITION
Yes
Inspect suspected circuit and/or part according to inspection results.
(See PCM INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
9
10
11
• Inspect the same PIDs as in Step 4 while simulating FREEZE FRAME DATA condition.
Then go to Step 21.
• Is there any signal which causes drastic changes?
No Go to the next step.
Yes Go to the next step.
INSPECT CMP SENSOR
• Inspect CMP sensor.
(See CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [LF] .)
• Is CMP sensor normal?
No
Inspect installation condition and damages on timing belt and gears, repair the malfunctioning part.
• If it is normal, replace the CMP sensor.
Then go to Step 21.
VERIFY CKP SENSOR INSTALLATION
CONDITION
Yes Retighten the CKP sensor, then go to Step 21.
• Inspect for CKP sensor looseness.
No Go to the next step.
• Is CKP sensor loosen?
INSPECT IGNITION COIL WIRING
HARNESSES
• Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
• Are wiring harness conditions normal?
Yes Go to the next step.
No Repair the wiring harnesses, then go to Step 21.
Yes Go to the next step.
INSPECT IGNITION SYSTEM
OPERATION
• Turn the ignition switch off.
• Perform spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
No
Repair or replace the malfunctioning part according to spark test result.
Then go to Step 21.
INSPECT POWER SUPPLY TERMINAL
AT IGNITION COIL CONNECTOR
Yes Go to the next step.
• Disconnect the ignition coil connector.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between ignition coil terminal A (wiring harness-side) and body ground.
No
Inspect for open circuit in wiring harness between ignition coil terminal A and ignition switch. Repair or replace the wiring harness, then go to Step 21.
• Is the voltage reading B+ ?
Yes Go to step 21.
INSPECT IGNITION COIL
RESISTANCE
• Inspect ignition coil resistance.
No Replace the ignition coil, then go to Step 21.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
(See IGNITION COIL INSPECTION
[LF] .)
• Is coil resistance normal?
INSPECT MAF PID
• Start the engine.
• Access MAF PID using the WDS or equivalent.
• Race the engine and verify that MAF
PID changes quickly according to change in the engine speed.
• Is MAF PID response normal?
Yes
No
Go to the next step.
Replace the MAF sensor, then go to Step 21.
INSPECT EXCESSIVE AIR SUCTION
IN INTAKE AIR SYSTEM
• Inspect for air leakage at following:
- Between the MAF sensor and throttle body
- Between throttle body and intake manifold
• Is there any malfunction?
Yes
Repair or replace suspected part, then go to Step
21.
No Go to the next step.
INSPECT FUEL LINE PRESSURE
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
Yes Go to step 16.
No
If the fuel line pressure is too low, go to the next step.
If the fuel line pressure is excess high, replace the fuel pump unit, then go to Step 21.
INSPECT FUEL LINE FROM FUEL
PUMP TO FUEL DELIVERY PIPE
• Visually inspect fuel line for fuel leakage.
• Is there any fuel leakage?
Yes Replace suspected fuel line, then go to Step 21.
Inspect fuel filters for following:
• Foreign materials or stain inside fuel filter (lowpressure side)
No
Perform following actions depend on the result above.
• If foreign materials or stain is found inside fuel filter (low-pressure side), clean the fuel tank and filter (low-pressure side).
• If normal, replace the fuel pump unit.
Then, go to Step 21.
Yes Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION
[LF] .)
No
Perform engine overhaul for repairs, then go to
Step 21.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
17
18
19
20
• Is it normal?
INSPECT OPERATION OF PURGE
CONTROL SOLENOID VALVE
• Turn the ignition switch off.
• Connect the vacuum pump to purge control solenoid valve and apply vacuum to solenoid.
• Verify that solenoid holds vacuum.
• Turn the ignition switch to the ON position (Engine off).
Yes Go to the next step.
• Access EVAPCP PID in SIMULATION
TEST using the WDS or equivalent.
• Set duty value to 100% for EVAPCP
PID.
• Apply vacuum while turning solenoid from OFF to ON and simulating EVAPCP
PID with 100% duty value.
No
Replace the purge control solenoid valve, then go to Step 21.
• Verify that solenoid releases vacuum while solenoid is turned ON.
• Is purge control solenoid valve operation normal?
INSPECT PCV VALVE OPERATION
• Turn the ignition switch off.
• Remove PCV valve and inspect valve operation.
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is PCV valve operation normal?
Yes Replace the PCV valve, then go to Step 21.
No Go to the next step.
INSPECT OPERATION OF EGR VALVE
Yes
• Remove the EGR valve.
Repair or replace the EGR valve, then go to Step
21.
• Visually inspect the EGR valve for stuck to open.
No Go to the next step.
• Is EGR valve stuck to open?
Yes Go to the next step.
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
• Perform engine coolant leakage inspection.
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
• Is there any malfunction?
No
Repair or replace the malfunctioning part according to inspection result.
Then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
21
22
VERIFY TROUBLESHOOTING OF
MISFIRE DTC COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the memory using the WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode. (See OBD DRIVE
MODE [LF] .)
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
No Go to the next step.
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0301, P0302, P0303, P0304 [LF]
B3E010201085W02
DTC P0301
DTC P0302
DTC P0303
DTC P0304
DETECTION
CONDITION
Cylinder No.1 misfire detected
Cylinder No.2 misfire detected
Cylinder No.3 misfire detected
Cylinder No.4 misfire detected
• The PCM monitors CKP sensor input signal interval time. The PCM calculates the change of interval time for each cylinder. If the change of interval time exceeds the preprogrammed criteria, the PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions and calculates misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can damage catalytic converter or affect emission performance, has occurred.
Diagnostic support note
• This is a continuous monitor (MISFIRE).
• The MIL illuminates if the PCM detects the misfire which affects emission performance in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• The MIL flashes if the PCM detects the misfire which can damage the catalytic converter during first drive cycle. Therefore, PENDING CODE is not available while the
MIL flashes.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• PENDING CODE is available if the PCM detects the misfire which affects emission performance during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Spark plug malfunction
• Erratic signal to ignition coil
• Fuel injector malfunction
• Air suction in intake air system (between dynamic chamber and cylinder head)
• Inadequate engine compression due to engine internal malfunction
• Related connector or terminal malfunction
• Related wiring harness malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then to the
ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Is other DTCs present?
Yes
Go to the appropriate DTC troubleshooting.
(See DTC TABLE [LF] .)
No Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON /IDLE)
• Access BOO, ECT, IAT, MAF, RPM, TP and VSS PIDs using WDS or equivalent.
Yes
Inspect suspected circuit and/or part according to inspection results. Then go to Step 13.
(See PCM INSPECTION [LF]
(See PCM INSPECTION [LF] .)
• Is there any signal that is far out of specification when ignition switch is turned to the ON position and engine idles?
No Go to the next step.
.)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as in Step 4 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected circuit and/or part according to inspection results. Then go to Step 13.
(See PCM INSPECTION [LF] .)
• Is there any signal which causes drastic changes?
No Go to the next step.
INSPECT SPARK PLUG CONDITION
• Turn the ignition switch off.
• Remove spark plug from suspected cylinder.
• Inspect spark plug condition:
- Cracks
- Excess wear
- Gap
- Wet
• Is any problem found on spark plug?
• If spark plug is wet, fuel flooding is suspected.
Go to step 13.
Yes • If spark plug has a cracks, excessive wear or improper gap, replace the malfunctioning spark plug. Then go to Step 13.
No Go to the next step.
Yes Go to the next step.
INSPECT IGNITION COIL WIRING
HARNESSES
• Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
• Are wiring harness conditions normal?
No
Repair the wiring harnesses, then go to Step
13.
INSPECT FOR AIR SUCTION AT
INTAKE-AIR SYSTEM
• Inspect for air leakage at following:
- Around connection of dynamic chamber and intake manifold
- Around connection of intake manifold and cylinder head
• Is air leakage found?
Yes
No
Repair or replace suspected part, then go to
Step 13.
Go to the next step.
INSPECT FUEL INJECTOR WIRING
HARNESS
• Remove intake air system parts.
Yes Go to the next step.
• Disconnect the fuel injector connector on suspected cylinder.
• Connect NOID LIGHT to fuel injector terminals.
Inspect for fuel injector wiring harnesses.
No
Repair or replace it if necessary, then go to
Step 13.
• Inspect dim of light during cranking.
• Does noid light illuminate?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
14
INSPECT SEALING OF ENGINE
COOLANT PASSAGE
• Perform ENGINE COOLANT LEAKAGE
INSPECTION.
Yes
Repair or replace the malfunctioning part according to inspection result.
Then go to Step 13.
(See ENGINE COOLANT LEAKAGE
INSPECTION .)
• Is there any malfunction?
No Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
Yes Go to the next step.
(See COMPRESSION INSPECTION [LF] .)
No Overhaul the engine, then go to Step 13.
• Is engine compression normal?
INSPECT FUEL INJECTOR OPERATION Yes Replace the injector, then go to the next step.
• Remove the fuel injector from suspected cylinder.
• Switch the injector with the injector on other cylinder.
• Start the engine and idle it.
No Go to the next step.
• Is misfire DTC for cylinder which has a suspected fuel injector?
VERIFY TROUBLESHOOTING OF
MISFIRE DTC COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start the engine.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode. (See OBD DRIVE
MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0327 [LF]
B3E010201085W03
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0327
DETECTION
CONDITION
POSSIBLE CAUSE
KS circuit low input
• The PCM monitors input signal from the KS when the engine is running. If the input voltage at PCM terminals between 2Q and 2R is below 0.9 V , the
PCM determines that the KS circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• KS malfunction
• Connector or terminal malfunction
• Open circuit or short to ground in wiring harness between KS connector terminal A and PCM terminal 2Q
• Open circuit or short to ground in wiring harness between KS connector terminal B and PCM terminal 2R
• Short KS two wires
Diagnostic procedure
STEP
1
INSPECTION ACTION
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the available repair information.
Yes
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT KS CONNECTOR TERMINAL
• Turn the ignition switch off.
• Disconnect the KS connector.
• Inspect for poor connection at terminals A and B (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes Repair the terminal, then go to Step 9.
No Go to the next step.
INSPECT KS
• Perform KS inspection.
(See KNOCK SENSOR (KS) INSPECTION
[LF] )
• Is KS normal?
Yes
No
Go to the next step.
Replace the KS, then go to Step 9.
INSPECT KS CIRCUITS FOR OPEN
CIRCUIT
• Disconnect the PCM connector.
• Inspect for continuity between the following terminals:
- KS female terminal A (wiring harness-side) and PCM terminal 2Q
(wiring harness-side)
- KS female terminal B (wiring harness-side) and PCM terminal 2R
(wiring harness-side)
• Are there continuities?
Yes Go to the next step.
No
Repair or replace the wiring harness, then go to Step 9.
INSPECT KS CIRCUITS FOR SHORT TO
GROUND
• Inspect the continuity between following terminals:
- KS female terminal A (wiring harness-side) and body ground
- KS female terminal B (wiring harness-side) and body ground
Yes
Repair or replace suspected wiring harness, then go to Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
9
10
• Are there continuities?
INSPECT FOR SHORT CIRCUITS
• Inspect for continuity between KS female terminals A and B (wiring harness-side).
• Is there continuity?
Yes
No
Repair or replace the wiring harness, then go to Step 9.
Go to the next step.
INSPECT PCM CONNECTOR TERMINAL
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection at terminals 2Q and 2R (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes Repair terminal, then go to Step 9.
No Go to the next step.
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
VERIFY TROUBLESHOOTING OF DTC
P0327 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the memory using the
WDS or equivalent.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No
Yes
No
Go to the next step.
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
Troubleshooting completed.
DTC P0328
DETECTION
CONDITION
DTC P0328 [LF]
B3E010201085W04
KS circuit high input
• The PCM monitors the input signal from the KS when the engine is running.
If the input voltage at PCM terminals between 2Q and 2R is above 4.9 V , the
PCM determines that KS circuit has a malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction conditions during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• KS malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between KS terminal A and PCM terminal 2Q
• Short to power supply in wiring harness between KS terminal B and PCM terminal 2R
Diagnostic procedure
STEP INSPECTION
1
2
3
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
INSPECT KS CONNECTOR TERMINAL
• Turn the ignition switch off.
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes Repair the terminal, then go to step 7.
No Go to the next step.
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4
5
6
7
8
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Disconnect KS connector.
• Inspect for poor connection at terminals A and B
(such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT KS
• Perform KS inspection.
(See KNOCK SENSOR (KS) INSPECTION [LF] )
• Is the KS normal?
Yes Go to the next step.
No Replace the KS, then go to step 7.
INSPECT KNOCK SIGNAL CIRCUIT FOR
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between KS terminal A
(wiring harness-side) and body GND and KS terminal B (wiring harness-side) and body GND?
• Is any voltage reading?
Yes
Repair or replace wiring harness for short to power supply, then go to step 7.
No Go to the next step.
INSPECT PCM CONNECTOR
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
Yes
No
Repair or replace the terminal, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC P0328
COMPLETED
• Make sure to connect all disconnected connectors.
• Clear the DTC from the PCM memory using the
WDS or equivalent.
• Start the engine.
• Is the same DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No
Go to the applicable DTC
Yes troubleshooting.
(See DTC TABLE [LF] .)
Troubleshooting completed.
DTC P0335 [LF]
B3E010201085W05
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P0335
DETECTION
CONDITION
POSSIBLE CAUSE
CKP sensor circuit problem
• If the PCM does not receive input voltage from the CKP sensor for 4.2 s while MAF is 2.0 g/s {0.26 lb/min} or above , the PCM determines that the
CKP sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if PCM detects the above malfunction conditions during first drive cycle.
• PENDING CODE is available if PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• CKP sensor malfunction
• Connector or terminal malfunction
• CKP sensor is dirty
• Short to power supply in wiring harness between CKP sensor terminal A to
PCM terminal 2Y
• Short to power supply in wiring harness between CKP sensor terminal B to
PCM terminal 2Z
• Short to ground in wiring harness between CKP sensor terminal A to PCM terminal 2Y
• Short to ground in wiring harness between CKP sensor terminal B to PCM terminal 2Z
• Open circuit in wiring harness between CKP sensor terminal A to PCM terminal 2Y
• Open circuit in wiring harness between CKP sensor terminal B to PCM terminal 2Z
• CKP sensor pulse wheel malfunction
• Both CKP sensor wires are shorted each other
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY CKP SENSOR VOLTAGE
• Disconnect the CKP sensor connector.
• Connect voltmeter between CKP sensor terminals A and B (sensor-side).
No Go to Step 10.
• Inspect the voltage in AC range while cranking the engine.
• Is any voltage reading?
Yes Go to the next step.
INSPECT POOR CONNECTION OF CKP
SENSOR CONNECTOR
Yes Go to the next step.
No Reconnect the connector, then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Verify that the CKP sensor connector is connected securely.
• Is the connector normal?
INSPECT CKP CIRCUIT FOR SHORT
TO POWER
• Turn the ignition switch to off.
Yes
Repair or replace the wiring harness, then go to
Step 11.
• Disconnect the CKP sensor connector.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between following terminals
No Go to the next step.
- CKP sensor terminal A
- CKP sensor terminal B
• Is any voltage reading?
INSPECT CKP CIRCUIT FOR SHORT
TO GROUND
• Inspect for continuity between following terminal and body ground:
Yes
Repair or replace the wiring harness, then go to
Step 11.
- CKP sensor terminal A (wiring harness-side)
- CKP sensor terminal B (wiring harness-side)
• Is there continuity?
No Go to the next step.
INSPECT CKP CIRCUITS FOR SHORTS
• Inspect for continuity between CKP
Yes
Repair or replace the wiring harness, then go to
Step 11.
sensor terminals A and B (wiring harnessside).
No Go to the next step.
• Is there continuity?
Yes Repair the terminal, then go to Step 11.
INSPECT POOR CONNECTION OF
PCM CONNECTOR
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT CKP CIRCUIT FOR OPEN
CIRCUIT
• Inspect for continuity between following terminals:
Yes Go to Step 11.
No
Repair or replace the suspected wiring harness, then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
- CKP sensor terminal A (wiring harness-side) and PCM terminal
2Y (wiring harness-side)
- CKP sensor terminal B (wiring harness-side) and PCM terminal
2Z (wiring harness-side)
• Is there continuity?
INSPECT CKP SENSOR
• Turn the ignition switch off.
• Perform CKP sensor inspection.
(See CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION [LF] )
• Is CKP sensor normal?
Yes Go to the next step.
No
Inspect the CKP sensor pulse wheel for damage.
Replace the CKP sensor pulse wheel and go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0335 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start engine.
• Access MAF PID using the WDS or equivalent.
No Go to the next step.
Note
• MAF PID should indicate 2.0 g/s
{0.26 lb/min} or above during this test
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0340 [LF]
B3E010201085W06
DTC P0340 CMP sensor circuit problem
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors input voltage from CMP sensor when engine is running.
If the PCM does not receive input voltage from CMP sensor while the PCM receives input signal from CKP sensor, PCM determines that CMP circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• CMP sensor malfunction
• Connector or terminal malfunction
• CMP sensor is dirty
• Short to power supply in wiring harness between CMP sensor terminal A and PCM terminal 2V
• Short to power supply in wiring harness between CMP sensor terminal B and PCM terminal 2U
• Short to ground in wiring harness between CMP sensor terminal A and
PCM terminal 2V
• Short to ground in wiring harness between CMP sensor terminal B and
PCM terminal 2U
• Open circuit in wiring harness between CMP sensor terminal A and PCM terminal 2V
• Open circuit in wiring harness between CMP sensor terminal B and PCM terminal 2U
• CKP sensor pulse wheel malfunction
• Both CMP sensor wires are shorted each other
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY CMP SENSOR VOLTAGE
• Disconnect the CMP sensor connector.
Yes Go to the next step.
• Connect voltmeter between CMP sensor terminals A and B (sensor-side).
No Go to step 10.
• Inspect the voltage in AC range while cranking the engine.
• Is any voltage reading?
INSPECT POOR CONNECTION OF CMP
SENSOR CONNECTOR
Yes Go to the next step.
No Reconnect the connector, then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
• Verify that the CMP sensor connector is connected securely.
• Is the connector normal?
INSPECT CMP CIRCUIT FOR SHORT TO
POWER
Yes
Repair or replace the wiring harness, then go to
Step 11.
• Turn the ignition switch to off.
• Disconnect the CMP sensor connector.
• Turn the ignition switch to the ON position
(Engine off).
No Go to the next step.
• Measure the voltage at CMP sensor terminals A and B.
• Is any voltage reading?
INSPECT CMP CIRCUIT FOR SHORT TO
GROUND
Yes
Repair or replace the suspected wiring harness, then go to Step 11.
• Inspect for continuity between following terminal and body ground:
- CMP sensor terminal A (wiring harness-side)
No Go to the next step.
- CMP sensor terminal B (wiring harness-side)
• Is there continuity?
INSPECT CMP CIRCUIT FOR SHORT
• Inspect continuity between CMP sensor terminals A and B (wiring harness-side).
• Is there continuity?
Yes
Repair or replace the wiring harness, then go to
Step 11.
No Go to the next step.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
Yes Repair the terminal, then go to Step 11.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
Yes Go to Step 11.
INSPECT CMP CIRCUIT FOR OPEN
CIRCUIT
• Inspect for continuity between following terminals:
- CMP sensor terminal A (wiring harness-side) and PCM terminal
2V (wiring harness-side)
No
Repair or replace the suspected wiring harness, then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
- CMP sensor terminal B (wiring harness-side) and PCM terminal
2U (wiring harness-side)
• Is there continuity?
INSPECT CMP SENSOR
• Turn the ignition switch off.
• Perform CMP sensor inspection.
(See CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [LF] .)
• Is the CMP sensor normal?
Yes
No
Go to the next step.
Inspect the CMP sensor pulse wheel for damage. Replace CMP sensor pulse wheel and go to step 10.
VERIFY TROUBLESHOOTING OF DTC
P0340 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start engine.
• Access MAF PID using the WDS or equivalent.
No Go to the next step.
Note
• MAF PID should indicate 1.95 g/s {0.25 lb/min} or above during this test.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0403
DETECTION
CONDITION
DTC P0403 [LF]
B3E010201086W01
EGR valve (stepper motor) circuit problem
• The PCM monitors the input voltage from EGR valve. If voltage at PCM terminals 2AU, 2AR, 2AY and/or 2AV remain low or high, the PCM determines that the EGR valve circuit has malfunction.
Diagnostic support note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• EGR valve malfunction
• Connector or terminal malfunction
• Short to power supply in wiring harness between EGR valve terminal E and
PCM terminal 2AU
• Short to power supply in wiring harness between EGR valve terminal A and
PCM terminal 2AR
• Short to power supply in wiring harness between EGR valve terminal B and
PCM terminal 2AY
• Short to power supply in wiring harness between EGR valve terminal F and
PCM terminal 2AV
• Short to ground circuit in wiring harness between EGR valve terminal E and
PCM terminal 2AU
• Short to ground circuit in wiring harness between EGR valve terminal A and
PCM terminal 2AR
• Short to ground circuit in wiring harness between EGR valve terminal B and
PCM terminal 2AY
• Short to ground circuit in wiring harness between EGR valve terminal F and
PCM terminal 2AV
• Open circuit in wiring harness between EGR valve terminal E and PCM terminal 2AU
• Open circuit in wiring harness between EGR valve terminal A and PCM terminal 2AR
• Open circuit in wiring harness between EGR valve terminal B and PCM terminal 2AY
• Open circuit in wiring harness between EGR valve terminal F and PCM terminal 2AV
• Open circuit in wiring harness between main relay terminal D and EGR valve terminal C
• Open circuit in wiring harness between main relay terminal D and EGR valve terminal D
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
Yes Go to the next step.
ACTION
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF EGR
VALVE
Yes
Repair or replace the terminals and/or connector, then go to Step 10.
• Turn the ignition switch off.
• Disconnect EGR valve connector.
No Go to the next step.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
INSPECT POWER CIRCUIT FOR OPEN
CIRCUIT
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage following terminal and body ground.
- EGR valve terminal C
- EGR valve terminal D
• Is the voltage B+ ?
Yes Go to the next step.
No
Repair or replace harness for open circuit then go to Step 10.
INSPECT EGR VALVE
• Perform EGR valve inspection.
(See EGR VALVE INSPECTION .)
• Is EGR valve normal?
Yes Go to the next step.
No Replace the EGR valve, then go to Step 10.
INSPECT FOR CONTROL CIRCUIT FOR
SHORT TO GROUND
Yes
Repair or replace wiring harness for short to ground, then go to Step 10.
• Turn the ignition switch off.
• Inspect for continuity following terminal and body ground:
- EGR valve terminal E
- EGR valve terminal A
No Go to the next step.
- EGR valve terminal B
- EGR valve terminal F
• is there continuity?
INSPECT FOR CONTROL CIRCUIT FOR
SHORT TO POWER
Yes
Repair or replace wiring harness for short to power supply, then go to Step 10.
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage following terminal and body ground:
- EGR valve terminal E
No Go to the next step.
- EGR valve terminal A
- EGR valve terminal B
- EGR valve terminal F
• Is the voltage B+ ?
INSPECT POOR CONNECTION OF PCM
• Turn the ignition switch off.
Yes
Repair or replace the terminals and/or connector, then go to Step 10.
• Disconnect the PCM connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
11
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
INSPECT CONTROL CIRCUIT FOR
OPEN CIRCUIT
• Inspect for continuity following terminals:
Yes Go to the next step.
- Between EGR valve terminal E and PCM terminal 2AU
- Between EGR valve terminal A and PCM terminal 2AR
- Between EGR valve terminal B and PCM terminal 2AY
- Between EGR valve terminal F and PCM terminal 2AV
• Is there continuity?
No
Repair or replace the wiring harness for open circuit then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0403 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear The DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0420 [LF]
B3E010201086W02
P0420 Catalyst system efficiency below threshold
DETECTION
CONDITION
• The PCM compares the number of front HO2S and rear HO2S inversions for a predetermined time. The PCM monitors number of inversions rear HO2S performs while front HO2S inverts for a specified number of times when the following monitoring conditions are met. The PCM detects inversion ratio. If the inversion ratio is below threshold, the PCM determine that catalyst system has deteriorated.
MONITORING CONDITION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
- Engine speed is 1,410- 3,100 rpm .
- Calculated TWC temperature in PCM is above 574 ° C {1065 ° F} .
- Calculated load is 15- 50% (at 2,000 rpm )
Diagnostic support note
• This is a intermittent monitor. (CATALYST)
• The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• DIAGNOSTIC MONITORING TEST RESULTS and PENDING CODE are stored if
PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• TWC deterioration or malfunction
• Exhaust gas leakage
• Loose front HO2S
• Loose rear HO2S
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes Go to appropriate DTC troubleshooting.
3
4
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off then to the ON position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
INSPECT GAS LEAKAGE OF EXHAUST
SYSTEM
• Visually inspect exhaust gas leakage in the exhaust system.
No Go to the next step.
Yes
Repair or replace the malfunctioning exhaust part, then go to Step 7.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
• Is there gas leakage?
INSPECT INSTALLATION OF FRONT AND
REAR OXYGEN SENSORS
• Inspect for looseness of front and rear oxygen sensors.
• Is it normal?
Yes Go to the next step.
No Retighten the sensor, then go to Step 7.
INSPECT TWC
Yes
Replace the heated oxygen sensor, then go to the next step.
• Clear the DTC using the WDS or equivalent generic OBD function.
• Turn the ignition switch off then back to the ON position.
• Inspect the TWC.
(See EXHAUST SYSTEM INSPECTION
[LF] .)
No
Replace the TWC, then go to the next step.
• Is it normal?
7
8
VERIFY TROUBLESHOOTING OF DTC P0420
OR P0431 COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using the
WDS or equivalent.
No Go to the next step.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0443
DETECTION
CONDITION
DTC P0443 [LF]
B3E010201086W03
Purge solenoid valve circuit problem
• The PCM monitors the input voltages from the purge solenoid valve. If the voltage at PCM terminal 2AN remains low or high, the PCM determines that the purge solenoid valve circuit has malfunction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Purge solenoid valve malfunction
• Connector or terminal malfunction
• Short to ground in wiring harness between purge solenoid valve terminal A and PCM terminal 2AN
• Open circuit in wiring harness between main relay and purge solenoid valve terminal B
• Open circuit in wiring harness between purge solenoid valve terminal A and
PCM terminal 2AN
• Short to power supply in wiring harness between purge solenoid valve terminal A and PCM terminal 2AN
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
CLASSIFY OPEN CIRCUIT OR SHORT
TO GROUND MALFUNCTION
Yes Go to Step 5.
• Disconnect purge solenoid valve tube that is connected to intake manifold.
• Connect vacuum pump to purge solenoid valve.
• Pump vacuum pump several times and stop.
No Go to the next step.
• Wait a few seconds .
• Is vacuum maintained?
INSPECT PASSAGE CONTROL OF
PURGE SOLENOID VALVE
• Turn the ignition switch off.
• Disconnect purge solenoid valve connector.
• Pump vacuum pump several times and wait a few seconds .
No
Replace the purge solenoid valve, then go to Step
10.
• Is vacuum maintained?
Yes
Repair or replace wiring harness for short to ground, then go to Step 10.
INSPECT PURGE SOLENOID VALVE
CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes Repair or replace the terminal, then go to Step 10.
No Go to the next step.
INSPECT PURGE SOLENOID VALVE
• Perform purge solenoid valve inspection.
(See PURGE SOLENOID VALVE
INSPECTION )
• Is purge solenoid valve normal?
Yes Go to the next step.
No
Replace the purge solenoid valve, then go to Step
10.
INSPECT PURGE SOLENOID VALVE
POWER SUPPLY CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
No
Repair or replace the wiring harness for open circuit, then go to Step 10.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between purge solenoid valve terminal B and body ground.
• Is the voltage B+ ?
INSPECT PCM CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes Repair or replace the terminal, then go to Step 10.
No Go to the next step.
INSPECT PURGE SOLENOID VALVE
CONTROL CIRCUIT
• Turn the ignition switch to the ON position (Engine off).
• Measure the voltage between purge solenoid valve terminal A (wiring harness-side) and body ground.
• Is the voltage B+ ?
Yes
Repair or replace the wiring harness for short to power supply, then go to the next step.
Inspect for continuity between purge solenoid valve terminal A (wiring harness-side) and PCM terminal 2AN (wiring harness-side).
No
• If there is continuity, go to the next step.
• If there is no continuity, repair or replace wiring harness for open circuit, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0443 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Make sure to reconnect all disconnected connectors.
• Start the engine.
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0480 [LF]
B3E010201086W04
DTC P0480 Fan control circuit problem
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors the input voltages from the fan control module. If the voltage at PCM terminal 1W remains low or high, the PCM determines that fan control circuit has malfunction.
Diagnostic support note
• This is an continuous monitor (other).
• The MIL does not illuminate.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• Connector or terminal malfunction
• Short to power supply in wiring harness between fan control module terminal B and PCM terminal 1W
• Short to ground in wiring harness between fan control module terminal B and PCM terminal 1W
• Open circuit in wiring harness between fan control module terminal B and
PCM terminal 1W
• Fan control module malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to the available repair information.
Yes
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT FAN CONTROL MODULE
CONNECTOR FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect fan control module connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR SHORT TO POWER SUPPLY
Yes
Repair or replace the wiring harness for open circuit, then go to Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fan control module terminal B (wiring harness-side) and body ground.
• Is the voltage B+ ?
No Go to the next step.
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR SHORT TO GROUND
• Turn the ignition switch off.
Yes
Repair or replace the wiring harness for open circuit, then go to Step 9.
• Inspect for continuity between fan control module terminal B (wiring harness-side) and body ground.
• Is there continuity?
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT FAN CONTROL MODULE SIGNAL
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between fan control module terminal B (wiring harness-side) and
PCM terminal 1W.
No
Repair or replace wiring harness for open circuit, then go to Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
• Is there continuity?
INSPECT FAN CONTROL MODULE
• Perform fan control module inspection.
• Is fan control module normal?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
No
Replace the fan control module, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0480 COMPLETED
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Turn A/C switch to ON.
• Is same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
No
Go to the next step.
Troubleshooting completed.
DTC P0500
DETECTION
CONDITION
DTC P0500 [LF]
B3E010201087W01
VSS circuit problem
• The PCM monitors the vehicle speed from the ABS HU/CM or DSC HU/CM. If the
PCM dose not receive the input vehicle speed signal, the PCM determines that the
VSS circuit problem.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• VSS circuit malfunction POSSIBLE
CAUSE
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
VERIFY STORED DTC IN ABS HU/CM
OR DSC HU/CM
• Turn the ignition switch to the ON position (Engine off).
• Verify stored DTCs in ABS HU/CM or
DSC HU/CM.
(See ON-BOARD DIAGNOSIS [ABS] .)
(See ON-BOARD DIAGNOSIS [DSC
(DYNAMIC STABILITY CONTROL)] )
• Are DTCs stored?
Go to the appropriate DTC inspection.
Yes (See DTC Table )
(See DTC Table .)
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0500 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
No Go to the next step.
• Is the PENDING CODE same as the
DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
No DTC troubleshooting completed.
• Are any DTCs present?
DTC P0505 [LF]
B3E010201087W02
DTC P0505 IAC system problem
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM cannot control idle speed toward target idle speed while KOER self test.
• IAC valve circuit malfunction
• Air cleaner element clogged
• Air intake passage clogged
• A/C relay control circuit malfunction
• Generator control circuit malfunction
• Low engine compression (Over capacity of blow-by gas)
• PCM malfunction
Diagnostic procedure
STEP
1
2
3
4
INSPECTION ACTION
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING OR
STORED DTC
Yes
Perform the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
• Turn the ignition switch off then to the
ON position (Engine off).
• Verify pending code or stored DTCs using the WDS or equivalent.
No Go to the next step.
• Does DTC P0511, P2502, P2503 or
P2504 present?
INSPECT IAC VALVE MALFUNCTION Yes Go to the next step.
• Start engine.
• Disconnect IAC valve connector.
• Is engine speed decreased?.
No Repair IAC valve, then go to Step 9.
INSPECT A/C MAGNETIC CLUTCH
OPERATION
Note
• The following test should be performed for the A/C. Go to the next step for vehicles without A/C
• Turn the fan switch off.
Go to "A/C ALWAYS ON / A/C COMPRESSOR
Yes
RUNS CONTINUOUSLY." of ENGINE SYMPTOM
TROUBLESHOOTING then go to step 9.
(See ENGINE SYMPTOM TROUBLESHOOTING
[LF] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
• Is the magnetic clutch still on?
INSPECT GENERATOR CONTROL
CIRCUIT MALFUNCTION
• Apply electrical load.
• Is engine speed increased?
Yes
No
Go to the next step.
Repair short to power supply in generator control circuit, then go to Step 9.
INSPECT AIR CLEANER ELEMENT
• Remove air cleaner element with the engine running.
• Is the engine speed increased?
Yes
Clean or replace the air cleaner element, then go to Step 9.
No Go to the next step.
7
8
9
10
INSPECT THROTTLE BODY
PASSAGE
• Is throttle body clogged?
Yes
Clean or replace the throttle body passage, then go to Step 9.
No Go to the next step.
Yes Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect engine compression.
(See COMPRESSION INSPECTION
[LF] .)
• Is engine compression normal?
No Overhaul the engine, then go to the next step.
VERIFY TROUBLESHOOTING OF
DTC P0505 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC using the WDS or equivalent.
• Perform the KOER Self-Test.
• Is the same DTC present?
Yes
No
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
Go to the next step.
VERIFY AFTER REPAIR
PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
.)
DTC P0506 [LF]
B3E010201087W03
Idle control system RPM lower than expected DTC P0506
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE
CAUSE
• Actual idle speed is lower than expected by 100 rpm for 14 s , when brake pedal is depressed (brake switch is on) and steering wheel is held straight ahead (power steering pressure switch is off).
Note
• If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or intake air temperature is below -10 ° C {14 ° F} , the PCM cancels diagnosis of P0506.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• IAC valve malfunction
• Air cleaner element clogged
• Air intake passage clogged
• A/C relay control circuit malfunction
• Generator malfunction
• Purge solenoid valve malfunction
• Low engine compression (Over capacity of blow-by gas)
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA
HAS BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes Repair the applicable DTCs.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
VERIFY RELATED PENDING OR
STORED DTC
• Turn the ignition switch to off then to the ON position (Engine off).
• Verify pending code or stored
DTCs using the WDS or equivalent.
• Is other DTC present?
(See DTC TABLE [LF]
No Go to the next step.
.)
Yes Go to the next step.
INSPECT IAC VALVE
MALFUNCTION
• Perform IAC valve inspection.
(See IDLE AIR CONTROL (IAC)
VALVE INSPECTION [LF] .)
• Is IAC valve normal?
No Replace the IAC valve, then go to Step 11.
INSPECT A/C MAGNET CLUTCH
OPERATION
Refer to "A/C is always on or A/C compressor runs
Yes continuously." of ENGINE SYMPTOM
TROUBLESHOOTING, then go to Step 11.
• Turn the fan switch off.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• Is the magnet clutch still on?
No Go to the next step.
INSPECT PURGE SOLENOID
VALVE MALFUNCTION
• Perform the purge solenoid valve inspection.
Yes Go to the next step.
(See PURGE SOLENOID VALVE
INSPECTION .)
• Is the purge solenoid valve normal?
No Replace the purge solenoid valve, then go to Step 11.
INSPECT AIR CLEANER
ELEMENT
• Remove the air cleaner element with the engine running.
• Is the engine speed increased?
Yes Replace air cleaner the element, then go to Step 11.
No Go to the next step.
INSPECT THROTTLE BODY
PASSAGE
• Is the throttle body clogged?
Yes
Clean or replace the throttle body passage, then go to
Step 11.
No Go to the next step.
Yes Go to the next step.
INSPECT ENGINE
COMPRESSION
• Inspect engine compression.
(See COMPRESSION
INSPECTION [LF] .)
No Overhaul the engine, then go to Step 11.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
• Is engine compression normal?
INSPECT GENERATOR
• Perform generator inspection.
(See GENERATOR
INSPECTION .)
• Is generator normal?
Yes
No
Go to the next step.
Repair or replace the related part, then go to the next step.
VERIFY TROUBLESHOOTING
OF DTC P0506 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
• Start engine.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Depress the brake pedal for 14 s or more .
No Go to the next step.
• Is the PENDING CODE for this
DTC present?
.)
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
VERIFY AFTER REPAIR
PROCEDURE
• Perform the "After Repair
Procedure".
(See AFTER REPAIR
PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0507
DETECTION
CONDITION
DTC P0507 [LF]
B3E010201087W04
Idle control system RPM higher than expected
• Actual idle speed is higher than expected by 200 rpm for 14 s , when the brake pedal is depressed (brake switch is on) and the steering wheel is held straight ahead
(power steering pressure switch is off).
Note
• If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or intake air temperature is below -10 ° C {14 ° F} , the PCM cancels diagnosis of
P0507.
Diagnostic support note
• This is a continuous monitor (CCM).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAC valve malfunction
• Accelerator cable misadjusting
• Actuator cable misadjusting
• Throttle valve malfunction
• Vacuum hose misconnection
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING OR
STORED DTC
• Turn the ignition switch off then to the ON position (Engine off).
Yes
Repair the applicable DTCs.
(See DTC TABLE [LF] .)
• Verify pending code or stored DTCs using the WDS or equivalent.
No Go to the next step.
• Is other DTC present?
Yes Go to the next step.
INSPECT IAC VALVE MALFUNCTION
• Perform IAC valve inspection.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [LF] .)
• Is IAC valve normal?
No Replace the IAC valve, then go to Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
10
INSPECT ACCELERATOR CABLE FREE
PLAY
• Turn the ignition switch off.
Yes Go to the next step.
• Is accelerator cable free play normal?
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [LF] .)
No
Adjust accelerator cable free play, then go to
Step 9.
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [LF] .)
INSPECT ACTUATOR CABLE FREE
PLAY
• Is actuator cable adjustments normal?
Yes Go to the next step.
No
Adjust actuator cable free play, then go to Step
9.
INSPECT VACUUM HOSE CONNECTION Yes Go to the next step.
• Are vacuum hoses connected completely?
(See INTAKE-AIR SYSTEM HOSE
ROUTING DIAGRAM [LF] .)
No
Reconnect the vacuum hose accurately, then go to step 9.
Yes Go to the next step.
VISUAL INSPECT THROTTLE VALVE
• Remove throttle body.
• Is throttle valve fully closed?
No
Clean or replace the throttle body, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0507 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start engine.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Depress brake pedal for 14 s or more .
• Is the PENDING CODE for this DTC present?
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0511 [LF]
B3E010201087W05
DTC P0511 IAC valve circuit problem
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• If the PCM detects that PCM terminal 2E voltage is above or below threshold * when the IAC control duty target is within 16-30% , the PCM determines that the IAC valve circuit has malfunction.
*: Detected threshold value depends on battery voltage and IAC control signal duty value.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction conditions in first consecutive drive cycles.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• IAC valve circuit malfunction
• Short to ground in wiring harness between IAC valve terminal A and PCM terminal 2E
• Short to ground in wiring harness between IAC valve terminal B and PCM terminal 2F
• Open circuit in wiring harness between IAC valve terminal A and PCM terminal 2E
• Open circuit in wiring harness between IAC valve terminal B and PCM terminal 2F
• Short to power supply in wiring harness between IAC valve terminal A and
PCM terminal 2E
• Short to power supply in wiring harness between IAC valve terminal B and
PCM terminal 2F
• Poor connection of IAC valve connector or PCM connector
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes
Repair or replace the terminal, then go to
Step 9.
INSPECT POOR CONNECTION OF IAC
VALVE CONNECTOR
• Turn the ignition switch off.
• Disconnect IAC valve connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
Yes Go to the next step.
INSPECT IAC VALVE ELECTRICAL
MALFUNCTION
• Inspect the IAC valve.
No Replace IAC valve, then go to Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [LF] .)
• Is IAC valve normal?
INSPECT CONTROL CIRCUIT FOR SHORT
TO POWER
Yes
Repair or replace wiring harness, then go to
Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between following terminal
(wiring harness-side) and body ground:
No Go to the next step.
- IAC valve terminal A
- IAC valve terminal B
• Is the voltage B+ ?
INSPECT CONTROL CIRCUIT FOR SHORT
TO GROUND
Yes
Repair or replace the wiring harness, then go to Step 9.
• Turn the ignition switch off.
• Inspect for continuity between following terminals (wiring harness-side) and body ground:
No Go to the next step.
- IAC valve terminal A
- IAC valve terminal B
• Is there continuity?
Yes Repair the terminal, then go to Step 9.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT CONTROL CIRCUIT
MALFUNCTION FOR OPEN CIRCUIT
• Inspect for continuity following terminals
(wiring harness-side):
Yes
Repair or replace the wiring harness, then go to the next step.
- Between IAC valve terminal A and
PCM terminal 2E
No Go to the next step.
- Between IAC valve terminal B and
PCM terminal 2F
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P0511 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
• Make sure to reconnect all disconnected connectors.
• Clear the DTC using the WDS or equivalent.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Go to the next step.
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0602
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P0602 [LF]
B3E010201088W01
PCM programming error
• No configuration data in the PCM
Note
• If "PCM CONFIGURATION" is successful, the PCM stored DTC P0602 and illuminates the MIL (System is normal). Clear the DTC P0602 using the WDS or equivalent after "PCM CONFIGURATION".
• The MIL goes out after three drive cycles with no failure (DTCs remain in
PCM).
• Complete configuration has not been completed
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
VERIFY TROUBLESHOOTING OF DTC P0602
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the HO2S heater, HO2S, and TWC
Repair Verification Drive Mode. (See OBD
DRIVE MODE [LF] .)
• Is the same DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0610 [LF]
B3E010201088W02
DTC P0610 PCM vehicle options error
DETECTION CONDITION
• PCM data configuration error
POSSIBLE CAUSE
• Configuration procedure has not been completed
• PCM malfunction
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
ACTION
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
VERIFY TROUBLESHOOTING OF DTC
P0610 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Turn the ignition switch to the ON position (Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0661
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0661 [LF]
B3E010201088W03
Variable intake-air solenoid valve circuit low input
• The PCM monitors the variable intake-air solenoid valve control signal at
PCM terminal 2AJ. If the PCM turns variable intake-air solenoid valve off but voltage at PCM terminal 2AJ still remains low, the PCM determines that variable intake-air solenoid valve circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• The FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• Variable intake-air solenoid valve malfunction
• Open circuit in wiring harness between main relay and variable intake-air solenoid valve terminal B
• Open circuit in wiring harness between variable intake-air solenoid valve terminal A and PCM terminal 2AJ
• Short to ground in wiring harness between variable intake-air solenoid valve terminal A and PCM terminal 2AJ
• Connector or terminal malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• PCM malfunction
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR SOLENOID
VALVE CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to Step 9.
• Disconnect the variable intake-air solenoid valve connector.
No Go to the next step.
• Inspect for poor connection (damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
Yes Go to the next step.
INSPECT VARIABLE INTAKE-AIR SOLENOID
VALVE MALFUNCTION
• Perform variable intake-air solenoid valve inspection.
No
Replace the variable intake-air solenoid valve, then go to step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
(See VARIABLE INTAKE-AIR SOLENOID VALVE
INSPECTION [LF] .)
• Is variable intake-air solenoid valve normal?
INSPECT VARIABLE INTAKE-AIR SOLENOID
VALVE POWER SUPPLY CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between variable intake-air solenoid valve terminal B (wiring harness-side) and body ground.
No
Repair or replace the wiring harness for open, then go to Step 9.
• Is the voltage B+ ?
INSPECT VARIABLE INTAKE-AIR SOLENOID
VALVE CONTROL CIRCUIT FOR SHORT TO
GROUND
• Is there continuity?
Yes
Repair or replace the wiring harness for short to ground, then go to Step 9.
• Inspect for continuity between variable intake-air solenoid valve terminal A (wiring harness-side) and body ground.
No Go to the next step.
Yes Repair the terminal, then go to Step 9.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Disconnect the PCM connector.
• Inspect for poor connection at terminal 2AJ.
(damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR SOLENOID
VALVE CONTROL CIRCUIT FOR OPEN
Yes Go to the next step.
• Inspect for continuity between variable intake-air solenoid valve terminal B (wiring harness-side) and
PCM terminal 2AJ (wiring harness-side).
No
Repair or replace the wiring harness for open circuit, then go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC P0661
COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
WDS or equivalent.
• Access RPM PID.
• Increase the engine speed 4,750 rpm or more for 10 times.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
DTC P0662
DETECTION
CONDITION
POSSIBLE CAUSE
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0662 [LF]
B3E010201088W04
Variable intake-air solenoid valve circuit high input
• The PCM monitors the variable intake-air solenoid valve control signal at
PCM terminal 2AJ. If the PCM turns variable intake-air solenoid valve on but voltage at PCM terminal 2AJ still remains high, the PCM determines that the variable intake-air solenoid valve circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is not available.
• The DTC is stored in the PCM memory.
• Variable intake-air solenoid valve malfunction
• Short to power supply in wiring harness between variable intake-air solenoid valve terminal B and PCM terminal 2AJ
• Shorted variable intake-air solenoid valve or PCM connector
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR
SOLENOID VALVE CONNECTOR FOR
POOR CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to
Step 7.
• Disconnect the variable intake-air solenoid valve connector.
• Inspect for poor connection (damaged/pulledout pins, corrosion, etc.).
• Is there malfunction?
No Go to the next step.
Yes Go to the next step.
INSPECT VARIABLE INTAKE-AIR
SOLENOID VALVE MALFUNCTION
• Perform variable intake-air solenoid valve inspection.
(See VARIABLE INTAKE-AIR SOLENOID
VALVE INSPECTION [LF] .)
No
Replace the variable intake-air solenoid valve, then go to Step 7.
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5
6
7
8
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Is the variable intake-air solenoid valve normal?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection at terminal 2AJ.
(such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes Repair the terminal, then go to Step 7.
No Go to the next step.
INSPECT VARIABLE INTAKE-AIR
SOLENOID VALVE CONTROL CIRCUIT
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between variable intakeair solenoid valve terminal A (wiring harnessside) and body ground.
No Go to the next step.
• Is the voltage B+ ?
Repair or replace the wiring harness for
Yes short to power supply, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0662 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Access RPM PID.
• Increase the engine speed 4,750 rpm or more for 10 times.
• Is the same DTC present?
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
DTC P0703 [LF]
Brake switch input circuit problem
B3E010201089W01
DTC P0703
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors changes in input voltage from the brake switch. If the
PCM does not detect PCM terminal 1AU voltage changes while alternately accelerating and decelerating 8 times , the PCM determines that brake switch circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Brake switch malfunction
• Poor connection of brake switch connector or PCM connector
• Short to power supply in wiring harness between brake switch terminal D and PCM connector terminal 1AU
• Open circuit in wiring harness between brake switch terminal D and PCM connector terminal 1AU
• Open circuit in wiring harness between battery positive terminal and brake switch terminal A
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
Go to the next step.
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
CLASSIFY HIGH INPUT OR LOW INPUT
• Connect the WDS or equivalent to DLC-2.
• Access BOO PID.
Yes Go to the next step.
No Go to Step 10.
• Verify BOO PID during brake pedal operation.
• Is BOO PID always OFF?
INSPECT BRAKE SWITCH CONNECTOR
FOR POOR CONNECTION
Yes
Repair or replace the terminal, then go to Step
14.
• Turn the ignition switch off.
• Disconnect the brake switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
No Go to the next step.
CLASSIFY BRAKE SWITCH OR CIRCUIT
• Connect the WDS or equivalent to DLC-2.
Yes Go to the next step.
• Access BOO PID.
• Connect a jumper wire between brake switch terminal A and D.
• Is BOO PID on?
No Go to Step 7.
INSPECT BRAKE SWITCH
• Perform brake switch inspection.
(See BRAKE SWITCH INSPECTION .)
• Is brake switch normal?
Yes
No
Go to Step 14.
Replace brake switch, then go to Step 14.
INSPECT BRAKE SWITCH POWER
CIRCUIT FOR OPEN CIRCUIT
Yes Go to the next step.
• Measure the voltage between brake switch terminal A and body ground.
No
Repair or replace brake switch power circuit for open, then Go to Step 14.
• Is the voltage B+ ?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
13
14
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to Step
14.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
No Go to the next step.
INSPECT BRAKE SWITCH SIGNAL
CIRCUIT FOR OPEN CIRCUIT
Yes
Repair or replace wiring harness for open circuit, then go to Step 14.
• Inspect for continuity between brake switch terminal D and PCM terminal 1AU.
No Go to Step 14.
• Is there continuity?
INSPECT BRAKE SWITCH CONNECTOR
FOR POOR CONNECTION
• Turn the ignition switch off.
Yes
Repair or replace the terminal, then go to Step
14.
• Disconnect the brake switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
No Go to the next step.
CLASSIFY BRAKE SWITCH OR CIRCUIT
• Connect the WDS or equivalent to DLC-2.
• Access BOO PID.
Yes Go to the next step.
• Verify that BOO PID changes from ON to
OFF when brake switch connector disconnected.
• Does BOO PID change from ON to OFF?
No Go to Step 13.
INSPECT BRAKE SWITCH
• Perform brake switch inspection.
(See BRAKE SWITCH INSPECTION .)
• Is brake switch normal?
Yes Go to Step 14.
No Replace the brake switch, then go to Step 14.
INSPECT BRAKE SWITCH SIGNAL
CIRCUIT FOR SHORT TO POWER
SUPPLY
• Is the voltage B+ ?
Yes
Repair or replace the wiring harness for short to power supply, then go to the next step.
• Measure the voltage between brake switch terminal D and body ground.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0703 COMPLETED
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
15
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the memory using the
WDS or equivalent.
• Drive the vehicle 30 km/h {18.6 mph} or more .
No Go to the next step.
• Depress and release the brake pedal more than 8 times while driving vehicle.
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0704
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P0704 [LF]
B3E010201089W02
CPP switch input circuit problem
• The PCM monitors changes in input voltage from the CPP switch. If the
PCM does not detect PCM terminal 1O voltage changes while the vehicle runs and stops 8 times alternately, the PCM determines that the CPP switch circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• CPP switch malfunction
• Poor connection of CPP switch connector or PCM connector
• Short to ground in wiring harness between CPP switch terminal A and PCM terminal 1O
• Open circuit in wiring harness between CPP switch terminal A and PCM terminal 1O
• Open circuit in wiring harness between ground and CPP switch terminal B
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
CLASSIFY HIGH INPUT OR LOW INPUT
• Connect the WDS or equivalent to DLC-2.
• Access CPP PID.
• Verify CPP PID during clutch pedal operation.
• Is CPP PID always OFF?.
Yes Go to the next step.
No Go to Step 10.
INSPECT CPP SWITCH CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 14.
• Turn the ignition switch off.
• Disconnect the CPP switch connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
10
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
CLASSIFY CPP SWITCH OR CIRCUIT
• Connect the WDS or equivalent to DLC-2.
• Access CPP PID.
• Connect a jumper wire between CPP switch terminal A and B.
• Is CPP PID on?
Yes Go to the next step.
No Go to Step 7.
INSPECT CPP SWITCH
• Perform CPP switch inspection.
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [LF] .)
• Is CPP switch normal?
Yes
No
Go to Step 14.
Replace CPP switch, then go to Step 14.
INSPECT CPP SWITCH GROUND CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity between CPP switch terminal B and ground.
• Is there continuity?
No
Repair or replace the CPP switch power circuit for open circuit, then Go to Step 14.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
Repair or replace the terminal, then go to
Step 14.
No Go to the next step.
INSPECT CPP SWITCH SIGNAL CIRCUIT
FOR OPEN CIRCUIT
• Inspect for continuity between CPP switch terminal A and PCM terminal 1O.
• Is there continuity?
Yes Go to the next step.
No
Repair or replace wiring harness for open circuit, then go to Step 14.
INSPECT CPP SWITCH CONNECTOR FOR
POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 14.
• Turn the ignition switch off.
• Disconnect the CPP switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11
12
CLASSIFY CPP SWITCH OR CIRCUIT
• Connect the WDS or equivalent to DLC-2.
• Access CPP PID.
• Verify that CPP PID changes from ON to
OFF when CPP switch connector disconnected.
• Does CPP PID change from ON to OFF?
Yes Go to the next step.
No Go to Step 13.
INSPECT CPP SWITCH
• Perform CPP switch inspection.
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [LF] .)
• Is CPP switch normal?
Yes Go to Step 14.
No Replace CPP switch, then go to Step 14.
13
14
15
INSPECT CPP SWITCH SIGNAL CIRCUIT
FOR SHORT TO GROUND
• Inspect for continuity between CPP switch terminal A and ground.
• Is there continuity?
Yes
Repair or replace wiring harness for short to ground, then go to Step 14.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P0704 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start the engine.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Operate the clutch pedal while the vehicle runs and stops 8 times alternately.
• Is the PENDING CODE for this DTC present?
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P0850 [LF]
Neutral switch input circuit problem
B3E010201089W03
DTC P0850
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors changes in input voltage from the neutral switch. If the
PCM does not detect PCM terminal 1S voltage changes while running vehicle with vehicle speed above 30 km/h {19 mph} and clutch pedal turns press and depress 10 times repeatedly, the PCM determines that the neutral switch circuit has malfunction
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Neutral switch malfunction
• Poor connection of neutral switch connector or PCM connector
• Short to ground in wiring harness between neutral switch terminal B and PCM terminal 1S
• Open circuit in wiring harness between neutral switch terminal B and PCM terminal 1S
• Open circuit in wiring harness between ground and neutral switch terminal A
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
2
3
4
5
6
7
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes Go to the next step.
CLASSIFY HIGH INPUT OR LOW INPUT
• Connect the WDS or equivalent to DLC-2.
• Access CPP PID.
• Verify CPP PID when gear is neutral position.
• Is CPP PID always OFF?.
No Go to Step 10.
INSPECT NEUTRAL SWITCH CONNECTOR
FOR POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 14.
• Turn the ignition switch off.
• Disconnect neutral switch connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
No Go to the next step.
CLASSIFY NEUTRAL SWITCH OR CIRCUIT Yes Go to the next step.
• Connect the WDS or equivalent to the DLC-
2.
• Access CPP PID.
• Connect a jumper wire between neutral switch terminal A and B.
• Is CPP PID on?
No Go to Step 7.
INSPECT NEUTRAL SWITCH Yes Go to Step 14.
• Perform the neutral switch inspection.
(See NEUTRAL SWITCH INSPECTION [LF] .)
No
• Is neutral switch normal?
Replace the neutral switch, then go to Step
14.
Yes Go to the next step.
INSPECT NEUTRAL SWITCH GROUND
CIRCUIT FOR OPEN CIRCUIT
No
Repair or replace neutral switch ground circuit for open circuit, then Go to Step 14.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
13
• Inspect for continuity between neutral switch terminal A and ground.
• Is there continuity?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 14.
Go to the next step.
INSPECT NEUTRAL SWITCH SIGNAL
CIRCUIT FOR OPEN CIRCUIT
Yes
Repair or replace the wiring harness for open circuit, then go to Step 14.
• Inspect for continuity between neutral switch terminal B and PCM terminal 1S.
No Go to Step 14.
• Is there continuity?
INSPECT NEUTRAL SWITCH CONNECTOR
FOR POOR CONNECTION
Yes
Repair or replace the terminal, then go to
Step 14.
• Turn the ignition switch off.
• Disconnect the neutral switch connector.
No Go to the next step.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
CLASSIFY NEUTRAL SWITCH OR CIRCUIT Yes Go to the next step.
• Connect the WDS or equivalent to DLC-2.
• Access CPP PID.
• Verify that CPP PID changes from ON to
OFF when the neutral switch connector disconnected.
• Does CPP PID change from ON to OFF?
No Go to Step 13.
INSPECT NEUTRAL SWITCH Yes Go to Step 14.
• Perform neutral switch inspection.
(See NEUTRAL SWITCH INSPECTION [LF] .)
No
Replace the neutral switch, then go to Step
14.
• Is neutral switch normal?
INSPECT NEUTRAL SWITCH SIGNAL
CIRCUIT FOR SHORT TO GROUND
Yes
Repair or replace wiring harness for short to ground, then go to Step 14.
• Inspect for continuity between neutral switch terminal B and ground.
No Go to the next step.
• Is there continuity?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
VERIFY TROUBLESHOOTING OF DTC
P0850 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start the engine.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Drive the vehicle above 30 km/h {19 mph} and stop vehicle.
No Go to the next step.
.)
• Depress and release the clutch pedal more than 10 times during drive cycle.
• Is the PENDING CODE for this DTC present?
15
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
DTC P1260
DETECTION
CONDITION
POSSIBLE CAUSE
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P1260 [LF]
B3E010201200W01
Immobilizer system problem
• The instrument cluster detects an immobilizer system malfunction.
Diagnostic support note
• This is a continuous monitor (Other).
• The MIL does not illuminate.
• PENDING CODE is available if the PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• The DTC is not stored in the PCM memory.
• Immobilizer system malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
Yes Go to the next step.
ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Perform repair or diagnosis according to the
Yes available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY STORED DTC IN INSTRUMENT
CLUSTER
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [IMMOBILIZER SYSTEM] .)
• Turn the ignition switch to the ON position (Engine off).
• Verify stored DTCs in instrument cluster.
No Go to the next step.
(See DTC INSPECTION [IMMOBILIZER
SYSTEM] .)
• Are DTCs stored?
VERIFY TROUBLESHOOTING OF DTC
P1260 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
5
VERIFY AFTER REPAIR PROCEDURE
• Perform the "AFTER REPAIR
PROCEDURE".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Are any DTCs present?
No DTC troubleshooting completed.
DTC P2006
DETECTION
CONDITION
DTC P2006 [LF]
B3E010202000W01
Variable tumble shutter valve stuck closed
• The PCM monitors mass air amount. If the actual air flow amount is below estimated air flow amount when the following monitoring conditions are met.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
The PCM determines that the variable tumble shutter valve has been stuck closed.
MONITORING CONDITIONS
- Engine coolant temperature is above 70 ° C {158 ° F} .
- Engine speed is 3,500 rpm or more .
- Throttle valve opening angle is above 75 % .
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• ECT sensor malfunction
• TP sensor malfunction
• CKP sensor malfunction
• Variable tumble solenoid valve malfunction
• Variable tumble shutter valve malfunction (stuck closed)
• Variable tumble shutter valve actuator malfunction (stuck closed)
• Short to ground in wiring harness between variable tumble solenoid valve terminal B and PCM terminal 2AI
• PCM malfunction
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
• If vehicle is not repaired, go to the next step.
• Verify related service repair information availability.
• Is any related repair information available?
No Go to the next step.
CLASSIFY INTERMITTENT CONCERN
OR CONTINUOUS CONCERN
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Drive vehicle under following conditions:
- Engine coolant temperature is above 70 ° C {158 ° F} .
Yes Go to the next step.
- Engine speed: 3,500 rpm or more
- Throttle opening angle is below as following
No
Intermittent concern exists. Go to
INTERMITTENT CONCERN
TROUBLESHOOTING procedure.
• Engine speed below 1,500 rpm : above 35 %
(See INTERMITTENT CONCERN
TROUBLESHOOTING [LF] .)
• Engine speed between 1,500-
2,500 rpm : between 25-35%
• Engine speed above
2,500 : below 25 %
• Is the PENDING CODE for this DTC present?
VERIFY STORED OTHER DTCS
• Verify the stored DTCs using the WDS or equivalent.
Yes
Go to the appropriate DTC troubleshooting procedures.
• Is other DTC present except P0117,
P0118, P0121, P0122, P0123 and/or
P0335?
No Go to the next step.
INSPECT VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR
Yes Go to the next step.
• Perform "VTCS operation inspection".
(See Variable Tumble Control Operation
Inspection .)
No
Replace the variable tumble shutter valve actuator, then go to Step 8.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
9
• Is the variable tumble shutter valve actuator normal?
INSPECT VTCS SOLENOID VALVE Yes Go to the next step.
• Perform "VTCS solenoid valve airflow inspection".
(See VARIABLE TUMBLE SOLENOID
VALVE INSPECTION [LF] .)
• Is variable tumble solenoid valve normal?
No
Replace the variable tumble solenoid valve, then go to Step 8.
INSPECT PCM FOR POOR CONNECTION Yes Repair the terminal, then go to the next step.
• Inspect for poor connection at PCM terminal 2AI (such as damaged/pulled-out pins, corrosion).
No Go to the next step.
• Is there malfunction?
VERIFY TROUBLESHOOTING OF DTC
P2006 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Start engine.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Drive the vehicle under following conditions:
- Engine coolant temperature is above 70 ° C {158 ° F} .
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF]
- Engine speed: 3,500 rpm or more
- Throttle opening angle is below as following
• Engine speed below 1,500 rpm : above 35 %
• Engine speed between 1,500-
2,500 rpm : between 25-35%
• Engine speed above
2,500 : below 25 %
• Is PENDING CODE for this DTC present?
No Go to the next step.
.)
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2009 [LF]
B3E010202000W02
DTC P2009 Variable tumble solenoid valve circuit low input
DETECTION
CONDITION
POSSIBLE CAUSE
• The PCM monitors variable tumble solenoid valve control signal at PCM terminal 2AI. If the PCM turns variable tumble solenoid valve off but voltage at PCM terminal 2AI still remains low, the PCM determines that variable tumble solenoid valve circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Poor connection of connectors at PCM and/or variable tumble solenoid valve
• Short to ground in wiring harness between variable tumble solenoid valve terminal B and PCM terminal 2AI
• Open circuit in wiring harness between main relay and variable tumble solenoid valve terminal A
• Open circuit in wiring harness between variable tumble solenoid valve terminal B and PCM terminal 2AI
• Variable tumble solenoid valve malfunction
• PCM malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
4
5
6
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Perform repair or diagnosis according to
Yes the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 9.
Go to the next step.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE
• Perform the variable tumble solenoid valve inspection.
(See VARIABLE TUMBLE SOLENOID VALVE
INSPECTION [LF] .)
• Is variable tumble solenoid valve normal?
Yes Go to the next step.
No
Replace the variable tumble solenoid valve, then go to Step 9.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE POWER SUPPLY CIRCUIT FOR
OPEN CIRCUIT
Yes Go to the next step.
• Disconnect the variable tumble solenoid valve connector.
• Turn the ignition switch to the ON position
(Engine off).
No
Repair or replace the wiring harness for open circuit, then go to Step 9.
• Measure the voltage between variable tumble solenoid valve terminal A (wiring harness-side) and body ground.
• Is the voltage B+ ?
Yes Repair the terminal, then go to Step 9.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
8
• Inspect for poor connection at PCM terminal
2AI. (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
INSPECT VARIABLE TUMBLE SOLENOID
VALVE CONTROL CIRCUIT FOR SHORT TO
GROUND
• Is there continuity?
Yes
Repair or replace the wiring harness for short to ground, then go to Step 9.
• Inspect for continuity between variable tumble solenoid valve terminal B (wiring harness-side) and body ground.
No Go to the next step.
Yes Go to the next step.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE CONTROL CIRCUIT FOR OPEN
CIRCUIT
• Connect variable tumble solenoid valve connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between PCM terminal 2AI
(wiring harness side) and body ground.
• Is the voltage B+ ?
No
Repair or replace wiring harness for open circuit, then go to the next step.
9
10
VERIFY TROUBLESHOOTING OF DTC P2009
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace the PCM, then go to the next
Yes step.
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Start the engine.
• Is the PENDING CODE for this DTC present?
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2010
DETECTION
CONDITION
DTC P2010 [LF]
B3E010202000W03
Variable tumble solenoid valve circuit high input
• The PCM monitors the variable tumble solenoid valve control signal at PCM terminal 2AI. If the PCM turns variable tumble solenoid valve on but the
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE voltage at PCM terminal 2AI still remains high, the PCM determines that the variable tumble solenoid valve circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Poor connection of connectors at PCM and/or variable tumble solenoid valve
• Short to power supply in wiring harness between variable tumble solenoid valve terminal B and PCM terminal 2AI
• Variable tumble solenoid valve malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Verify related service repair information availability.
• Is any related repair information available?
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
INSPECT POOR CONNECTION OF
VARIABLE TUMBLE SOLENOID VALVE
CONNECTOR
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes
No
Repair or replace the terminal, then go to
Step 7.
Go to the next step.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE
Yes Go to the next step.
• Perform variable tumble solenoid valve inspection.
(See VARIABLE TUMBLE SOLENOID VALVE
INSPECTION [LF] .)
No
Replace the variable tumble solenoid valve, then go to Step 7.
• Is variable tumble solenoid valve normal?
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection at PCM terminal
2AI. (such as damaged/pulled-out pins, corrosion).
• Is there malfunction?
Yes Repair terminal, then go to Step 7.
No Go to the next step.
INSPECT VARIABLE TUMBLE SOLENOID
VALVE CONTROL CIRCUIT FOR SHORT TO
POWER SUPPLY
Repair or replace the wiring harness for
Yes short to power supply, then go to the next step.
• Remove the variable tumble solenoid valve.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between PCM terminal
2AI and body ground.
• Is the voltage B+ ?
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2010 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Replace the PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Start the engine.
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2096
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P2096 [LF]
B3E010202000W04
Target A/F feedback system too lean
• The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is more than the specification, the PCM determines that the target A/F feedback system is too lean.
Diagnostic support note
• This is a continuous monitor (FUEL SYSTEM).
• The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
• Leakage exhaust gas
• Rear HO2S malfunction
• IAT sensor malfunction
• ECT sensor malfunction
• Air suction in intake-air system
• Front HO2S malfunction
• MAF sensor malfunction
• Insufficient fuel line pressure
• Fuel pump unit malfunction
• Leakage fuel
• Improper operation ignition system
• Insufficient engine compression
• Fuel injector malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off then to the ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2177 or P2187 also present?
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2096 on FREEZE FRAME DATA?
No
Go to FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [LF] .)
VERIFY CURRENT INPUT SIGNAL
STATUS OF REAR HO2S
• Connect the WDS or equivalent to the DLC-
2.
Yes Go to the next step.
• Start the engine and warm it up completely.
• Access O2S12 PID.
Visually inspect for the exhaust gas leakage between the TWC and rear HO2S.
• Read O2S12 PID under following accelerator pedal condition (in NEUTRAL).
- More than 0.45 V when accelerator pedal is suddenly depressed (rich condition).
No
• If there is no leakage, replace the rear
HO2S.
(See HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [LF] .)
Then go to Step 17.
- Less than 0.45 V just after release of accelerator pedal (lean condition)
• Is the PID normal?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
9
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the DLC-
2.
• Verify the following PIDs.
Yes Go to the next step.
(See PCM INSPECTION [LF] .)
- ECT No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 17.
- MAF
- TP
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME DATA
CONDITION
• Connect the WDS or equivalent to the DLC-
2.
Yes Go to the next step.
• Verify the following PIDs under the
FREEZE FRAME DATA condition.
(See PCM INSPECTION [LF]
- ECT
- MAF
.)
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 17.
- TP
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Connect the WDS or equivalent to the DLC-
2.
Yes Go to the next step.
• Start the engine and warm it up completely.
• Access O2S11 PID.
Visually inspect for the exhaust gas leakage between the exhaust manifold and front
HO2S.
• Read O2S11 PID under following accelerator pedal condition (in NEUTRAL).
- More than 0.45 V when accelerator pedal is suddenly depressed (rich condition).
No
• If there is no leakage, replace front HO2S.
(See HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [LF] .)
Then go to Step 17.
- Less than 0.45 V just after release of accelerator pedal (lean condition)
• Is the PID normal?
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
14
15
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the DLC-
2.
• Start the engine.
• Access the MAF PID.
No
Replace the MAF/IAT sensor, then go to Step
17.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes
Repair or replace the malfunctioning part, then go to Step 17.
INSPECT INTAKE-AIR SYSTEM FOR
EXCESSIVE AIR SUCTION
• Visually inspect the hose in intake-air system for looseness, cracks or damages.
• Is there any malfunction?
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
No
Yes
No
Go to the next step.
Go to the next step.
Go to Step 13.
INSPECT FUEL SYSTEM FOR FUEL
LEAKAGE
• Visually inspect fuel leakage in the fuel system.
• Is there fuel leakage?
Yes
Repair or replace the malfunctioning part, then go to Step 17.
No
Replace the fuel pump unit, then go to Step
17.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
INSPECT IGNITION COIL WIRING
HARNESSES
Yes Go to the next step.
• Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
No
Repair the wiring harnesses, then go to Step
17.
• Are wiring harness conditions normal?
INSPECT IGNITION SYSTEM OPERATION Yes Go to the next step.
• Perform spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
No
Repair or replace malfunctioning part according to spark test result.
Then go to Step 17.
Yes Go to the next step.
INSPECT ENGINE COMPRESSION
• Inspect the engine compression.
No Overhaul engine, then go to Step 17.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See COMPRESSION INSPECTION [LF] .)
• Is there any malfunction?
16
17
18
INSPECT FUEL INJECTOR
• Inspect fuel injector.
(See
• Is there any malfunction?
FUEL INJECTOR INSPECTION .)
Yes
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2096 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Perform the PCM Adaptive Memory
Produce Drive Mode.
No Go to the next step.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2097
DETECTION
CONDITION
DTC P2097 [LF]
B3E010202000W05
Target A/F feedback system too rich
• The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is less than specification, the PCM determines that the target
A/F feedback system is too rich.
Diagnostic support note
• This is a continuous monitor. (FUEL SYSTEM)
• The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• The DTC is stored in the PCM memory.
• Leakage exhaust gas
• Rear HO2S malfunction
• IAT sensor malfunction
• ECT sensor malfunction
• Front HO2S malfunction
• Excessive fuel line pressure
• Fuel pump unit malfunction
• Purge valve malfunction
• Insufficient engine compression
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
Yes
Go to the applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
• Turn the ignition switch off, then ON position (Engine off).
• Verify the related PENDING CODE or stored DTCs.
• Is the DTC P2178 or P2188 also present?
No Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2097 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [LF] .)
Yes Go to the next step.
VERIFY CURRENT INPUT SIGNAL
STATUS OF REAR HO2S
No
Visually inspect for the exhaust gas leakage between TWC and rear HO2S.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
7
8
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine and warm it up completely.
• Access O2S12 PID.
• Read O2S12 PID under following accelerator pedal condition (in NEUTRAL).
- More than 0.45 V when accelerator pedal is suddenly depressed (rich condition).
- Less than 0.45 V just after release of accelerator pedal (lean condition)
• Is the PID normal?
• If there is no leakage, replace rear HO2S.
(See HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [LF] .)
Then go to Step 11.
VERIFY CURRENT INPUT SIGNAL
STATUS
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs.
(See PCM INSPECTION [LF] .)
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
Yes
No
Go to the next step.
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
VERIFY CURRENT INPUT SIGNAL
STATUS UNDER FREEZE FRAME DATA
CONDITION
Yes Go to the next step.
• Connect the WDS or equivalent to the
DLC-2.
• Verify the following PIDs under FREEZE
FRAME DATA condition.
(See PCM INSPECTION [LF] .)
- ECT
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 11.
- MAF
- TP
- VSS
• Are the PIDs normal?
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
11
VERIFY CURRENT INPUT SIGNAL
STATUS OF FRONT HO2S
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine and warm it up completely.
• Access O2S11 PID.
• Read O2S11 PID under following accelerator pedal condition (in NEUTRAL).
- More than 0.45 V when accelerator pedal is suddenly depressed (rich condition).
Visually inspect for exhaust gas leakage between the exhaust manifold and front
HO2S.
No
• If there is no leakage, replace front HO2S.
(See HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [LF] .)
Then go to Step 11.
- Less than 0.45 V just after release of accelerator pedal (lean condition)
• Is the PID normal?
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE
INSPECTION .)
• Is there any malfunction?
Yes
No
Replace the fuel pump unit, then go to Step
11.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION
Go to the next step.
.)
Inspect the purge valve.
INSPECT LONG TERM FUEL TRIM
• Connect the WDS or equivalent to the
DLC-2.
(See PURGE SOLENOID VALVE
INSPECTION .)
• Access LONGFT1 PID.
• Compare the LONGFT1 PID with recorded
FREEZE FRAME DATA at Step 1.
Yes
• If there is any malfunction, replace the purge valve.
(See INTAKE-AIR SYSTEM HOSE ROUTING
DIAGRAM [LF] .)
• Is the LONGFT1 PID above FREEZE
FRAME DATA?
Then go to Step 11.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2097 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode.
(See OBD DRIVE MODE [LF] .)
Yes
Replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After repair procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2177
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P2177 [LF]
B3E010202100W01
Fuel system too lean at off idle
• PCM monitors short term fuel trim (SHRTFT), long term fuel trim (LONGFT) during closed loop fuel control at off-idle. If the LONGFT or the sum total of these fuel trims exceed preprogrammed criteria. PCM determines that fuel system is too lean at offidle.
Diagnostic support note
• This is a continuous monitor. (FUEL SYSTEM)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel injection pump) malfunction
• Fuel pump malfunction
• Fuel filter clogged or restricted
• Fuel leakage on fuel line from fuel delivery pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
• Purge solenoid hoses improper connection
• Air suction in intake-air system
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Insufficient engine compression
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTCS
• Turn ignition switch to off, then the ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Is other DTC present?
If misfire DTC is present, go to Step 8.
Yes
If other DTC is present, go to appropriate DTC troubleshooting procedure.
(See DTC TABLE [LF] .)
No
If drivability concern is present, go to Step 8.
If not, go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2177 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
5
6
7
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.
• Is there any signal that is far out of specification when key is ON and engine runs?
Yes
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Repair or if necessary.
Then go to Step 16.
No Go to the next step.
VERIFY CURRENT INPUT SIGANL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 5 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected sensor and related wiring harnesses repair or replace it.
Then go to Step 16.
• Is there any signal which causes drastic changes?
No Go to the next step.
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
VERIFY CURRENT INUPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using WDS or equivalent.
• Check PID under following accelerator pedal condition (in NEUTRAL).
• Is PID reading normal?
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 16.
- Above 0.45 V when accelerator pedal is suddenly depressed (rich condition).
- Below 0.45 V just after release of accelerator pedal (lean condition).
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
No Replace MAF/IAT sensor, then go to Step 16.
INSPECT FOR EXCESSIVE AIR
SUCTION OF INTAKE AIR SYSTEM
• Visually inspect for loosen, cracks or damages hoses on intake-air system.
• Is there any malfunction?
Yes
Repair or replace source of air suction, then go to Step 16.
No Go to the next step.
Yes Go to the next step.
INSPECT PURGE SOLENOID
OPERATION
• Carry out Purge Control System
Inspection.
(See Purge Control System Inspection .)
• Does purge control system work properly?
INSPECT FUEL LINE PRESSURE
• Turn ignition switch to off.
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
No
Yes
No
Repair or replace malfunctioning part according to inspection result, then go to Step 16.
Go to Step 12.
If fuel pressure is too high, replace fuel pump nit, then go to Step 16.
If fuel line pressure is low, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
17
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
Yes
Replace suspected fuel line, then go to Step
16.
Inspect for foreign materials or stain inside fuel filter (low-pressure).
• Is any fuel leakage found?
No If for foreign materials or stain inside fuel filter
(low-pressure), clean of fuel tank and filter.
Then go to Step 16.
INSPECT IGNITION SYSTEM
• Carry out spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
Yes Go to the next step.
No
Repair or replace malfunctioning part according to spark test result, then go to Step 16.
INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect engine compression.
(See COMPRESSION INSPECTION [LF] .)
No
Implement engine overhaul for repairs, then go to Step 16.
• Is it normal?
INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove fuel injector.
• Inspect fuel injector (resistance, injection amount).
No
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR INSPECTION .)
• Is fuel injector normal?
VERIFY TROUBLESHOOTING OF DTC
P2177 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace PCM, then go to the next step.
(See
• Clear DTC from PCM memory using WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode.
No Go to the next step.
PCM REMOVAL/INSTALLATION [LF] .)
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2178 [LF]
B3E010202100W02
DTC P2178 Fuel system too rich at off idle
DETECTION
CONDITION
POSSIBLE
CAUSE
• PCM monitors short term fuel trim (SHRTFT), long term fuel trim (LONGFT) during closed loop fuel control at off-idle. If the LONGFT or the sum total of these fuel trims exceed preprogrammed criteria. PCM determines that fuel system is too rich at offidle.
Diagnostic support note
• This is a continuous monitor. (FUEL SYSTEM)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel injection pump) malfunction
• Fuel pump malfunction
• EGR valve improper operation
• VTCS improper operation
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
• Purge solenoid hoses improper connection
• PCV valve malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
6
7
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTCS
• Turn ignition switch to off, then the ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Is other DTC present?
If misfire DTC is present, go to Step 8.
Yes
If other DTC is present, go to appropriate DTC troubleshooting procedure.
(See DTC TABLE [LF] .)
No
If drivability concern is present, go to Step 8.
If not, go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2178 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.)
• Is there any signal that is far out of specification when key is ON and engine runs?
Yes
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Repair or if necessary.
Then go to Step 15.
No Go to the next step.
VERIFY CURRENT INPUT SIGANL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 5 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected sensor and related wiring harnesses, repair or replace it.
Then go to Step 15.
• Is there any signal which causes drastic changes?
No Go to the next step.
VERIFY CURRENT INUPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using WDS or equivalent.
Yes Go to the next step.
• Check PID under following accelerator pedal condition (in NEUTRAL).
• Is PID reading normal?
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 15.
- Above 0.45 V when accelerator pedal is suddenly depressed (rich condition).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
13
- Below 0.45 V just after release of accelerator pedal (lean condition)
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
No Replace MAF/IAT sensor, then go to Step 15.
Yes Go to the next step.
INSPECT PURGE SOLENOID
OPERATION
• Carry out Purge Control System
Inspection.
(See Purge Control System Inspection .)
• Does purge control system work properly?
No
Repair or replace malfunctioning part according to inspection result, then go to Step 15.
INSPECT PCV VALVE OPERATION
• Inspect PCV valve operation.
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is PCV valve normal?
Yes
No
Go to the next step.
Replace PCV valve, then go to Step 15.
INSPECT EGR VALVE OPERATION Yes Go to the next step.
• Carry out EGR Control System
Inspection.
(See EGR Control System Inspection .)
• Does EGR control system work properly?
No
Repair or replace malfunctioning part according to inspection result, then go to Step 15.
INSPECT VTCS OPERATION
• Carry out Variable Tumble Control
System (VTCS) Operation Inspection.
(See Variable Tumble Control Operation
Inspection .)
• Does VTCS work properly?
INSPECT FUEL LINE PRESSURE
• Turn ignition switch to off.
• Inspect fuel line pressure.
Yes Go to the next step.
No
Yes
No
Repair or replace malfunctioning part according to inspection result, then go to Step 15.
Go to the next step.
If fuel pressure is too high, replace fuel pump nit, then go to Step 15.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
If fuel line pressure is low, go to the next step.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
14
15
16
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
Yes
Replace suspected fuel line, then go to the next step.
Inspect for foreign materials or stain inside fuel filter (low-pressure).
• Is any fuel leakage found?
No If for foreign materials or stain inside fuel filter
(low-pressure), clean of fuel tank and filter.
Then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2178 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace PCM, then go to the next step.
(See
• Clear DTC from PCM memory using WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode.
No Go to the next step.
PCM REMOVAL/INSTALLATION [LF] .)
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
No Troubleshooting completed.
DTC P2187
DETECTION
CONDITION
DTC P2187 [LF]
B3E010202100W03
Fuel system too lean at idle
• PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control at idle. If the LONGFT or the sum total of these fuel terms exceed preprogrammed criteria. PCM determines that fuel system is too lean at idle.
Diagnostic support note
• This is a continuous monitor. (FUEL SYSTEM)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE
CAUSE
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel injection pump) malfunction
• Fuel pump malfunction
• Fuel filter clogged or restricted
• Fuel leakage on fuel line from fuel delivery pipe and fuel pump
• Leakage exhaust system
• Purge solenoid valve malfunction
• Purge solenoid hoses improper connection
• Air suction in intake-air system
• Insufficient engine compression
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
No
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTCS
• Turn ignition switch to off, then the ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Is other DTC present?
If misfire DTC is present, go to Step 8.
Yes
If other DTC is present, go to appropriate DTC troubleshooting procedure.
(See DTC TABLE [LF] .)
No
If drivability concern is present, go to Step 8.
If not, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2177 on FREEZE FRAME
DATA?
Yes Go to the next step.
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON/IDLE)
• Access ECT, MAF and TP PIDs using
WDS or equivalent.)
• Is there any signal that is far out of specification when key is ON and engine runs?
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Yes
Repair or if necessary.
Then go to Step 16.
No Go to the next step.
VERIFY CURRENT INPUT SIGANL
STATUS UNDER TROUBLE CONDITION
• Inspect same PIDs as Step 4 while simulating FREEZE FRAME DATA condition.
Yes
Inspect suspected sensor and related wiring harnesses, repair or replace it.
Then go to Step 16.
• Is there any signal which causes drastic changes?
No Go to the next step.
VERIFY CURRENT INUPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using WDS or equivalent.
Yes Go to the next step.
• Check PID under following accelerator pedal condition (in NEUTRAL).
• Is PID reading normal?
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 16.
- Above 0.45 V when accelerator pedal is suddenly depressed (rich condition).
- Below 0.45 V just after release of accelerator pedal (lean condition)
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
No Replace MAF/IAT sensor, then go to Step 16.
INSPECT FOR EXCESSIVE AIR
SUCTION OF INTAKE AIR SYSTEM
Yes
Repair or replace source of air suction, then go to Step 16.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
14
15
• Visually inspect for loosen, cracks or damages hoses on intake-air system.
• Is there any malfunction?
No Go to the next step.
INSPECT PURGE SOLENOID VALVE
STUCK OPEN
• Turn ignition switch to off.
• Disconnect both hoses from purge solenoid valve.
• Blow air through purge solenoid valve.
• Does air blow through?
INSPECT FUEL LINE PRESSURE
• Turn ignition switch to off.
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
Yes
No
Yes
No
Replace purge solenoid valve.
Then go to Step 16.
Go to the next step.
Go to Step 13.
If fuel pressure is too high, replace fuel pump unit, then go to Step 16.
If fuel line pressure is low, go to the next step.
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
Yes
Replace suspected fuel line, then go to Step
16.
Inspect for foreign materials or stain inside fuel filter (low-pressure).
• Is any fuel leakage found?
No If for foreign materials or stain inside fuel filter
(low-pressure), clean of fuel tank and filter.
Then go to Step 16.
INSPECT IGNITION SYSTEM
• Carry out spark test.
(See Spark Test .)
• Is strong blue spark visible at each cylinder?
Yes Go to the next step.
No
Repair or replace malfunctioning part according to spark test results, then go to Step 16.
INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect engine compression.
(See COMPRESSION INSPECTION [LF] .)
No
• Is it normal?
Implement engine overhaul for repairs, then go to Step 16.
INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove fuel injector.
• Inspect fuel injector (resistance, injection amount).
No
Replace suspected fuel injector, then go to the next step.
(See FUEL INJECTOR INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
16
17
• Is fuel injector normal?
VERIFY TROUBLESHOOTING OF DTC
P2187 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace PCM, then go to the next step.
(See
• Clear DTC from PCM memory using WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode.
No Go to the next step.
PCM REMOVAL/INSTALLATION [LF] .)
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
No Troubleshooting completed.
DTC P2188
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P2188 [LF]
B3E010202100W04
Fuel system too rich at idle
• PCM monitors short term fuel trim (SHRTFT), long term fuel trim (LONGFT) during closed loop fuel control at idle. If the LONGFT or the sum total of these fuel terms exceed preprogrammed criteria. PCM determines that fuel system is too rich at idle.
Diagnostic support note
• This is a continuous monitor. (FUEL SYSTEM)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Misfire
• Front HO2S deterioration
• Front HO2S heater malfunction
• MAF sensor malfunction
• Pressure regulator (built-in fuel injection pump) malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel pump malfunction
• EGR valve stuck open
• VTCS improper operation
• Purge solenoid valve improper operation
• Purge solenoid valve malfunction (stuck open)
• Purge solenoid hoses improper connection
• PCV valve malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
2
3
4
5
6
ACTION
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTCS
• Turn ignition switch to off, then the ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Is other DTC present?
If misfire DTC is present, go to Step 8.
Yes
If other DTC is present, go to appropriate DTC troubleshooting procedure.
(See DTC TABLE [LF] .)
No
If drivability concern is present, go to Step 8.
If not, go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2178 on FREEZE FRAME
DATA?
No
Go to troubleshooting procedures for DTC on
FREEZE FRAME DATA.
VERIFY CURRENT INPUT SIGNAL
STATUS (KEY TO ON/IDLE)
• Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.
• Is there any signal that is far out of specification when key is ON and engine runs?
Yes
No
Inspect suspected sensor and excessive resistance in related wiring harnesses.
Repair or if necessary.
Then go to Step 15.
Go to the next step.
VERIFY CURRENT INPUT SIGANL
STATUS UNDER TROUBLE CONDITION
Yes
Inspect suspected sensor and related wiring harnesses, repair or replace it.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
• Inspect same PIDs as Step 5 while simulating FREEZE FRAME DATA condition.
• Is there any signal which causes drastic changes?
No
Then go to Step 15.
Go to the next step.
VERIFY CURRENT INUPUT SIGNAL
STATUS OF FRONT HO2S
• Access O2S11 for P2177 PID using WDS or equivalent.
Yes Go to the next step.
• Check PID under following accelerator pedal condition (in NEUTRAL).
• Is PID reading normal?
No
Visually inspect for any gas leakage between exhaust manifold and front HO2S.
Then go to Step 15.
- Above 0.45 V when accelerator pedal is suddenly depressed (rich condition).
- Below 0.45 V just after release of accelerator pedal (lean condition).
8
9
10
VERIFY CURRENT INPUT SIGNAL
STATUS OF MAF SENSOR
• Connect the WDS or equivalent to the
DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
Yes Go to the next step.
No Replace MAF/IAT sensor, then go to Step 15.
INSPECT PURGE SOLENOID
OPERATION
Yes Go to the next step.
• Carry out Purge Control System
Inspection.
(See Purge Control System Inspection .)
• Does purge control system work properly?
No
Repair or replace malfunctioning part according to inspection result, then go to Step
15.
Yes Go to the next step.
INSPECT PCV VALVE OPERATION
• Inspect PCV valve operation.
(See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE
INSPECTION .)
• Is PCV valve normal?
No Replace PCV valve, then go to Step 15.
11 INSPECT VTCS OPERATION Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
14
15
16
• Carry out Variable Tumble Control System
(VTCS) Operation Inspection.
(See Variable Tumble Control Operation
Inspection .)
No
Repair or replace malfunctioning part according to inspection result, then go to Step
15.
• Does VTCS work properly?
Yes Go to the next step.
INSPECT FUEL LINE PRESSURE
• Turn ignition switch to off.
• Inspect fuel line pressure.
(See FUEL LINE PRESSURE
INSPECTION .)
• Is fuel line pressure normal?
No
If fuel pressure is too high, replace fuel pump nit, then go to Step 15.
If fuel line pressure is low, go to the next step.
Yes
Replace suspected fuel line, then go to Step
15.
INSPECT FUEL LINE FROM FUEL PUMP
TO FUEL DELIVERY PIPE
• Visually inspect fuel line for any leakage.
• Is any fuel leakage found?
Inspect for foreign materials or stain inside fuel filter (low-pressure).
No If for foreign materials or stain inside fuel filter
(low-pressure), clean of fuel tank and filter.
Then go to Step 15.
INSPECT EGR VALVE STUCK OPEN
• Remove EGR valve.
• Does EGR valve stuck open?
Yes
No
Clean or replace EGR valve, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2188 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace PCM, then go to the next step.
(See
• Clear DTC from PCM memory using WDS or equivalent.
• Perform the PCM Adaptive Memory
Produce Drive Mode. (See OBD DRIVE
MODE [LF] .)
• Is the PENDING CODE for this DTC present?
No Go to the next step.
PCM REMOVAL/INSTALLATION [LF] .)
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
No Troubleshooting completed.
DTC P2195 [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2195
DETECTION
CONDITION
POSSIBLE
CAUSE
B3E010202100W05
Front HO2S signal stuck lean
• The PCM monitors the front HO2S output voltage when the following conditions are met. If output voltage is less than 0.45 V for 41 s , the PCM determines that the front
HO2S signal remains lean.
MONITORING CONDITION
- Fuel injection control system status: feedback zone
- ECT: more than 70 ° C {158 ° F}
- Engine speed: more than 1,500 rpm
Diagnostic support note
• This is a continuous monitor. (HO2S)
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Front HO2S malfunction
• Fuel injector malfunction
• Insufficient fuel line pressure
• Leakage exhaust gas
• Air suction at intake-air system
• Leakage fuel
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
VERIFY REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Is any related repair information available?
No Go to the next step.
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then ON position
(Engine off).
• Verify the related PENDING CODE or stored
DTCs.
• Is the DTC P2177 or P2187 also present?
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2195 on FREEZE FRAME DATA?
No
Go to FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [LF] .)
VERIFY CURRENT INPUT SIGNAL STATUS
• Connect the WDS or equivalent to the DLC-2.
Yes Go to the next step.
• Verify the following PIDs.
(See PCM INSPECTION [LF] .)
- ECT
- MAF
- TP
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 14.
- VSS
• Are the PIDs normal?
VERIFY CURRENT INPUT SIGNAL STATUS
UNDER FREEZE FRAME DATA CONDITION
• Connect the WDS or equivalent to the DLC-2.
Yes Go to the next step.
• Verify the following PIDs under FREEZE
FRAME DATA condition.
(See PCM INSPECTION [LF] .)
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 14.
INSPECT INTAKE-AIR SYSTEM FOR
EXCESSIVE AIR SUCTION
Yes
Repair or replace the malfunctioning part, then go to Step 14.
• Visually inspect for loosen, cracks or damages hose in intake-air system.
No Go to the next step.
• Is there any malfunction?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
13
VERIFY CURRENT INPUT SIGNAL STATUS
OF MAF SENSOR
• Connect the WDS or equivalent to the DLC-2.
Yes Go to the next step.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
No
Replace MAF/IAT sensor, then go to Step
14.
INSPECT FRONT HO2S
• Inspect front HO2S.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is there any malfunction?
Replace front HO2S, then go to Step 14.
Yes
(See HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
INSPECT FUEL INJECTOR
• Inspect fuel injector.
(See FUEL INJECTOR INSPECTION .)
• Is there any malfunction?
Yes
Replace suspected fuel injector, then go to
Step 14.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [LF] .)
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE INSPECTION .)
• Is there any malfunction?
No Go to the next step.
Yes Go to the next step.
No Go to Step 13.
INSPECT FUEL SYSTEM FOR FUEL
LEAKAGE
• Visually inspect fuel leakage in the fuel system.
• Is there fuel leakage?
Yes
Repair or replace the malfunctioning part, then go to the next step.
No
Replace the fuel pump unit, then go to the next step.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
VERIFY TROUBLESHOOTING OF DTC P2195
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the PCM Adopted Memory Produce
Drive Mode and HO2S heater, and TWC Repair
Verification Drive Mode.
No Go to the next step.
(See OBD DRIVE MODE [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
• Is the PENDING CODE for this DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2196
DETECTION
CONDITION
POSSIBLE
CAUSE
DTC P2196 [LF]
B3E010202100W06
Front HO2S signal stuck rich
• The PCM monitors the front HO2S output voltage when the following conditions are met. If output voltage is more than 0.45 V for 41 s , the PCM determines that the front
HO2S signal remains rich.
MONITORING CONDITION
- Fuel injection control system status: feedback zone
- ECT: more than 70 ° C {158 ° F}
- Engine speed: more than 1,500 rpm
Diagnostic support note
• This is a continuous monitor (HO2S).
• MIL illuminates if PCM detects the above malfunctioning condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
• Front HO2S malfunction
• Fuel injector malfunction
• Excessive fuel pressure
• Restriction in intake-air system
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
If the vehicle is not repaired, go to the next step.
No
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
VERIFY RELATED PENDING CODE OR
STORED DTC
• Turn the ignition switch off, then ON position
(Engine off).
• Verify the related PENDING CODE or stored
DTCs.
• Is the DTC P2177 or P2187 also present?
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No Go to the next step.
Yes Go to the next step.
IDENTIFY TRIGGER DTC FOR FREEZE
FRAME DATA
• Is DTC P2196 on FREEZE FRAME DATA?
No
Go to FREEZE FRAME DATA DTC inspection.
(See DTC TABLE [LF] .)
VERIFY CURRENT INPUT SIGNAL STATUS
• Connect the WDS or equivalent to the DLC-2.
Yes Go to the next step.
• Verify the following PIDs.
(See PCM INSPECTION [LF] .)
- ECT
- MAF
- TP
- VSS
• Are the PIDs normal?
No
Inspect the malfunctioning part according to the inspection results.
Then go to Step 10.
VERIFY CURRENT INPUT SIGNAL STATUS
OF MAF SENSOR
• Connect the WDS or equivalent to the DLC-2.
Yes Go to the next step.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to engine speed.
• Is the PID normal?
No
Replace MAF/IAT sensor, then go to Step
10.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7
INSPECT FRONT HO2S
• Inspect the front HO2S.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
• Is there any malfunction?
Replace front HO2S, then go to Step 10.
Yes
(See HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
8
INSPECT FUEL INJECTOR
• Inspect fuel injector.
(See FUEL INJECTOR INSPECTION .)
• Is there any malfunction?
Yes
Replace suspected fuel injector, then go to
Step 10.
(See FUEL INJECTOR
REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
9
10
11
INSPECT FUEL LINE PRESSURE
• Perform the "FUEL LINE PRESSURE
INSPECTION".
(See FUEL LINE PRESSURE INSPECTION .)
• Is there any malfunction?
VERIFY AFTER REPAIR PROCEDURE
• Perform the "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
Yes
No
Replace the fuel pump unit, then go to the next step.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
VERIFY TROUBLESHOOTING OF DTC P2196
COMPLETED
• Make sure to reconnect all disconnected connectors.
Replace PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear the DTC from the PCM memory using the WDS or equivalent.
• Perform the PCM Adopted Memory Produce
Drive Mode and HO2S heater, and TWC Repair
Verification Drive Mode.
No Go to the next step.
(See OBD DRIVE MODE [LF] .)
• Is the PENDING CODE for this DTC present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
No
Go to the next step.
Troubleshooting completed.
DTC P2228
DETECTION
CONDITION
DTC P2228 [LF]
B3E010201083W01
BARO sensor circuit low input
• PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1AG is below 1.99 V , PCM determines that BARO sensor circuit has malfunction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
POSSIBLE CAUSE
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in PCM memory.
• BARO sensor malfunction
• Connector or terminal malfunction
• Short to ground in wiring between BARO sensor terminal A and PCM terminal 1AG
• Open circuit in wiring between BARO sensor terminal C and PCM terminal
1AE
• PCM malfunction
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
ACTION
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
Yes
Perform repair or diagnosis according to the available repair information.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
6
7
• Verify related service repair information availability.
• Is any related repair information available?
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes Go to the next step.
INSPECT CONNECTION OF BARO
SENSOR CONNECTOR
• Turn the ignition switch to off.
• Verify that BARO sensor connector is connected securely.
• Is connection normal?
No Reconnect the connector, then go to Step 9.
INSPECT BARO SENSOR CONNECTOR
FOR POOR CONNECTION
• Disconnect the BARO sensor connector.
• Inspect for poor connection
(damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
Yes
No
Repair or replace suspected terminal, then go to Step 8.
Go to the next step.
INSPECT BARO SENSOR MALFUNCTION Yes Go to the next step.
• Perform BARO sensor inspection.
(See BAROMETRIC PRESSURE (BARO)
SENSOR INSPECTION [LF] .)
• Is BARO sensor normal?
No Replace BARO sensor, then go to Step 9.
INSPECT POWER SUPPLY CIRCUIT
VOLTAGE AT BARO SENSOR
CONNECTOR
Yes Go to the next step.
Note
• If DTCs P0107 and P0122 are also retrieved with P2228, go to
REFERENCE VOLTAGE troubleshooting procedure.
No
Inspect for open circuit between PCM terminal 1AE (harness-side) and BARO sensor terminal C (harness-side).
Repair or replace suspected harness, then go to Step 9.
• Measure voltage between BARO sensor terminal C (harness-side) and body ground.
• Is voltage within 4.5-5.5 V?
INSPECT BARO SENSOR SIGNAL
CIRCUIT FOR SHORT TO GROUND
• Turn the ignition switch to off.
• Disconnect PCM connector.
• Inspect for continuity between BARO sensor terminal B (harness-side) and body ground.
• Is there continuity?
Yes
Repair or replace suspected harness, then go to Step 9.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Disconnect PCM connector.
• Inspect for poor connection at terminals
(damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
Yes Repair terminal, then go to Step 9.
No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2228 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear DTC from memory using WDS or equivalent.
• Start the engine.
• Is same DTC present?
Yes
Replace PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
No No concern is detected. Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2229
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2229 [LF]
B3E010201083W02
BARO sensor circuit high input
• PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1AG is above 4.43 V , PCM determines that BARO sensor circuit has malfunction.
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
• PENDING CODE is available if PCM detects the above malfunction condition.
• FREEZE FRAME DATA is available.
• DTC is stored in PCM memory.
• BARO sensor malfunction
• Connector or terminal malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Open circuit in wiring between BARO sensor terminal A and PCM terminal
1AG
• Open circuit in wiring between BARO sensor terminal B and PCM terminal
1AA
• Short to power circuit in wiring between BARO sensor terminal A and PCM terminal 1AG
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION ACTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
• Has FREEZE FRAME DATA been recorded?
No
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
2
3
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
No Go to the next step.
Yes Go to the next step.
INSPECT CONNECTION OF BARO
SENSOR CONNECTOR
• Turn the ignition switch to off.
• Verify that BARO sensor connector is connected securely.
• Is connection normal?
No Reconnect the connector, then go to Step 9.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
9
INSPECT BARO SENSOR CONNECTOR
FOR POOR CONNECTION
• Disconnect the BARO sensor connector.
• Inspect for poor connection
(damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
Yes
No
Repair or replace suspected terminal, then go to Step 9.
Go to the next step.
INSPECT BARO SENSOR MALFUNCTiON
• Perform BARO sensor inspection.
(See BAROMETRIC PRESSURE (BARO)
SENSOR INSPECTION [LF] .)
• Is BARO sensor normal?
Yes Go to the next step.
No Replace BARO sensor, then go to Step 9.
VERIFY BARO SENSOR SIGNAL CIRCUIT
FOR SHORT TO REFERENCE VOLTAGE
CIRCUIT
• Measure voltage between BARO sensor terminal A and body ground.
• Is voltage above 4.43 V?
Yes
Repair or replace short to power supply harness, then go to Step 9.
No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
• Disconnect PCM connector.
• Inspect for poor connection at terminals
(damaged/pulled-out pins, corrosion, etc.).
• Is there malfunction?
VERIFY BARO SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
Yes Go to the next step.
• Inspect for continuity following terminals:
- Between BARO sensor terminal A and PCM terminal 1AG
No
Repair or replace open harness, then go to
Step 9.
- Between BARO sensor terminal B and PCM terminal 1AA
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P2229 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Turn the ignition switch to the ON position
(Engine off).
• Clear DTC from memory using WDS or equivalent.
• Start the engine.
Yes
No
Replace PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
No
Repair terminal, then go to Step 9.
Go to the next step.
No concern is detected. Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
• Is same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
DTC P2502
DETECTION
CONDITION
POSSIBLE CAUSE
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2502 [LF]
B3E010201083W03
Charging system voltage problem
• PCM judges generator output voltage is above 17 V or battery voltage is below 11 V during engine running.
• Open circuit between generator terminal B and battery positive terminal
• Battery malfunction
• Generator malfunction
• PCM is poorly connected
• PCM, generator and/or battery are poorly connected
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
Yes Go to the next step.
INSPECT BATTERY
• Turn the ignition switch to off.
• Inspect battery.
• Is battery normal?
No Replace battery, then go to Step 7.
INSPECT POOR INSTALLATION OF
GENERATOR TERMINAL
• Turn the ignition switch to off.
• Inspect for looseness of generator terminal B installation nut.
• Is the nut loose?
Yes
Tighten generator terminal B installation nut, then go to Step 7.
No Go to the next step.
INSPECT POOR INSTALLATION OF
BATTERY POSITIVE TERMINAL
• Inspect for looseness of battery positive terminal.
• Is the terminal loose?
Yes
No
Connect battery positive terminal correctly, then go to Step 7.
Go to the next step.
INSPECT BATTERY CHARGING
CIRCUIT
• Disconnect the generator terminal B.
• Measure the voltage between the generator terminal B (wiring harnessside) and the body ground.
• Is the voltage B+ ?
Yes
No
Go to the next step.
Repair or replace wiring harness between the generator terminal B and the battery positive terminal, then go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2502 COMPLETED
Yes
Replace PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
• Make sure to reconnect all connectors.
• Clear DTC from memory using WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is same DTC present?
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE
[LF] .)
• Is there any DTC present?
No Troubleshooting completed.
DTC P2503
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2503 [LF]
B3E010201083W04
Charging system voltage low
• PCM needs more than 20 A from generator, and judges generator output voltage to be below 8.5 V during engine running.
• Generator malfunction
• PCM and/or generator are poorly connected
• Open and/or short to GND in wiring from between generator terminal P and
PCM terminal 2AM
• Open and/or short to GND in wiring from between generator terminal D and
PCM terminal 2AQ
• Drive belt misadjustment
Diagnostic procedure
STEP INSPECTION ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
2
3
4
5
6
7
8
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes Go to the next step.
No
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
• Is any related repair information available?
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
INSPECT DRIVE BELT CONDITION
• Verify that drive belt auto tensioner indicator mark does not exceed limit.
• Is front drive belt normal?
No Go to the next step.
Yes
No
Go to the next step.
Replace and/or adjust drive belt, then go to Step 10.
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch to off.
• Disconnect PCM connector.
• Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).
• Is there a malfunction?
Yes Repair terminals, then go to Step 10.
No Go to the next step.
INSPECT POOR CONNECTION OF
GENERATOR CONNECTOR
• Disconnect generator connector.
• Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).
• Is there a malfunction?
Yes
Repair or replace terminals, then go to
Step 10.
No Go to the next step.
INSPECT GENERATOR CONTROL CIRCUIT
FOR SHORT TO GROUND
• Inspect for continuity between generator terminal D (wiring harness-side) and body ground.
• Is there continuity?
Yes
Repair or replace wiring harness for short to ground, then go to Step 10.
No Go to the next step.
INSPECT GENERATOR OUTPUT VOLTAGE
MONITOR CIRCUIT FOR SHORT TO GROUND
Yes
Repair or replace wiring harness for short to ground, then go to Step 10.
• Inspect for continuity between generator terminal P (wiring harness-side) and body ground.
• Is there continuity?
No Go to the next step.
Yes Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INSPECT GENERATOR CONTROL CIRCUIT
FOR OPEN
• Inspect for continuity between generator terminal D (wiring harness-side) and PCM terminal 2AQ (wiring harness-side).
• Is there continuity?
No
Repair or replace wiring harness for open circuit, then go to Step 10.
9
10
11
INSPECT GENERATOR OUTPUT VOLTAGE
MONITOR CIRCUIT FOR OPEN CIRCUIT
• Inspect for continuity between generator terminal P (wiring harness-side) and PCM terminal 2AM (wiring harness-side).
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC P2503
COMPLETED
• Make sure to reconnect all connectors.
Replace PCM, then go to the next step.
Yes
(See PCM REMOVAL/INSTALLATION
[LF] .)
• Clear DTC from PCM memory using WDS or equivalent.
No Go to the next step.
• Start the engine.
• Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
Yes
No
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No
Repair or replace generator, then go to the next step.
Repair or replace wiring harness for open circuit, then go to the next step.
Troubleshooting completed.
DTC P2504
DETECTION
CONDITION
POSSIBLE CAUSE
DTC P2504 [LF]
B3E010201083W05
Charging system voltage high
• PCM judges generator output voltage is above 18.5 V or battery voltage is above 16.0 V during engine running.
• Short to power circuit between generator connector terminal D and PCM connector terminal 2AQ
• Generator malfunction
• PCM and/or generator are poorly connected
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
No
ACTION
Go to the next step.
Record the FREEZE FRAME DATA on the repair order, then go to the next step.
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
• Verify related service repair information availability.
Yes
Perform repair or diagnosis according to the available repair information.
• If the vehicle is not repaired, go to the next step.
• Is any related repair information available?
No Go to the next step.
3
4
INSPECT POOR CONNECTION OF
GENERATOR CONNECTOR
• Turn the ignition switch to off.
• Disconnect generator connector.
• Inspect for poor connection (damaged, pulled-out terminals, corrosion, etc.).
• Is there a malfunction?
Yes
No
Repair or replace terminals, then go to Step
8.
Go to the next step.
CLASSIFY GENERATOR MALFUNCTION
OR OTHER MALFUNCTION
• Turn the ignition switch to the ON position
(Engine off).
Yes Go to the next step.
No
Malfunction at generator.
Go to Step 7.
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5
6
7
8
9
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Measure voltage between generator terminal D (wiring harness-side) and body ground.
• Is the voltage B+ ?
INSPECT POOR CONNECTION OF PCM
CONNECTOR
• Turn the ignition switch to off.
• Disconnect PCM connector.
• Inspect for poor connection (damaged, pulled-out terminals, corrosion, etc.).
• Is there a malfunction?
Yes
No
Repair or replace pins, then go to Step 8.
Go to the next step.
INSPECT GENERATOR CONTROL
CIRCUIT FOR SHORT TO POWER
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between generator terminal D (wiring harness-side) and body ground.
• Is the voltage B+ ?
Yes
Repair or replace wiring harness for short to power supply, then go to Step 8.
No Go to Step 8.
INSPECT GENERATOR CONTROL
TERMINAL FOR SHORT TO POWER
• Measure voltage between generator terminal D (part-side) and body ground.
• Is the voltage B+ ?
Yes
No
Repair or replace generator, then go to the next step.
Go to the next step.
VERIFY TROUBLESHOOTING OF DTC
P2504 COMPLETED
• Make sure to reconnect all connectors.
• Clear DTC from PCM memory using WDS or equivalent.
• Perform KOER self-test.
Start the engine.
• Is same DTC present?
Yes
Replace PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [LF] .)
No Go to the next step.
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
(See AFTER REPAIR PROCEDURE [LF] .)
• Is there any DTC present?
Yes
Go to applicable DTC troubleshooting.
(See DTC TABLE [LF] .)
No Troubleshooting completed.
DTC P2507 [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DTC P2507
DETECTION
CONDITION
POSSIBLE CAUSE
B3E010201083W06
PCM B+ voltage low
• The PCM monitors the voltage of back-up battery positive terminal at PCM terminal 1BA. If the PCM detected battery positive terminal voltage below
2.5 V for 2 s , the PCM determines that the backup voltage circuit has malfunction.
• Melt down EEC fuse
• Open circuit in wiring between EEC fuse and PCM terminal 1BA
• Short to ground between EEC fuse and PCM terminal 1BA
• Poor connection of PCM connector
• PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS
BEEN RECORDED
• Has FREEZE FRAME PID DATA been recorded?
2
3
ACTION
Yes Go to the next step.
No
Record FREEZE FRAME PID DATA on repair order, then go to the next step.
VERIFY RELATED REPAIR
INFORMATION AVAILABILITY
Yes
Perform repair or diagnosis according to available repair information.
• If vehicle is not repaired, go to the next step.
• Check for related service repair information availability.
• Is any related repair information available?
No Go to the next step.
INSPECT EEC FUSE Yes Go to step 6.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
6
7
8
• Turn the ignition switch to off.
• Inspect EEC fuse for failure and proper.
• Is it normal?
No
• If EEC fuse has been melt down, then go to the next step.
• If EEC fuse is not installed correctly, install it correctly then go to Step 7.
INSPECT MONITOR CIRCUIT FOR
SHORT TO GROUND
• Disconnect battery cables.
• Inspect continuity between EEC fuse terminal and body ground.
• Is there continuity?
Yes
No
Repair or replace wiring harness for short to ground and install new fuse, then go to Step 7.
Go to step 7.
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Yes Repair terminals, then go to Step 7.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged, pulled-out terminals, corrosion).
• Is there any malfunction?
No Go to the next step.
INSPECT MONITOR CIRCUIT FOR OPEN
CIRCUIT
Yes Go to the next step.
• Disconnect battery cables.
• Inspect continuity between EEC fuse terminal and PCM terminal 1BA (wiring harness-side).
No
Repair or replace wiring harness for open circuit, then go to the next step.
• Is there continuity?
VERIFY TROUBLESHOOTING OF DTC
P2507 COMPLETED
• Make sure to reconnect all disconnected connectors.
Yes
Replace PCM, then go to the next step.
(See
• Turn the ignition switch to the ON position
(Engine off).
• Clear DTC from PCM memory using WDS or equivalent.
No Go to the next step.
• Start engine and warm it up completely.
• Is same DTC present?
PCM REMOVAL/INSTALLATION [LF] .)
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [LF] .)
(See AFTER REPAIR PROCEDURE [LF] .)
• Are any DTC present?
No Troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
SYMPTOM
TROUBLESHOOTING[ENGINE
CONTROL SYSTEM (Z6)]
ENGINE SYMPTOM TROUBLESHOOTING [Z6]
B3E010318881W32
• Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
Diagnostic Index
No.
TROUBLESHOOTING ITEM
1 Melting of main or other fuses
2 MIL illuminates.
3 Will not crank
DESCRIPTION
-
The MIL is illuminated incorrectly.
The starter does not work.
4
Hard to start/long crank/erratic start/erratic crank
The starter cranks the engine at normal speed but the engine requires excessive cranking time before starting.
5 Engine stalls.
After start/at idle
6 Cranks normally but will not start
7 Slow return to idle
8 Engine runs rough/rolling idle
9 Fast idle/runs on
10 Low idle/stalls during deceleration
The engine stops unexpectedly at idle and/or after start.
The starter cranks the engine at normal speed but the engine will not run.
The engine takes more time than normal to return to idle speed.
The engine speed fluctuates between specified idle speed and lower speed and the engine shakes excessively.
The engine speed continues at fast idle after warmup.
The engine runs after the ignition switch is turned off.
The engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11
12
13
Misses
Buck/jerk
14 Poor fuel economy
15 Emission compliance
16 High oil consumption/leakage
17
Cooling system concerns
Overheating
18
Cooling system concerns
Runs cold
19 Exhaust smoke
20 Fuel odor (in engine compartment)
21 Engine noise
22 Vibration concerns (engine)
23
25
26
27
Engine stalls/quits.
Engine runs rough.
Hesitation/stumble
Surges
Lack/loss of power
Knocking/pinging
A/C does not work sufficiently.
Exhaust sulphur smell
Spark plug condition
Acceleration/cruise
Acceleration/cruise
Acceleration
Acceleration/cruise
Acceleration/cruise
Acceleration/cruise
A/C is not cut off under WOT conditions.
Acceleration/cruise
Acceleration/cruise/ deceleration
24
A/C is always on or A/C compressor runs continuously.
The engine stops unexpectedly at beginning of acceleration or during acceleration.
The engine stops unexpectedly while cruising.
The engine speed fluctuates during acceleration or cruising.
The engine misses during acceleration or cruising.
The vehicle bucks/jerks during acceleration, cruising, or deceleration.
Momentary pause at beginning of acceleration or during acceleration
Momentary minor irregularity in engine output
Performance is poor under load. (e.g. power down when climbing hills)
Sound is produced when air/fuel mixture is ignited by something other than spark plug. (e.g. hot spot in combustion chamber)
Fuel economy is unsatisfactory.
Fails emissions test.
Oil consumption is excessive.
The engine runs at higher than normal temperature/overheats.
The engine does not reach normal operating temperature.
Blue, black, or white smoke from exhaust system
Gasoline fuel smell or visible leakage
Engine noise from under hood
Vibration from under hood or driveline
The A/C compressor magnetic clutch does not engage when the A/C is turned on.
The A/C compressor magnetic clutch does not disengage.
The A/C compressor magnetic clutch does not disengage under WOT.
Rotten egg smell (sulphur) from exhaust
Incorrect spark plug condition
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
28 ATX concerns
Upshift/downshift/ engagement
ATX concerns not related to engine performance
QUICK DIAGNOSIS CHART [Z6]
B3E010318881W33
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
NO.1 MELTING OF MAIN OR OTHER FUSES [Z6]
B3E010318881W34
MELTING OF MAIN OR OTHER FUSES
[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Damaged fuse Related wiring harness
IG KEY1 fuse
IG KEY1
(30 A)
• Ignition switch
- ENGINE fuse
ENGINE fuse
ENGINE
(20 A) • Main relay
IG KEY2
(30 A)
IG KEY2 fuse
• Ignition switch
- BACK fuse
BACK
(10 A)
ENG +B
(10 A)
ENGINE
(30 A)
EGI INJ1
(10 A)
EGI INJ2
(10 A)
ENG BAR1
BACK fuse
• TR switch
ENG +B
• PCM
ENGINE fuse
• Main relay
- EGI INJ1 fuse
- EGI INJ2 fuse
- EGI BAR1 fuse
EGI INJ1 fuse
• PCM
EGI INJ2 fuse
• PCM
ENG BAR1 fuse
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(10 A) • PCM
• Fuel pump relay
FUEL PUMP
(15 A)
FUEL PUMP fuse
• Fuel pump relay
FAN
(40 A)
FAN fuse
• FAN control module
BTN fuse
BTN
(40 A)
OBD
(10 A)
• OBD fuse
OBD fuse
• DLC-2
NO.2 MIL ILLUMINATES [Z6]
B3E010318881W35
2 MIL ILLUMITATES
DESCRIPTION
The MIL is illuminated incorrectly.
• The PCM illuminates for emission-related concern (DTC is stored in the PCM).
POSSIBLE CAUSE
• Instrument cluster malfunction
Note
• If the MIL blinks at steady rate, misfire condition could exist.
Diagnostic procedure
STEP
1
INSPECTION RESULTS
DTC is displayed:
ACTION
Yes
Connect WDS or equivalent to DLC-
2.
Retrieve any DTC.
Are there any DTCs displayed?
No
• Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
• Inspect the instrument cluster operation.
(See INSTRUMENT CLUSTER
INSPECTION .)
2 Verify test results.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.3 WILL NOT CRANK [Z6]
B3E010318881W36
3 WILL NOT CRANK
DESCRIPTION
The starter does not work.
• Open starter circuit between ignition switch and starter
• TR switch malfunction (ATX)
• TR switch misadjustment (ATX)
• Low or dead battery
POSSIBLE CAUSE
• Charging system malfunction
• Starter malfunction
• Seized/hydrolocked engine, flywheel or drive plate
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly. (Ignition key is not registered.)
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
Both conditions appear: Note
• The following test should be perform for vehicles with immobilizer system. Go to Step 8 for vehicles without immobilizer system.
Connect the WDS or equivalent to the
DLC-2.
Do the following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
Yes
No
Go to Step 4.
Either or other condition appears:
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
Yes
Is the coil connector securely connected to the coil?
No
Does the security light illuminate?
Yes
No
Go to the next step.
Return to Step 1.
Connect the coil connector securely.
Go to the next step.
Inspect the instrument cluster.
(See INSTRUMENT CLUSTER
INSPECTION .)
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
4
5
6
7
8
9
Connect the WDS or equivalent to the
DLC-2 and retrieve DTC.
DTC
Yes
B1213, B1600, B1601, B1602, B1681,
B2103, B2139, B2141, B2431, U2510
Inspect for the following wiring harnesses and connectors:
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
Is there any malfunction?
No
Yes
No
Inspect for the following wiring harnesses and connectors:
Is there any malfunction?
Yes
• Between PCM terminal 1W and instrument cluster terminal 1O
• Between PCM terminal 1S and instrument cluster terminal 1M
No
Yes Change the selector lever in the P or N position. (ATX)
Is there continuity between the PCM terminal 1AB and the starter relay?
Inspect following:
• Battery connection
• Battery condition
• Transaxle is in Park or Neutral. (ATX)
• Fuses
Are all items normal?
No
No
Yes
Yes
Go to the next step.
Repair or replace suspected wiring harness and connector.
Go to the next step.
Repair or replace suspected wiring harness and connector.
Go to the next step.
Go to the next step.
Repair or replace the wiring harness.
Go to the next step.
Service if necessary.
Repeat Step 8.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Is clicking sound heard from the starter when the ignition switch is turned to START position?
No Go to Step 11.
10
Inspect the starting system.
(See STARTER INSPECTION .)
Is starting system normal?
Yes
No
Yes
11 Do any other electrical accessories work?
No
12
Note
• The Following test should be performed on ATX only. For MTX, go to the next step.
Yes
Connect the WDS or equivalent to the
DLC-2.
Access TR PID.
Turn the ignition switch to the ON position.
No
Is TR PID indicated P/N when selecting the
P or N position?
Inspect for seized/hydrolocked the engine, flywheel or drive plate.
(See FLYWHEEL INSPECTION .)
Repair or replace the components as required.
Go to the next step.
Inspect the charging system.
(See BATTERY INSPECTION .)
(See GENERATOR INSPECTION .)
Go to the next step.
Inspect the TR switch adjustment.
(See TRANSAXLE RANGE (TR)
SWITCH INSPECTION .)
• If the TR switch is adjusted properly, inspect for open circuit between the TR switch and the PCM terminal 1X or starter.
13
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory DTCs.
Are there any continuous memory DTCs displayed?
Yes
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
Communication error message is displayed:
Inspect for following:
• Open circuit in wiring harness between main relay and PCM terminal 1BF, or
1BG (ATX)
• Open circuit in wiring harness between main relay terminal B and PCM terminal
1AW
• The main relay is stuck open.
• Open or poor GND circuit (PCM terminal 2BH, 2AZ or 2BD)
• Poor connection of vehicle body GND
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
15
No DTC is displayed:
No
Inspect following:
• START circuit in ignition switch
• Open circuit in wiring harness between ignition switch and starter
DTC is displayed:
Retrieve any KOEO DTCs using WDS or equivalent.
Are there DTCs displayed during KOEO inspection?
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
No
Inspect following:
• START circuit in ignition switch
• Open circuit in wiring harness between ignition switch and starter
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.4 HARD TO START/LONG CRANK/ERRATIC
START/ERRATIC CRANK [Z6]
B3E010318881W37
4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK
• The starter cranks the engine at normal speed but the engine requires excessive cranking time before starting.
DESCRIPTION
• The battery is in normal condition.
POSSIBLE
CAUSE
• Erratic signal to ignition coil
• Vacuum leakage
• Poor fuel quality
• Starting system malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Spark plug malfunction
• Air leakage from intake-air system
• Erratic signal from CKP sensor
• Erratic signal from CMP sensor
• Improper air/fuel mixture ratio control
• Air cleaner restriction
• IAC valve malfunction
• PCV valve malfunction
• Inadequate fuel pressure
• Purge solenoid valve malfunction
• MAF sensor contamination
• Incorrect MAF sensor GND voltage
• Restriction in exhaust system
• EGR valve malfunction
• Pressure regulator malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP INSPECTION
1
Inspect for the following:
• Vacuum leakage
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Proper fuel quality (such as proper octane, contamination, winter/summer blend)
• Loose bands on intake-air system
• Cracks on intake-air system parts
• Air cleaner restriction
Are all items normal?
2
3
4
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any KOEO and KOER DTCs using WDS or equivalent.
Is any KOEO or KOER DTC displayed?
No
Yes
Is the engine overheating?
No
Inspect the ignition coil related wiring harnesses condition (intermittent open or short circuit) for all cylinders.
Yes
Are wiring harness conditions normal?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
Go to the next step.
Go to the next step.
Repair the wiring harnesses.
5
Inspect the spark plug conditions.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
6
7
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
Yes
No
Measure gap between the CKP sensor and teeth of the crankshaft pulley.
Yes
Specification
0.5-1.5 mm {0.02-0.05 in}
No
Replace the malfunctioning part.
Go to the next step.
Replace the crankshaft pulley.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
Is the gap within specification?
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect WDS or equivalent to DLC-2.
Turn ON fuel pump using FP PID in output state control of datalogger function.
Is fuel line pressure correct?
No
(See FUEL LINE PRESSURE
INSPECTION .)
Yes
Yes
10
Is fuel line pressure held after FP PID is turned OFF?
(See FUEL LINE PRESSURE
INSPECTION .)
No
11
12
13
Disconnect a vacuum hose from the purge solenoid valve and plug opening end of the vacuum hose.
Yes
Start the engine.
Is starting condition improved?
No
Inspect the MAF sensor for the following:
• Contamination
Yes
• MAF sensor terminal B voltage (GND circuit)
No
Is there any contamination?
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Go to the next step.
Go to the next step.
Replace the part.
Go to the next step.
Replace the PCV valve.
Go to the next step.
Zero or low:
Inspect the fuel pump relay and the fuel pump unit related circuits.
Inspect the fuel line for clogging.
• If normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the pressure regulator diaphragm condition.
• If condition is normal, inspect the fuel injector.
• If condition is not normal, replace the pressure regulator.
Inspect if the purge solenoid valve is stuck open.
Go to the next step.
Replace the MAF sensor.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
Inspect engine condition while tapping the EGR valve housing.
Does the engine condition improve?
Yes
No
Replace EGR valve.
Go to the next step.
15
Inspect the starting system.
(See STARTER INSPECTION .)
Is the starting system normal?
Yes
Inspect for loose connectors or poor terminal contact.
• If normal, remove the EGR valve and visually inspect for mechanically stuck EGR valve.
No
Repair or replace the components as required.
16
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.5 ENGINE STALLS-AFTER START/AT IDLE [Z6]
B3E010318881W38
5 ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION
• The engine stops unexpectedly.
POSSIBLE
CAUSE
• Improper A/C system operation
• Air leakage from intake-air system parts
• Purge solenoid valve malfunction
• Improper IAC valve operation
• EGR valve malfunction
• No signal from the CKP sensor due to sensor, related wire or wrong installation
• Vacuum leakage
• Engine overheating
• Low engine compression
• Erratic signal to ignition coil
• Poor fuel quality
• PCV valve malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Air cleaner restriction
• Restriction in exhaust system
• Electrical connector disconnection
• Open or short circuit in fuel pump body and related wiring harness
• No battery power supply to PCM or poor GND
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Fuel leakage from fuel injector
• Fuel injector clogging
• Ignition coil malfunction
• Improper air/fuel mixture ratio control
• Improper valve timing
• Improper operation variable valve timing control system
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly. (Ignition key is not registered.)
• Pressure regulator malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP INSPECTION
1 Note
RESULTS ACTION
Both conditions appear:
Yes
Go to Step 3.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
• The following test should be performed for vehicles with immobilizer system. Go to Step
8 for vehicles without immobilizer system.
Connect the WDS or equivalent to the
DLC-2.
Do the following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
No
Yes
Does the engine stall after approx. 2 s since the engine is started?
No
Is the coil connector securely connected to the coil?
Does the security light illuminate?
Yes
No
Yes
No
Either or other condition appears:
Go to the next step.
Go to the next step.
The immobilizer system is normal.
Go to Step 8.
Go to the next step.
Connect the coil connector securely.
Return to Step 2.
Go to the next step.
Inspect the instrument cluster and wiring harness.
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
5
6
7
Connect the WDS or equivalent to the
DLC-2 and retrieve the DTC.
Are any of following DTCs displayed?
Yes
DTC
No
B1213, B1600, B1601, B1602, B1681,
B2103, B2139, B2141, B2431, U2510
Inspect for the following wiring harnesses and connectors:
Yes
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
No
Is there any malfunction?
Inspect for the following wiring harnesses and connectors:
• Between PCM terminal 1W and instrument cluster terminal 1O
• Between PCM terminal 1S and instrument cluster terminal 1M
Is there any malfunction?
Yes
No
Go to the next step.
Repair or replace the wiring harness and connector.
Go to the next step.
Repair or replace the wiring harness and connector.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Go to the next step.
8
Verify the following:
• Vacuum connection
• Air cleaner element
• No air leakage from intake-air system
• Fuel quality: proper octane, contamination, winter/summer blend
• Electrical connections
• Smooth operation of throttle valve
Are all items normal?
Yes
• No restriction of intake-air system
• Proper sealing of intake manifold and components attached to intake manifold:
IAC valve, EGR valve
• Ignition wiring
No
Service if necessary.
Repeat Step 8.
9
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory, KOEO
Yes and KOER DTCs using WDS or equivalent.
If the engine stalls, retrieve continuous memory and KOEO DTCs.
Are there any DTCs displayed?
No
10
Attempt to start the engine at part throttle.
Does the engine run smoothly at part throttle?
Yes
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
Communication error message is displayed:
Inspect for the following:
• Open circuit in wiring harness between main relay and PCM terminal 1BF, or 1BG
(ATX)
• Open circuit in wiring harness between main relay terminal B and PCM terminal
1AW.
• The main relay is stuck open.
• Open or poor GND circuit (PCM terminal
2BH, 2AZ or 2BD)
• Poor connection of vehicle body GND
No DTC is displayed:
Go to the next step.
Inspect the IAC valve and wiring harness.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Yes
11
Connect the WDS or equivalent to the
DLC-2.
Access RPM PID.
Is RPM PID indicating the engine speed while the engine is cranking?
No
Go to the next step.
Inspect for the following:
• Open or short circuit in CKP sensor
• Open or short circuit between CKP sensor terminal A and PCM terminal 2T
• Open or short circuit between CKP sensor terminal B and PCM terminal 2P
• Open or short circuit between CKP sensor terminal C and PCM terminal 2BF
• Open or short circuit in CKP sensor wiring harnesses
If the CKP sensor and wiring harness are normal, go to the next step.
Go to the next step.
12
13
14
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
Yes
No
Measure gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
No
0.5-1.5 mm {0.02-0.05 in}
Is the gap within specification?
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Are wiring harness conditions normal?
Yes
No
Replace the malfunctioning part.
Go to the next step.
Replace the crankshaft pulley.
Go to the next step.
Repair the wiring harnesses.
15
Perform the spark test.
(See Spark Test .)
Is strong blue spark visible at each cylinder?
16
Inspect the spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
Yes
Go to the next step.
If symptom occurs with the A/C on, go to
Step 21.
Repair or replace the malfunctioning part according to spark test result.
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No
17
18
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes
19
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
Is fuel line pressure correct?
No
(See FUEL LINE PRESSURE
INSPECTION .)
20
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line. Service if necessary.
Yes
Is the fuel line pressure held after FP
PID is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
21
Note
• Following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
Yes
Connect pressure gauges to the A/C low and high pressure side lines.
No
Turn the A/C on and measure low side and high side pressures.
Are pressures within specifications?
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
Go to the next step.
Go to the next step.
Zero or low:
Inspect the fuel pump relay and the fuel pump related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the fuel the injector.
(See FUEL INJECTOR INSPECTION .)
• If the fuel injector is normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
For other symptoms, inspect the following:
• Refrigerant charging amount
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
22
23
24
25
26
27
(See REFRIGERANT PRESSURE
CHECK .)
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid side.
Plug the opening end of vacuum hose.
Start the engine.
Is the engine stall now eliminated?
Yes
No
Is air leakage felt or heard at the intakeair system components while racing the engine to higher speed?
Yes
No
Yes Inspect engine condition while tapping the EGR valve housing.
Does the engine condition improve?
No
Yes Inspect variable valve timing control system operation.
(See Variable Valve Timing Control
System Operation Inspection .)
Does the variable valve timing control work properly?
No
• Condenser fan operation open mechanically.
(See Purge Control System Inspection
Go to the next step.
Go to the next step.
Go to the next step.
Inspect if the purge solenoid valve is stuck
Inspect EVAP control system.
Repair or replace malfunctioning part.
Go to the next step.
Replace EGR valve.
Repair or replace malfunctioning part.
.)
Is the engine compression correct?
(See COMPRESSION INSPECTION
[Z6] .)
Yes
Remove EGR valve and visually inspect for mechanically stuck EGR valve.
• If there is no malfunction, inspect valve timing.
(See Timing Chain Installation Note .)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.6 CRANKS NORMALLY BUT WILL NOT START
[Z6]
B3E010318881W39
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6 CRANKS NORMALLY BUT WILL NOT START
• The starter cranks the engine at normal speed but the engine will not run.
• Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after the engine stall.
DESCRIPTION
• Fuel is in the tank.
• The battery is in normal condition.
POSSIBLE
CAUSE
• No battery power supply to PCM
• Air leakage from intake-air system
• Open PCM GND or vehicle body GND
• Improper operation of IAC valve
• EGR valve malfunction
• No signal from CKP sensor due to sensor, related wire or incorrect installation
• No signal from CMP sensor due to sensor, related wire or incorrect installation
• Low engine compression
• Engine overheating
• Vacuum leakage
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control
• Poor fuel quality
• PCV valve malfunction
• Restriction in intake-air system
• Restriction in exhaust system
• Disconnected electrical connector
• Open or short circuit in fuel pump body and related wiring harness
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel leakage from injector
• Fuel injector is clogged.
• Purge solenoid valve malfunction
• Spark plug malfunction
• Ignition coil malfunction
• Improper variable valve timing control system operation
• Improper valve timing
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly. (Ignition key is not registered.)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Pressure regulator malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS ACTION
Both conditions appear: Note
• Following test should be performed for vehicles with immobilizer system. Go to Step 8 for vehicles without immobilizer system.
Yes
Connect the WDS or equivalent to the DLC-
2.
No
Do any of following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
Yes
Does the engine stall after approx. 2 s since the engine is started?
No
Go to Step 3.
Either or other condition appears:
Go to the next step.
Go to the next step.
The immobilizer system is normal.
Go to Step 10.
3
4
Yes
Is the coil connector securely connected to the coil?
No
Does the security light illuminate?
Yes
Go to the next step.
Connect the coil connector securely.
Return to Step 2.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No
Inspect the instrument cluster and wiring harness.
(See INSTRUMENT CLUSTER
INSPECTION .)
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
5
6
7
8
Connect the WDS equivalent to the DLC-2 and retrieve DTC.
Yes
Are any of following DTCs displayed?
DTC
No
B1213, B1600, B1601, B1602, B1681,
B2103, B2139, B2141, B2431, U2510
Inspect for the following wiring harnesses and connectors:
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
Yes
No
Is there any malfunction?
Inspect for the following wiring harnesses and connectors:
• Between PCM terminal 1W and instrument cluster terminal 1O
Yes
• Between PCM terminal 1S and instrument cluster terminal 1M
No
Is there any malfunction?
Verify the following:
• Vacuum connection
• External fuel shut off or accessory (such as kill switch, alarm etc.)
• Fuel quality: proper octane, contamination, winter/summer blend
• No air leakage from intake-air system
• Intake-air system restriction (such as air cleaner element, fresh air dust)
• Proper sealing of the intake manifold and components attached to intake manifold:
IAC valve, EGR valve
• Ignition wiring
• Electrical connections
• Fuses
• Smooth operation of throttle valve
Yes
No
Go to the next step.
Repair or replace the suspected wiring harness and connector.
Go to the next step.
Repair or replace the suspected wiring harness and connector.
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 8.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Are all items normal?
9
Connect the WDS or equivalent to the DLC-
2.
Yes
Retrieve any continuous memory and
KOEO DTCs using WDS or equivalent.
Are there any DTCs displayed?
10
Does engine start with the throttle valve closed?
No
Yes
No
11
Does the engine start and run smoothly at part throttle?
Yes
No
Yes
12
Connect WDS or equivalent to DLC-2.
Access RPM PID.
Is RPM PID indicating the engine speed when cranking engine?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
Communication error message is displayed:
Inspect for following:
• Open circuit in wiring harness between main relay and PCM terminal 1BF or
1BG (ATX)
• Open circuit in wiring harness between main relay terminal B and PCM terminal
1AW.
• Main relay is stuck open.
• Open or poor GND circuit (PCM terminal 2BH, 2AZ or 2BD)
• Poor connection of vehicle body GND
No DTC is displayed:
Go to the next step.
Go to Step 27.
Go to the next step.
Inspect the IAC valve and wiring harness.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
Go to the next step.
Go to the next step.
Inspect for the following:
• Open or short circuit in CKP sensor
• Open or short circuit between CKP sensor terminal A and PCM terminal 2T
• Open or short circuit between CKP sensor terminal B and PCM terminal 2P
• Open or short circuit between CKP sensor terminal C and PCM terminal
2BF
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
13
14
15
16
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
Yes
No
Measure the gap between the CKP sensor and teeth of the crankshaft pulley.
Yes
Specification
0.5-1.5 mm {0.02-0.05 in}
Is the gap within specification?
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Are wiring harness conditions normal?
Perform the spark test.
(See Spark Test .)
Is strong blue spark visible at each cylinder?
No
Yes
No
Yes
No
• Open or short circuit in CKP sensor wiring harnesses
If the CKP sensor and wiring harness are normal, go to the next step.
Go to the next step.
Replace the malfunctioning crankshaft pulley.
Go to the next step.
Replace the crankshaft pulley.
Go to the next step.
Repair the wiring harnesses.
Go to the next step.
Repair or replace the malfunctioning part according to spark test result.
17
Inspect the spark plug conditions.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
18
19
20
Remove and shake the PCV valve.
Does the PCV valve rattle?
Visually inspect the exhaust system part.
Is there any deformed exhaust system part?
No
Yes
No
Yes
Yes
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Install fuel pressure gauge between fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the DLC-
2.
Turn ON and/or OFF using FP PID in output state control of datalogger function.
No
Is fuel line pressure correct when FP PID is turned ON/OFF five times ?
(See FUEL LINE PRESSURE
INSPECTION .)
21
Yes
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line.
Service if necessary.
Turn OFF from ON using FP PID in output state control of datalogger function.
Is fuel line pressure held after FP PID is turned OFF?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Zero or low:
Inspect the fuel pump relay and the fuel pump related circuit.
(See FUEL PUMP UNIT INSPECTION .)
Inspect the main fuel line for clogging.
• If there is no malfunction, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the pressure regulator diaphragm condition.
• If condition is normal, inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• If condition is not normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Inspect if the purge solenoid valve is stuck open mechanically.
Inspect the evaporative emission control system.
22
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Plug the opening end of vacuum hose.
Attempt to start engine.
Is starting condition improved?
Yes
No
23
24
25
Is air leakage felt or heard at intake-air system components while the racing the engine to higher speed?
Yes
No
Inspect engine condition while tapping the
EGR valve housing.
Does engine condition improve?
Yes
No
Yes
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Replace the EGR valve.
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspect variable valve timing control system operation.
(See Variable Valve Timing Control System
Operation Inspection .)
No
Does variable valve timing control work properly?
Repair or replace the malfunctioning part.
26
27
Is engine compression correct?
(See COMPRESSION INSPECTION [Z6] .)
Yes
Remove the EGR valve and visually inspect for mechanically stuck EGR valve.
• If normal, inspect valve timing.
(See Timing Chain Installation Note .)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.7 SLOW RETURN TO IDLE [Z6]
B3E010318881W40
SLOW RETURN TO IDLE 7
DESCRIPTION
The engine takes more time than normal to return to the idle speed.
• ECT sensor malfunction
• Thermostat is stuck open.
POSSIBLE CAUSE
• Throttle body malfunction
• Air leakage from intake-air system
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
DTC is displayed:
Connect the WDS or equivalent to the
DLC-2.
Yes
Go to the appropriate DTC inspection.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
Are there DTCs displayed?
No
Remove the thermostat and inspect operation.
(See THERMOSTAT
REMOVAL/INSTALLATION [Z6] .)
(See THERMOSTAT INSPECTION
[Z6] .)
Is the thermostat normal?
Yes
No
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
The ECT sensor and thermostat are normal.
Go to the next step.
Access ECT PID on WDS or equivalent.
Inspect for both ECT PID and temperature gauge on the instrument cluster readings.
• If the temperature gauge on the instrument cluster indicates normal range but ECT PID is not same as temperature gauge reading, inspect the ECT sensor.
• If the temperature gauge on the instrument cluster indicates cold range but ECT PID is normal, inspect the temperature gauge and the heat gauge unit.
3
4
Is the throttle body free of contaminations?
Yes
Inspect for air leakage from intake-air system components while racing the engine to higher speed.
Clean or replace the throttle body.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [Z6]
B3E010318881W41
8 ENGINE RUNS ROUGH/ROLLING IDLE
• The engine speed fluctuates between the specified idle speed and lower speed and the engine shakes excessively.
DESCRIPTION
• The idle speed is too slow and the engine shakes excessively.
POSSIBLE
CAUSE
• Air leakage from intake-air system parts
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• A/C system operation is improper
• Erratic signal to ignition coil
• Spark plug malfunction
• Purge solenoid valve malfunction
• IAC valve improper operation
• Idle learning of IAC system is not completed
• EGR valve malfunction
• Erratic or no signal from CMP sensor
• Low engine compression
• Improper valve timing
• Improper variable valve timing control system operation
• Erratic signal from CKP sensor
• Improper air/fuel mixture ratio control operation (abnormal signal from MAF sensor, front HO2S or rear HO2S)
• Open or short circuit in PCM GND circuit
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Restriction in exhaust system
• Disconnected electrical connectors
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Improper load signal input
• Fuel line restriction or clogging
• Improper fuel injection control operation
• Fuel leakage from fuel injector
• Fuel injector clogging
• Engine overheating
• Vacuum leakage
• Pressure regulator malfunction (built-in fuel pump unit)
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
2
INSPECTION
Warm up the engine.
Idle the engine for 5 min .
Is the symptom disappeared?
Yes
No
Verify the following:
• External fuel shut off or accessory
(kill switch, alarm etc.)
• Fuel quality (such as proper octane, contamination, winter/summer blend)
• No air leakage from intake-air system
Yes
• Proper sealing of intake manifold and components attached to intake manifold: IAC valve, EGR valve
• Ignition wiring
No
• Electrical connections
• Fuses
• Smooth operation of throttle valve
• PCM GND circuit (PCM terminal 1AZ,
1BC, 1BD, 1BG and/or 1BH)
Are all items normal?
RESULTS ACTION
Troubleshooting completed. (Cause of this symptom is that the idle learning of IAC system is not completed.)
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 2.
DTC is displayed:
3
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4 Is the engine overheating?
Yes
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [Z6] .)
Go to the next step.
Go to the next step.
5
6
7
8
No
Connect WDS or equivalent to DLC-2.
Yes
Access MAF PID.
Drive vehicle with monitoring PID.
Is MAF PID within specification?
(See PCM INSPECTION [Z6] .)
No
Note
• Following test is for engine running rough idle with the A/C on concerns. If other symptoms exist, go to the next step.
Yes
Connect pressure gauge to the A/C low and high pressure side lines.
Start the engine and idle it.
Turn the A/C switch on.
No
Measure low side and high side pressures.
Are pressures within specifications?
(See REFRIGERANT PRESSURE
CHECK .)
Note
• Following test is for engine running rough with the P/S on.
If other symptoms exist, go to the next step.
Yes
Connect WDS or equivalent to DLC-2.
Start the engine and idle it.
No
Access PSP PID.
Inspect if PSP PID is On while turning steering wheel right to left.
Is PSP PID normal?
Yes Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
No
Inspect for open or short circuit of MAF sensor and related wiring harness.
Go to the next step.
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
For other symptoms, inspect following:
• Refrigerant charging amount
• Condenser fan operation
Inspect the PSP switch operation and wiring harness between the PSP switch connector and the PCM connector terminal 2AC.
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Go to the next step.
9
10
Measure gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
0.5-1.5 mm {0.02-0.05 in}
No
Is gap within specification?
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Yes
No
Are wiring harness conditions normal?
Replace the crankshaft pulley.
Go to the next step.
Repair the wiring harnesses.
11
Inspect the spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
12
Yes
Start the engine and disconnect the
IAC valve connector.
Does engine speed drop or the engine stall?
No
Yes
13
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
No
14
Visually inspect the fuel injector, Oring, and fuel line for fuel leakage.
Service if necessary.
Yes
No
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Inspect the IAC valve and wiring harness.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [Z6] .)
Go to the next step.
Low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the pressure regulator diaphragm condition.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Does fuel line pressure hold after the ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
• If condition is normal, inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• If condition is not normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
15
16
17
18
19
Connect the WDS or equivalent to the
DLC-2.
Yes
Start the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
No
• More than 0.45 V when accelerator pedal is suddenly depressed: rich condition
• Less than 0.45 V during fuel cut: lean condition
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Yes
Plug the opening end of vacuum hose.
Start the engine.
No
Does engine condition improve?
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Visually inspect the CMP sensor and teeth of camshaft pulley.
Are the CMP sensor and teeth of the camshaft pulley normal?
Yes
No
Inspect and repair or replace the front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
Inspect if the purge solenoid valve is stuck open mechanically.
Inspect EVAP control system.
(See Purge Control System Inspection .)
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
20
21
Inspect engine condition while tapping the EGR valve housing.
Yes
Does engine condition improve?
No
Yes
Replace the EGR valve.
(See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspect variable valve timing control system operation.
(See Variable Valve Timing Control
System Operation Inspection .)
Does variable valve timing control system work properly?
No Repair or replace the malfunctioning part.
22
23
Is engine compression correct?
[Z6] .)
(See COMPRESSION INSPECTION
Yes
Remove EGR valve and visually inspect for mechanically stuck EGR valve.
If there is no malfunction, inspect valve timing.
(See Timing Chain Installation Note .)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.9 FAST IDLE/RUNS ON [Z6]
B3E010318881W42
9
DESCRIPTION
FAST IDLE/RUNS ON
• The engine speed continues during at fast idle after warm-up.
• The engine runs after the ignition switch is off.
• ECT sensor malfunction
• Air leakage from intake-air system
POSSIBLE CAUSE
• Throttle body malfunction
• Accelerator cable free play misadjustment
• Improper load signal input
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Yes
1
2
3
Connect the WDS or equivalent to the
DLC-2.
Access ECT PID.
Start and warm-up the engine to normal operating temperature.
No
Is ECT PID between 82-112 ° C {180-
234 ° F} ?
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory DTCs.
Yes
Are there any DTCs displayed?
No
Yes
Connect the WDS or equivalent to the
DLC-2.
Access AC_REQ, CPP, CPP/PNP, TR and PSP PIDs.
Monitor each PID.
(See PCM INSPECTION [Z6] .)
Are PIDs normal?
No
Go to the next step.
ECT PID is more than 112 ° C {234 ° F}:
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [Z6] .)
ECT PID is less than 82 ° C {180 ° F}:
Go to symptom troubleshooting "No.18
Cooling system concerns - Runs cold".
(See NO.18 COOLING SYSTEM
CONCERNS-RUNS COLD [Z6] .)
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
AC_REQ PID :
Inspect the A/C switch, refrigerant pressure switch and fan switch.
(See REFRIGERANT PRESSURE
SWITCH INSPECTION .)
CPP PID :
Inspect the clutch pedal position switch
(MTX).
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [Z6] .)
CPP/PNP PID :
Inspect the neutral switch (MTX).
(See NEUTRAL SWITCH INSPECTION
[Z6] .)
TR PID :
Inspect the TR switch (ATX).
(See TRANSAXLE RANGE (TR) SWITCH
INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
PSP PID :
Inspect the PSP switch.
(See POWER STEERING PRESSURE
(PSP) SWITCH INSPECTION [Z6] .)
Repair or replace part if necessary.
Is there air leakage felt or heard at the intake-air system components while racing the engine to higher speed?
Yes
No
Verify accelerator cable free play.
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [Z6] .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.10 LOW IDLE/STALLS DURING DECELERATION
[Z6]
B3E010318881W43
10 LOW IDLE/STALLS DURING DECELERATION
DESCRIPTION
POSSIBLE
CAUSE
• The engine stops unexpectedly at the beginning of deceleration or recovery from deceleration.
• Vacuum leakage
• IAC valve malfunction
• Air leakage from intake-air system
• Improper air/fuel mixture ratio control
• Evaporative emission control system malfunction
• TP sensor misadjustment
• TP sensor or related circuit malfunction
• MAF sensor or related circuit malfunction
• Brake switch or related circuit malfunction
• Neutral/clutch pedal position switch or related circuit malfunction (MTX)
• TR switch or related circuit malfunction (ATX)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Improper A/C magnetic clutch operation
Diagnostic procedure
STEP
1
2
3
INSPECTION
Does the engine idle rough?
Turn off the A/C switch and fan switch.
Does the A/C magnetic clutch engage?
RESULTS
Yes
No
ACTION
Go to symptom troubleshooting "No.8
Engine runs rough/rolling idle".
(See NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE [Z6] .)
Go to the next step.
Yes
No
Yes
Go to symptom troubleshooting "No.24
A/C is always on or A/C compressor runs continuously."
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
Go to the next step.
Go to the next step.
Verify the following:
• Proper routing and no damage of vacuum lines
• IAC valve is connected properly.
• No air leakage from intake-air system
Are all items normal?
No
Service if necessary.
Repeat Step 3.
4
5
6
Connect WDS or equivalent to DLC-2.
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
Yes
No
Does the idle speed drop or stall when disconnecting the IAC valve?
Yes
No
Disconnect the vacuum hose between the purge solenoid valve and the intake
Yes
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
Inspect the following:
• Circuit from IAC valve to PCM terminal
2X or 2AB for open and short
• IAC valve for sticking
If normal, go to the next step.
Inspect EVAP control system.
(See Purge Control System Inspection .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes manifold from the purge solenoid valve side.
Plug the opening end of vacuum hose.
Drive the vehicle.
Does the engine condition improve?
No Go to the next step.
Yes
7
Connect the WDS or equivalent to DLC-2.
Access TP, MAF, VSS, BOO, CPP,
CPP/PNP and TR PIDs.
Monitor each PID while driving the vehicle.
(See PCM INSPECTION [Z6] .)
No
Are PIDs normal?
Intermittent concern exists.
(See INTERMITTENT CONCERN
TROUBLESHOOTING [Z6] .)
TP PID:
Inspect the TP sensor.
(See THROTTLE POSITION (TP)
SENSOR INSPECTION [Z6] .)
MAF PID:
Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
VSS PID:
Inspect the VSS.
(See DTC TABLE [Z6] .)
BOO PID:
Inspect the brake switch.
(See BRAKE SWITCH INSPECTION .)
CPP PID:
Inspect the clutch pedal position switch
(MTX).
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [Z6] .)
CPP/PNP PID:
Inspect the neutral switch (MTX).
(See NEUTRAL SWITCH INSPECTION
[Z6] .)
TR PID:
Inspect the TR switch (ATX).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
(See TRANSAXLE RANGE (TR)
SWITCH INSPECTION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
11
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS
ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES [Z6]
B3E010318881W44
ENGINE STALLS/QUITS - ACCELERATION/CRUISE
ENGINE RUNS ROUGH - ACCELERATION/CRUISE
MISSES - ACCELERATION/CRUISE
BUCK/JERK - ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE - ACCELERATION
SURGES - ACCELERATION/CRUISE
• The engine stops unexpectedly at beginning of acceleration or during acceleration.
• The engine stops unexpectedly while cruising.
• The engine speed fluctuates during acceleration or cruising.
DESCRIPTION
• The engine misses during acceleration or cruising.
• The vehicle bucks/jerks during acceleration, cruising, or deceleration.
• Momentary pause at beginning of acceleration or during acceleration
• Momentary minor irregularity in engine output
POSSIBLE
CAUSE
• A/C system operation is improper.
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
• Purge solenoid valve malfunction
• IAC valve improper operation
• Improper EGR valve operation
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Erratic signal from CKP sensor
• Low engine compression
• Vacuum leakage
• Poor fuel quality
• Main relay intermittent malfunction
• Throttle body malfunction
• Engine overheating
• Spark plug malfunction
• Improper air/fuel mixture ratio control operation
• Improper variable tumble control operation
• Erratic signal to ignition coil
• Air cleaner restriction
• PCV valve malfunction
• Fuel flow into evaporative purge hose
• Improper valve timing due to jumping out timing belt
• Restriction in exhaust system
• Intermittent open or short circuit in fuel body pump circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Check valve (two-way) malfunction (integrated with fuel tank)
• Fuel leakage from fuel injector
• Fuel injector clogging
• Fuel line restriction or clogging
• Pressure regulator malfunction (built-in fuel pump unit)
• TP sensor misadjustment
• Intermittent open or short circuit of MAF sensor, TP sensor and VSS
• ATX malfunction (ATX)
• Clutch slippage (MTX)
• Loose attaching bolts or worn engine mounts.
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent
Downloaded from https://carmanualshub.com/ - automotive repair manuals website
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes this, always complete the "BEFORE SERVICE PRECAUTION" and "AFTER
SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION
Are all items normal?
RESULTS
Verify the following:
• Vacuum connection
• Air cleaner element
• No air leakage from the intake-air system
• No restriction of the intake-air system
Yes
• Proper sealing of the intake manifold and components attached to the intake manifold: such as the IAC valve, EGR valve
No
• Ignition wiring
• Fuel quality (such as proper octane, contamination, winter/summer blend)
• Electrical connections
• Smooth operation of throttle valve
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory,
KOEO and KOER DTCs.
Yes
If the engine stall, condition exists retrieve continuous memory and KOEO
DTCs using WDS or equivalent.
No
Are there any DTCs displayed?
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
3 Is the engine overheating?
Yes
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
No
Yes
Connect the WDS or equivalent to the
DLC-2.
Access RPM, VPWR, MAF, TP and
VSS PIDs.
Drive vehicle with monitoring PIDs.
Are PIDs within specifications?
(See PCM INSPECTION [Z6] .)
No
Go to the next step.
Go to the next step.
RPM PID:
Inspect the CKP sensor and related harness for such as vibration, intermittent open/short circuit.
VPWR PID:
Inspect for open circuit intermittently.
MAF PID:
Inspect for open circuit of the MAF sensor and related wire harness intermittently.
TP PID:
Inspect if output signal from the TP sensor changes smoothly.
VSS PID:
Inspect for open circuit of the VSS and related wire harness intermittently. (except
MTX with ABS)
Inspect the ABS or DSC system . (MTX with
ABS)
Go to the next step.
5
6
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
Yes
No
Measure gap between the CKP sensor and teeth of the crankshaft pulley.
Yes
Specification
0.5-1.5 mm {0.02-0.05 in}
Is gap within specification?
No
Replace the malfunctioning part.
Go to the next step.
Replace the crankshaft pulley.
7
Inspect the spark plug conditions.
Is the spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
No
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Verify that the throttle lever is resting on Yes the throttle valve stop screw and/or the throttle valve orifice plug.
No
Is lever in correct position?
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Go to the next step.
Adjust if necessary.
Go to the next step.
Replace the suspected part.
11
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
Is fuel line pressure correct?
No
(See FUEL LINE PRESSURE
INSPECTION .)
Yes
12
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line.
Service if necessary.
Is fuel line pressure held after FP PID is turned Off?
No
(See FUEL LINE PRESSURE
INSPECTION .)
13 Yes
Go to the next step.
Zero or low:
Inspect the fuel pump relay and the fuel pump related circuit.
Inspect the fuel line for clogging.
• if there is no malfunction, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the pressure regulator diaphragm condition.
• If the condition is normal, inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• If the condition is not normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
14
15
16
17
18
Note
• Following test is for engine stalling with the A/C on. If other symptom exists, go to the next step.
Connect a pressure gauge to the A/C low and high pressure side lines.
Turn the A/C on and measure low side and high side pressure.
Are pressure within specifications?
(See REFRIGERANT PRESSURE
CHECK .)
No
Connect the WDS or equivalent to the
DLC-2. Warm up engine and idle it.
Access O2S11 PID
Is O2S11 PID normal?
• More than 0.45 V when the accelerator pedal is suddenly depressed: rich condition.
• Less than 0.45 V during fuel cut: lean condition
Yes
No
Inspect the evaporative purge hose between the fuel tank and purge valve.
Yes
Does fuel flow into the evaporative purge hose?
No
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Yes
Plug the opening end of the vacuum hose.
Drive the vehicle.
Does engine condition improve?
No
Visually inspect the CMP sensor and projections of the camshaft pulley.
Yes
Are the CMP sensor and projections of the camshaft pulley normal?
No
Inspect variable tumble control operation.
(See Variable Tumble Control
Operation Inspection .)
Is the variable tumble control normal?
Yes
No
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
For other symptoms, inspect the following:
• Refrigerant charging amount
• Condenser fan operation
Go to the next step.
Inspect and repair or replace the front
HO2S, wiring harness, connector or terminal, then go to the next step.
Inspect the check valve (two-way).
(See FUEL TANK INSPECTION ).
Go to the next step.
Go to the next step.
Go to the next step.
Inspect if the purge solenoid valve is stuck open mechanically.
Inspect the EVAP control system.
(See Purge Control System Inspection .)
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
Replace or replace the malfunctioning part.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
19
20
21
Inspect the EGR system.
(See EGR Control System Inspection .)
Is the EGR system normal?
Yes
No
Go to the next step.
Replace or replace the malfunctioning parts.
Is engine compression correct?
(See COMPRESSION INSPECTION
[Z6] .)
Yes
Inspect the following:
• Valve timing.
(See Timing Chain Installation Note .)
• Engine mounts
• Check valve (two-way)
• Internal transaxle part (ATX)
• Clutch (MTX)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.12 LACK/LOSS OF POWER-
ACCELERATION/CRUISE [Z6]
B3E010318881W45
LACK/LOSS OF POWER - ACCELERATION/CRUISE 12
DESCRIPTION
Performance is poor under load (such as power down when climbing hills).
POSSIBLE
CAUSE
• Improper A/C system operation
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
• Restriction in intake-air system
• Intake air temperature too hot
• Improper variable intake-air control operation
• Improper variable tumble control operation
• Purge control solenoid malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Brake dragging
• Erratic signal from CKP sensor
• Low engine compression
• Vacuum leakage
• Poor fuel quality
• Erratic signal to ignition coil
• Engine overheating
• Throttle body malfunction
• Spark plug malfunction
• Air cleaner restriction
• PCV valve malfunction
• Improper valve timing due to jumping out of timing belt
• Improper variable valve timing control operation
• Restriction in exhaust system
• Intermittent open or short circuit in fuel pump related circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel line restriction or clogging
• Fuel leakage from fuel injector
• Fuel injector clogging
• Intermittent open or short circuit of MAF sensor, TP sensor, IAT sensor and VSS
• ATX malfunction (ATX)
• Clutch slippage (MTX)
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION RESULTS
• No restriction of the intake-air system
• Proper sealing of the intake manifold and components attached to intake manifold; such as IAC valve, EGR valve
No
• Fuel quality (such as proper octane, contamination, winter/summer blend)
Are all items normal?
Verify the following:
• Vacuum connection
• Restriction in intake-air system (such as air cleaner element, fresh duct)
• No air leakage from the intake-air system
Yes
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs.
If engine stall condition exists, retrieve continuous memory and KOEO DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
3
4
Is the engine overheating?
Yes
No
Connect the WDS or equivalent to the
DLC-2.
Yes
Access RPM, MAF, TP, IAT and VSS
PIDs.
Drive vehicle while monitoring PIDs.
Are PIDs within specifications?
(See PCM INSPECTION [Z6] .)
No
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [Z6] .)
Go to the next step.
Go to the next step.
RPM PID:
Inspect the CKP sensor and related wiring harness for vibration and/or intermittent open/short circuit.
MAF PID:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Are the CKP sensor and teeth of the crankshaft pulley normal?
Yes
No
Measure gap between the CKP sensor and teeth of the crankshaft pulley.
Yes
Specification
No
0.5-1.5 mm {0.02-0.05 in}
Is gap within specification?
Inspect for intermittent open circuit of the
MAF sensor and related wiring harness.
TP PID:
Inspect if the TP sensor output increases smoothly.
IAT PID:
Inspect for air suction in the intake-air system.
If normal, inspect intermittent short circuit of
IAT sensor and, related wiring harness.
VSS PID:
Inspect for intermittent open circuit of the
VSS and related wiring harness.
Go to the next step.
Replace the malfunctioning crankshaft pulley.
Go to the next step.
Replace the crankshaft pulley.
7
Inspect the spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
8
9
Remove and shake the PCV valve.
Does the PCV valve rattle?
Visually inspect the exhaust system part.
Yes
No
Yes
No
Spark plug is wet or covered with carbon:
Inspect the fuel injector for fuel leakage.
Spark plug is grayish white:
Inspect for clogged the fuel injector.
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Is there any deformed exhaust system part?
Yes
10
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
No
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
11
Inspect variable tumble control operation.
(See Variable Tumble Control
Operation Inspection .)
Does the variable tumble control function properly?
Yes
No
12
Inspect variable intake-air control operation.
(See Variable Intake-air Control
Operation Inspection .)
Does the variable intake-air control function properly?
Yes
No
13
Note
• Following test is for the engine stalling with the A/C on concern. If other symptoms exist, go to the next step.
Yes
Connect pressure gauge to the A/C low and high side pressure lines.
No
Turn the A/C on and measure low side and high side pressures.
Are pressures within specifications?
(See REFRIGERANT PRESSURE
CHECK .)
14 Inspect A/C cut-off operation.
Yes
Go to the next step.
Zero or low:
Inspect the fuel pump relay and the fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
If the A/C is always on, go to symptom troubleshooting "No. 24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
For other symptoms, inspect the following:
• Refrigerant charging amount
• Condenser fan operation
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
15
16
17
18
19
20
(See A/C Cut-off Control System
Inspection .)
Does A/C cut-off function properly?
No
Inspect the A/C cut-off system components.
(See A/C Cut-off Control System
Inspection .)
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Yes
Plug opening end of vacuum hose.
Drive the vehicle.
Does the engine condition improve?
No
Visually inspect the CMP sensor and projections of the camshaft pulley.
Yes
Are the CMP sensor and projections of the camshaft pulley normal?
No
Inspect the EGR system.
(See EGR Control System Inspection .)
Is EGR system normal?
Yes
No
Inspect if the purge solenoid valve is stuck open mechanically.
Inspect EVAP control system.
(See Purge Control System Inspection .)
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part according to inspection result.
Inspect variable valve timing control system operation.
(See Variable Valve Timing Control
System Operation Inspection .)
Does variable valve timing control system function properly?
Yes
No
Go to the next step.
Repair or replace the malfunctioning part.
Is engine compression correct?
(See COMPRESSION INSPECTION
[Z6] .)
Yes
Inspect the following:
• Valve timing.
(See Timing Chain Installation Note .)
• Shift point (ATX)
• Clutch (MTX)
• Brake system for dragging
No Inspect for cause.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE
[Z6]
B3E010318881W46
13 KNOCKING/PINGING - ACCELERATION/CRUISE
DESCRIPTION
Sound is produced when air/fuel mixture is ignited by something other than spark plug
(e.g. hot spot in combustion chamber).
• Engine overheating due to cooling system malfunction
• ECT sensor malfunction
• IAT sensor malfunction
• MAF sensor malfunction
• Knock sensor malfunction
• Erratic signal from CMP sensor
• Inadequate engine compression
• Inadequate fuel pressure
Warning
POSSIBLE
CAUSE
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION RESULTS
Yes
ACTION
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Connect the WDS or equivalent to the
DLC-2.
Access ECT PID.
Verify ECT PID is less than 116 ° C
{241 ° F} during driving.
Is ECT PID less than specification?
No
Yes
Inspect cooling system for cause of overheating.
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [Z6] .)
2
Connect the WDS or equivalent to the
DLC-2.
Access IAT, MAF and SPARKADV PIDs.
Monitor each PID.
No
(See PCM INSPECTION [Z6] .)
Are PIDs normal?
3
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
4
5
Is engine compression correct?
(See COMPRESSION INSPECTION
[Z6] .)
Yes
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
Yes
No
Go to the next step.
IAT PID :
Inspect the IAT sensor.
(See INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [Z6] .)
MAF PID :
Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [Z6] .)
SPARKADV PID :
Inspect the CMP sensor and the knock sensor.
(See CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [Z6] .)
(See KNOCK SENSOR (KS)
INSPECTION [Z6] .)
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
Inspect for cause.
Inspect ignition timing.
Low:
Inspect the fuel line for clogging.
• If normal, replace fuel pump unit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See FUEL LINE PRESSURE
INSPECTION .)
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
6
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.14 POOR FUEL ECONOMY [Z6]
B3E010318881W47
POOR FUEL ECONOMY 14
DESCRIPTION
Fuel economy is unsatisfactory.
POSSIBLE
CAUSE
• Contaminated air cleaner element
• Variable intake-air control malfunction
• Engine cooling system malfunction
• Improper ATF level (ATX)
• Weak spark
• Poor fuel quality
• Erratic or no signal from CMP sensor
• Clutch slippage (MTX)
• Variable tumble control malfunction
• Improper variable valve timing control system operation
• Improper coolant level
• Inadequate fuel pressure
• Spark plug malfunction
• PCV valve malfunction
• Brake dragging
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Improper valve timing due to jumping out of timing belt
• Contaminated MAF sensor
• Improper engine compression
• Exhaust system clogging
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION
Inspect for following:
• Air cleaner element for contamination
• ATF level
• Fuel quality
• Coolant level
• Brake dragging
• Clutch slippage
Are all items normal?
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Yes Go to the next step.
3
4
Access ECT PID.
Drive vehicle while monitoring PID.
(See PCM INSPECTION [Z6] .)
Is PID within specification?
Perform the spark test.
(See Spark Test .)
Is strong blue spark visible at each cylinder?
No
Yes
No
Inspect for coolant leakage, cooling fan operations or thermostat operation.
Go to the next step.
Repair or replace the malfunctioning part according to spark test results.
Yes
5
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Go to the next step.
Low:
Inspect for clogged fuel line.
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
6
7
8
9
Inspect for variable tumble control operation.
Yes
(See Variable Tumble Control Operation
Inspection .)
No
Does variable tumble control function properly?
Inspect for variable valve timing control system operation.
(See Variable Valve Timing Control
System Operation Inspection .)
Does the variable valve timing control system function properly?
Yes
No
Yes Inspect for variable intake-air control operation.
(See Variable Intake-air Control
Operation Inspection .)
Does the variable control function properly?
Remove and shake the PCV valve.
No
Yes
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
13
14
Does the PCV valve rattle?
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes Inspect for contaminated the MAF sensor.
Is there any contamination?
No
Replace the PCV valve.
Go to the next step.
Go to the next step.
Inspect for cause.
Replace the suspected part.
Inspect the MAF sensor for contamination.
Is there any contamination?
Yes
No
Replace the MAF sensor.
Go to the next step.
Is engine compression correct?
(See COMPRESSION INSPECTION
[Z6] .)
Yes
Inspect valve timing.
(See Timing Chain Installation Note .)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.15 EMISSION COMPLIANCE [Z6]
B3E010318881W48
EMISSION COMPLIANCE 15
DESCRIPTION
Fails emissions test.
POSSIBLE
CAUSE
• Vacuum lines leakage or blockage
• Cooling system malfunction
• Spark plug malfunction
• Leakage from intake manifold
• Erratic or no signal from CMP sensor
• Inadequate fuel pressure
• PCV valve malfunction or incorrect valve installation
• EGR valve malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Exhaust system clogging
• Fuel tank ventilation system malfunction
• Charcoal canister damage
• Air cleaner element clogging or restriction
• Throttle body malfunction
• Spark leakage from high-tension leads
• Improper air/fuel mixture ratio control operation
• Bend or open circuit front HO2S or rear HO2S wiring harness
• Catalyst converter malfunction
• Engine internal parts malfunction
• Excessive carbon is built up in combustion chamber
• Improper engine compression
• Improper valve timing
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION
Inspect for following:
• Vacuum lines for leakage or blockage
• Electrical connections
• Proper maintenance schedule followed
RESULTS
Yes Go to the next step.
ACTION
No
Service if necessary.
Repeat Step 1.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness
Are all items normal?
2
3
Connect the WDS or equivalent to the DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using
WDS or equivalent.
Are there any DTCs displayed?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to appropriate symptom troubleshooting.
Go to the next step.
Go to the next step.
4
5
6
7
Yes
Is any other drivability concern present?
No
Connect the WDS or equivalent to the DLC-2.
Yes
Access ECT PID.
Warm-up the engine and idle it.
Verify ECT PID is correct.
No
(See PCM INSPECTION [Z6] .)
Is ECT PID correct?
Connect the WDS or equivalent to
DLC-2.
Yes
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
No
• More than 0.45 V when accelerator pedal is suddenly depressed: rich condition.
• Less than 0.45 V during fuel cut: lean condition
Perform the spark test.
Yes
(See Spark Test .)
Is strong blue spark visible at each cylinder?
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Yes
No
Start the engine and idle it.
Inspect for coolant leakage, cooling fan and thermostat operation.
Go to the next step.
Inspect and repair or replace front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [Z6] .)
Go to the next step.
Repair or replace the malfunctioning part according to spark test results.
Go to the next step.
Low:
Inspect for clogged fuel line.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
Remove and shake the PCV valve.
Does the PCV valve rattle?
Inspect inside charcoal canister for fuel saturation.
Yes
Is excess amount of liquid fuel present in the charcoal canister?
Yes
No
No
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Replace the PCV valve.
Replace the charcoal canister.
Inspect fuel tank vent system.
(See FUEL TANK INSPECTION .)
Then, go to the next step.
Visually inspect the exhaust system part. Is there any defective exhaust system part?
Yes
No
Replace the suspected part.
Go to the next step.
Inspect the three way catalytic converter.
Yes
(See EXHAUST SYSTEM
INSPECTION [Z6] .)
Is the three way catalytic converter normal?
No
Inspect the EGR system.
(See EGR Control System Inspection .)
Replace the three way catalytic converter.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [Z6]
B3E010318881W49
16 HIGH OIL CONSUMPTION/LEAKAGE
Oil consumption is excessive.
DESCRIPTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• PCV valve malfunction
• Improper dipstick
POSSIBLE CAUSE
• Improper engine oil viscosity
• Engine internal parts malfunction
Diagnostic procedure
STEP INSPECTION RESULTS
Yes
1
Remove and shake the PCV valve.
Does the PCV valve rattle?
No
Go to the next step.
Replace the PCV valve.
ACTION
2
3
Inspect for the following:
• External leakage
• Proper dipstick
• Proper engine oil viscosity
Are all the items normal?
Yes
No
Inspect the internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, and piston rings.
Service if necessary.
Repeat Step 2.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING
[Z6]
B3E010318881W50
17 COOLING SYSTEM CONCERNS -OVERHEATING
DESCRIPTION
Engine runs at higher than normal temperature/overheats.
• Improper coolant level
POSSIBLE CAUSE
• Blown fuses
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Coolant leakage
• Excessive A/C system pressure
• A/C system operation is improper.
• Improper water/anti-freeze mixture
• Fans reverse rotation
• Poor radiator condition
• Thermostat malfunction
• Radiator hose damage
• Improper or damaged radiator cap
• Cooling fan is inoperative.
• Coolant overflow system malfunction
• Improper tension of drive belt
• Drive belt damage
Diagnostic procedure
STEP
1
INSPECTION
Inspect the following:
• Engine coolant level
• Coolant leakage
• Fan rotational direction
• Fuses
Are all items normal?
RESULTS
Yes
• Water and anti-freeze mixture
• Radiator condition
• Collapsed or restricted radiator hoses
• Radiator pressure cap
No
• Overflow system
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
3
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Start the engine and idle it.
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to Step 5.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
Turn the A/C switch on.
Does A/C compressor engage?
Connect the WDS or equivalent to the
DLC-2.
Access AC_REQ PID.
Start the engine and idle it.
Turn the A/C switch on.
Does AC_REQ PID read On?
No
No
Yes
Inspect for the following and repair or replace if necessary:
• Refrigerant charging amount
• Open circuit in wiring harness between A/C relay and PCM terminal 1AL
• Seized A/C magnetic clutch
• A/C magnetic clutch malfunction
If all items are normal, go to the next step.
Go to the next step.
Inspect the following:
• Refrigerant pressure switch operation
• A/C switch is stuck open.
• Open or short circuit between refrigerant pressure switch and PCM terminal 1Q
• Open circuit of blower motor fan switch and resistor (if blower motor does not operate)
• Evaporator temperature sensor and A/C amplifier
Go to the next step.
5
6
Inspect cooling fan control system operation.
(See Cooling Fan Motor Operation
Inspection .)
Does the cooling fan control system function properly?
Yes
No
Yes
Is the drive belt normal?
No
Repair or replace the malfunctioning part.
7
8
9
Is there leakage around heater unit in passenger compartment?
Is there leakage at coolant hoses and/or radiator?
Cool down the engine.
Remove the thermostat and inspect operation.
(See THERMOSTAT
REMOVAL/INSTALLATION [Z6] .)
Yes
No
Yes
No
Yes
No
Go to the next step.
Replace the drive belt.
(See DRIVE BELT REPLACEMENT [Z6] .)
Inspect and service heater for leakage.
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
Engine coolant temperature sensor and the thermostat are normal, inspect the engine block for leakage or blockage.
Access ECT PID.
Inspect for both ECT PID and the temperature gauge readings.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
(See THERMOSTAT INSPECTION
[Z6] .)
Is the thermostat normal?
• If the temperature gauge on the instrument cluster indicates normal range but ECT PID is not same as the temperature gauge reading, inspect the ECT sensor.
• If the temperature gauge on the instrument cluster indicates overheating but ECT PID is normal, inspect the temperature gauge and the heat gauge unit.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD
[Z6]
B3E010318881W51
18 COOLING SYSTEM CONCERNS - RUNS COLD
DESCRIPTION
Engine takes excessive period for reaching normal operating temperature.
• Thermostat malfunction
POSSIBLE CAUSE
• Condenser fan system malfunction
• Cooling fan system malfunction
Diagnostic procedure
STEP
1
2
3
INSPECTION
Is customer complaint "Lack of passenger compartment heat" only?
Does engine speed continue at fast idle?
RESULTS
Yes
ACTION
Inspect A/C and heater system.
No Go to the next step.
Yes
No
Yes
Go to symptom troubleshooting "No.9 Fast idle/runs on".
(See NO.9 FAST IDLE/RUNS ON [Z6] .)
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
Remove the thermostat and inspect operation.
(See THERMOSTAT
REMOVAL/INSTALLATION [Z6] .)
No
(See THERMOSTAT
INSPECTION [Z6] .)
Is the thermostat normal?
Replace the thermostat.
(See THERMOSTAT REMOVAL/INSTALLATION
[Z6] .)
Inspect cooling fan control system operation.
(See Cooling Fan Motor Operation
Inspection .)
Yes
Does cooling fan control system work properly?
Access ECT PID.
Inspect for both ECT PID and the temperature gauge on the instrument cluster readings.
• If the temperature gauge on instrument cluster indicates normal range but ECT PID is not same as the temperature gauge reading, inspect the
ECT sensor.
• If the temperature gauge on the instrument cluster indicates cold range but ECT PID is normal, inspect the temperature gauge and the heat gauge unit.
No Repair or replace the malfunctioning part.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.19 EXHAUST SMOKE [Z6]
B3E010318881W52
EXHAUST SMOKE 19
DESCRIPTION
Blue, black, or white smoke from exhaust system
Blue smoke (Burning oil):
POSSIBLE
CAUSE
• PCV valve malfunction
• Engine internal oil leakage
White smoke (Water in combustion):
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Cooling system malfunction (coolant loss)
• Engine internal coolant leakage
Black smoke (Rich fuel mixture):
• Air cleaner restriction
• Intake-air system is collapsed or restricted.
• Fuel return line is restricted.
• Excessive fuel pressure
• Improper engine compression
• Injector fuel leakage
• Ignition system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
2
INSPECTION
What color is smoke coming from the exhaust system?
RESULTS
Blue
ACTION
Burning oil is indicated.
Go to the next step.
White
Black
Yes
Water in combustion is indicated.
Go to Step 3.
Rich fuel mixture is indicated.
Go to Step 4.
Inspect for the following:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
Remove and shake the PCV valve.
Does the PCV valve rattle?
Does the cooling system hold pressure?
No
Yes
• Damaged valve guide, stems or valve seals
• Blocked oil drain passage in cylinder head
• Piston ring is not seated, seized or worn.
• Damaged cylinder bore
If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
Replace the PCV valve.
Inspect for the following:
• Cylinder head gasket leakage
• Intake manifold gasket leakage
• Cracked or porous engine block
If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
Inspect for cause.
Go to the next step.
4
No
Inspect for the following:
• Air cleaner restriction
• Collapsed or restricted intake-air system
No
• Restricted fuel return line
Are all items normal?
Yes
Service if necessary.
Repeat Step 4.
5
6
Connect the WDS or equivalent to the DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using
WDS or equivalent.
Are there any DTCs displayed?
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Yes
Start the engine and idle it.
Measure fuel line pressure during idle.
No
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
Low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
7
8
Perform the spark test.
(See Spark Test .)
Yes
Is strong blue spark visible at each cylinder?
No
Inspect the CMP sensor.
(See CAMSHAFT POSITION (CMP) SENSOR
INSPECTION [Z6] .)
Repair or replace the malfunctioning part according to spark test result.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [Z6]
B3E010318881W53
20 FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION
Gasoline fuel smell or visible leakage
• Excessive fuel pressure
• Purge solenoid valve malfunction
• Fuel tank vent system blockage
• Charcoal canister malfunction
• Fuel leakage from fuel system
Warning
POSSIBLE
CAUSE
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
INSPECTION
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line.
Service if necessary.
(See FUEL LINE PRESSURE
INSPECTION .)
RESULTS
Yes
Install fuel pressure gauge between fuel pipe and the fuel distributor.
Start the engine and idle it.
No
Measure fuel line pressure at idle.
Is fuel line pressure correct at idle?
ACTION
Go to the next step.
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Replace the vacuum hose.
2
3
Inspect for blockage/restriction or open circuit in wiring harness between the engine vacuum port and the charcoal canister.
Yes
Inspect for blockage in fuel tank vent system.
Is fault indicated?
No
Yes Inspect the purge solenoid valve.
(See PURGE SOLENOID VALVE
INSPECTION .)
Is the solenoid operating properly?
No
Go to the next step.
Go to the next step.
Replace the purge solenoid valve.
DTC is displayed:
4
Yes
Connect the WDS or equivalent to the DLC-
2.
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Inspect the charcoal canister for fuel saturation.
• If excess amount of liquid fuel is present, replace the charcoal canister.
5 Verify test results.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.21 ENGINE NOISE [Z6]
B3E010318881W54
21 ENGINE NOISE
Engine noise from under hood
DESCRIPTION
Squeal, click or chirp noise:
• Improper engine oil level
• Improper drive belt tension
• Generator installation (alignment)
• Splash shield or under cover looseness (splashed water to drive belt)
Rattle sound noise:
• Loose parts
Hiss sound noise:
• Vacuum leakage
POSSIBLE CAUSE
• Loose spark plug
• Air leakage from intake-air system
Rumble or grind noise:
• Improper drive belt tension
• Improper P/S fluid level
Rap or roar sound noise:
• Dynamic damper looseness
• Exhaust system looseness
• Intake-air system looseness
Other noise:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Camshaft friction gear noise or MLA noise
• Timing chain noise
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
Is a squealing, click or chirping sound present?
No
Yes
Is a rumbling or grinding sound present?
No
Is a rattling sound present?
Yes
No
RESULTS
Yes
ACTION
Inspect for following:
• Engine oil
• Drive belt tension
• Splash shield or under cover looseness
• Generator installation (alignment)
Go to the next step.
Inspect drive belts.
Go to the next step.
Inspect rattling location for loose parts.
Is a hissing sound present?
Yes
No
Go to the next step.
Inspect for the following:
• Vacuum leakage
• Spark plug looseness
• Intake-air system leakage
Go to the next step.
5
Is a rapping or roaring sound present?
Yes
No
Inspect the following for looseness:
• Dynamic chamber
• Intake-air system
• Exhaust system
Go to the next step.
6
7
Is a knocking sound present?
Yes
Go to symptom troubleshooting "No.11
Knocking/pinging".
(See NO.13 KNOCKING/PINGING-
ACCELERATION/CRUISE [Z6] .)
No
If noise comes from engine internal, inspect for friction gear, timing chain or MLA noise.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.22 VIBRATION CONCERNS (ENGINE) [Z6]
B3E010318881W55
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION
• Vibration from under hood or driveline
• Loose attaching bolts or worn parts
POSSIBLE CAUSE
• Components malfunction such as worn parts
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS ACTION
Inspect following components for loose attaching bolts or worn parts:
• Cooling fan
• Generator
• Drive belt and pulleys
• Exhaust system mounting
• Engine mounting
All the items normal?
Yes
Inspect the following systems:
• Wheels
• ATX
• Driveline
• Suspension
No
Readjust or retighten engine mounting installation position.
Service if necessary for other parts.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.23 A/C DOES NOT WORK SUFFICIENTLY [Z6]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
23
DESCRIPTION
POSSIBLE
CAUSE
B3E010318881W56
A/C DOES NOT WORK SUFFICIENTLY.
The A/C compressor magnetic clutch does not engage when the A/C switch is turned on.
• Improper refrigerant charging amount
• Open A/C magnetic clutch
• Open circuit in wiring harness between A/C relay and A/C magnetic clutch
• Poor GND of A/C magnetic clutch
• Refrigerant pressure switch is stuck open.
• A/C relay is stuck open.
• Seized A/C compressor
• Open circuit in wiring harness between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
DTC is displayed:
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
2
Disconnect the A/C compressor connector.
Start the engine and turn the A/C switch on.
Yes
Is there correct voltage at the A/C compressor magnetic clutch terminal?
No
Specification
Inspect for GND condition of the magnetic clutch on the A/C compressor.
• If GND condition is normal, inspect for open circuit magnetic clutch coil.
Go to the next step.
3
0.5-1.5 mm {0.02-0.05 in}
Disconnect the refrigerant pressure switch connector.
Connect jumper wire between A/C highpressure switch terminals.
Connect jumper wires between refrigerant pressure switch terminals.
Connect WDS or equivalent to DLC-2.
Yes
No
Inspect the refrigerant pressure switch operation.
• If the switch is normal, go to the next step.
Inspect for following:
• A/C switch is stuck open.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
Access AC_REQ PID.
Turn the ignition switch to the ON position position.
Turn the A/C switch on and set the blower fan at any speed.
Does AC_REQ PID read On?
• Open circuit in wiring harness between refrigerant pressure switch and PCM terminal 1Q
• Open circuit of blower motor fan switch and resistor (if blower motor does not operate)
• Evaporator temperature sensor and A/C amplifier
Inspect for stuck open the A/C relay.
Replace if necessary.
Remove jumper wire from the switch connector.
Reconnect connector to the refrigerant pressure switch.
Yes
Start the engine and turn the A/C switch on.
Does the fan operate?
No
Inspect following and repair or replace if necessary:
• Refrigerant charging amount
• A/C compressor for being seized
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR
RUNS CONTINUOUSLY [Z6]
B3E010318881W57
24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
POSSIBLE
CAUSE
The A/C compressor magnetic clutch does not disengage.
• Stuck engagement A/C compressor magnetic clutch
• A/C relay is stuck closed.
• Short to GND in wiring harness between A/C switch and PCM
• Short to GND in wiring harness between A/C relay and PCM
• Short to battery power in A/C relay to magnetic clutch circuit shorted to battery power
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
2
3
INSPECTION
Connect the WDS or equivalent to the DLC-2.
Retrieve any continuous memory, KOEO and
KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
Yes
No
Start the engine and idle it.
Turn the A/C switch on.
Remove the A/C relay.
Does the A/C magnetic clutch disengage?
Connect the WDS or equivalent to the DLC-2.
Access AC_REQ PID.
Start the engine and turn the A/C switch on.
Read AC_REQ PID while disconnecting the refrigerant pressure switch connector.
Yes
Note
• AC_REQ PID should read Off when disconnecting connector. If AC_REQ
PID remains On, short to GND may be present.
Does AC_REQ PID remain On?
No
RESULTS ACTION
DTC is displayed:
Yes
No
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Go to the next step.
Inspect for the following:
• A/C relay is stuck closed.
• Short to GND in wiring harness between A/C relay and PCM terminal 1AL.
If both items normal, go to the next step.
Inspect if circuit between the A/C relay and the magnetic clutch shorts to battery power circuit.
• If circuit is normal, inspect the magnetic clutch stuck engagement or clearance.
Inspect for short to GND in wiring harness between the refrigerant pressure switch and the PCM terminal 1Q.
Go to the next step.
4
Reconnect the refrigerant pressure switch connector.
Read AC_REQ PID while turning off the A/C switch.
Note
Yes
Inspect following:
• Short to GND in wiring harness between A/C switch and A/C amplifier
• Short to GND in wiring harness between A/C amplifier and refrigerant pressure switch
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
• AC_REQ PID should read Off when turning A/C switch off. If AC_REQ PID remains On, short to GND may be present.
Does AC_REQ PID remain On?
No
Inspect for stuck closed the A/C switch.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN
THROTTLE CONDITIONS [Z6]
B3E010318881W58
25 A/C IS NOT CUT OFF UNDER WOT CONDITIONS.
DESCRIPTION
The A/C compressor magnetic clutch does not disengage under WOT.
• TP sensor malfunction
POSSIBLE CAUSE
• TP sensor misadjustment
• Loosely installed TP sensor
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS
Yes
ACTION
Go to the next step.
Does the A/C compressor disengage when the A/C switch is turned off?
No
Connect WDS or equivalent to DLC-2.
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
Yes
Go to symptom troubleshooting "No.24 A/C is always on or A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[Z6] .)
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
Are there any DTCs displayed?
No DTC is displayed:
No
Inspect the TP sensor for proper adjustment.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.26 EXHAUST SULPHUR SMELL [Z6]
B3E010318881W59
EXHAUST SULPHUR SMELL 26
DESCRIPTION
Rotten egg smell (sulphur) from exhaust
• Electrical connectors are disconnected or connected poorly
• Charcoal canister malfunction
• Vacuum lines are disconnected or connected improperly.
• Improper fuel pressure
• Poor fuel quality
Warning
POSSIBLE
CAUSE
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
INSPECTION RESULTS
Yes
ACTION
Go to appropriate flow chart.
Are any drive ability or exhaust smoke concerns present?
No Go to the next step.
2
Inspect following:
• Electrical connections
• Vacuum lines
• Fuel quality
Are all items normal?
Yes
No
Go to the next step.
Service if necessary.
Repeat Step 2.
3
4
5
6
Connect WDS or equivalent to
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER
DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [Z6] .)
No DTC is displayed:
Yes
Go to the next step.
Go to the next step.
Low:
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Inspect the fuel line for clogging.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
• If normal, replace the fuel pump unit.
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Replace the charcoal canister.
Yes
Inspect the charcoal canister for fuel saturation.
Is excess amount of liquid fuel present in the charcoal canister?
No
Inspect fuel tank vent system.
• If fuel tank vent system is normal, suggest trying a different brand since sulfur content can vary in different fuels.
• If the fuel tank vent system is not normal, repair or replace the malfunctioning part.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
NO.27 SPARK PLUG CONDITION [Z6]
B3E010318881W60
SPARK PLUG CONDITION 27
DESCRIPTION
Incorrect spark plug condition
POSSIBLE
CAUSE
Note
• Inspecting spark plug condition can determine whether problem is related to a specific cylinder possibly all cylinders.
Wet/carbon stuck on specific plug:
• Spark-Weak, not visible
• Air/fuel mixture-Excessive fuel injection volume
• Compression-No compression, low compression
• Malfunctioning spark plug
Grayish white with specific plug:
• Air/fuel mixture-Insufficient fuel injection volume
• Malfunctioning spark plug
Wet/carbon is stuck on all plugs:
• Spark-Spark weak
• Air/fuel mixture-Too rich
• Compression-Low compression
• Clogging in intake/exhaust system
Grayish white with all plugs:
• Air/fuel mixture-Too lean
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
Downloaded from https://carmanualshub.com/ - automotive repair manuals website
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION " described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
Remove all the spark plugs.
Inspect the spark plug condition.
Is the spark plug condition normal?
Are the spark plugs wet/covered with carbon by engine oil?
Yes
No
Yes Inspect the spark plug for the following:
• Cracked insulator
• Heat range
• Air gap
• Worn electrode
Is the spark plug normal?
No
Yes
RESULTS
Yes
ACTION
Troubleshooting completed.
Specific plug is wet or covered with carbon:
Go to the next step.
Specific plug looks grayish white:
Go to Step 7.
No
All plugs are wet or covered with carbon:
Go to Step 10.
All plugs look grayish white:
Go to Step 16.
Inspect all areas related to oil working up and down.
Go to the next step.
Go to the next step.
Replace the spark plug.
(See SPARK PLUG
REMOVAL/INSTALLATION [Z6] .)
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
Inspect compression pressure at suspected malfunctioning cylinder.
Is compression pressure correct?
(See COMPRESSION INSPECTION [Z6] .)
Install all spark plugs.
Perform the spark test at suspected malfunctioning cylinder.
Is strong blue spark visible?
(See Spark Test .)
(Compare with normal cylinder.)
No
Yes
No
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
Yes
6
Perform the fuel line pressure inspection.
(See FUEL LINE PRESSURE INSPECTION .)
Is fuel line pressure correct?
No
7
8
Inspect the spark plug for following.
• Heat range
• Air gap
Is spark plug normal?
Yes
No
Turn the ignition switch off.
Disconnect suspected fuel injector connector.
Turn the ignition switch to the ON position.
Measure terminal voltage for the fuel injector terminal A.
Is voltage B+ ?
Yes
No
Inspect the fuel injector for following:
• Open or short circuit in injector
• Leakage
• Injection volume
Zero or low:
Inspect fuel pump and the fuel pump relay related circuit.
Inspect the main fuel line for clogging.
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Replace the spark plug.
Go to the next step.
Repair open or short fuel injector power supply circuit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
11
Turn the ignition switch off.
Disconnect the PCM connector.
Measure resistance between suspected the fuel injector terminal B and the PCM connector following terminal:
Yes
• For No.1 cylinder: 2B
• For No.2 cylinder: 2C
• For No.3 cylinder: 2D
• For No.4 cylinder: 2H
Is resistance less than 5.0 ohms ?
Perform the spark test.
Is strong blue spark visible at each cylinder?
13
Inspect the following PIDs.
• ECT
• O2S11 (When engine can be started)
• MAF
(See PCM INSPECTION [Z6] .)
Are PIDs normal?
14
No
Yes
No
Yes
12
Perform the fuel line pressure inspection.
Is fuel line pressure correct?
(See FUEL LINE PRESSURE INSPECTION .)
No
No
Yes
10 Is the air cleaner element free of restrictions?
No
Yes
Yes
Inspect the fuel injector for following:
(See FUEL INJECTOR
INSPECTION .)
• Resistance
• Fuel injection volume
Repair open the fuel injector control circuit.
Go to the next step.
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Replace the air cleaner element.
Repair or replace the malfunctioning part.
Go to the next step.
Zero or low:
Inspect the fuel pump and fuel pump relay related circuit.
Inspect the main fuel line for clogging.
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
15
16
17
18
Perform the purge control inspection. (When engine can be started)
(See Purge Control System Inspection .)
Is purge control correct?
No
Repair or replace the malfunctioning part.
Perform the compression inspection.
Is compression correct?
Yes
No
Inspect for deformed exhaust system part.
Repair or replace the malfunctioning part.
Repair or replace the malfunctioning part.
When the engine cannot be started, inspect the intake-air system for air leakage.
Yes
When the engine can be started, perform the intake manifold vacuum inspection.
Is air sucked in from intake-air system?
No Go to the next step.
Perform the fuel line pressure inspection.
Is fuel line pressure correct?
(See FUEL LINE PRESSURE INSPECTION .)
Yes
No
Inspect following PIDs:
• ECT
• O2S11
• O2S12
• MAF
(See PCM INSPECTION
[Z6] .)
Inspect PCM GND condition.
Zero or low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [Z6] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- If vehicle not repaired or additional diagnostic information not available, replace PCM.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
INTERMITTENT CONCERN TROUBLESHOOTING [Z6]
B3E010318881W61
Vibration Method
1. If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below.
Note
• There are several reasons vehicle or engine vibration could cause an electrical malfunction.
Some of the things to inspect for are:
- Connectors not fully seated
- Wiring harnesses not having full play
- Wiring harnesses laying across brackets or moving parts
- Wiring harnesses routed too close to hot parts
• An improperly routed, improperly clamped, or loose wiring harness can cause wiring to become pinched between parts.
• The connector joints, points of vibration, and places where wiring harnesses pass through the fire wall, body panels, etc. are the major areas to be inspected.
Inspection Method for Switch Connectors or Wiring Harnesses
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position. (Engine off).
Note
• If engine starts and runs, perform the following steps during idle.
3. Access PIDs for the switch you are inspecting.
4. Turn the switch on manually.
5. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.
• If PID value is unstable, inspect for poor connection.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspection Method for Sensor Connectors or Wiring Harnesses
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If engine starts and runs, perform the following steps during idle.
3. Access PIDs for the switch you are inspecting.
4. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.
• If PID value is unstable, inspect for poor connection.
Inspection Method for Sensors
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If engine starts and runs, perform the following steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Vibrate the sensor slightly with your finger.
• If PID value is unstable or malfunction occurs, check for poor connection and/or poorly mounted sensor.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspection Method for Actuators or Relays
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If engine starts and runs, perform the following steps during idle.
3. Prepare the Output State Control for actuators or relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3 s are Output State Control is activated.
• If variable click sound is heard, inspect for poor connection and/or poorly mounted actuator or relay.
Note
• Vibrating relays excessively may result in open relays.
Water Sprinkling Method
Caution
• Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
• If a vehicle is subject to water leakage, the leakage may damage the control module. When testing a vehicle with a water leakage problem, special caution must be used.
If malfunction occurs only during high humidity or rainy/snowy weather, perform the following steps.
1. Connect WDS or equivalent to DLC-2 if inspecting sensors or switches.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If the engine starts and runs, perform the following steps during idle.
3. Access PIDs for sensor or switch if 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.
• If PID value is unstable or malfunction occurs, repair or replace part.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ENGINE CONTROL SYSTEM OPERATION
INSPECTION [Z6]
B3E010318881W62
Main Relay Operation Inspection
1. Verify that the main relay clicks when the ignition switch turned to the ON position and off.
• If there is no operation sound, inspect the following.
- Main relay (See RELAY INSPECTION .)
- Wiring harness and connector between ignition switch and main relay terminal A
- Wiring harness and connector between PCM terminal 1AW and main relay terminal B
Intake Manifold Vacuum Inspection
1. Verify the air intake hoses are installed properly.
2. Start the engine and idle it.
3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the intake manifold side.
4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
• If not as specified, inspect the following.
Specification (ATX)
More than 71 kPa {533 mmHg, 21 inHg}
Specification (MTX)
More than 72 kPa {541 mmHg, 22 inHg}
Note
• Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.
- Air suction at throttle body, intake manifold and PCV valve installation points
- Accelerator cable free play
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Fuel injector insulator
- Engine compression (See COMPRESSION INSPECTION [Z6] .)
Idle Air Control System Inspection
Engine coolant temperature compensation inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Access the following PIDs.
• ECT
• IAT
• RPM
3. Verify that the engine is in cold condition, then start the engine.
4. Verify that the engine speed decreases as the engine warms up.
• If the engine speed does not decrease or decreases slowly, inspect the following.
- ECT sensor and related wiring harness (See ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION [Z6] .)
- IAC valve and related wiring harness (See IDLE AIR CONTROL (IAC) VALVE INSPECTION
[Z6] .)
Load compensation inspection
1. Start the engine and run is during idle.
2. Connect the WDS or equivalent to the DLC-2.
3. Verify that P0511 not displayed.
• If P0511 shown, perform the DTC inspection. (See DTC P0511 [Z6] .)
4. Change the duty value of the IAC valve to 100% using the IAC PID.
5. Verify that the idle speed increases.
• If the idle speed does not change, inspect the following.
- IAC valve air passage
- Open or short circuit in wiring harness between IAC valve terminals and PCM terminals 2X and
2AB
6. Access the following PIDs.
• AC_REQ
• IAC
• PSP
• RPM
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Excludes temporary idle speed drop just after the loads are turned on.
7. Verify that the engine speed is within the specification under each load condition.
• If not as specified under each load condition, inspect the following.
- Refrigerant pressure switch (low, high) and related wiring harness (See REFRIGERANT
PRESSURE SWITCH INSPECTION .)
- Fan switch and related wiring harness (See FAN SWITCH INSPECTION .)
- PSP switch and related wiring harness (See POWER STEERING PRESSURE (PSP) SWITCH
INSPECTION [Z6] .)
Engine speed
Engine speed (rpm) *1
Load condition
No load
E/L operating *2
34-42 A more than 42 A
P/S operating
MTX ATX
640-740 700-800
650-750 700-800
700-800
700-800
Refrigerant pressure low *4 650-750 700-800
A/C operating *3
Refrigerant pressure high *5 700-800
*1 :
Neutral or P position
*2 :
Generator generating current value
*3 :
A/C switch and fan switch are on.
*4 :
Refrigerant pressure switch (middle pressure) is off.
*5 :
Refrigerant pressure switch (middle pressure) is on.
Variable Intake-air Control Operation Inspection
1. Connect the WDS or equivalent to DLC-2.
2. Perform the KOEO self-test using WDS or equivalent.
3. Verify that DTC P0660 is not displayed.
• If DTC P0660 is shown, perform the DTC inspection. (See DTC P0660 [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Turn the ignition switch to the ON position (Engine off).
5. Turn variable intake-air shutter valve actuator from on to off and from off to on using the IMTV PID and verify that operation sound of the actuator is heard.
• If operation sound is not head, inspect the following.
- Variable intake-air shutter valve actuator (See VARIABLE INTAKE-AIR SHUTTER VALVE
ACTUATOR INSPECTION [Z6] .)
- Variable intake shutter valve actuator stuck open or close
Variable Tumble Control Operation Inspection
1. Connect the WDS or equivalent to DLC-2.
2. Perform the KOEO self-test using WDS or equivalent.
3. Verify that DTC P2006 and P2008 are not displayed.
• If DTC P2006 or P2008 is shown, perform the DTC inspection. (See DTC TABLE [Z6] .)
4. Turn the ignition switch to the ON position (Engine off).
5. Monitor ECT, RPM and IMRC PIDs.
6. Verify that ECT PID is 60 ° C {140 ° F} or less .
7. Start engine.
8. Verify that IMRC PID is following while ECT PID is 60 ° C {140 ° F} or less .
• If the IMRC PID is not specified, inspect TP sensor (misadjustment).
Engine speed
3,250 rpm
Engine speed
Less than More than
IMRC PID On Off
9. Turn variable tumble shutter valve actuator from on to off and from off to on using IMRC PID and verify that operation sound of the actuator is heard.
• If operation sound is not heard, inspect the following.
- Variable tumble shutter valve actuator (See VARIABLE TUMBLE SHUTTER VALVE
ACTUATOR INSPECTION [Z6] .)
- Variable tumble shutter valve actuator stuck open or close
Fuel Injector Operation Inspection
STEP INSPECTION RESULTS ACTION
1 Yes Fuel injector operation is normal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
While cranking engine, inspect for fuel injector operation sound at each cylinder using a soundscope.
Is operation sound heard?
No
Perform the main relay operation inspection.
Is main relay operation normal?
Yes
No
Yes
Change fuel injector connector of not operating fuel injector and operating fuel injector.
Is operation sound heard?
No
All cylinders no heard:
Go to the next step.
Some cylinders no heard:
Go to Step 3.
Inspect the following:
• Fuel injector power system related wiring harness and connectors
• PCM connectors
• Fuel injector GND and related wiring harness and connectors
Repair or replace the malfunctioning part.
Go to the next step.
Replace fuel injector.
Fuel pump relay (See FUEL
INJECTOR INSPECTION .)
4
Are wiring harness and connectors of not operation fuel injector normal? (Open or short circuit)
Yes
Inspect the PCM terminal voltage of fuel injector signal.
No
Repair or replace the malfunctioning part.
Fuel Cut Control System Inspection
1. Warm-up engine and idle it.
2. Turn off the electrical loads and A/C switch.
3. Connect WDS or equivalent to the DLC-2.
4. Access RPM and FUELPW PIDs.
5. Monitor both PIDs while performing the following steps.
(1) Depress the accelerator pedal and increase the engine speed to 4,000 rpm .
(2) Release the accelerator pedal (brake pedal is not depressed) and verify that the fuel injector duration time is 0 ms , and 2-5 ms when the engine speed drops 1,200 rpm or less .
• If not as specified, inspect the following.
- ECT sensor and related wiring harness (See ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION [Z6] .)
- Neutral/clutch pedal position switch and related wiring harness (MTX) (See CLUTCH PEDAL
POSITION (CPP) SWITCH INSPECTION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- TR switch and related wiring harness (ATX) (See TRANSAXLE RANGE (TR) SWITCH
INSPECTION .)
Fuel Pump Operation Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Remove the fuel-filler cap.
3. Turn the ignition switch to the ON position.
4. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard.
• If no operation sounds is heard, proceed to next step.
5. Measure the voltage at wiring harness-side fuel pump terminal A.
Specification
B+ (Ignition switch is ON position)
• If the voltage is as specified, inspect the following.
- Fuel pump continuity
- Fuel pump GND
- Wiring harness between fuel pump relay and PCM terminal 1AH (without immobilizer system),
1AC (with immobilizer system)
• If not as specified, inspect the following.
- Fuel pump relay (See RELAY INSPECTION .)
- Wiring harness and connector (Main relay-fuel pump relay-fuel pump)
Fuel Pump Control System Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position.
3. Access FP PID.
4. Turn the fuel pump relay from off to on and inspect if the operation sound of the fuel pump relay is heard.
• If no operation sound is heard, inspect the fuel pump relay.
• If the fuel pump relay is normal, inspect the following.
- Wiring harnesses and connectors (Main relay-fuel pump relay-PCM)
Spark Test
1. Remove the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Warning
• High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test.
STEP
1
INSPECTION
• Disconnect ignition coil from spark plugs.
• Remove spark plugs.
• Reconnect spark plugs to ignition coil.
• Ground spark plugs to engine.
• Is strong blue spark visible at each cylinder while cranking?
ACTION
Yes Ignition system is normal.
Some cylinders do not spark:
No
• Go to the next step.
All cylinders do not spark:
• Go to Step 4.
2
3
4
• Inspect the spark plugs for damage, wear, carbon deposits and proper plug gap.
• Are the spark plugs normal?
Yes Go to the next step.
No
Replace the spark plugs, then return to
Step.1.
• Inspect following wiring harnesses for open or short circuit:
- Ignition coil No.1 terminal C-PCM terminal 2Y
- Ignition coil No.2 terminal C-PCM terminal 2U
- Ignition coil No.3 terminal C-PCM terminal 2Q
- Ignition coil No.4 terminal C-PCM terminal 2M
• Are wiring harnesses normal?
Yes
Inspect and replace the ignition coil.
(See IGNITION COIL INSPECTION [Z6] .)
No
Repair or replace the malfunctioning part, then return to Step.1.
• Measure the voltage at terminal A in each ignition coils.
• Is voltage B+ ?
Yes
No
Go to the next step.
Inspect power supply circuit of ignition coils.
5
• Does the PCM connector or ignition coil connectors have poor connection?
Yes
Repair or replace the connector, then return to Step.1.
No Go to the next step.
6
• Are following parts normal?
- CKP sensor and crankshaft pulley
Yes
Inspect for open or short circuit in wiring harness and connector of CKP sensor.
No
Repair or replace the malfunctioning part, then return to Step.1.
EGR Control System Inspection
1. Crank the engine and verify that EGR valve operation (initial operation) sound is heard.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the operation sound is not heard, connect WDS or equivalent to the DLC-2 and verify that the
DTC P0403 is shown. Perform the DTC inspection. (See DTC TABLE [Z6] .)
2. Start the engine and idle it.
3. Increase the step value of EGR valve from 0 to 40 using SEGRP PID.
4. Operate the EGR valve and inspect if the engine speed becomes unstable or the engine stalls.
• If the engine speed will not change, proceed to following.
(1) Stop the engine.
(2) Remove the EGR valve.
(3) Connect the EGR valve connector.
(4) Turn the ignition switch to the ON position.
(5) Increase the step value of EGR valve from 0 to 40 using SEGRP PID.
(6) Inspect the EGR operation.
• If the EGR valve is operated, clean the EGR valve and reinspect from Step 2.
• If the EGR valve will not operate, replace the EGR valve and reinspect from Step 2.
5. Start the engine and warm it up completely.
6. Access the following PIDs.
• ECT
• RPM
• SEGRP
• TP
• VSS
7. Idle the vehicle and verify that the SEGRP value is 0 .
8. Drive the vehicle.
9. Depress the accelerator pedal and verify that the SEGRP value is increased.
• If the SEGRP value will not increase, inspect the VSS, TP and ECT PIDs. (See PCM
INSPECTION [Z6] .)
10. Stop the vehicle and verify that the SEGRP value is returned 0 .
Purge Control System Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Start the engine and idle it.
3. Access ECT PID.
4. Verify that the engine coolant temperature is 60 ° C {140 ° F} or more .
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the WDS or equivalent indicates 60 ° C {140 ° F} or less , perform out the ECT sensor inspection.
5. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
6. Put a finger to the purge solenoid valve and verify that there is vacuum applied when the engine is cold.
• If there is no vacuum, inspect the following.
- Wiring harness and connectors (Purge solenoid valve-PCM terminal 2AV)
- Purge solenoid valve
7. Stop the engine.
8. Verify that the DTC P0443 is shown. Perform out DTC inspection. (See DTC P0443 [Z6] .)
9. Turn the ignition switch to the ON position.
10. Access EVAPCP PID.
11. 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 the loose or damaged vacuum hose. (Intake manifold-purge solenoid valve-charcoal canister)
• If the operation sound is not heard, perform the purge solenoid valve inspection.
A/C Cut-off Control System Inspection
1. Start the engine.
2. Turn the A/C switch and fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
• If it does not actuate, go to symptom troubleshooting "No.23 A/C does not work sufficiently".
(See NO.23 A/C DOES NOT WORK SUFFICIENTLY [Z6] .)
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2-
5 s .
• If it actuates, inspect as follows.
(1) Connect WDS or equivalent to the DLC-2.
(2) Turn the A/C switch off.
(3) Turn the ignition switch to the ON position.
(4) Access ACCS PID.
(5) Turn the A/C relay from off to on and inspect if the operation sound of the relay is heard.
• If the operation sound is heard, inspect TP PID.
• If the operation sound is not heard, inspect following.
- A/C relay
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Open circuit or short to GND in wiring harness and connectors (Ignition switch-A/C relay-PCM terminal 1AL)
- A/C related parts
Cooling Fan Motor Operation Inspection
1. Verify that the battery voltage is above 12.4 V .
• If the battery voltage is below 12.4 V , charge the battery or connect the external power supply.
2. Connect the WDS or equivalent to the DLC-2.
3. Access the following PIDs.
• ECT
• AC_REQ
• COLP
4. Turn the A/C switch to off.
5. Verify that ECT PID is below 98 ° C {209 ° F} and the AC_REQ is off.
• If the ECT PID is below 98 ° C {209 ° F} , inspect the ECT sensor.
• If the AC_REQ PID is on, inspect the A/C switch and A/C refrigerant pressure switch (high/low pressure).
6. Turn the ignition switch to the ON position while the temperature is below 98 ° C {209 ° F} with the ignition switch in the ON position.
7. Verify that the cooling fan is not operating.
• If the cooling fan is operating inspect the following:
(1) Verify that the FAN DUTY PID is 0 % .
• If the FAN DUTY PID is not 0 % , inspect the following PID and related parts.
- ECT (ECT sensor)
- AC_REQ (A/C switch and A/C refrigerant pressure switch (high/low) pressure)
- COLP (A/C refrigerant pressure switch (medium pressure))
- VSS (Vehicle speed sensor)
- ACCS (A/C magnetic clutch)
• If the FAN DUTY PID is 0 % , replace cooling fan component.
8. Turn the A/C switch to on.
9. Verify that the cooling fan is operating while the ECT PID is below 98 ° C {209 ° F} .
• If the cooling fan does not operate, inspect for the following:
- A/C switch
- A/C refrigerant pressure switch
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Fan control module power supply circuit (open or short circuit)
- Fan control module GND circuit (open or short circuit)
- Fan control module control signal circuit (open or short circuit between fan control module terminal B and PCM terminal 1AP)
- Fan control module
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
10. Verify that the cooling fan operates at medium speed while the COLP PID is off and high speed while the COLP PID is on.
• If the cooling fan does not operate medium and/or high speed, inspect for the following:
- A/C refrigerant pressure switch (medium switch)
- Fan control module
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
11. Turn the A/C switch to the off position.
12. Start the engine and idle it.
13. Verify that the cooling fan operating speed increases relative to the ECT PID increase.
• If the cooling fan speed does not increase inspect the following:
- ECT sensor (characteristic)
- Fan control signal circuit (between fan control module terminal B and PCM terminal 1AP)
• If the all items are normal, replace the cooling fan component.
Variable Valve Timing Control System Operation Inspection
When idling cannot be continued
1. Remove the OCV and verify that the spool valve is at maximum retard position.
2. If the spool valve is stuck in advance direction, replace the OCV.
3. Connect the OCV.
4. Turn the ignition switch to the ON position.
5. Verify that the spool valve is at maximum retard position.
6. If the spool valve is stuck in advance direction, inspect for the following.
• Short circuit in wiring harnesses or connectors between the OCV and the PCM.
7. Inspect the variable valve timing actuator.
When idling can be continued
1. Warn-up the engine.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Connect the WDS or equivalent to the DLC-2.
3. Idle the engine.
4. Access VT DUTY1 PID.
5. Set the OCV duty valve to 100% and verify that the engine idles roughly or stalls.
• If as specified, inspect the timing belt component (valve timing deviation).
• If not as specified, go to the next step.
6. Remove the OCV and connect the OCV connector to the OCV.
7. Turn the ignition switch to the ON position.
8. Access VT DUTY1 PID.
9. Set the OCV duty value to 100% and verify that the spool valve operates in the advance direction.
10. If not as specified, inspect the following.
• OCV operation.
• Wiring harness and connectors between the OCV and the PCM for open or short circuit.
11. Inspect the following hydraulic passages for clogging and/or leakage.
• Oil pressure switch-OCV
• OCV-camshaft
• Camshaft internal passage
12. If they are normal, replace the intake camshaft pulley (with a built-in variable valve timing actuator).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
SYMPTOM TROUBLESHOOTING
[ENGINE CONTROL SYSTEM (LF)]
ENGINE SYMPTOM TROUBLESHOOTING [LF]
B3E010318881W01
• Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
Diagnostic Index
No.
TROUBLESHOOTING ITEM
1 Melting of main or other fuses
2 MIL illuminates.
3 Will not crank
DESCRIPTION
-
MIL is illuminated incorrectly.
Starter does not work.
4
Hard to start/long crank/erratic start/erratic crank
5 Engine stalls.
After start/at idle
Starter cranks engine at normal speed but engine requires excessive cranking time before starting.
Engine stops unexpectedly at idle and/or after start.
6 Cranks normally but will not start
7 Slow return to idle
8 Engine runs rough/rolling idle
9 Fast idle/runs on
10 Low idle/stalls during deceleration
11
Engine stalls/quits.
Acceleration/cruise
Engine runs rough.
Acceleration/cruise
Starter cranks engine at normal speed but engine will not run.
Engine takes more time than normal to return to idle speed.
Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
Engine speed continues at fast idle after warm-up.
Engine runs after ignition switch is turned off.
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
Engine stops unexpectedly at beginning of acceleration or during acceleration.
Engine stops unexpectedly while cruising.
Engine speed fluctuates during acceleration or cruising.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Misses
Buck/jerk
Surges
Acceleration/cruise
Acceleration/cruise/ deceleration
Hesitation/stumble Acceleration
Acceleration/cruise
12 Lack/loss of power Acceleration/cruise
13 Knocking/pinging Acceleration/cruise
14 Poor fuel economy
15 Emission compliance
16 High oil consumption/leakage
17
Cooling system concerns
Overheating
18
Cooling system concerns
19 Exhaust smoke
Runs cold
20 Fuel odor (in engine compartment)
21 Engine noise
22 Vibration concerns (engine)
23 A/C does not work sufficiently.
24
A/C is always on or A/C compressor runs continuously.
25 A/C is not cut off under WOT conditions.
Engine misses during acceleration or cruising.
Vehicle bucks/jerks during acceleration, cruising, or deceleration.
Momentary pause at beginning of acceleration or during acceleration
Momentary minor irregularity in engine output
Performance is poor under load.
(e.g. power down when climbing hills)
Sound is produced when air/fuel mixture is ignited by something other than spark plug. (e.g. hot spot in combustion chamber)
Fuel economy is unsatisfactory.
Fails emissions test.
Oil consumption is excessive.
Engine runs at higher than normal temperature/overheats.
Engine does not reach normal operating temperature.
Blue, black, or white smoke from exhaust system
Gasoline fuel smell or visible leakage
Engine noise from under hood
Vibration from under hood or driveline
A/C compressor magnetic clutch does not engage when A/C is turned on.
A/C compressor magnetic clutch does not disengage.
A/C compressor magnetic clutch does not disengage under WOT.
Rotten egg smell (sulphur) from exhaust
Incorrect spark plug condition
26 Exhaust sulphur smell
27 Spark plug condition
28 ATX concerns
Upshift/downshift/ engagement
ATX concerns not related to engine performance
QUICK DIAGNOSTIC CHART [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E010318881W02
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
NO.1 MELTING OF MAIN OR OTHER FUSES [LF]
B3E010318881W03
MELTING OF MAIN OR OTHER FUSES
[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Damaged fuse Related wiring harness
IG KEY1 fuse
IG KEY1
(30 A)
• Ignition switch
- ENGINE fuse
ENGINE fuse
ENGINE
(20 A)
• Main relay
• Ignition coil No.1
• Ignition coil No.2
• Ignition coil No.3
• Ignition coil No.4
• Condenser
IG KEY2 fuse
IG KEY2
(30 A)
ENG +B
(10 A)
• Ignition switch
ENG +B fuse
• PCM
ENGINE fuse
ENGINE
(30 A)
EGI INJ1
(10 A)
• Main relay
- EGI INJ1 fuse
- EGI INJ2 fuse
- ENG BAR1 fuse
- ENG BAR2 fuse
EGI INJ1 fuse
• Fuel injector No.1
• Fuel injector No.2
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
EGI INJ2
(10 A)
ENG BAR1
(10 A)
ENG BAR2
(10 A)
• Fuel injector No.3
• Fuel injector No.4
EGI INJ2 fuse
• PCM
ENG BAR1 fuse
• EGR valve
• Variable intake-air solenoid valve
• Variable tumble solenoid valve
• Purge solenoid valve
• MAF sensor
• Fuel pump relay
ENG BAR2 fuse
• HO2S (front)
• HO2S (rear)
BTN
(40 A)
BTN fuse
• OBD fuse
OBD
(10 A)
OBD fuse
• DLC-2
FUEL PUMP
(15 A)
FUEL PUMP fuse
• Fuel pump relay
FAN fuse
FAN
(40 A) • Fan control module
NO.2 MIL ILLUMINATES [LF]
B3E010318881W04
2 MIL ILLUMITATES
DESCRIPTION
The MIL is illuminated incorrectly.
• The PCM illuminates for emission-related concern (DTC is stored in PCM).
POSSIBLE CAUSE
• Instrument cluster malfunction
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the MIL blinks at steady rate, misfire condition could possibly exist.
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS ACTION
DTC is displayed:
Connect the WDS or equivalent to the
DLC-2.
Retrieve any DTC.
Are there DTC displayed?
Yes • Go to the appropriate DTC inspection.
(See DTC TABLE [LF]
No DTC is displayed:
.)
No
• Inspect instrument cluster operation.
(See INSTRUMENT CLUSTER
INSPECTION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.3 WILL NOT CRANK [LF]
B3E010318881W05
3 WILL NOT CRANK
DESCRIPTION
The starter does not work.
• Open starter circuit between ignition switch and starter
• Low or dead battery
• Charging system malfunction
POSSIBLE CAUSE
• Starter malfunction
• Seized/hydrolocked engine, flywheel
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly (Ignition key is not registered)
Diagnostic procedure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STEP
1
2
INSPECTION RESULTS ACTION
Both conditions appear: Note
• The following test should be performed
Yes for vehicles with immobilizer system. Go to Step 7 for vehicles without immobilizer system.
Connect the WDS or equivalent to the DLC-2.
Do the following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
No
Yes
Is the coil connector securely connected to the coil?
No
Yes
Go to Step 4.
Either or other condition appears:
Go to the next step.
Go to the next step.
Connect the coil connector securely.
Return to Step 1.
Go to the next step.
3 Does the security light illuminate?
No
Inspect the instrument cluster and wiring harness.
(See INSTRUMENT CLUSTER
INSPECTION .)
Go to appropriate DTC inspection.
(See DTC TABLE [LF] .)
4
5
Connect the WDS or equivalent to the DLC-2 and retrieve DTC.
DTC
Yes
B1213, B1600, B1601, B1602, B1681, B2103,
B2139, B2141, B2431, U2510
Inspect for the following wiring harnesses and connectors:
No
Yes
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
No
Go to the next step.
Repair or replace the wiring harness and connector.
Go to the next step.
6
7
Inspect for the following wiring harnesses and connectors:
• Between PCM terminal 1AI and instrument cluster terminal 1O
• Between coil terminal 1AM and instrument cluster terminal 1M
Yes
No
Inspect the following:
• Battery connection
Yes
No
Repair or replace the wiring harness and connector.
Go to the next step.
Go to the next step.
Service if necessary.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Battery condition
• Fuses
Are all items normal?
Is clicking sound heard from starter when the ignition switch is turned to START?
Yes
No
Repeat Step 7.
9
Inspect the starting system.
(See STARTER INSPECTION .)
Is starting system normal?
Yes
No
Yes
10 Do any other electrical accessories function?
No
11
Connect the WDS or equivalent to the DLC-2.
Retrieve any continuous memory DTCs.
Are there any continuous memory DTCs displayed?
Yes
No
Go to the next step.
Go to Step 13.
Inspect for seized/hydrolocked engine or flywheel.
(See FLYWHEEL INSPECTION .)
Repair or replace components as required.
Go to the next step.
Inspect charging system.
(See BATTERY INSPECTION .)
(See GENERATOR INSPECTION .)
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
Communication error message is displayed:
Inspect for following:
• Open circuit in wiring harness between main relay and PCM terminal 1BE
• Open circuit in wiring harness between main relay terminal B and
PCM terminal 1AT
• Main relay is stuck open.
• Open or poor GND circuit (PCM terminal 1BH, 1AZ, 1BD, 1BC or
1BG)
• Poor connection of vehicle body
GND
No DTC is displayed:
Inspect following:
• START circuit in ignition switch
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12
13
• Open circuit in wiring harness between ignition switch and starter
DTC is displayed:
Retrieve any KOEO DTCs using WDS or equivalent.
Are there DTCs displayed during KOEO inspection?
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
No
Inspect the following:
• START circuit in ignition switch
• Open circuit in wiring harness between ignition switch and starter
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.4 HARD TO START/LONG CRANK/ERRATIC
START/ERRATIC CRANK [LF]
B3E010318881W06
4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION
• The starter cranks engine at normal speed but engine requires excessive cranking time before starting.
• The battery is in normal condition.
POSSIBLE
CAUSE
• Erratic signal to ignition coil
• Vacuum leakage
• Poor fuel quality
• Starting system malfunction
• Spark plug malfunction
• Air leakage from intake-air system
• Erratic signal from CKP sensor
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Erratic signal from CMP sensor
• Improper air/fuel mixture ratio control
• Air cleaner restriction
• IAC valve malfunction
• PCV valve malfunction
• Inadequate fuel pressure
• Purge valve malfunction
• MAF sensor contamination
• Incorrect MAF sensor GND voltage
• Restriction in exhaust system
• EGR valve malfunction
• Pressure regulator malfunction (built-in fuel pump unit)
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Inspect for the following:
• Vacuum leakage
• Proper fuel quality (such as proper octane, contamination, winter/summer blend)
• Loose bands on intake-air system
• Cracks on intake-air system parts
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Intake-air system restriction (e.g. air cleaner element, fresh air duct.)
Are all items normal?
2
3
4
Connect the WDS or equivalent to the DLC-2.
Retrieve any KOEO and KOER DTCs using WDS or equivalent.
Yes
Is any KOEO or KOER DTC displayed?
No
Is the engine overheating?
Yes
No
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Yes
No
Are wiring harness conditions normal?
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [LF] .)
Go to the next step.
Go to the next step.
Repair the wiring harnesses
5
Inspect spark plug conditions.
Is spark plug wet, covered with carbon or grayish white?
Yes
No
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from fuel injector.
Spark plug is grayish white:
Inspect the fuel injector for clogging.
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
6
7
8
Visually inspect the CKP sensor and teeth of crankshaft pulley.
Yes
Are the CKP sensor and teeth of crankshaft pulley normal?
No
Measure the gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
0.5-1.9 mm {0.020-0.75 in}
No
Is the gap within the specification?
Remove and shake the PCV valve.
Yes
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [LF] .)
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
Does the PCV valve rattle?
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the DLC-2 in
Turn the fuel pump on using FP PID in output state control of data logger function.
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
No
10
Is the fuel line pressure held after the ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Yes
Yes
Replace the PCV valve.
Go to the next step.
Zero or low:
Inspect the fuel pump and fuel pump relay related circuit.
Inspect for clogged fuel line.
• If normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• If the fuel injector is normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Inspect if the purge valve is stuck open.
11
12
13
14
Disconnect a vacuum hose from the purge valve and plug opening end of vacuum hose.
Yes
Start the engine.
No
Is starting condition improved?
Yes Inspect the MAF sensor for the following:
• Contamination
• MAF sensor terminal B voltage
(GND circuit)
Is there any contamination?
No
Visually inspect the exhaust system part.
Is there any deformed exhaust system part?
Yes
No
Yes
Go to the next step.
Repair or replace malfunctioning part.
Go to the next step.
Replace the suspected part.
Go to the next step.
Replace the EGR valve.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspect engine condition while tapping the EGR valve housing.
Does engine condition improve?
No Go to the next step.
15
16
Inspect the starting system.
(See STARTER INSPECTION .)
Is starting system normal?
Yes
Inspect for loose connectors or poor terminal contact.
• If there is no malfunction, remove EGR valve and visually inspect for mechanically stuck
EGR valve
No Repair or replace components as required.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.5 ENGINE STALLS-AFTER START/AT IDLE [LF]
B3E010318881W07
5 ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION
• The engine stops unexpectedly.
POSSIBLE
CAUSE
• A/C system operation is improper
• Air leakage from intake-air system parts
• Purge valve malfunction
• Improper operation of IAC valve
• EGR valve malfunction
• No signal from CKP sensor due to sensor, related wire or wrong installation
• Vacuum leakage
• Engine overheating
• Low engine compression
• Erratic signal to ignition coil
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Restriction in exhaust system
• Electrical connector disconnection
• Open or short circuit in fuel pump body and related wiring harness
• No battery power supply to PCM or poor GND
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Fuel leakage from fuel injector
• Fuel injector clogging
• Ignition coil malfunction
• Improper air/fuel mixture ratio control
• Improper valve timing
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly. (Ignition key is not registered.)
• Pressure regulator malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
Both conditions appear: Note
• The following test should be performed for vehicles with immobilizer system. Go to Step
8 for vehicles without immobilizer system.
Yes
No
Go to Step 3.
Either or other condition appears:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Go to the next step.
2
Connect the WDS or equivalent to the
DLC-2.
Do the following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
Yes
Does the engine stall after approx. 2 s since the engine is started?
No
3
4
Is the coil connector securely connected to the coil?
Yes
No
Go to the next step.
Immobilizer system is normal.
Go to Step 10.
Go to the next step.
Connect the coil connector securely.
Return to Step 2.
Go to the next step.
Inspect the instrument cluster and wiring harness.
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
5
6
7
8
Does the security light illuminate?
Yes
No
Connect the WDS or equivalent to the
DLC-2 and retrieve DTC.
Are any of following DTCs displayed?
Yes
DTC
No
B1213, B1600,B1601, B1602, B1681,
B2103,B2139,B2141, B2431,U2510
Inspect for the following wiring harnesses and connectors:
Yes
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
No
Is there any malfunction?
Inspect for the following wiring harnesses and connectors:
• Between PCM terminal 1AI and instrument cluster terminal 1O
• Between PCM terminal 1AM and instrument cluster terminal 1M
Is there any malfunction?
Yes
No
Yes
Verify the following:
• Vacuum connection
• Air cleaner element
No
Go to the next step.
Repair or replace the suspected wiring harness and connector.
Go to the next step.
Repair or replace the suspected wiring harness and connector.
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 8.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and components attached to intake manifold:
EGR valve, IAC valve
• Ignition wiring
• Fuel quality: proper octane, contamination, winter/summer blend
• Electrical connections
• Smooth operation of throttle valve
Are all items normal?
9
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory, KOEO
Yes and KOER DTCs using WDS or equivalent.
If the engine stalls, retrieve continuous memory and KOEO DTCs.
Are there any DTCs displayed?
No
10
11
Attempt to start engine at part throttle.
Does engine run smoothly at part throttle?
Yes
No
Yes Connect the WDS or equivalent to the
DLC-2.
Access RPM PID.
Is RPM PID indicating engine speed during engine cranking?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
Communication error message is displayed:
Inspect for the following:
• Open circuit in wiring harness between main relay and PCM terminal 1BE
• Open circuit in wiring harness between main relay terminal B and PCM terminal
1AT
• The main relay is stuck open.
• Open or poor GND circuit (PCM terminal
1BH, 1AZ, 1BC, 1BD or 1BG)
• Poor connection of vehicle body GND
No DTC is displayed:
Go to the next step.
Inspect the IAC valve and wiring harness.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [LF] .)
Go to the next step.
Go to the next step.
Inspect for following:
• Open or short circuit in CKP sensor
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Open or short circuit between CKP sensor terminal A and PCM terminal 2Y
• Open or short circuit in between CKP sensor terminal B and PCM terminal 2Z
• Open or short circuit in CKP sensor wiring harnesses
If CKP sensor and wiring harness are normal, go to the next step.
Go to the next step.
12
13
14
Visually inspect CKP sensor and teeth of crankshaft pulley.
Yes
Are CKP sensor and teeth of crankshaft pulley normal?
No
Measure gap between CKP sensor and teeth of crankshaft pulley.
Yes
Specification
No
0.5-1.9 mm {0.020-0.75 in}
Is gap within specification?
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Are harness conditions normal?
Yes
No
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION
[LF] .)
Go to the next step.
Repair the wiring harnesses.
15
Perform the spark test.
(See Spark Test .)
Is strong blue spark visible at each cylinder?
16
Inspect spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
Yes
No
17
Remove and shake PCV valve.
Does PCV valve rattle?
Yes
No
18 Visually inspect the exhaust system part.
Yes
Go to the next step.
If symptoms occurs with the A/C on, go to
Step 21.
Repair or replace the malfunctioning part according to spark test result.
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from injector.
Spark plug is grayish white:
Inspect for clogged fuel injector.
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Is there any deformed exhaust system part?
No
Yes
19
Install the fuel pressure gauge between the fuel pipe and fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
Is the fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
No
20
21
22
Visually inspect the fuel injector for fuel leakage O-ring and fuel line. Service if necessary.
Yes
Is the fuel line pressure held after the ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Note
• Following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
Yes
Connect pressure gauges to A/C low and high pressure side lines.
Turn A/C on and measure low side and high side pressures.
Are pressures within specifications?
No
(See REFRIGERANT PRESSURE
CHECK .)
Disconnect vacuum hose between the purge valve and intake manifold from purge valve side.
Plug the opening end of vacuum hose.
Start the engine.
Is the engine stall now eliminated?
Yes
No
Go to the next step.
Go to the next step.
Zero or low:
Inspect the fuel pump and fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the fuel injector.
• If fuel injector is normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
For other symptoms, inspect the following:
• Refrigerant charging amount
• Condenser fan operation
Inspect if the purge valve is stuck open.
Inspect the evaporative emission control system.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
23
24
Is air leakage felt or heard at the intakeair system components while racing the engine to higher speed?
Yes
No
Yes Inspect engine condition while tapping the EGR valve housing.
Does the engine condition improve?
No
Repair or replace the malfunctioning part.
Go to the next step.
Replace the EGR valve.
Go to the next step.
25
26
Is the engine compression correct?
Yes
No
Inspect the valve timing.
Inspect for cause.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.6 CRANKS NORMALLY BUT WILL NOT START
[LF]
B3E010318881W08
6 CRANKS NORMALLY BUT WILL NOT START
• The starter cranks engine at normal speed but the engine will not run.
DESCRIPTION
• Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after engine stall.
• Fuel is in tank.
• Battery is in normal condition.
POSSIBLE
CAUSE
• No battery power supply to PCM
• Air leakage from intake-air system
• Open PCM GND or vehicle body GND
• Improper operation of IAC valve
• EGR valve malfunction
• No signal from CKP sensor due to sensor, related wire or incorrect installation
• No signal from CMP sensor due to sensor, related wire or incorrect installation
• Low engine compression
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Engine overheating
• Vacuum leakage
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control
• Poor fuel quality
• PCV valve malfunction
• Restriction in intake-air system
• Restriction in exhaust system
• Disconnected electrical connector
• Open or short circuit in fuel pump body and related wiring harness
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel leakage from injector
• Fuel injector is clogged.
• Purge valve malfunction
• Spark plug malfunction
• Ignition coil malfunction
• Improper valve timing
• Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly. (Ignition key is not registered)
• Pressure regulator malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS ACTION
Both conditions appear: Note
• Following test should be performed for vehicles with immobilizer system. Go to Step 8 for vehicles without immobilizer system.
Yes
Connect the WDS or equivalent to the DLC-
2.
No
Do any of the following conditions appear?
• The engine is not completely started.
• DTC P1260 is displayed.
Yes
Does the engine stall after approx. 2 s since the engine is started?
No
Go to Step 3.
Either or other condition appears:
Go to the next step.
Go to the next step.
Immobilizer system is normal.
Go to Step 10.
3
Yes
Is the coil connector securely connected to the coil?
No
Yes
Go to the next step.
Connect the coil connector securely.
Return to Step 2.
Go to the next step.
4 Does the security light illuminate?
No
Inspect the instrument cluster and wiring harness.
Go to appropriate DTC inspection.
(See DTC TABLE [LF] .)
5
6
Connect the WDS equivalent to the DLC-2 and retrieve DTC.
Are any of the following DTCs displayed?
DTC
Yes
No
B1213, B1600, B1601, B1602, B1681,
B2103,B2139,B2141, B2431,U2510
Inspect the following wiring harnesses and connectors:
• Between coil terminal A and instrument cluster terminal 2Q
• Between coil terminal B and instrument cluster terminal 2S
Is there any malfunction?
Yes
No
Go to the next step.
Repair or replace the suspected wiring harness and connector.
Go to the next step.
7
Inspect the following wiring harnesses and connectors:
Yes
Repair or replace the suspected wiring harness and connector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
• Between PCM terminal 1AI and instrument cluster terminal 1O
• Between PCM terminal 1AM and instrument cluster terminal 1M
No
Is there any malfunction?
Verify following:
• Vacuum connection
• External fuel shut off or accessory (such as kill switch, alarm)
• Fuel quality: proper octane, contamination, winter/summer blend
Yes
• No air leakage from intake-air system
• Intake-air system restriction (such as air cleaner element, fresh air duct)
• Proper sealing of intake manifold and components attached to intake manifold:
EGR valve, IAC valve
• Ignition wiring
• Electrical connections
• Fuses
• Smooth operation of throttle valve
No
Are all items normal?
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 8.
9
Connect the WDS or equivalent to the DLC-
2.
Yes
Retrieve any continuous memory and
KOEO DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
Communication error message is displayed:
Inspect for the following:
• Open circuit in wiring harness between main relay and PCM terminal 1BE
• Open circuit in wiring harness between main relay terminal B and PCM terminal
1AT
• Main relay is stuck open.
• Open or poor GND circuit (PCM terminal 1BH,1AZ,1BD,1BC or 1BG)
• Poor connection of vehicle body GND
No DTC is displayed:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
11
12
Does the engine start with the throttle valve closed?
Will the engine start and run smoothly at part throttle?
Is RPM PID indicating the engine speed when cranking the engine?
Yes
No
Yes
No
Yes
Connect the WDS or equivalent to the DLC-
2.
Access RPM PID.
No
Go to the next step.
Go to Step 29.
Go to the next step.
Inspect the IAC valve and wiring harness.
Go to the next step.
Go to the next step.
Inspect for the following:
• Open or short circuit in CKP sensor
• Open or short circuit between CKP sensor terminal A and PCM terminal 2Y
• Open or short circuit between CKP sensor terminal B and PCM terminal 2Z
• Open or short circuit in CKP sensor wiring harnesses
If CKP sensor and wiring harness are normal, go to the next step.
Go to the next step.
13
14
15
16
17
Visually inspect the CKP sensor and teeth of crankshaft pulley.
Yes
Are the CKP sensor and teeth of crankshaft pulley normal?
No
Measure the gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
0.5-1.9 mm {0.020-0.75 in}
No
Is the gap within the specification?
Inspect the ignition coil related wiring Yes harness condition (intermittent open or short circuit) for all cylinders.
No
Are wiring harness conditions normal?
Perform the spark test.
Yes
(See Spark Test .)
Is strong blue spark visible at each cylinder?
No
Inspect spark plug conditions.
Is the spark plug wet, covered with carbon or grayish white?
Yes
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION
[LF] .)
Go to the next step.
Repair the wiring harnesses.
Go to the next step.
Repair or replace the malfunctioning part according to spark test result.
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No
18
19
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes
20
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the DLC-
2.
Turn ON and/or OFF using FP PID in output state control of datalogger function.
No
Is fuel line pressure correct when FP PID is turned On/Off five times ?
(See FUEL LINE PRESSURE
INSPECTION .)
21
Visually inspect the fuel injector O-ring and fuel line for fuel leakage.
Service as necessary.
Yes
Is fuel line pressure held after the ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
22
Disconnect the vacuum hose between the purge valve and the intake manifold from the purge valve side.
Plug the opening end of vacuum hose.
Start the engine.
Is starting condition improved?
Yes
No
Spark plug is grayish white:
Inspect the fuel injector for clogging.
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Replace the suspected part.
Go to the next step.
Go to the next step.
Zero or low:
Inspect the fuel pump and the fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION .)
• If fuel injector is normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION )
Inspect if the purge valve is stuck open mechanically.
Inspect evaporative emission control system.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
23
Is air leakage felt or heard at the intake-air system components while racing the engine to higher speed?
Yes
No
Repair or replace the malfunctioning part.
Go to the next step.
24
Inspect engine condition while tapping the
EGR valve housing.
Is engine condition improved?
Yes
No
Replace the EGR valve.
Go to the next step.
Yes Inspect the valve timing.
25 Is engine compression correct?
26
No Inspect for causes.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.7 SLOW RETURN TO IDLE [LF]
B3E010318881W09
SLOW RETURN TO IDLE 7
DESCRIPTION
Engine takes more time than normal to return to idle speed.
• ECT sensor malfunction
• Thermostat is stuck open.
POSSIBLE CAUSE
• Throttle body malfunction
• Air leakage from intake-air system
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
DTC is displayed: Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory, KOEO
Yes and KOER DTCs using WDS or equivalent.
Are there DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
Remove thermostat and inspect operation.
(See THERMOSTAT
REMOVAL/INSTALLATION [LF] .)
(See THERMOSTAT INSPECTION
[LF] .)
Is thermostat normal?
Yes
No
Go to the next step.
ECT sensor and thermostat are normal.
Go to the next step.
Access ECT PID on the WDS or equivalent.
Inspect for both ECT PID and temperature gauge on instrument cluster readings.
• If temperature gauge on instrument cluster indicates normal range but ECT PID is not same as temperature gauge reading, inspect ECT sensor.
• If temperature gauge on instrument cluster indicates cold range but ECT PID is normal, inspect temperature gauge and heat gauge unit.
3 Is throttle body free of contaminations?
Yes
No
Inspect for air leakage from the intake-air system components while racing engine to higher speed.
Clean or replace the throttle body.
4
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [LF]
B3E010318881W10
8 ENGINE RUNS ROUGH/ROLLING IDLE
DESCRIPTION
• Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
• Idle speed is too slow and engine shakes excessively.
POSSIBLE
CAUSE
• Air leakage from intake-air system parts
• A/C system operation is improper
• Erratic signal to ignition coil
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Spark plug malfunction
• Purge valve malfunction
• IAC valve improper operation
• Idle learning of IAC system is not completed
• EGR valve malfunction
• Erratic or no signal from CMP sensor
• Low engine compression
• Improper valve timing
• Erratic signal from CKP sensor
• Improper air/fuel ratio mixture ratio control operation (abnormal signal from MAF sensor or HO2S)
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Restriction in exhaust system
• Disconnected electrical connectors
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Improper load signal input
• Fuel line restriction or clogging
• Improper fuel injection control operation
• Fuel leakage from fuel injector
• Fuel injector clogging
• Engine overheating
• Vacuum leakage
• Pressure regulator malfunction (built-in fuel pump unit)
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
2
INSPECTION
Warm up the engine.
Idle the engine for 5 min.
Is the symptom disappeared?
Yes
No
Verify following:
• External fuel shut off or accessory
(such as kill switch, alarm)
• Fuel quality (such as proper octane, contamination, winter/summer blend)
• No air leakage from intake-air system
Yes
• Proper sealing of intake manifold and components attached to intake manifold: EGR valve, IAC valve
• Ignition wiring
No
• Electrical connections
• Fuses
• Smooth operation of throttle valve
• PCM GND circuit (PCM terminal 1AZ,
1BC, 1BD, 1BG and/or 1BH)
Are all items normal?
RESULTS ACTION
Troubleshooting completed. (Cause of this symptom is that the idle learning of IAC system is not completed.)
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 2.
DTC is displayed:
3
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
4 Is the engine overheating?
Yes
Go to the next step.
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
7
8
9
No
Connect the WDS or equivalent to the
DLC-2.
Access MAF PID.
Drive vehicle with monitoring PID.
Is MAF PID within specification?
(See PCM INSPECTION [LF] .)
Yes
No
Note
• Following test is for engine running rough idle with A/C on concerns. If other symptoms exist, go to the next step.
Yes
Connect pressure gauge to A/C low and high pressure side lines.
Start engine and run it at idle.
Turn A/C switch on.
Measure low side and high side pressures.
Are pressures within specifications?
(See REFRIGERANT PRESSURE
CHECK .)
No
Note
• Following test is for engine running rough with P/S on. If other symptoms exist, go to the next step.
Yes
Start engine and idle it.
Access PSP PID.
Inspect if PSP PID is On while turning the steering wheel right to left.
Is PSP PID normal?
No
Yes Visually inspect the CKP sensor and teeth of crankshaft pulley.
Are the CKP sensor and teeth of crankshaft pulley normal?
No
Measure the gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
No
Go to the next step.
Go to the next step.
Inspect for open or short circuit of MAF sensor and related wiring harness.
Go to the next step.
If A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
For other symptoms, inspect the following:
• Refrigerant charging amount
• Condenser fan operation
Inspect the EHPAS.
• If there is no malfunction, inspect the following wiring harnesses:
- Between PCM terminal 1AI and
EHPAS module terminal 1F
- Between PCM terminal 1AM and
EHPAS module terminal 1D
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
(See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
0.5-1.9 mm {0.020-0.75 in}
Is the gap within the specification?
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Yes
No
Are wiring harness conditions normal?
Go to the next step.
Repair the wiring harnesses.
11
Inspect spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
12
Yes
Start engine and disconnect IAC valve connector.
Does rpm drop or engine stall?
No
Yes
13
Install fuel pressure gauge between fuel pipe and fuel distributor.
Start engine and run it at idle.
Measure fuel line pressure at idle.
Is fuel line pressure correct at idle?
(See FUEL LINE PRESSURE
INSPECTION .)
No
14
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line.
Yes
Service as necessary.
Does fuel line pressure hold after ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from injector.
Spark plug is grayish white:
Inspect for clogged fuel injector.
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Inspect IAC valve and wiring harness.
(See IDLE AIR CONTROL (IAC) VALVE
INSPECTION [LF] .)
Go to the next step.
Low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect fuel injector.
• If fuel injector is normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
15
16
Connect the WDS or equivalent to the
DLC-2.
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
Yes
No
• More than 0.45 V when the accelerator pedal is suddenly depressed: rich condition.
• Less than 0.45 V during fuel cut: lean condition.
Disconnect the vacuum hose between purge valve and intake manifold from purge valve side.
Yes
Plug opening end of vacuum hose.
Start engine.
Does engine condition improve?
No
Go to the next step.
Inspect and repair or replace the front
HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
Inspect if the purge valve is stuck open mechanically.
Inspect EVAP control system.
Go to the next step.
17
18
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Go to the next step.
Replace the part.
Go to the next step.
Replace the PCV valve.
19
20
Visually inspect the CMP sensor and teeth of camshaft.
Yes
Are CMP sensor and teeth of camshaft normal?
No
Inspect engine condition while tapping the EGR valve housing.
Does engine condition improve?
Yes
No
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
Replace the EGR valve.
21
22
Is engine compression correct?
Yes
No
Inspect valve timing.
Inspect for causes.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.9 FAST IDLE/RUNS ON [LF]
B3E010318881W11
9
DESCRIPTION
FAST IDLE/RUNS ON
• The engine speed continues at fast idle after warm-up.
• The engine runs after the ignition switch is turned off.
• ECT sensor malfunction
• Air leakage from intake-air system
POSSIBLE CAUSE
• Throttle body malfunction
• Accelerator cable free play misadjustment
• Improper load signal input
Diagnostic procedure
STEP
1
INSPECTION
Connect the WDS or equivalent to the
DLC-2.
Access ECT PID.
Start and warm up engine to normal operating temperature.
Is ECT PID between 82-112 ° C {180-
234 ° F} ?
No
RESULTS
Yes
ACTION
Go to the next step.
ECT PID is higher than 112 ° C {234 ° F}:
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [LF] .)
ECT PID is less than 82 ° C {180 ° F}:
Go to symptom troubleshooting "No.18
Cooling system concerns - Runs cold".
(See NO.18 COOLING SYSTEM
CONCERNS-RUNS COLD [LF] .)
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory DTCs.
Yes
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
3 Yes
Go to the next step.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5
AC_REQ PID:
Connect the WDS or equivalent to the
DLC-2.
Access AC_REQ, CPP, CPP/PNP and
PSP PIDs.
Monitor each PID.
(See PCM INSPECTION [LF] .)
Are PIDs normal?
No
Inspect the A/C switch, refrigerant pressure switch and the fan switch.
CPP PID:
Inspect the clutch pedal position switch.
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [LF] .)
CPP/PNP PID:
Inspect neutral switch.
(See NEUTRAL SWITCH INSPECTION
[LF] .)
PSP PID:
Inspect PSP switch.
Is there air leakage felt or heard at the intake-air system components while racing engine to higher speed?
Yes
No
Repair or replace part if necessary.
Verify the accelerator cable free play.
(See ACCELERATOR CABLE
INSPECTION/ADJUSTMENT [LF] .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.10 LOW IDLE/STALLS DURING DECELERATION
[LF]
B3E010318881W12
10 LOW IDLE/STALLS DURING DECELERATION
• Engine stops unexpectedly at the beginning of deceleration or recovery from deceleration.
DESCRIPTION
• Vacuum leakage POSSIBLE
CAUSE
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• IAC valve malfunction
• Air leakage from intake-air system
• Improper air/fuel mixture ratio control
• Evaporative emission control system malfunction
• TP sensor misadjustment
• TP sensor or related circuit malfunction
• MAF sensor or related circuit malfunction
• Brake switch or related circuit malfunction
• Neutral/clutch pedal position switch or related circuit malfunction
• Improper A/C magnetic clutch operation
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
• Does the engine idle rough?
Turn off the A/C switch and fan switch.
Does the A/C magnetic clutch engage?
Verify the following:
• Proper routing and no damage of vacuum lines
• IAC valve is connected properly.
• No air leakage from intake-air system
Are all items normal?
No
Yes
No
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
Yes
No
RESULTS
Yes
No
ACTION
Go to symptom troubleshooting "No.8
Engine runs rough/rolling idle".
(See NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE [LF] .)
Go to the next step.
Yes
Go to symptom troubleshooting "No.24
A/C is always on or A/C compressor runs continuously."
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
Go to the next step.
Go to the next step.
Service if necessary.
Repeat Step 3.
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
Does the idle speed drop or stall when disconnecting the IAC valve?
Yes
No
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Yes
Plug opening end of vacuum hose.
No
Drive vehicle.
Does engine condition improve?
Go to the next step.
Go to the next step.
Inspect the following:
• Circuit from IAC valve to the PCM terminal 2E or 2F for open and short
• IAC valve for sticking
If normal, go to the next step.
Inspect the evaporative emission control system.
Go to the next step.
7
Yes
Connect the WDS or equivalent to the
DLC-2.
Access TP, MAF, VSS, BOO, CPP and
PNP PIDs.
Monitor each PID while driving the vehicle.
(See PCM INSPECTION [LF] .)
No
Are PIDs normal?
Intermittent concern exists.
(See INTERMITTENT CONCERN
TROUBLESHOOTING [LF] .)
TP PID: Inspect the TP sensor.
(See THROTTLE POSITION (TP)
SENSOR INSPECTION [LF] .)
MAF PID: Inspect the MAF sensor.
(See MASS AIR FLOW (MAF) SENSOR
INSPECTION [LF] .)
VSS PID: Inspect the VSS.
(See DTC TABLE [LF] .)
BOO PID: Inspect the brake switch.
(See BRAKE SWITCH INSPECTION .)
CPP PID: Inspect the clutch pedal position switch.
(See CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [LF] .)
PNP PID: Inspect the neutral switch.
(See NEUTRAL SWITCH INSPECTION
[LF] .)
8 Verify test results.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS
ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES [LF]
B3E010318881W13
11
ENGINE STALLS/QUITS - ACCELERATION/CRUISE
ENGINE RUNS ROUGH - ACCELERATION/CRUISE
MISSES - ACCELERATION/CRUISE
BUCK/JERK - ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE - ACCELERATION
SURGES - ACCELERATION/CRUISE
• Engine stops unexpectedly at the beginning of acceleration or during acceleration.
• Engine stops unexpectedly while cruising.
• Engine speed fluctuates during acceleration or cruising.
DESCRIPTION
• Engine misses during acceleration or cruising.
• Vehicle bucks/jerks during acceleration, cruising, or deceleration.
• Momentary pause at beginning of acceleration or during acceleration
• Momentary minor irregularity in engine output
POSSIBLE
CAUSE
• Improper A/C system operation
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
• Purge valve malfunction
• IAC valve improper operation
• EGR valve malfunction
• Erratic signal from CKP sensor
• Low engine compression
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Vacuum leakage
• Poor fuel quality
• Main relay intermittent malfunction
• Throttle body malfunction
• Engine overheating
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control operation
• Improper variable tumble control operation
• Erratic signal to ignition coil
• Air cleaner restriction
• PCV valve malfunction
• Fuel flow into evaporative purge hose
• Improper valve timing due to jumping out timing belt
• Restriction in exhaust system
• Intermittent open or short circuit in fuel body pump circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Check valve (two-way) malfunction (integrated with fuel tank)
• Fuel leakage from fuel injector
• Fuel injector clogging
• Fuel line restriction or clogging
• Pressure regulator malfunction (built-in fuel pump unit)
• TP sensor misadjustment
• Intermittent open or short circuit of MAF sensor, TP sensor and VSS
• Clutch slippage
• Loose attaching bolts or worn engine mounts
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and "AFTER
SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Are all items normal?
Verify for the following:
• Vacuum connection
• Air cleaner element
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and components attached to intake manifold: such as EGR valve, IAC valve
• Ignition wiring
• Fuel quality (e.g. proper octane, contamination, winter/summer blend)
• Electrical connections
• Smooth operation of throttle valve
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
If stall, condition exists retrieve continuous memory and KOEO DTCs.
No
Are there any DTCs displayed?
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
3
4
Yes
Is the engine overheating?
No
Connect the WDS or equivalent to the
DLC-2.
Yes
No
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
Go to the next step.
Go to the next step.
RPM PID:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Access RPM, VPWR, MAF, TP and
VSS PIDs.
Drive the vehicle with monitoring
PIDs.
Are PIDs within specifications?
(See PCM INSPECTION [LF] .)
Inspect the CKP sensor and related wiring harness for such as vibration, intermittent open/short circuit.
VPWR PID:
Inspect for open circuit intermittently.
MAF PID:
Inspect for open circuit of the MAF sensor and related wire harness intermittently.
TP PID:
Inspect if output signal from the TP sensor changes smoothly.
VSS PID:
Inspect for open circuit of the VSS and related wire harness intermittently.
Go to the next step.
5
6
Visually inspect the CKP sensor and teeth of crankshaft pulley.
Are the CKP sensor and teeth of crankshaft pulley normal?
Yes
No
Measure the gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
0.5-1.9 mm {0.020-0.75 in}
Is the gap within specification?
No
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
7
Inspect spark plug conditions.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
8
9
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug.
Yes
No
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from the fuel injector.
Spark plug is grayish white:
Inspect the fuel injector for clogging.
Install the spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace the PCV valve.
Go to the next step.
Adjust if necessary.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
Is the lever in correct position?
Visually inspect deformed exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes
Replace the suspected part.
Go to the next step.
11
Install fuel pressure gauge between the fuel pipe and fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
No
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
12
13
14
Visually inspect for fuel leakage at fuel injector O-ring and fuel line.
Yes
Service if necessary.
Is fuel line pressure held after the ignition switch is turned off?
(See FUEL LINE PRESSURE
INSPECTION .)
No
Note
• Following test is for engine stall with the A/C on. If other symptom exists, go to the next step.
(See REFRIGERANT PRESSURE
CHECK .)
Yes
Connect a pressure gauge to the A/C low and high pressure side lines.
No
Turn the A/C on and measure low side and high side pressure.
Are pressure within specifications?
Yes
Go to the next step.
Zero or low:
Inspect the fuel pump and the fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Inspect the fuel injector.
• If the fuel injector is normal, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
For other symptoms, inspect following:
• Refrigerant charging amount
• Condenser fan operation
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
15
16
17
18
19
Connect the WDS or equivalent to the
DLC-2.
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
No
• More than 0.45 V when the accelerator pedal is suddenly depressed: rich condition.
• Less than 0.45 V during fuel cut: lean condition.
Inspect the evaporative purge hose between the fuel tank and the purge valve.
Yes
Dose fuel flow into evaporative purge hose?
No
Disconnect the vacuum hose between the purge valve and the intake manifold from the purge valve side.
Yes
Plug the opening end of vacuum hose.
Drive the vehicle.
Does the engine condition improve?
No
Visually inspect the CMP sensor and projections of the camshaft pulley.
Yes
Are the CMP sensor and projections of camshaft pulley normal?
No
Inspect the variable tumble control operation.
Yes
(See Variable Tumble Control
Operation Inspection .)
Is the variable tumble control normal?
No
Yes Inspect the EGR system.
(See EGR Control System
Inspection .)
Is EGR system normal?
No
Inspect and repair or replace the front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
Inspect the check valve (two-way).
(See FUEL TANK INSPECTION .)
Go to the next step.
Go to the next step.
Inspect if the purge valve is stuck open mechanically.
Inspect the evaporative emission control system.
Go to the next step.
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
Replace or replace the malfunctioning part.
Go to the next step.
Replace the malfunctioning part.
20 Is engine compression correct?
Yes
Inspect the following:
• Valve timing
• Clutch
• EGR valve (mechanical stuck)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
21
• Engine mounts
• Check valve (two-way)
Inspect for cause.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.12 LACK/LOSS OF POWER-
ACCELERATION/CRUISE [LF]
B3E010318881W14
LACK/LOSS OF POWER - ACCELERATION/CRUISE 12
DESCRIPTION
Performance is poor under load (such as power down when climbing hills).
POSSIBLE
CAUSE
• Improper A/C system operation
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
• Restriction in intake-air system
• Intake-air temperature too hot
• Improper variable intake-air control operation
• Improper variable tumble control operation
• Purge valve malfunction
• Improper EGR valve operation
• Brake dragging
• Erratic signal from CKP sensor
• Low engine compression
• Vacuum leakage
• Poor fuel quality
• Erratic signal to ignition coil
• Engine overheating
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Throttle body malfunction
• Spark plug malfunction
• PCV valve malfunction
• Improper valve timing due to jumping out of timing belt
• Restriction in exhaust system
• Intermittent open or short in fuel pump related circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel line restriction or clogging
• Fuel leakage from fuel injector
• Fuel injector clogging
• Intermittent open or short circuit of MAF sensor, TP sensor, IAT sensor and VSS
• Clutch slippage
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Verify the following:
• Vacuum connection
• No air leakage from intake-air system
RESULTS
Yes
• Restriction in the intake-air system
(such as air cleaner element, fresh air duct)
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
• No restriction of intake-air system
• Proper sealing of intake manifold and components attached to intake manifold; such as EGR valve, IAC valve
• Fuel quality (such as proper octane, contamination, winter/summer blend)
Are all items normal?
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
If engine stall condition exists, retrieve continuous memory and KOEO DTCs.
No
Are there any DTCs displayed?
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
3
4
Is the engine overheating?
Yes
No
Yes
Connect the WDS or equivalent to the
DLC-2.
Access RPM, MAF, TP, IAT and VSS
PIDs.
Drive the vehicle while monitoring
PIDs.
Are PIDs within specifications?
(See PCM INSPECTION [LF] .)
No
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
(See NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [LF] .)
Go to the next step.
Go to the next step.
RPM PID:
Inspect the CKP sensor and related wiring harness for vibration and/or intermittent open/short circuit.
MAF PID:
Inspect for intermittent open circuit of MAF sensor and related wiring harness.
TP PID:
Inspect if TP sensor output increases smoothly.
IAT PID:
Inspect for air suction in intake-air system.
If normal, inspect intermittent short circuit of
IAT sensor and related wiring harness.
VSS PID:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Inspect for intermittent open circuit of VSS and related wiring harness.
Go to the next step.
5
6
Visually inspect CKP sensor and teeth of crankshaft pulley.
Yes
Are CKP sensor and teeth of crankshaft pulley normal?
No
Measure the gap between the CKP sensor and teeth of crankshaft pulley.
Yes
Specification
0.5-1.9 mm {0.020-0.75 in}
Is the gap within the specification?
No
Replace the malfunctioning part.
Go to the next step.
Adjust the CKP sensor.
7
Inspect spark plug condition.
Is the spark plug wet, covered with carbon or grayish white?
Yes
No
8
9
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Yes
10
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Connect the WDS or equivalent to the
DLC-2.
Turn the fuel pump on using FP PID in output state control of datalogger function.
No
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
Spark plug is wet or covered with carbon:
Inspect the fuel injector for fuel leakage.
Spark plug is grayish white:
Inspect the fuel injector for clogging.
Install spark plugs on original cylinders.
Go to the next step.
Go to the next step.
Replace PCV valve.
Replace the part.
Go to the next step.
Go to the next step.
Zero or low:
Inspect the fuel pump and the fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
11
12
13
14
15
16
Inspect the variable tumble control operation.
(See Variable Tumble Control
Operation Inspection .)
Does the variable tumble control function properly?
Yes
No
Inspect the variable intake-air operation.
(See Variable Intake-air Control
Operation Inspection .)
Does the variable intake-air function properly?
Yes
No
Note
• The following test is for engine stall with the A/C on concern. If other symptoms exist, go to the next step.
(See REFRIGERANT PRESSURE
CHECK .)
Yes
Connect pressure gauge to A/C low and high side pressure lines.
Turn the A/C on and measure low side and high side pressures.
No
Are pressures within specifications?
Inspect A/C cut-off operation.
(See A/C Cut-off Control System
Inspection .)
Does A/C cut-off work properly?
Yes
No
Disconnect vacuum hose between the purge valve and the intake manifold from the purge valve side.
Yes
Plug opening end of vacuum hose.
Drive the vehicle.
Does the engine condition improve?
No
Visually inspect the CMP sensor and projections of camshaft pulley.
Are CMP sensor and projections of camshaft pulley normal?
Yes
No
Repair or replace the malfunctioning part.
Go to the next step.
Go to the next step.
Inspect if the purge valve is stuck open mechanically.
Inspect the EVAP control system.
(See Purge Control System Inspection .)
Go to the next step.
Go to the next step.
Repair or replace the malfunctioning part.
If the A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or
A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
For other symptoms, inspect following:
• Refrigerant charging amount
• Condenser fan operation
Go to the next step.
Replace the malfunctioning part.
Inspect the A/C cut-off system components.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
17
Inspect the EGR system.
Yes
(See EGR Control System Inspection .)
No
Is the EGR system normal?
Go to the next step.
Replace the malfunctioning part.
18
19
Is engine compression correct?
Yes
Inspect the following:
• Valve timing
• Internal transaxle components (ATX)
• Clutch (MTX)
• Brake system for dragging
No Inspect for cause.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE
[LF]
B3E010318881W15
13 KNOCKING/PINGING - ACCELERATION/CRUISE
DESCRIPTION
Sound is heard when air/fuel mixture is ignited by something other than spark plug
(e.g. hot spot in combustion chamber).
POSSIBLE
CAUSE
• Engine overheating due to cooling system malfunction
• ECT sensor malfunction
• IAT sensor malfunction
• MAF sensor malfunction
• Knock sensor malfunction
• Erratic signal from CMP sensor
• Inadequate engine compression
• Inadequate fuel pressure
Warning
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
2
INSPECTION RESULTS
Yes
ACTION
Go to the next step.
Connect the WDS or equivalent to the
DLC-2.
Access ECT PID.
Verify ECT PID is less than 116 ° C
{241 ° F} during driving.
Is ECT PID less than specification?
No
Connect the WDS or equivalent to the
DLC-2.
Access IAT, MAF and SPARKADV PIDs.
Monitor each PID.
(See PCM INSPECTION [LF] .)
Are PIDs normal?
Yes
No
Inspect the cooling system for cause of overheating.
Go to the next step.
IAT PID : Inspect IAT sensor.
MAF PID
SPARKADV PID : Inspect CMP sensor and knock sensor.
DTC is displayed:
: Inspect MAF sensor.
3
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
4 Is engine compression correct?
Yes
No
Go to the next step.
Go to the next step.
Inspect for cause.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
6
Yes Inspect ignition timing.
Low:
Install fuel pressure gauge between the fuel pipe and fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
No
(See FUEL LINE PRESSURE
INSPECTION .)
Inspect the fuel line for clogging.
REMOVAL/INSTALLATION .)
High:
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.14 POOR FUEL ECONOMY [LF]
B3E010318881W16
POOR FUEL ECONOMY 14
DESCRIPTION
Fuel economy is unsatisfactory.
POSSIBLE
CAUSE
• Contaminated air cleaner element
• Variable intake-air control malfunction
• Engine cooling system malfunction
• Weak spark
• Poor fuel quality
• Erratic or no signal from CMP sensor
• Clutch slippage
• Variable tumble control malfunction
• Improper coolant level
• Inadequate fuel pressure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Spark plug malfunction
• PCV valve malfunction
• Brake dragging
• Improper valve timing due to jumping out of timing belt
• Contaminated MAF sensor
• Improper engine compression
• Exhaust system clogging
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Inspect the following:
• Air cleaner element for contamination
• Fuel quality
• Coolant level
• Brake dragging
• Clutch slippage
Are all items normal?
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
No
Are there any DTCs displayed?
Yes Access ECT PID.
Drive the vehicle while monitoring PID.
(See PCM INSPECTION [LF] .)
Is PID within specification?
No
Perform the spark test.
(See Spark Test .)
Is strong blue spark visible at each cylinder?
Yes
No
Yes
5
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
No
No DTC is displayed:
Go to the next step.
Go to the next step.
Inspect for coolant leakage, cooling fan and thermostat operation.
Go to the next step.
Repair or replace malfunctioning part according to spark test result.
Go to the next step.
Low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
6
7
8
Inspect variable tumble control operation.
Yes
(See Variable Tumble Control Operation
Inspection .)
No
Does the variable tumble control function properly?
Yes Inspect variable intake-air control operation.
(See Variable Intake-air Control
Operation Inspection .)
Does the variable intake-air control function properly?
No
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Replace the PCV valve.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
10
11
12
Visually inspect the exhaust system part.
Yes
Is there any deformed exhaust system part?
No
Inspect for contaminated MAF sensor.
Is there any contamination?
Yes
No
Yes Inspect the MAF sensor for contamination.
Is there any contamination?
No
Is engine compression correct?
Yes
No
13
Replace the suspected part.
Go to the next step.
Go to the next step.
Inspect for cause.
Go to the next step.
Replace the MAF sensor.
Inspect valve timing.
Inspect for cause.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.15 EMISSION COMPLIANCE [LF]
B3E010318881W17
EMISSION COMPLIANCE 15
DESCRIPTION
Fails emissions test.
POSSIBLE
CAUSE
• Vacuum lines leakage or blockage
• Cooling system malfunction
• Spark plug malfunction
• Leakage from intake manifold
• Erratic or no signal from CMP sensor
• Inadequate fuel pressure
• PCV valve malfunction or incorrect valve installation
• EGR valve malfunction
• Exhaust system clogging
• Fuel tank ventilation system malfunction
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Charcoal canister damage
• Air cleaner element clogging or restriction
• Throttle body malfunction
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control operation
• Bend or open circuit HO2S wiring harness
• Catalyst converter malfunction
• Engine internal parts malfunction
• Excessive carbon is built up in combustion chamber
• Improper engine compression
• Improper valve timing
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Inspect the following:
• Vacuum lines for leakage or blockage
• Electrical connections
• Proper maintenance schedule followed
RESULTS
Yes Go to the next step.
ACTION
No
Service if necessary.
Repeat Step 1.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness
Are all items normal?
2
3
Connect the WDS or equivalent to the DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using
WDS or equivalent.
Are there any DTCs displayed?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
Go to appropriate symptom troubleshooting.
Go to the next step.
Go to the next step.
4
5
6
7
Yes
Is any other drivability concern present?
No
Connect the WDS or equivalent to the DLC-2.
Yes
Access ECT PID.
Warm up the engine and idle it.
Verify ECT PID is correct.
No
(See PCM INSPECTION [LF] .)
Is ECT PID correct?
Connect the WDS or equivalent to the DLC-2.
Yes
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
No
• More than 0.45 V when the accelerator pedal is suddenly depressed: rich condition.
• Less than 0.45 V during fuel cut: lean condition.
Perform the spark test.
Yes
(See Spark Test .)
Is strong blue spark visible at each cylinder?
No
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Yes
No
Start the engine and idle it.
Inspect for coolant leakage, cooling fan and thermostat operation.
Go to the next step.
Inspect and repair or replace the front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [LF] .)
Go to the next step.
Repair or replace the malfunctioning part according to spark test result.
Go to the next step.
Low:
Inspect the fuel line for clogging.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
9
10
11
12
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE
INSPECTION .)
• If normal, replace fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
No Replace the PCV valve.
Inspect for fuel saturation inside the charcoal canister.
Is excess amount of liquid fuel present in canister?
Yes
No
Replace the charcoal canister.
Inspect the fuel tank vent system.
Then, go to the next step.
(See FUEL TANK INSPECTION .)
Replace the part.
Visually inspect the exhaust system part.
Is there any deformed exhaust system part?
Yes
No Go to the next step.
Inspect the threeway catalytic converter.
Yes
(See EXHAUST SYSTEM
INSPECTION [LF] .)
Is the threeway catalytic converter normal?
No
Inspect the EGR system.
(See EGR Control System Inspection .)
Replace the threeway catalytic converter.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [LF]
B3E010318881W18
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
16 HIGH OIL CONSUMPTION/LEAKAGE
DESCRIPTION
Oil consumption is excessive.
• PCV valve malfunction
• Improper dipstick
POSSIBLE CAUSE
• Improper engine oil viscosity
• Engine internal parts malfunction
Diagnostic procedure
STEP INSPECTION RESULTS
Yes
1
Remove and shake the PCV valve.
Does the PCV valve rattle?
No
Go to the next step.
Replace the PCV valve.
ACTION
2
3
Inspect for following:
• External leakage
• Proper dipstick
• Proper engine oil viscosity
Are all items normal?
Yes
No
Inspect the internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, and piston rings.
Service if necessary.
Repeat Step 2.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING
[LF]
B3E010318881W19
17 COOLING SYSTEM CONCERNS -OVERHEATING
Engine runs at higher than normal temperature/overheats.
DESCRIPTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Improper coolant level
• Blown fuses
• Coolant leakage
• Excessive A/C system pressure
• A/C system operation is improper
• Improper water/anti-freeze mixture
• Fans reverse rotation
POSSIBLE CAUSE
• Poor radiator condition
• Thermostat malfunction
• Radiator hoses damage
• Improper or damaged radiator cap
• Cooling fan is inoperative.
• Coolant overflow system malfunction
• Improper tension of drive belt
• Drive belt damage
Diagnostic procedure
STEP
1
INSPECTION
Are all items normal?
Inspect the following:
• Engine coolant level
• Coolant leakage
• Water and anti-freeze mixture
• Radiator condition
• Collapsed or restricted radiator hoses
• Radiator pressure cap
• Overflow system
• Fan rotational direction
• Fuses
RESULTS
Yes
No
ACTION
Go to the next step.
Service if necessary.
Repeat Step 1.
DTC is displayed:
2
Connect the WDS or equivalent to the
DLC-2.
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
Yes
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
Start the engine and idle it.
Turn the A/C switch on.
Does the A/C compressor engage?
Connect the WDS or equivalent to the
DLC-2.
Access AC_REQ PID.
Start the engine and idle it.
Turn the A/C switch on.
Does AC_REQ PID read On?
Yes
No
No
Yes
Go to the next step.
Go to Step 5.
Inspect for following and repair or replace if necessary:
• Refrigerant charging amount
• Open circuit in wiring harness between
A/C relay and PCM terminal 1AN
• Seized A/C magnetic clutch
• A/C magnetic clutch malfunction
If all items are normal, go to the next step.
Go to the next step.
Inspect the following:
• Refrigerant pressure switch operation
• The A/C switch is stuck open.
• Open or short circuit between refrigerant pressure switch and PCM terminal 1AP
• Open circuit of blower motor fan switch and resistor (if blower motor does not operate)
• The evaporator temperature sensor and
A/C amplifier
Go to the next step.
5
6
7
8
9
Inspect cooling fan control system operation.
(See Cooling Fan Motor Operation
Inspection .)
Does the cooling fan control system function properly?
Yes
No
Yes
Is the drive belt normal?
No
Is there leakage around the heater unit in passenger compartment?
Yes
No
Is there leakage at the coolant hoses and/or radiator?
Yes
No
Cool down the engine.
Remove thermostat and inspect operation.
Yes
Repair or replace the malfunctioning part.
Go to the next step.
Replace the drive belt.
Inspect and service the heater for leakage.
Go to the next step.
Replace the malfunctioning part.
Go to the next step.
The ECT sensor and thermostat are normal.
Inspect engine block for leakage or blockage.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10
(See THERMOSTAT
REMOVAL/INSTALLATION [LF] .)
(See THERMOSTAT INSPECTION
[LF] .)
Is thermostat normal?
No
Access ECT PID.
Inspect for both ECT PID and temperature gauge readings.
• If temperature gauge on instrument cluster indicates normal range but ECT PID is not same as temperature gauge reading, inspect ECT sensor.
• If temperature gauge on instrument cluster indicates overheating but ECT PID is normal, inspect temperature gauge and heat gauge unit.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD
[LF]
B3E010318881W20
18 COOLING SYSTEM CONCERNS -RUNS COLD
DESCRIPTION
Engine takes excessive period for reaching normal operating temperature.
• Thermostat malfunction
POSSIBLE CAUSE
• Cooling fan system malfunction
Diagnostic procedure
STEP
1
INSPECTION
Is customer complaint "Lack of passenger compartment heat" only?
RESULTS
Yes
No
ACTION
Inspect A/C and heater system.
Go to the next step.
2
Does the engine speed continue at fast idle?
Yes
Go to symptom troubleshooting "No.9 Fast idle/runs on".
(See NO.9 FAST IDLE/RUNS ON [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
No
Remove thermostat and inspect operation.
Yes
(See THERMOSTAT
REMOVAL/INSTALLATION [LF] .)
(See THERMOSTAT INSPECTION
[LF] .)
No
Is thermostat normal?
Go to the next step.
Go to the next step.
Replace the thermostat.
4
5
Inspect cooling fan control system operation.
(See Cooling Fan Motor Operation
Inspection .)
Does the cooling fan control system work properly?
Yes
Access ECT PID.
Inspect for both ECT PID and temperature gauge on instrument cluster readings.
• If the temperature gauge on the instrument cluster indicates normal range but ECT PID is not the same as the temperature gauge reading, inspect the ECT sensor.
• If the temperature gauge on the instrument cluster indicates cold range but ECT PID is normal, inspect temperature gauge and heat gauge unit.
Repair or replace the malfunctioning part.
No
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.19 EXHAUST SMOKE [LF]
B3E010318881W21
19 EXHAUST SMOKE
DESCRIPTION
Blue, black, or white smoke from exhaust system
Blue smoke (Burning oil):
POSSIBLE
CAUSE
• PCV valve malfunction
• Engine internal oil leakage
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
White smoke (Water in combustion):
• Cooling system malfunction (coolant loss)
• Engine internal coolant leakage
Black smoke (Rich fuel mixture):
• Air cleaner restriction
• Intake-air system is collapsed or restricted.
• Fuel return line is restricted.
• Excessive fuel pressure
• Improper engine compression
• Injector fuel leakage
• Ignition system malfunction
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION RESULTS
Blue
ACTION
Burning oil is indicated.
Go to the next step.
What color is smoke coming from the exhaust system?
White
Water in combustion is indicated.
Go to Step 3.
Black Rich fuel mixture is indicated.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
Remove and shake the PCV valve.
Does the PCV valve rattle?
pressure?
Does the cooling system hold
Yes
No
Yes
Go to Step 4.
Inspect for the following:
• Damaged valve guide, stems or valve seals
• Blocked oil drain passage in cylinder head
• Piston ring is not seated, seized or worn.
• Damaged cylinder bore
If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
Replace the PCV valve.
Inspect for the following:
• Cylinder head gasket leakage
• Intake manifold gasket leakage
• Cracked or porous engine block
If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
Inspect for cause.
Go to the next step.
4
No
Inspect for the following:
• Air cleaner restriction
• Collapsed or restricted intake-air system
• Restricted fuel return line
Are all items normal?
Yes
No
Service if necessary.
Repeat Step 4.
5
6
Connect the WDS or equivalent to the DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using
WDS or equivalent.
Are there any DTCs displayed?
No
Install fuel pressure gauge between the fuel pipe and fuel distributor.
Yes
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
No
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
Low:
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See FUEL LINE PRESSURE
INSPECTION .)
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
7
8
Is strong blue spark visible at each disconnected high-tension lead while cranking the engine?
Yes
No
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Inspect spark plugs and CMP sensor.
(See SPARK PLUG REMOVAL/INSTALLATION
[LF] .)
(See CAMSHAFT POSITION (CMP) SENSOR
INSPECTION [LF] .)
Inspect following:
• High-tension leads
• Ignition coil and connector
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [LF]
B3E010318881W22
20 FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION
Gasoline fuel smell or visible leakage
POSSIBLE
CAUSE
• Excessive fuel pressure
• Purge valve malfunction
• Fuel tank vent system blockage
• Charcoal canister malfunction
• Fuel leakage from fuel system
Warning
Downloaded from https://carmanualshub.com/ - automotive repair manuals website
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
INSPECTION
Visually inspect for fuel leakage at fuel injector O-ring and fuel line.
Service if necessary.
(See FUEL LINE PRESSURE
INSPECTION .)
RESULTS
Yes
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure the fuel line pressure during idle.
Is fuel line pressure correct during idle?
No
ACTION
Go to the next step.
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
2
Inspect for blockage/restriction or open circuit in wiring harness between the engine vacuum port and charcoal canister.
Yes
Inspect for blockage in the fuel tank vent system.
Is malfunction indicated?
No
Replace the vacuum hose.
Go to the next step.
Yes
3
4
Inspect purge valve.
(See PURGE SOLENOID VALVE
INSPECTION .)
Is purge valve operating properly?
No
Yes
Go to the next step.
Replace the purge valve.
(See PURGE SOLENOID VALVE
REMOVAL/INSTALLATION [LF] .)
DTC is displayed:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Connect the WDS or equivalent to the DLC-
2.
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
No
Are there any DTCs displayed?
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Inspect the charcoal canister for fuel saturation.
• If excess amount of liquid fuel is present, replace the charcoal canister.
5
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.21 ENGINE NOISE [LF]
B3E010318881W23
21 ENGINE NOISE
Engine noise from under hood
DESCRIPTION
Squeal, click or chirp noise:
• Improper engine oil level
• Improper drive belt tension
• Generation installation (alignment)
• Splash shield or under cover looseness (splashed water to drive belts)
Rattle sound noise:
POSSIBLE CAUSE • Loose parts
Hiss sound noise:
• Vacuum leakage
• Loose spark plug
• Air leakage from intake-air system
Rumble or grind noise:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Improper drive belt tension
• Improper P/S fluid level
Rap or roar sound noise:
• Dynamic dumper looseness
• Exhaust system looseness
• Intake-air system looseness
Other noise:
• Camshaft friction gear noise or MLA noise
• Timing chain noise
Diagnostic procedure
STEP
1
2
3
4
INSPECTION
Is a squealing, click or chirping sound present?
Is a rumbling or grinding sound present?
RESULTS
Yes
ACTION
Inspect for the following:
• Engine oil level
• Drive belt tension
• Splash shield or under cover looseness
• Generator installation (alignment)
No
Yes
No
Yes
Is a rattling sound present?
No
Go to the next step.
Go to the next step.
Inspect the drive belts or P/S fluid level.
Is a hissing sound present?
Yes
Inspect rattling location for loose parts.
Go to the next step.
Inspect for the following:
• Vacuum leakage
• Spark plug looseness
• Intake-air system leakage
5
Is a rapping or roaring sound present?
No
Yes
Go to the next step.
Inspect looseness for the following:
• Dynamic damper
• Intake-air system
• Exhaust system
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No Go to the next step.
6
7
Is a knocking sound present?
Yes
Go to symptom troubleshooting "No.11
Knocking/pinging".
(See NO.13 KNOCKING/PINGING-
ACCELERATION/CRUISE [LF] .)
No
If the noise comes from the engine internal, inspect for friction gear, timing chain or MLA noise.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.22 VIBRATION CONCERNS (ENGINE) [LF]
B3E010318881W24
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION
• Vibration from under hood or driveline
• Loose attaching bolts or worn parts
POSSIBLE CAUSE
• Components malfunction such as worn parts
Diagnostic procedure
STEP
1
2
INSPECTION
Inspect the following components for loose attaching bolts or worn parts:
• Cooling fan
• Drive belt and pulleys
• Generator
• Engine mounts
• Exhaust system mounts
All items normal?
Verify test results.
RESULTS
Yes
ACTION
Inspect following systems:
• Wheels
• Driveline
• Suspension
No
Readjust or retighten engine mount installation position.
Service if necessary for other parts.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.23 A/C DOES NOT WORK SUFFICIENTLY [LF]
B3E010318881W25
23 A/C DOES NOT WORK SUFFICIENTLY.
DESCRIPTION
POSSIBLE
CAUSE
A/C compressor magnetic clutch does not engage when the A/C switch is turned on.
• Improper refrigerant charging amount
• Open circuit A/C magnetic clutch
• Open circuit in wiring harness between A/C relay and A/C magnetic clutch
• Poor GND of A/C magnetic clutch
• Refrigerant pressure switch is stuck open.
• A/C relay is stuck open.
• Seized A/C compressor
• Open circuit in wiring harness between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
Diagnostic procedure
STEP
1
INSPECTION RESULTS ACTION
DTC is displayed:
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
2
Disconnect A/C compressor connector.
Start engine and turn A/C switch on.
Yes
Inspect for GND condition of magnetic clutch on A/C compressor.
• If GND condition is normal, inspect for open circuit magnetic clutch coil.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3
4
5
Is there correct voltage A/C compressor magnetic clutch terminal?
Specification
No Go to the next step.
More than 10.5 V
Disconnect the refrigerant pressure switch connector.
Connect jumper wire between A/C highpressure switch terminal.
Connect jumper wires between refrigerant pressure switch terminal.
Connect the WDS or equivalent to the
DLC-2.
Access AC_REQ PID.
Turn the ignition switch to the ON position.
Turn A/C switch on and set blower fan at any speed.
Does AC_REQ PID read On?
Yes
No
Inspect refrigerant pressure switch operation.
• If switch is normal, go to the next step.
Inspect for following:
• A/C switch is stuck open.
• Open circuit in wiring harness between refrigerant pressure switch and PCM terminal 1AP
• Open circuit of blower motor fan switch and resistor (if blower motor does not operate)
• Evaporator temperature sensor and A/C amplifier
Remove jumper wire from the switch connector.
Reconnect connector to refrigerant pressure switch.
Start the engine and turn the A/C switch on.
Does the fan operate?
Yes
No
Inspect for stuck open A/C relay.
Replace if necessary.
Inspect following and repair or replace if necessary:
• Refrigerant charging amount
• A/C compressor for being seized
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR
RUNS CONTINUOUSLY [LF]
B3E010318881W26
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
A/C compressor magnetic clutch does not disengage.
• Stuck engagement A/C compressor magnetic clutch
• A/C relay is stuck closed.
POSSIBLE CAUSE
• Short to GND in wiring harness between A/C switch and PCM
• Short to GND in wiring harness between A/C relay and PCM
• Short circuit to battery power in A/C relay to magnetic clutch
Diagnostic procedure
STEP
1
2
3
INSPECTION
Connect the WDS or equivalent to the DLC-2.
Retrieve any continuous memory, KOEO and
KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
Start the engine and idle it.
Turn the A/C switch on.
Remove the A/C relay.
Does the A/C magnetic clutch disengage?
Connect WDS or equivalent to DLC-2.
Access AC_REQ PID.
Start engine and turn A/C switch on.
Yes
Read AC_REQ PID while disconnecting refrigerant pressure switch connector.
Note
• AC_REQ PID should read Off when disconnecting connector. If AC_REQ PID
No
RESULTS ACTION
DTC is displayed:
Yes
Go to appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
No
Go to the next step.
Yes
Inspect for following:
• The A/C relay is stuck closed.
• Short to GND in wiring harness between A/C relay and PCM terminal 1AN.
If both items normal, go to the next step.
No
Inspect if circuit between the A/C relay and magnetic clutch shorts to battery power circuit.
• If the circuit is normal, inspect for magnetic clutch stuck engagement or clearance.
Inspect for short to GND in wiring harness between refrigerant pressure switch and PCM terminal
1AP.
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4
5 remains On, short to GND may be present.
Does AC_REQ PID remain On?
Reconnect refrigerant pressure switch connector.
Read AC_REQ PID while turning off A/C switch.
Note
• AC_REQ PID should read Off when turning A/C switch off. If AC_REQ PID remains On, short to GND may be present.
Does AC_REQ PID remain On?
Yes
No
Inspect the following:
• Short to GND in wiring harness between the A/C switch and A/C amplifier
• Short to GND in wiring harness between the A/C amplifier and refrigerant pressure switch
Inspect for stuck closed A/C switch.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN
THROTTLE CONDITIONS [LF]
B3E010318881W27
25 A/C IS NOT CUT OFF UNDER WOT CONDITIONS.
DESCRIPTION
A/C compressor magnetic clutch does not disengage under WOT.
• TP sensor malfunction
POSSIBLE CAUSE
• TP sensor misadjustment
• Loosely installed TP sensor
Diagnostic procedure
STEP
1
INSPECTION RESULTS
Yes
ACTION
Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
Does A/C compressor disengage when the A/C switch is turned off?
No
Go to symptom troubleshooting "No.24 A/C is always on or A/C compressor runs continuously".
(See NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY
[LF] .)
DTC is displayed:
Connect the WDS or equivalent to the
DLC-2.
Yes
Retrieve any continuous memory,
KOEO and KOER DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF]
No DTC is displayed:
.)
Inspect TP sensor for proper adjustment.
(See THROTTLE POSITION (TP) SENSOR
INSPECTION [LF] .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.26 EXHAUST SULPHUR SMELL [LF]
B3E010318881W28
EXHAUST SULPHUR SMELL 26
DESCRIPTION
Rotten egg smell (sulphur) from exhaust
POSSIBLE
CAUSE
• Electrical connectors are disconnected or connected poorly
• Charcoal canister malfunction
• Vacuum lines are disconnected or connected improperly.
• Improper fuel pressure
• Poor fuel quality
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP
1
2
INSPECTION
Are any driveability or exhaust smoke concerns present?
RESULTS
Yes
ACTION
Go to appropriate flow chart.
No Go to the next step.
Yes Go to the next step.
Inspect the following:
• Electrical connections
• Vacuum lines
• Fuel quality
Are all items normal?
No
Service if necessary.
Repeat Step 2.
DTC is displayed:
3
Connect the WDS or equivalent to the DLC-2.
Yes
Retrieve any continuous memory, KOEO and KOER
DTCs using WDS or equivalent.
Are there any DTCs displayed?
No
Go to the appropriate DTC inspection.
(See DTC TABLE [LF] .)
No DTC is displayed:
Go to the next step.
Go to the next step.
Low:
4
Install the fuel pressure gauge between fuel pipe and fuel distributor.
Start engine and run it at idle.
Is fuel line pressure correct at idle?
(See FUEL LINE PRESSURE
INSPECTION .)
Yes
No
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
High:
5
6
Inspect the charcoal canister for fuel saturation.
Is excess amount of liquid fuel present in canister?
Yes
No
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Replace the charcoal canister.
Inspect the fuel tank vent system.
• If the fuel tank vent system is normal, suggest trying a different brand since sulfur content can vary in different fuels.
• If the fuel tank vent system is not normal, repair or replace the malfunctioning part.
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
NO.27 SPARK PLUG CONDITION [LF]
B3E010318881W29
SPARK PLUG CONDITION 27
DESCRIPTION
Incorrect spark plug condition
POSSIBLE
CAUSE
Note
• Inspecting spark plugs condition can determine whether problem is related to a specific cylinder possibly all cylinders.
Wet/carbon stuck on specific plug:
• Spark-Weak, not visible
• Air/fuel mixture-Excessive fuel injection volume
• Compression-No compression, low compression
• Malfunction spark plug
Grayish white with specific plug:
• Air/fuel mixture-Insufficient fuel injection volume
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Malfunction spark plug
Wet/carbon is stuck on all plugs:
• Spark-Spark weak
• Air/fuel mixture-Too rich
• Compression-Low compression
• Clogging in intake/exhaust system
Grayish white with all plugs:
• Air/fuel mixture-Too lean
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and
"AFTER SERVICE PRECAUTION" described in this manual.
(See BEFORE SERVICE PRECAUTION .)
(See AFTER SERVICE PRECAUTION .)
Caution
• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
Diagnostic procedure
STEP INSPECTION
1
Remove all the spark plugs.
Inspect spark plug condition.
Is spark plug condition normal?
RESULTS
Yes
ACTION
Troubleshooting completed.
Specific plug is wet or covered with carbon:
No
Go to the next step.
Specific plug looks grayish white:
Go to Step 7.
All plugs are wet or covered with carbon:
Go to Step 9.
All plugs look grayish white:
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
3
4
5
Are the spark plug wet/covered with carbon by engine oil?
Yes
No
Inspect the spark plug for following:
• Cracked insulator
• Heat range
Yes
• Air gap
• Worn electrode
No
Is the spark plug normal?
Inspect compression pressure at suspected malfunction cylinder.
Yes
Is compression pressure correct?
(See COMPRESSION INSPECTION
[LF] .)
No
Install all spark plugs.
Yes
Perform the spark test at suspected malfunction cylinder.
No
Is strong blue spark visible?
(Compare with normal cylinder.)
Go to Step 15.
Inspect all areas related to oil, working up and down.
Go to the next step.
Go to the next step.
Replace the spark plug.
(See SPARK PLUG
REMOVAL/INSTALLATION [LF] .)
Go to the next step.
Repair or replace the malfunctioning part.
Go to the next step.
Repair or replace the malfunctioning part.
6
Perform the fuel line pressure inspection.
Is the fuel line pressure correct?
Yes
No
Inspect fuel injector for following:
• Open or short circuit in injector
• Leakage
• Injection volume
Zero or low:
Inspect the fuel pump and fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Go to the next step.
7
8
9
10
Inspect the spark plug for following.
Yes
• Heat range
• Air gap
No
Is the spark plug normal?
Remove the suspected fuel injector.
Inspect the following:
• Resistance
Yes
(See FUEL INJECTOR
INSPECTION .)
• Fuel injection volume
(See FUEL INJECTOR
INSPECTION .)
Are all above items normal?
No
Is air cleaner element free of restrictions?
Yes
No
Perform the spark test.
(See FUEL LINE PRESSURE
INSPECTION .)
Is strong blue spark visible at each cylinder?
Yes
No
Yes
Replace the spark plug.
Inspect for open circuit in wiring harness between the fuel injector terminal and PCM following terminals:
• For No.1 cylinder: 2BB
• For No.2 cylinder: 2BC
• For No.3 cylinder: 2BD
• For No.4 cylinder: 2AZ
Replace the fuel injector.
Go to the next step.
Go to the next step.
Replace the air cleaner element.
Repair or replace the malfunctioning part.
11
Perform the fuel line pressure inspection.
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
12
Inspect the following PIDs.
• ECT
No
Yes
No
Go to the next step.
Zero or low:
Inspect the fuel pump and fuel pump relay elated circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Go to the next step.
Repair or replace the malfunctioning part.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
13
14
15
• O2S11 (When engine can be started)
• O2S12 (When engine can be started)
• MAF
(See PCM INSPECTION [LF] .)
Are PIDs normal?
Perform the purge control inspection. (When engine can be started)
(See Purge Control System
Inspection .)
Is the purge control correct?
Yes
No
Perform the compression inspection.
Yes
(See COMPRESSION INSPECTION
[LF] .)
No
Is compression correct?
When the engine cannot be started, inspect intake-air system for air leakage.
Yes
When the engine can be started, perform the intake manifold vacuum inspection.
No
Is air sucked in from the intake-air system?
Go to the next step.
Repair or replace the malfunctioning part.
Visually inspect for deformed in exhaust system part.
Repair or replace the malfunctioning part.
Repair or replace the malfunctioning part.
Go to the next step.
16
Perform the fuel line pressure inspection.
Is fuel line pressure correct?
(See FUEL LINE PRESSURE
INSPECTION .)
Yes
No
Inspect the following PIDs.
• ECT
• O2S11
• O2S12
• MAF
(See PCM INSPECTION [LF] .)
Inspect PCM GND condition.
Zero or low:
Inspect the fuel pump and fuel pump relay related circuit.
Inspect the fuel line for clogging.
• If there is no malfunction, replace the fuel pump unit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
High:
17
Replace the fuel pump unit.
(See FUEL PUMP UNIT
REMOVAL/INSTALLATION .)
Verify test results.
• If normal, return to diagnostic index to service any additional symptoms.
(See ENGINE SYMPTOM TROUBLESHOOTING [LF] .)
• If malfunction remains, inspect related Service information perform repair or diagnosis.
- If vehicle repaired, troubleshooting completed.
- If vehicle not repaired or additional diagnostic information not available, replace the
PCM.
(See PCM REMOVAL/INSTALLATION [LF] .)
INTERMITTENT CONCERN TROUBLESHOOTING [LF]
B3E010318881W30
Vibration Method
1. If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below.
Note
• There are several reasons vehicle or engine vibration could cause an electrical malfunction.
Some of the things to inspect for are:
- Connectors not fully seated
- Wiring harnesses not having full play
- Wiring harnesses laying across brackets or moving parts
- Wiring harnesses routed too close to hot parts
• An improperly routed, improperly clamped, or loose wiring harness can cause wiring to become pinched between parts.
• The connector joints, points of vibration, and places where wire harnesses pass through the fire wall, body panels, etc. are the major areas to be inspected.
Inspection Method for Switch Connectors or Wiring Harnesses
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If engine starts and runs, perform the following steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Turn switch on manually.
5. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.
• If PID value is unstable, inspect for poor connection.
Inspection Method for Sensor Connectors or Wiring Harnesses
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If the engine starts and runs, perform the following steps during idle.
3. Access PIDs for the switch you are inspecting.
4. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.
• If PID value is unstable, inspect for poor connection.
Inspection Method for Sensors
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If engine starts and runs, perform the following steps at idle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Access PIDs for the switch you are inspecting.
4. Vibrate the sensor slightly with your finger.
• If PID value is unstable or malfunction occurs, check for poor connection and/or poorly mounted sensor.
Inspection Method for Actuators or Relays
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If the engine starts and runs, perform the following steps at idle.
3. Prepare the Output State Control for actuators or relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3 s are Output State Control is activated.
• If variable click sound is heard, inspect for poor connection and/or poorly mounted actuator or relay.
Note
• Vibrating relays too strongly may result in open relays.
Water Sprinkling Method
Caution
• Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
• If a vehicle is subject to water leakage, the leakage may damage the control module. When testing a vehicle with a water leakage problem, special caution must be used.
If malfunction occurs only during high humidity or rainy/snowy weather, perform the following steps.
1. Connect WDS or equivalent to DLC-2 if you are inspecting sensors or switches.
2. Turn the ignition switch to the ON position (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.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a car wash.
• If PID value is unstable or malfunction occurs, repair or replace part.
ENGINE CONTROL SYSTEM OPERATION
INSPECTION [LF]
B3E010318881W31
Main Relay Operation Inspection
1. Verify that the main relay clicks when the ignition switch is turned to ON position and off.
• If there is no operation sound, inspect the following.
- Main relay (See RELAY INSPECTION .)
- Wiring harness and connector between ignition switch and main relay terminal A
- Wiring harness and connector between PCM terminal 1AT and main relay terminal B
Intake Manifold Vacuum Inspection
1. Verify air intake hoses are installed properly.
2. Start the engine and run it at idle.
3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the intake manifold side.
4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
• If not as specified, inspect the following.
Specification
More than 60 kPa {451 mmHg, 18 inHg}
Note
• Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Air suction at throttle body, intake manifold and PCV valve installation points
- Accelerator cable free play
- Fuel injector insulator
- Engine compression (See COMPRESSION INSPECTION [LF] .)
Idle Air Control System Inspection
Engine coolant temperature compensation inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Access the following PIDs.
• ECT
• IAT
• RPM
3. Verify that the engine is in cold condition, then start the engine.
4. Verify that the engine speed decreases as the engine warms up.
• If the engine speed does not decrease or decreases slowly, inspect the following.
- ECT sensor and related wiring harness (See ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION [LF] .)
- IAC valve and related wiring harness (See IDLE AIR CONTROL (IAC) VALVE INSPECTION
[LF] .)
Load compensation inspection
1. Start the engine and idle it.
2. Connect WDS or equivalent to the DLC-2.
3. Verify that P0506, P0507 or P0511 not displayed.
• If P0506, P0507 or P0511 shown, perform the DTC inspection. (See DTC TABLE [LF] .)
4. Change the duty value of the IAC valve to 100% using the IAC PID.
5. Verify that the idle speed increases.
• If the idle speed does not change, inspect the following.
- IAC valve air passage
- Open or short circuit in wiring harness between IAC valve terminals and PCM terminals 2E and
2F
6. Access the following PIDs.
• AC_REQ
• IAC
• PSP
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• RPM
Note
• Excludes temporary idle speed drop just after the loads are turned on.
7. Verify that the engine speed is within the specification under each load condition.
• If not as specified under each load condition, inspect the following.
- A/C switch and related wiring harness.
- Fan switch and related wiring harness (See FAN SWITCH INSPECTION .)
- PSP switch and related wiring harness.
Engine speed
No load
Load condition Engine speed (rpm) *1
600-700
38-48 A
E/L operating *2 more than 48 A
650-750
700-800
Refrigerant pressure low *4 700-800
A/C operating *3
Refrigerant pressure high *5 700-800
*1 :
Neutral or P position
*2 :
Generator generating current value
*3 :
A/C switch and fan switch are on.
*4 :
Refrigerant pressure switch (middle pressure) is off.
*5 :
Refrigerant pressure switch (middle pressure) is on.
Variable Intake-air Control Operation Inspection
1. Start the engine.
2. Inspect the rod operation under the following condition.
Rod operation
Engine speed
4,750 rpm
Less than More than
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Shutter valve actuator
Operate Not operate
• If the rod operation is not as specified, inspect as follows.
(1) Stop the engine.
(2) Connect WDS or equivalent to the DLC-2.
(3) Verify that DTC P0661 or P0662 is not displayed.
• If DTC P0661 or P0662 is shown, perform the DTC inspection. (See DTC TABLE [LF] .)
(4) Turn the ignition switch to the ON position.
(5) Turn the variable intake-air control solenoid valve from on to off using the IMTV PID and verify that operation sound of the solenoid valve is heard.
• If the operation sound is heard, inspect the following.
- Vacuum hose and vacuum chamber for looseness or damage
- Shutter valve actuator (See VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR
INSPECTION [LF] .)
- Shutter valve stuck open or close
• If the operation sound is not heard, inspect the following.
- Variable intake-air solenoid valve (See VARIABLE INTAKE-AIR SOLENOID VALVE
INSPECTION [LF] .)
Variable Tumble Control Operation Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Access ECT PID.
3. Verify that ECT PID is below 63 ° C {145 ° F} .
4. Start the engine.
5. Inspect rod operation under the following condition.
Rod operation
Engine speed
3,750 rpm
Less than More than
Shutter valve actuator
Operate Not operate
• If the rod operation is not specified, inspect as follows.
(1) Verify that DTC No. P2009 or P2010 is not displayed.
• If DTC No. P2009 or P2010 are shown, perform the DTC inspection. (See DTC TABLE [LF] .)
(2) Turn the ignition switch to the ON position.
(3) Turn the variable tumble solenoid valve from on to off using the IMRC PID and verify that operation sound of the solenoid valve is heard.
• If the operation sound is heard, inspect the following.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Vacuum hose and vacuum chamber for looseness or damage
- Shutter valve actuator (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION
[LF] .)
- Shutter valve stuck open or close
• If the operation sound is not heard, inspect the following.
- Variable tumble solenoid valve (See VARIABLE TUMBLE SOLENOID VALVE INSPECTION
[LF] .)
Fuel Injector Operation Inspection
STEP INSPECTION RESULTS ACTION
Yes Fuel injector operation is normal.
All cylinders no heard:
1
While cranking the engine, inspect for fuel injector operation sound at each cylinder using a soundscope.
No
Is operation sound heard?
Go to the next step.
Some cylinders no heard:
2
3
4
Perform the main relay operation inspection.
Is main relay operation normal?
Yes
Change fuel injector connector of not operating fuel injector and operating fuel injector.
Is operation sound heard?
No
Are wiring harness and connectors of not operation fuel injector normal? (Open or short circuit)
Yes
No
Yes
No
Go to Step 3.
Inspect following:
• Fuel injector power system related wiring harness and connectors
• PCM connectors
• Fuel injector GND and related wiring harness and connectors
Repair or replace the malfunctioning part.
Go to the next step.
Replace fuel injector.
(See FUEL INJECTOR
INSPECTION )
Inspect PCM terminal voltage of fuel injector signal.
Repair or replace the malfunctioning part.
Fuel Cut Control System Inspection
1. Warm up the engine and idle it.
2. Turn off the electrical loads and A/C switch.
3. Connect the WDS or equivalent to the DLC-2.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Access RPM and FUELPW1 PIDs.
5. Monitor both PIDs while performing the following steps.
(1) Depress the accelerator pedal and increase the engine speed to 4,000 rpm .
(2) Release the accelerator pedal (brake pedal is not depressed) and verify that the fuel injector duration time is 0 ms.
, and 2-5 ms.
when the engine speed drops below 1,300 rpm .
• If not as specified, inspect the following.
- ECT sensor and related wiring harness (See ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION [LF] .)
- Neutral/clutch pedal position switch and related wiring harness (See CLUTCH PEDAL
POSITION (CPP) SWITCH INSPECTION [LF] .)
Fuel Pump Operation Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Remove the fuel-filler cap.
3. Turn the ignition switch to the ON position.
4. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard.
• If no operation sounds is heard, proceed to next step.
5. Measure the voltage at wiring harness-side fuel pump terminal A.
Specification
B+ (Ignition switch is ON position)
• If the voltage is as specified, inspect the following.
- Fuel pump continuity
- Fuel pump GND
- Wiring harness between fuel pump relay and PCM terminal 1AQ (without immobilizer system),
1AR (with immobilizer system)
• If not as specified, inspect the following.
- Fuel pump relay (See RELAY INSPECTION .)
- Wiring harness and connector (Main relay-fuel pump relay-fuel pump)
Fuel Pump Control System Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position.
3. Access FP PID.
4. Turn the fuel pump relay from off to on and inspect if the operation sound of the fuel pump relay is heard.
• If no operation sound is heard, inspect the fuel pump relay.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the fuel pump relay is normal, inspect the following.
- Wiring harnesses and connectors (Main relay-fuel pump relay-PCM)
Spark Test
1. Remove the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure.
Warning
• High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test.
STEP
1
2
INSPECTION ACTION
• Disconnect ignition coil from spark plugs.
• Remove spark plugs.
• Reconnect spark plugs to ignition coil.
• Ground spark plugs to engine.
• Is strong blue spark visible at each cylinder while cranking?
Yes Ignition system is normal.
Some cylinders do not spark:
No
• Go to the next step.
All cylinders do not spark:
• Go to Step 4.
• Inspect spark plugs for damage, wear, carbon deposits and proper plug gap.
• Are spark plugs normal?
Yes
No
Go to the next step.
Replace spark plugs, then return to Step.1.
3
4
• Inspect following wiring harnesses for open or short circuit:
Yes
Inspect and replace ignition coil.
(See IGNITION COIL INSPECTION [LF] .)
- Ignition coil No.1 terminal B-PCM terminal 2BE
- Ignition coil No.2 terminal B-PCM terminal 2BF
- Ignition coil No.3 terminal B-PCM terminal 2BG
- Ignition coil No.4 terminal B-PCM terminal 2BH
• Are wiring harnesses normal?
No
Repair or replace the malfunctioning part, then return to Step.1.
• Measure the voltage at terminal A in each ignition coils.
• Is voltage reading B+ ?
Yes
No
Go to the next step.
Inspect power supply circuit of ignition coils.
5
• Does PCM connector or ignition coil connectors have poor connection?
Yes
Repair or replace connector, then return to
Step.1.
No Go to the next step.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
• Are following parts normal?
- CKP sensor and crankshaft pulley
Yes
Inspect for open or short circuit in wiring harness and connector of CKP sensor.
No
Repair or replace the malfunctioning part, then return to Step.1.
EGR Control System Inspection
1. Crank the engine and verify that EGR valve operation (initial operation) sound is heard.
• If the operation sound is not heard, connect WDS or equivalent to the DLC-2 and verify that the
DTC P0403 is shown. Perform the DTC inspection. (See DTC TABLE [LF] .)
2. Start the engine and run it at idle.
3. Increase the step value of EGR valve from 0 to 40 using SEGRP PID.
4. Operate the EGR valve and inspect if the engine speed becomes unstable or the engine stalls.
• If the engine speed will not change, proceed to following.
(1) Stop the engine.
(2) Remove the EGR valve.
(3) Connect the EGR valve connector.
(4) Turn the ignition switch to the ON position.
(5) Increase the step value of EGR valve from 0 to 40 using SEGRP PID.
(6) Inspect the EGR operation.
• If the EGR valve is operated, clean the EGR valve and reinspect from Step 2.
• If the EGR valve will not operate, replace the EGR valve and reinspect from Step 2.
5. Start the engine and warm it up completely.
6. Access the following PIDs.
• ECT
• RPM
• SEGRP
• TP
• VSS
7. Idle the vehicle and verify that the SEGRP value is 0 .
8. Put the vehicle in drive.
9. Depress the accelerator pedal and verify that the SEGRP value is increased.
• If the SEGRP value will not increase, inspect the VSS, TP and ECT PIDs. (See PCM
INSPECTION [LF] .)
10. Stop the vehicle and verify that the SEGRP value is returned 0 .
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Purge Control System Inspection
1. Start the engine.
2. Disconnect the vacuum hose between the purge valve and the charcoal canister.
3. Put a finger to the purge 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 valve-PCM terminal 2AN)
- Purge valve
4. Start the engine and warm it up completely.
5. Stop the engine.
6. Connect the WDS or equivalent to the DLC-2 and verify that the DTC P0443 is shown. Perform the
DTC inspection. (See DTC TABLE [LF] .)
7. Turn the ignition switch to the ON position.
8. Access ECT PID.
9. Verify that the engine coolant temperature is above 78 ° C {173 ° F} .
• If WDS or equivalent indicates below 78 ° C {173 ° F} , perform the ECT sensor inspection.
10. Access EVAPCP PID.
11. Increase the duty value of the purge valve to 50% and inspect if the operation sound of the valve is heard.
• If the operation sound is heard, inspect for the loose or damaged vacuum hose. (Intake manifold-purge valve-charcoal canister)
• If the operation sound is not heard, perform the purge valve inspection.
A/C Cut-off Control System Inspection
1. Start the engine.
2. Turn the A/C switch and fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
• If it does not actuate, go to symptom troubleshooting "No.23 A/C does not work sufficiently".
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2-
5 s .
• If it actuates, inspect as follows.
(1) Connect the WDS or equivalent to the DLC-2.
(2) Turn the A/C switch off.
(3) Turn the ignition switch to the ON position.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(4) Access ACCS PID.
(5) Turn the A/C relay from off to on and inspect if the operation sound of the relay is heard.
• If the operation sound is heard, inspect TP PID.
• If the operation sound is not heard, inspect following.
- A/C relay
- Open circuit or short to GND in wiring harness and connectors (Ignition switch-A/C relay-PCM terminal 1AN)
- A/C related parts
Cooling Fan Motor Operation Inspection
1. Verify that the battery voltage is above 12.4 V .
• If the battery voltage is below 12.4 V , charge the battery or connect the external power supply.
2. Connect the WDS or equivalent to the DLC-2.
3. Access the following PIDs.
• ECT
• AC_REQ
• COLP
4. Turn the A/C switch to off.
5. Verify that ECT PID is below 98 ° C {209 ° F} and the AC_REQ is off.
• If the ECT PID is below 98 ° C {209 ° F} , inspect the ECT sensor.
• If the AC_REQ PID is on, inspect the A/C switch and A/C refrigerant pressure switch (high/low pressure).
6. Turn the ignition switch to the ON position while the temperature is below 98 ° C {209 ° F} with the ignition switch in the ON position.
7. Verify that the cooling fan is not operating.
• If the cooling fan is operating inspect the following:
(1) Verify that the FAN DUTY PID is 0 % .
• If the FAN DUTY PID is not 0 % , inspect the following PID and related parts.
- ECT (ECT sensor)
- AC_REQ (A/C switch and A/C refrigerant pressure switch (high/low) pressure)
- COLP (A/C refrigerant pressure switch (medium pressure))
- VSS (Vehicle speed sensor)
- ACCS (A/C magnetic clutch)
• If the FAN DUTY PID is 0 % , replace cooling fan component.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8. Turn the A/C switch to on.
9. Verify that the cooling fan is operating while the ECT PID is below 98 ° C {209 ° F} .
• If the cooling fan does not operate, inspect for the following:
- A/C switch
- A/C refrigerant pressure switch
- Fan control module power supply circuit (open or short circuit)
- Fan control module GND circuit (open or short circuit)
- Fan control module control signal circuit (open or short circuit between fan control module terminal B and PCM terminal 1W)
- Fan control module
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
10. Verify that the cooling fan operates at medium speed while the COLP PID is off and high speed while the COLP PID is on.
• If the cooling fan does not operate middle and/or high speed, inspect for the following:
- A/C refrigerant pressure switch (medium switch)
- Fan control module
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
11. Turn the A/C switch to the off position.
12. Start the engine and idle it.
13. Verify that the cooling fan operating speed increases relative to the ECT PID increase.
• If the cooling fan speed does not increase inspect the following:
- ECT sensor (characteristic).
- Fan control signal circuit (between fan control module terminal B and PCM terminal 1W)
• If the all items are normal, replace the cooling fan component.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MECHANICAL[Z6]
ENGINE LOCATION INDEX [Z6]
B3E011015800W01
Drive belt
1 (See DRIVE BELT INSPECTION [Z6] .)
(See DRIVE BELT REPLACEMENT [Z6] .)
2
Drive belt auto tensioner
(See DRIVE BELT AUTO TENSIONER INSPECTION [Z6] .)
3 Tappet
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See VALVE CLEARANCE INSPECTION [Z6] .)
(See VALVE CLEARANCE ADJUSTMENT [Z6] .)
4
Timing chain
(See TIMING CHAIN REMOVAL/INSTALLATION [Z6] .)
5
Cylinder head gasket
(See CYLINDER HEAD GASKET REPLACEMENT [Z6] .)
6
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [Z6] .)
7
Rear oil seal
(See REAR OIL SEAL REPLACEMENT [Z6] .)
Engine
8
(See COMPRESSION INSPECTION [Z6] .)
(See ENGINE REMOVAL/INSTALLATION [Z6] .)
(See ENGINE DISASSEMBLY/ASSEMBLY [Z6] .)
Oil control valve (OCV)
9 (See OIL CONTROL VALVE (OCV) INSPECTION [Z6] .)
(See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [Z6] .)
Variable valve timing actuator
10 (See VARIABLE VALVE TIMING ACTUATOR INSPECTION [Z6] .)
(See VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [Z6] .)
DRIVE BELT INSPECTION [Z6]
B3E011015800W02
Note
• Drive belt deflection/tension inspection is not necessary because of the use of the drive belt auto tensioner.
1. Remove the under cover and splash shield (RH).
2. Verify that the drive belt auto tensioner indicator mark does not exceed the limit.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it exceeds the limit, replace the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
3. Install the under cover and splash shield (RH).
DRIVE BELT REPLACEMENT [Z6]
B3E011015800W03
1. Remove the under cover and splash shield (RH).
2. Rotate the drive belt auto tensioner in the direction shown in the figure and remove the drive belt.
3. Install the new drive belt.
4. Verify that the drive belt auto tensioner indicator mark does not exceed the limit. (See DRIVE BELT
INSPECTION [Z6] .)
5. Install the under cover and splash shield (RH).
DRIVE BELT AUTO TENSIONER INSPECTION [Z6]
B3E011015800W04
1. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
2. Verify that the drive belt auto tensioner moves smoothly in the operational direction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it does not move smoothly, replace the drive belt auto tensioner.
3. Rotate the drive belt auto tensioner pulley by hand and verify that it rotates smoothly.
• If it does not move smoothly, replace the drive belt auto tensioner.
4. Install the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
VALVE CLEARANCE INSPECTION [Z6]
B3E011012111W01
1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield (RH).
4. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
6. Disconnect the ventilation hose.
7. Remove the cylinder head cover.
8. Measure the valve clearance.
(1) Rotate the crankshaft clockwise so that the No.1 cylinder is at TDC of the compression stroke.
(2) Measure the valve clearance at A shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If not within the specification, replace the tappet and adjust the valve clearance to the median value. (See VALVE CLEARANCE ADJUSTMENT [Z6] .)
Standard valve clearance [Engine cold]
0.27-0.33 mm {0.0107-0.0129 in}
Note
• Make sure to note down the measured values for choosing the suitable replacement tappets.
(3) Rotate the crankshaft clockwise 360 ° so that the No.4 cylinder is at TDC of the compression stroke.
(4) Measure the valve clearance at B shown in the figure.
• If not within the specification, replace the tappet and adjust the valve clearance to the median value. (See VALVE CLEARANCE ADJUSTMENT [Z6] .)
Standard valve clearance [Engine cold]
0.27-0.33 mm {0.0107-0.0129 in}
Note
• Make sure to note down the measured values for choosing the suitable replacement tappets.
9. Install the cylinder head cover. (See Cylinder Head Cover Installation Note .)
10. Connect the ventilation hose.
11. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
12. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
13. Install the under cover and splash shield (RH).
VALVE CLEARANCE ADJUSTMENT [Z6]
B3E011012111W02
1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
6. Disconnect the ventilation hose.
7. Remove the cylinder head cover.
8. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
9. Remove the engine front cover blind plug shown in the figure.
10. Insert a bolt (M10 × 1.25, length 25 mm {0.98 in} or more) into the service hole on the right side by hand as shown in the figure until it stops on the tensioner arm. Then rotate the bolt back out approx. halfway so that it sits slightly in front of the tensioner arm.
11. Release tension on the timing chain.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(1) Press down the link plate of the chain tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver). Then rotate the crank pulley backwards
(counterclockwise) with the plunger lock released.
(2) When the timing chain loosens, shift the tensioner arm to the position shown in the figure at the same time.
Note
• The timing chain presses the tensioner arm by the rotation of the crank pulley backwards
(counterclockwise).
(3) Rotate the bolt (M10 × 1.25) installed to the front cover by hand and insert it to the position where it catches the inside of the rib on the tensioner arm.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Note
• Fix the tensioner arm by inserting the bolt and rotate it to the right six to seven times until it reaches to the position shown in the figure.
12. Fix the camshaft using a wrench on the cast hexagon.
13. Remove the camshaft sprocket installation bolt.
14. Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.
15. Loosen the camshaft cap installation bolts in 2-3 passes in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
16. Remove the camshaft caps.
17. Remove the intake and exhaust camshafts.
18. Remove the tappets.
19. Select a proper tappet according to the result of the valve clearance inspection and install it.
Tappet to be selected: thickness of the removed tappet + measured valve clearance - standard valve clearance (0.3 mm {0.0118 in})
Standard valve clearance [Engine cold]
0.27-0.33 mm {0.0107-0.0129 in}
20. Align the timing marks on the crank pulley and the engine front cover, and then align the No.1 cylinder to the TDC.
21. Install the intake and exhaust camshafts with the No.1 cylinder so that it is near TDC of the compression stroke.
22. Install the camshaft caps to the position shown in the figure, and temporarily tighten the No.2 and
No.7 camshaft installation bolts.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
23. Tighten the camshaft installation bolts in 2-3 passes uniformly in the order shown in the figure.
Tightening torque
11.314.2 N·m {1.16-1.44 kgf·m, 8.4-10.4 ft·lbf}
24. Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
25. Fix the camshaft using a wrench on the cast hexagon.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
26. Tighten the camshaft sprocket installation bolt.
Tightening torque
49.660.8 N·m {5.06-6.19 kgf·m, 36.6-44.8 ft·lbf}
27. Remove the bolt (M10 × 1.25) holding the tensioner arm.
28. Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.
29. Inspect the valve timing by rotating the crankshaft clockwise twice.
30. Apply silicone sealant to the blind plug as shown in the figure.
31. Install the engine front cover blind plug.
Tightening torque
3.05.0 N·m {31-50 kgf·cm, 26.6-44.2 in·lbf}
32. Install the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
33. Install the cylinder head cover. (See Cylinder Head Cover Installation Note .)
34. Connect the ventilation hose.
35. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
36. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
37. Install the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
COMPRESSION INSPECTION [Z6]
B3E011001001W01
Warning
• Hot engines can cause severe burns. Be careful not to burn yourself during removal/installation of each component.
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure" when servicing the fuel system, and remove the fuel pump relay.
(See BEFORE SERVICE PRECAUTION .)
1. Verify that the battery is fully charged. (See BATTERY INSPECTION .)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and leave it for approx.10 min to cool down the exhaust system.
4. Remove the fuel pump relay. (See BEFORE SERVICE PRECAUTION .)
5. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
6. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
7. Remove all the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [Z6] .)
8. Measure the compression pressure using the following procedure.
(1) Connect the compression gauge into the spark plug hole.
(2) Fully open the throttle valve.
(3) Crank the engine and measure the compression pressure.
Compression pressure
• Standard
1,470 kPa {14.99 kgf/cm 2 , 213.2 psi} [250 rpm]
• Minimum
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1,029 kPa {10.49 kgf/cm 2 , 149.2 psi} [250 rpm]
• Maximum difference between cylinders 196.1 kPa {2.0 kgf/cm 2 , 28.5 psi}
(4) Perform Steps (1) to (3) all of the cylinders.
(5) If it is less than the minimum specification, or there is a cylinder with a compression value that varies from that of other cylinders by 196.1 kPa {2.0 kgf/cm 2 , 28.5 psi} or more perform Steps
(1) to (3) adding a small quantity of engine oil from the spark plug hole.
• If the pressure increases by adding the engine oil, the piston ring or the cylinder surface is worn, or they are damaged. Perform overhaul servicing.
• If the pressure does not increase, valve seizure, valve attachment failure, or pressure leaking from the cylinder head gasket might be occuring. Perform overhaul servicing.
9. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [Z6] .)
10. Install the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
11. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
12. Install the fuel pump relay. (See BEFORE SERVICE PRECAUTION .)
TIMING CHAIN REMOVAL/INSTALLATION [Z6]
B3E011012040W01
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See AFTER SERVICE PRECAUTION .)
1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
4. Remove the following parts:
(1) Front wheel and tire (RH) (See GENERAL PROCEDURES (SUSPENSION) .)
(2) Under cover and splash shield (RH)
(3) Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
(4) Ignition coils (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
(5) Drive belt (See DRIVE BELT REPLACEMENT [Z6] .)
(6) P/S oil pump with the oil hose and oil pipe still connected (See POWER STEERING OIL
PUMP (Z6) REMOVAL/INSTALLATION .)
Note
• Fix the P/S oil pump with rope at a position not obstructing the servicing.
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(7) Coolant and P/S reserve tank with the hoses and pipes still connected
(8) Generator (See GENERATOR REMOVAL/INSTALLATION [Z6] .)
(9) Water pump (See WATER PUMP REMOVAL/INSTALLATION [Z6] .)
(10) Accelerator cable bracket (body side)
(11) Earth (No.3 engine mount)
5. Disconnect the following parts:
(1) Ventilation hose
(2) OCV wiring harness
(3) CKP sensor connector
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Start the engine.
9. Inspect the following and adjust them if necessary.
(1) Amount of engine oil (See ENGINE OIL LEVEL INSPECTION [Z6] .)
(2) Pulley and belt for runout and contact
(3) Ignition timing and idle speed. Verify the amount of CO and HC. (See ENGINE TUNE-UP
[Z6] .)
10. Perform a road test and verify that there is no abnormal vibration or noise.
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1
Cylinder head cover
(See Cylinder Head Cover Installation Note .)
Crankshaft pulley installation bolt
2
(See Crankshaft Pulley Installation Bolt Removal Note .) (See Crankshaft Pulley Installation Bolt
Installation Note .)
3 Crankshaft pulley
4 Idler pulley
5 Drive belt auto tensioner
No.3 engine mount
6 (See No.3 Engine Mount Removal Note .)
(See No.3 Engine Mount Installation Note .)
7 Oil level gauge pipe
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Engine front cover
8 (See Engine Front Cover Removal Note .)
(See Engine Front Cover Installation Note .)
9 Chain tensioner (See Chain Tensioner Removal Note .)
10 Chain tensioner arm
11 Chain guide
12 Timing chain (See Timing Chain Removal Note .) (See Timing Chain Installation Note .)
13 Crankshaft sprocket
14 Key
Crankshaft Pulley Installation Bolt Removal Note
1. Fix the crankshaft pulley using the SSTs .
No.3 Engine Mount Removal Note
1. Secure the engine using an engine jack and attachment.
Engine Front Cover Removal Note
1. Remove the front oil seal using a flathead screwdriver.
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Chain Tensioner Removal Note
1. Push down the link plate of the timing chain tensioner using a thin flathead screwdriver (precision screwdriver), and release the plunger lock.
2. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.
3. Release the link plate with the plunger still pressed down.
4. Release the pressure slightly from the plunger, and move the plunger back and forth 2-3 mm {0.08-
0.11 in) .
5. Insert an approx. 1.5 mm {0.06 in) thick wire or paper clip where the link plate hole and the tensioner body hole overlap to fix the link plate and lock the plunger.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Timing Chain Removal Note
1. Rotate the crankshaft clockwise and align the key groove of the crankshaft sprocket with the timing mark, and then position the No.1 cylinder to TDC.
2. Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
3. Remove the timing chain.
Timing Chain Installation Note
1. Align the key groove of the crank sprocket to the timing mark, and then position the No.1 cylinder to
TDC.
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2. Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
3. Install the timing chain.
4. After installing the chain adjuster, remove the wire or the paper clip installed to the chain tensioner, and apply tension to the timing chain. (Remove the installed stopper when installing the new chain tensioner.)
5. Verify that there is no slack on the timing chain, and then verify that each sprocket is positioned in the proper place again.
6. Rotate the crankshaft clockwise twice, and then inspect the valve timing.
Engine Front Cover Installation Note
1. Apply the silicon sealant to the engine front cover as shown in the figure.
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Caution
• Install the engine front cover within 10 min of applying the silicone sealant.
Thickness
2-4 mm {0.08-0.15 in)
2. Tighten the engine front cover installation bolts in the order shown in the figure.
• Install a No.1 bolt using a new seal washer.
Bolt number Tightening torque
1-6, 8, 10, 18.625.5 N·m
12-15, 17, 18 {1.902.29kgf·m, 13.8-16.5 ft·lbf}
7, 11, 16
9
37.251.9 N·m
{3.805.29 kgf·m, 27.5-38.2 ft·lbf}
7.810.8 N·m
{80110 kgf·cm, 69.1-95.5 in·lbf}
3. Apply clean engine oil to the new front oil seal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Insert the front oil seal into the engine front cover by hand.
5. Tap in the front oil seal using the SST and a hammer.
Compression amount
From the engine front cover
0-0.5 mm {0-0.019 in)
No.3 Engine Mount Installation
Note
1. Tighten the No.3 engine mount installation stud bolts.
Tightening torque
713 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf}
2. Install the No.3 engine mount and temporarily tighten the installation bolts and nuts.
3. Tighten the installation bolts in the order shown in the figure.
Tightening torque
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 (nuts) : 4461 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf}
2 (bolts) : 74.5104.9 N·m {7.60-10.70 kgf·m, 55.0-77.3 ft·lbf}
Crankshaft Pulley Installation Bolt Installation Note
1. Fix the crankshaft pulley using the SSTs .
2. Tighten the crankshaft pulley installation bolt.
Tightening torque
157167 N·m {16.1-17.0 kgf·m, 116-123 ft·lbf}
Cylinder Head Cover Installation Note
1. Apply silicon sealant as shown in the figure.
Thickness
2-6 mm {0.08-0.23 in}
Length
6-26 mm {0.24-1.02 in}
2. Tighten the cylinder head cover installation bolts in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
6.910.8 N·m {70-110 kgf·cm, 61.1-95.5 in·lbf}
CYLINDER HEAD GASKET REPLACEMENT [Z6]
B3E011010271W01
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See BEFORE SERVICE PRECAUTION .)
1. Remove the following parts:
(1) Timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [Z6] .)
(2) EGR pipe and EGR valve bracket (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[Z6] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .) (See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
(3) Front HO2S (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(4) Accelerator cable and bracket
(5) Fuel hose and fuel injector wiring harness (See QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION .) (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .)
(6) Air hose, throttle body and intake manifold (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the following parts:
(1) Rear HO2S connector
(2) Main silencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(3) WU-TWC (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(4) Upper radiator hose
(5) Heater hose
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
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5. Inspect the compression. (See COMPRESSION INSPECTION [Z6] .)
6.
Camshaft cap
1 (See Camshaft Cap Removal Note )
(See Camshaft Cap Installation Note )
2 Camshaft
Cylinder head
3 (See Cylinder Head Removal Note )
(See Cylinder Head Installation Note )
4 Cylinder head gasket
Camshaft Cap Removal Note
1. Loosen the camshaft cap installation bolts in 2-3 passes in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Remove the camshaft caps.
Cylinder Head Removal Note
1. Loosen the cylinder head installation bolts in 2-3 passes in the order shown in the figure, and remove them.
Cylinder Head Installation Note
1. Measure the length of each cylinder head installation bolt.
• If it exceeds the maximum specification, replace the cylinder head installation bolt.
Standard
L: 128.9-129.5 mm {5.075-5.098 in}
Maximum
L:130.2 mm {5.125 in}
2. Tighten the cylinder head installation bolts in three steps in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1. Tightening torque: 17.522.5 N·m {1.79-2.29 kgf·m, 13.0-16.5 ft·lbf}
2. Tightening angle: 85°-95°
3. Tightening angle: 85°-95°
Camshaft Cap Installation Note
1. Align the No.1 cylinder camshaft position to the TDC position, and install the camshaft.
2. Install the camshaft caps in the positions numbered as shown in the figure, and then temporarily tighten the No.2 and No.7 camshaft cap installation bolts.
3. Tighten the camshaft cap installation bolts in 2-3 passes uniformly in the order shown in the figure.
Tightening torque
11.314.2 N·m {116-144 kgf·cm, 101-125 in·lbf}
FRONT OIL SEAL REPLACEMENT [Z6]
B3E011010602W01
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1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
Crankshaft pulley installation bolt
1 (See Crankshaft Pulley Installation Bolt Removal Note )
(See Crankshaft Pulley Installation Bolt Installation Note )
2 Crankshaft pulley
Front oil seal
3 (See Front Oil Seal Removal Note )
(See Front Oil Seal Installation Note )
Crankshaft Pulley Installation Bolt Removal Note
1. Fix the crankshaft pulley using the SSTs .
2. Remove the crankshaft pulley installation bolt.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Front Oil Seal Removal Note
1. Remove the oil seal lip using a cutting knife.
2. Remove the oil seal using a flathead screwdriver with the tip protected by a rag to prevent crankshaft oil seal damage.
Front Oil Seal Installation Note
1. Apply clean engine oil to the new front oil seal.
2. Insert the front oil seal into the engine front cover by hand.
3. Tap the front oil seal in using the SST and a hammer.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Compression amount
From the engine front cover
0-0.5 mm {0-0.019 in}
Crankshaft Pulley Installation
Bolt Installation Note
1. Fix the crankshaft pulley using the SSTs .
2. Tighten the crankshaft pulley installation bolt.
Tightening torque
157167 N·m {16.1-17.0 kgf·m, 116-123 ft·lbf}
REAR OIL SEAL REPLACEMENT [Z6]
B3E011011399W01
1. Remove the following parts:
ATX
1. Automatic transaxle (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION .)
2. Drive plate (See DRIVE PLATE REMOVAL/INSTALLATION .)
MTX
1. Clutch release cylinder (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
2. Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R] .)
3. Flywheel (See CLUTCH UNIT REMOVAL/INSTALLATION .)
2. Remove the oil seal lip using a cutting knife.
3. Remove the oil seal using a flathead screwdriver with the tip protected by a rag to prevent crankshaft oil seal damage.
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4. Apply clean engine oil to a new rear oil seal.
5. Insert the oil seal into the cylinder block by hand.
6. Install the rear oil seal using the SST .
Compression amount
From the cylinder block side end
0-0.5 mm {0-0.019 in)
7. Install the following parts:
ATX
1. Drive plate (See DRIVE PLATE
REMOVAL/INSTALLATION .)
2. Automatic transaxle (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION .)
MTX
1. Flywheel (See CLUTCH UNIT REMOVAL/INSTALLATION .)
2. Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R] .)
3. Clutch release cylinder (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
ENGINE REMOVAL/INSTALLATION [Z6]
B3E011001001W02
Warning
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See BEFORE SERVICE PRECAUTION .)
Note
• Perform the engine and transaxle component removal/installation from below the vehicle.
1. Remove the following parts:
(1) Battery cover, battery box, battery clamp, battery and battery tray (See BATTERY
REMOVAL/INSTALLATION [Z6] .)
(2) Front wheels and tires (See GENERAL PROCEDURES (SUSPENSION) .)
(3) Under cover and splash shields
(4) Flesh-air duct, air hose and air cleaner component (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
(5) Accelerator cable and bracket
(6) Drive belt (See DRIVE BELT REPLACEMENT [Z6] .)
2. Drain the following fluids:
(1) ATF (ATX) or transaxle oil (MTX) (See AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT .) (See TRANSAXLE OIL REPLACEMENT [F35M-R] .)
(2) Engine coolant (See ENGINE COOLANT REPLACEMENT .)
(3) P/S fluid (See AIR BLEEDING .)
3. Disconnect the purge solenoid ventilation hose.
4. Disconnect the P/S return hose from the P/S oil pump side.
5. Disconnect the P/S pressure pipe from the steering gear side.
6. Disconnect the P/S return hose from the P/S reserve tank side.
7. Remove the following parts:
(1) Member (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(2) Front crossmember, front stabilizer, lower arm, steering gear and No.1 engine mount rubber component (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION .)
(3) Drive shaft (See DRIVE SHAFT REMOVAL/INSTALLATION .)
(4) P/S reserve tank with the hose still connected
(5) Coolant reserve tank with the hose still connected
(6) Cooling fan component (See RADIATOR REMOVAL/INSTALLATION .)
(7) ATF hose, selector cable and wiring harness (ATX) (See AUTOMATIC TRANSAXLE
REMOVAL/INSTALLATION .)
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(8) Select cable and shift cable (MTX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION
[F35M-R] .)
(9) Clutch release cylinder with the pipe still connected (MTX) (See CLUTCH RELEASE
CYLINDER REMOVAL/INSTALLATION .)
(10) Earth (No.3 engine mount)
(11) The A/C compressor with the pipes still connected.
Note
• Secure the A/C compressor using wire or rope so that it is out of the way.
8. Disconnect the following parts:
(1) Brake vacuum hose
(2) Fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
(3) Heater hose
(4) Upper and lower radiator hose
(5) Main silencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
Caution
• Do not tighten the No.1 engine mount rubber installation bolt before installing the No.3 engine mount. (See No.3 Engine Mount Installation Note .)
11. Inspect the following and adjust them if necessary.
• Front wheel alignment (See FRONT WHEEL ALIGNMENT .)
• Pulley and belt for runout and contact.
• Leakage of engine oil, engine coolant, ATF, MT oil, and fuel.
• Ignition timing and idle speed. Verify the amount of CO, HC. (See ENGINE TUNE-UP [Z6] .)
• Engine-driven accessories operation
Note
• If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no abnormality.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Main fuse block connector (See Main Fuse Block Connector Removal Note .)
2
No.3 Engine mount (See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note .) (See No.3
Engine Mount Installation Note .)
3 Battery tray bracket
No.4 Engine mount rubber
4 (See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note .)
(See No.4 Engine Mount Rubber Installation Note .)
5 Engine, transaxle
Main Fuse Block Connector Removal Note
1. Release the tab in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Pull the lock lever up and remove the connector.
No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note
1. Secure the engine and the transaxle using an engine jack and attachment.
No.4 Engine Mount Rubber Installation Note
1. Secure the engine and the transaxle using an engine jack and attachment.
2. Install the No.1 engine mount rubber and No.4 engine mount rubber.
Note
• Do not tighten the bolt and nut for the No.1 engine mount rubber and No.4 engine mount rubber during this step.
3. Tighten the No.4 engine mount rubber installation bolt shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
66.693.1 N·m {6.80-9.49 kgf·m, 49.2-68.6 ft·lbf}
4. Tighten the No.4 engine mount rubber and battery tray bracket installation bolt and nut in the order shown in the figure.
Tightening torque
1: 4461 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf}
2: 6.99.8 N·m {70.4-99.9 kgf·cm, 61.1-86.7 in·lbf}
No.3 Engine Mount Installation Note
1. Tighten the No.3 engine mount installation stud bolts.
Tightening torque
713 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf}
2. Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.
3. Tighten the installation bolts in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
1 (nuts) : 4461 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf}
2 (bolts) : 74.5104.9 N·m {7.60-10.70 kgf·m, 55.0-77.3 ft·lbf}
4. Remove the engine jack and attachment.
5. Tighten the No.1 engine mount rubber installation bolts.
Tightening torque
93.1116.6 N·m {9.50-11.88 kgf·m, 68.7-85.9 ft·lbf}
ENGINE DISASSEMBLY/ASSEMBLY [Z6]
B3E011001001W03
1. Using the bolts part number 99794 1025 or M10 × 1.25, length 25 mm {0.98 in} to install the SST to the position shown in the figure, hang the engine and transaxle, and then take it down from the engine jack.
Caution
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• When attaching the SST in the engine rear side, install a suitable nut between the engine and the SST.
Tightening torque
3851 N·m {3.9-5.2 kgf·m, 29-37 ft·lbf}
2. Remove following parts:
(1) Starter (See STARTER REMOVAL/INSTALLATION [Z6] .)
(2) Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION .)
(3) Transaxle (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION .) (See MANUAL
TRANSAXLE REMOVAL/INSTALLATION [F35M-R] .)
(4) EGR pipe and EGR valve bracket (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[Z6] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .) (See EGR VALVE
REMOVAL/INSTALLATION [Z6] .)
(5) Exhaust manifold (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(6) Generator (See GENERATOR REMOVAL/INSTALLATION [Z6] .)
(7) P/S oil pump (See POWER STEERING OIL PUMP (Z6) REMOVAL/INSTALLATION .)
(8) Fuel hose, fuel distributor and fuel injector (See FUEL INJECTOR REMOVAL/INSTALLATION
[Z6] .)
(9) Intake manifold (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
(10) Ignition coils (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
(11) CKP sensor (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION
[Z6] .)
3. Install in the reverse order of removal.
VARIABLE VALVE TIMING ACTUATOR INSPECTION
[Z6]
B3E011000142W01
Caution
• The variable valve timing actuator cannot be disassembled since it is a precision unit.
1. Remove the battery cover.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Disconnect the negative battery cable.
3. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
5. Disconnect the ventilation hose.
6. Remove the cylinder head cover.
7. Remove the under cover and splash shield (RH).
8. Verify that the camshaft knock pin hole of the variable valve timing actuator and the T- mark of the cover are aligned and fixed as shown in the figure.
• If the camshaft knock pin hole and the T-mark of the cover do not align, rotate the crankshaft two times in the direction the engine rotates, and then verify that they are aligned.
- If they do not align, replace the variable valve timing actuator.
• If under any condition the variable valve timing actuator makes a hitting noise directly after the camshaft exceeds maximum lift while rotating the crankshaft two times in the direction of engine rotation, replace the variable valve timing actuator as it has not been fixed.
9. Install the under cover splash shield (RH). (See DRIVE BELT REPLACEMENT [Z6] .)
10. Install the cylinder head cover. (See Cylinder Head Cover Installation Note .)
11. Install the ventilation hose.
12. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
13. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
VARIABLE VALVE TIMING ACTUATOR
REMOVAL/INSTALLATION [Z6]
B3E011000142W02
Caution
• Remove the variable valve timing actuator as a single unit with the camshaft sprocket.
1. Remove the camshaft component according to steps 1 to 17 in the valve clearance adjustment.
(See VALVE CLEARANCE ADJUSTMENT [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Secure the camshaft in a vise and fix the camshaft using a wrench on the cast hexagon as shown in the figure.
3. Loosen the variable valve timing actuator installation bolt, and then remove the variable valve timing actuator.
4. Fix the camshaft using a wrench on the cast hexagon as shown in the figure.
5. Tighten the variable valve timing actuator installation bolt.
Tightening torque
49.660.8 N·m {5.10-6.19 kgf·m, 36.6-44.8 ft·lbf}
6. Install the camshaft component according to steps 19 to 35 in the valve clearance adjustment.
(See VALVE CLEARANCE ADJUSTMENT [Z6] .)
OIL CONTROL VALVE (OCV)
REMOVAL/INSTALLATION [Z6]
B3E011014420W01
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Remove the accelerator cable and bracket.
5. Remove the P/S reserve tank and coolant reserve tank with the hose still connected.
6. Remove the ground. (No.3 engine mount)
7. Using the bolts part number 99794 1025 or M10 × 1.25, length 25 mm {0.98 in} to install the SST to the position shown in the figure.
Caution
• When attaching the SST in the engine rear side, install a suitable nut between the engine and the SST.
Tightening torque
3851 N·m {3.9-5.2 kgf·m, 29-37 ft·lbf}
8. Install suitable wood slabs between the front fender panel and apron reinforcement upper.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Note
• Wood slab height
4SD: approx. 35 mm {1.4 in}
5HB: approx. 60 mm {2.4 in}
• Cut the wood slab into two pieces and insert.
9. Support the engine using the SST .
Note
• A hoist or small crane can be used in place of the SST (49E 017 5A0).
10. Remove the No.3 engine mount.
11. Disconnect the OCV connector.
12. Remove the OCV installation bolt.
13. Remove the OCV.
14. Install the new O-ring.
15. Install the OCV.
16. Tighten the OCV installation bolt.
Tightening torque
7.810.8 N·m {80-110 kgf·cm, 69.1-95.5 in·lbf}
17. Connect the OCV connector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
18. Tighten the No.3 engine mount installation stud bolts.
Tightening torque
713 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf}
19. Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.
20. Tighten the installation bolts and nuts in the order shown in the figure.
Tightening torque
1 (nuts) : 4461 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf}
2 (bolts) : 74.5104.9 N·m {7.60-10.70 kgf·m, 55.0-77.3 ft·lbf}
21. Install the ground. (No.3 engine mount)
22. Install the P/S reserve tank and coolant reserve tank with the hose still connected.
23. Install the accelerator cable and bracket.
24. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
25. Connect the negative battery cable.
26. Install the battery cover.
OIL CONTROL VALVE (OCV) INSPECTION [Z6]
B3E011014420W02
Coil resistance inspection
1. Remove the battery cover.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Disconnect the negative battery cable.
3. Disconnect the OCV connector.
4. Measure the coil resistance between terminals A and B using a tester.
• If not within the specification, replace the OCV.
Standard
6.9-7.9 o hms [20°C {68°F}]
5. Connect the OCV connector.
Spool Valve Operation Inspection
1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [Z6] .)
4. Verify that the spool valve inside the OCV is at the maximum valve timing retard position as shown in the figure.
• If it cannot be verified, replace the OCV.
5. Verify that the battery is fully charged.
6. Apply battery positive voltage between oil control valve terminals A and B, and verify that the spool valve operates and moves to the maximum valve timing advance position.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If there is any malfunction, replace the OCV.
Note
• When applying battery positive voltage between the oil control valve terminals, the connection of the negative and positive cable can be either the A or B terminal.
7. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.
• If it cannot be verified, replace the OCV.
8. Install the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [Z6] .)
ENGINE TUNE-UP [Z6]
B3E011002000W01
Engine Tune-up Preparation
1. Warm up the engine to normal operating temperature.
(1) Increase the engine speed to 2,500-3,000 rpm until the cooling fan starts running.
(2) When the cooling fan starts running, release the accelerator pedal and wait until the cooling fan stops running.
2. Verify the following:
• ATX: Selector lever is in P or N position.
• MTX: Shift lever is in neutral position.
3. Turn off all electrical loads.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Connect the WDS or equivalent to the DLC-2.
5. Turn the test mode on using a simulation function.
6. Verify that the idle speed is within the specification using the RPM DATA MONITOR function.
• If not within the specification, adjust the idle speed.
Idle speed
ATX: 700-800 rpm
MTX: 640-740 rpm
Ignition Timing Inspection
Note
• The ignition timing cannot be adjusted.
• The WDS or equivalent is required to verify the ignition timing.
1. Complete the engine tune-up preparation.
Note
• Use a timing light that can detect the primary ignition signal.
2. Remove the PCM connector cover.
3. By referring to the following procedure, connect the timing light to the PCM terminal 2A wire.
Caution
• To prevent poor contact at the connector terminal, be careful not to pull the wire on the connector side.
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Pull out the wire 20-30 mm so that the pickup clip of the timing light can be connected. After the ignition timing inspection, bundle the pulled out wire back together with other wires using tape.
(1) Pull the PCM terminal 2A wire out of the bundle (pull the bundled side only, not the connector side).
(2) Connect the pickup clip of the timing light to the PCM terminal 2A wire.
4. Verify that the crankshaft pulley alignment mark (white) is within the specification.
Ignition timing (Test mode on)
BTDC 911°
5. Turn the test mode off using a simulation test.
6. Using the timing light, verify again that the crankshaft pulley alignment mark (white) is within the specification.
• If not within the specification, inspect the following parts:
- CMP sensor
- CKP sensor
- TP sensor
- ECT sensor
- TR switch (ATX)
- Neutral/clutch switch (MTX)
Ignition timing (Test mode off)
BTDC 618°
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Idle Speed Inspection
Caution
• Changing the TAS while attempting to adjust the idle speed could cause an engine malfunction.
Do not change the TAS adjustment position.
1. Complete the engine tune-up preparation.
2. Verify that the ignition timing is within the specification. (See Ignition Timing Inspection .)
3. Verify that the idle speed is within the specification using the RPM DATA MONITOR function.
• If not within the specification, adjust the idle speed to within the specification by turning the AAS after verifying that the ignition timing is within the specification.
Idle speed
ATX: 700-800 rpm
MTX: 640-740 rpm
4. Verify that the idle speed is within the specification when each load is applied. (The speed decrease just after the load is applied is not considered.)
• If not within the specification with any of the specified loads applied, inspect the IAC valve.
• If not within the specification when a specified load is applied, inspect the related input parts, wiring harnesses, and connectors.
Standard
Load status
Idle speed (rpm)
N, D position (ATX), Neutral position (MTX)
ATX
MTX
N range D range
No load 700-800
Electrical loads on *1
34-42 A 700-800
Above 42 A 700-800
A/C on Low load *2 700-800
650-750
650-750
670-770
650-750
640-740
650-750
700-800
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
High load *3 700-800
P/S on 700-800
* 1 :
Generator generating current value
* 2 :
Refrigerant pressure switch (middle pressure switch) is off.
* 3 :
Refrigerant pressure switch (middle pressure switch) is on.
Idle Mixture Inspection
1. Warm up the engine to normal operating temperature.
(1) Increase the engine speed to 2,500-3,000 rpm until the cooling fan starts running.
(2) When the cooling fan starts running, release the accelerator pedal and wait until the cooling fan stops running.
2. Verify that the idle speed and ignition timing are within the specification. (See Idle Speed Inspection .)
(See Ignition Timing Inspection .)
3. Insert an exhaust gas analyzer into the tailpipe.
4. Verify that the CO and HC concentrations are within the regulation.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MECHANICAL
ENGINE LOCATION INDEX [LF]
B3E011001002W01
Drive belt
1
(See DRIVE BELT INSPECTION [LF] .)
(See DRIVE BELT REPLACEMENT [LF] .)
(See DRIVE BELT AUTO TENSIONER INSPECTION [LF] .)
2
Tappet
(See VALVE CLEARANCE INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See VALVE CLEARANCE ADJUSTMENT [LF] .)
Engine
3
(See COMPRESSION INSPECTION [LF] .)
(See ENGINE REMOVAL/INSTALLATION [LF] .)
(See ENGINE DISASSEMBLY/ASSEMBLY [LF] .)
4
Timing chain
(See TIMING CHAIN REMOVAL/INSTALLATION [LF] .)
5
Cylinder head gasket
(See CYLINDER HEAD GASKET REPLACEMENT [LF] .)
6
Front oil seal
(See FRONT OIL SEAL REPLACEMENT [LF] .)
7
Rear oil seal
(See REAR OIL SEAL REPLACEMENT [LF] .)
8
Plug hole plate
(See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
DRIVE BELT INSPECTION [LF]
B3E011015800W05
Generator Drive Belt
Note
• Drive belt deflection/tension inspection is not necessary because of the use of the generator drive belt auto tensioner.
1. Verify that the drive belt auto tensioner indicator mark does not exceed the limit.
• If it exceeds the limit, replace the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
A/C Drive Belt
Note
• Drive belt deflection/tension inspection is not necessary because of the use of the maintenancefree type A/C drive belt.
• Replace the drive belt if it is found to be damaged during visual inspection, or if there is a malfunction or noise in the A/C compressor.
DRIVE BELT REPLACEMENT [LF]
B3E011015800W06
A/C Drive belt
1. Remove the engine under cover and splash shield (RH).
2. Remove the A/C compressor protector.
3. Cut the A/C drive belt using scissors.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Set a new A/C drive belt and jig as shown in the figure.
Caution
• The A/C drive belt cannot be reused. Do not reinstall the A/C drive belt that was installed to the engine.
Note
• The jig is supplied with a new A/C drive belt.
5. Rotate the crankshaft pulley clockwise and install the A/C drive belt.
6. Install the A/C compressor protector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
17.626.5 N·m
{1.8- 2.7kgf·m, 13.0-19.5ft·lbf}
7. Install the engine under cover and splash shield (RH).
Generator Drive Belt
1. Remove the plug hole plate.
(See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the A/C drive belt.
3. Turn the center of the auto tensioner pulley counterclockwise to release tension to the drive belt tension.
4. Remove the generator drive belt.
5. Install a new generator drive belt.
6. Verify that the generator drive belt auto tensioner indicator mark does not exceed the limit. (See DRIVE
BELT REPLACEMENT [LF] .)
• If it exceeds the limit, replace the drive belt.
7. Install the A/C drive belt.
8. Install the plug hole plate.
(See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
DRIVE BELT AUTO TENSIONER INSPECTION [LF]
B3E011015980W01
1. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
2. Verify that the generator drive belt auto tensioner moves smoothly in the operational direction.
• If it does not move smoothly, replace the generator drive belt auto tensioner.
3. Turn the generator drive belt auto tensioner pulley by hand and verify that it rotates smoothly.
• If it does not move smoothly, replace the generator drive belt auto tensioner.
4. Install the generator drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
VALVE CLEARANCE INSPECTION [LF]
B3E011012111W03
1. Remove the plug hole plate and bracket (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the negative battery cable.
4. Disconnect the wiring harness.
5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
6. Remove the ventilation hose.
7. Remove the cylinder head cover.
8. Verify that the engine is cold.
9. Measure the valve clearance.
(1) Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
(2) Measure the valve clearance at A in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the valve clearance is out of the standard value, adjust it. (See VALVE CLEARANCE
ADJUSTMENT [LF] .)
Note
• Make sure to note down the measured values for choosing the suitable replacement tappets.
Standard [Engine cold]
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0107-0.0129 in}
(3) Turn the crankshaft 360 ° clockwise so that the No.4 piston is at TDC of the compression stroke.
(4) Measure the valve clearance at B in the figure.
• If the valve clearance is out of the standard value, adjust it. (See VALVE CLEARANCE
ADJUSTMENT [LF] .)
Note
• Make sure to note down the measured values for choosing the suitable replacement tappets.
Standard [Engine cold]
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0107-0.0129 in}
10. Install the cylinder head cover. (See Cylinder Head Cover Installation Note .)
11. Install the ventilation hose.
12. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
13. Connect the wiring harness.
14. Connect the negative battery cable.
15. Install the battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
16. Install the plug hole plate and bracket (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
VALVE CLEARANCE ADJUSTMENT [LF]
B3E011012111W04
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the negative battery cable.
4. Disconnect the wiring harness.
5. Remove the following parts.
(1) Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
(2) Engine under cover and splash shield (RH).
(3) Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(4) Ventilation hose.
(5) Cylinder head cover.
(6) Engine front cover lower blind plug.
(7) Engine front cover upper blind plug.
(8) Cylinder block lower blind plug.
6. Install the SST as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
8. Loosen the timing chain.
(1) Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool.
(2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.
(3) Placing the suitable bolt (M6 X 1.0 length 25mm-35mm {0.99-1.37in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
9. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
10. Remove the exhaust camshaft sprocket.
11. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure.
Note
• The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head they were removed from.
Do not mix the caps.
12. Remove the camshaft.
13. Remove the tappet.
14. Select proper adjustment shim.
New adjustment shim
= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN:
0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in})
Standard [Engine cold]
IN: 0.22-0.28 mm {0.0087-0.0110 in}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
EX: 0.27-0.33 mm {0.0107-0.0129 in}
15. Install the camshaft with No.1 cylinder aligned with the TDC position.
16. Tighten the camshaft cap bolt with the following 2 steps.
Tightening torque
(1) 5.09.0 N·m
{51.091.7 kgf·cm, 44.3-79.6 in·lbf}
(2) 14.017.0 N·m
{1.5-1.
7 kgf·m, 10.4-12.5 ft·lbf}
17. Install the exhaust camshaft sprocket.
Note
• Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.
18. Install the SST to the camshaft as shown in the figure.
19. Remove the (M6 X 1.0 length 25mm-35mm
{0.99-1.37in}) bolt from the engine front cover to apply tension to the timing chain.
20. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position
(until the balance weight is attached to the SST ).
21. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
22. Tighten the exhaust camshaft sprocket lock bolt.
Tightening torque
6975 N·m
{7.17.6 kgf·m, 50.9-55.3 ft·lbf}
23. Remove the SST from the camshaft.
24. Remove the SST from the block lower blind plug.
25. Rotate the crankshaft clockwise two turns until the TDC position.
• If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 14.
26. Apply silicone sealant to the engine front cover upper blind plug.
27. Install the following parts.
(1) New engine front cover upper blind plug.
Tightening torque
8.011.5 N·m
{81.6117.2 kgf·cm, 70.9-101.7 in·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(2) Cylinder block lower blind plug.
Tightening torque
1822 N·m
{1.92.2 kgf·m, 14-16 ft·lbf}
(3) Engine front cover lower blind plug.
Tightening torque
1014 N·m
{1.11.4 kgf·m, 7.4-10.3 ft·lbf}
(4) Cylinder head cover. (See Cylinder Head Cover Installation Note .)
(5) Ventilation hose.
(6) Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(7) Engine under cover and splash shield (RH).
(8) Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
28. Connect the wiring harness.
29. Connect the negative battery cable.
30. Install the battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
31. Install the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
COMPRESSION INSPECTION [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E011002000W02
Warning
• Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/installation of each component.
1. Verify that the battery is fully charged.
• Recharge it if necessary. (See BATTERY INSPECTION .)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool down for about 10 min .
4. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. (See BEFORE SERVICE
PRECAUTION .)
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See Fuel Line Safety Procedure .)
5. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
6. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
7. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [LF] .)
8. Connect a compression gauge into the spark plug hole.
9. Fully depress the accelerator pedal and crank the engine.
10. Note down the maximum gauge reading.
11. Inspect each cylinder as above.
• If the measured value is less than the limited value, or there is a cylinder whose compression value varies from that of other cylinders by 196.1 kPa {2.0 kgf/cm 2 , 28.5 psi } or more, add a small amount of engine oil through the spark plug hole. Then measure the compression pressure and perform the respective operations for the following cases.
- If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required.
- If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
- If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.
Compression kPa {kgf/cm 2 , psi} [rpm]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Engine type
Item
Standard
Minimum
LF
1,720 {17.54, 246.8} [300]
1,204 {12.28, 174.6} [300]
Maximum difference between cylinders 196.1 {2.0, 28.5}
12. Disconnect the compression gauge.
13. Install the following parts.
(1) Spark plug (See SPARK PLUG REMOVAL/INSTALLATION [LF] .)
(2) Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(3) Fuel pump relay. (See BEFORE SERVICE PRECAUTION .)
(4) Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
TIMING CHAIN REMOVAL/INSTALLATION [LF]
B3E011012201W01
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See Fuel Line Safety Procedure .)
1. Remove the following parts.
(1) Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
(2) Plug hole plate bracket.
(3) Accelerator cable and bracket.
(4) Battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the following parts.
(1) Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(2) Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
(3) Under cover and splash shields
(4) Crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [LF] .)
(5) Drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(6) A/C compressor with the oil hose still connected and position the A/C compressor so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [LF] .)
(7) Coolant reserve tank with the hose still connected and position the coolant reserve tank so that it is out of the way.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Start the engine.
7. Inspect the following and adjust if necessary.
• Pulley and belt for runout and contact.
• Leakage of engine oil.
• Ignition timing and idle speed. Verify the amount of CO and HC. (See ENGINE TUNE-UP [LF] .)
• Engine-driven accessories operation.
8. Perform a road test and verify that there is no abnormal vibration or noise.
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1
Cylinder head cover
(See Cylinder Head Cover Installation Note .)
Crankshaft pulley lock bolt
2 (See Crankshaft Pulley Lock Bolt Removal Note .)
(See Crankshaft Pulley Lock Bolt Installation Note .)
3 Crankshaft pulley
4 Water pump pulley
5 Drive belt auto tensioner
6 No.3 engine mount rubber and No.3 engine joint bracket
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(See No.3 Engine Mount Removal Note .)
(See No.3 Engine Mount Rubber and No.3 Engine Mount Bracket Installation Note .)
7
Engine front cover
(See Engine Front Cover Installation Note .)
Front oil seal
8 (See Engine Front Cover Removal Note .)
(See Front Oil Seal Installation Note .)
9
Chain tensioner
(See Chain Tensioner Removal Note .)
10 Tensioner arm
11 Chain guide
12
Timing chain
(See Timing Chain Installation Note .)
13 Oil pump chain tensioner
14 Oil pump chain guide
Oil pump sprocket
15 (See Oil Pump Sprocket Removal Note .)
(See Oil Pump Sprocket Installation Note .)
16 Oil pump chain
17 Crankshaft sprocket
Crankshaft Pulley Lock Bolt Removal Note
1. Remove the cylinder block lower blind plug.
2. Install the SST .
3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Hold the crankshaft pulley using the SSTs .
No.3 Engine Mount Removal Note
1. Install the suitable wood slabs between the front fender panel and apron reinforcement upper.
Note
• Wood slab height
4SD: approx. 35 mm {1.38 in}
5HB: approx. 60 mm {2.36 in}
• Cut the wood slab into two piece and insert.
2. Support the engine using the SST .
Note
• A hoist or small crane can be used in place of the SST (49E 017 5A0) .
Engine Front Cover Removal Note
1. Remove the oil seal using a screwdriver as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Chain Tensioner Removal Note
1. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem using a thin screwdriver.
2. Slowly compress the tensioner piston.
3. Hold the tensioner piston using a 1.5 mm {0.059 in} wire or paper clip.
Oil Pump Sprocket Removal Note
1. Hold the oil pump sprocket using the SST .
Oil Pump Sprocket Installation Note
1. Hold the oil pump sprocket using the SST .
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Timing Chain Installation Note
1. Install the SST to the camshaft as shown in the figure.
cover as shown in the figure.
2. Install the timing chain.
3. Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.
Engine Front Cover Installation
Note
1. Apply silicone sealant to the engine front
Caution
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Install the engine front cover within 10 min of applying the silicone sealant.
Thickness
A: 2.2-3.2 mm {0.087-0.125 in}
B: 1.5-2.5 mm {0.059-0.098 in}
2. Install the engine front cover bolts in the order shown in the figure.
Bolt No.
Tightening torque
8.011.5 N·m
1-18
19-22
{81.6117.2 kgf·cm, 70.9-101.7 in·lbf}
4055 N·m {4.1-5.6 kgf·m, 29.7-40.5 ft·lbf}
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Compress the oil seal using the SST and a hammer.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
No.3 Engine Mount Rubber and
No.3 Engine Mount Bracket
Installation Note
1. Tighten the stud bolt of the No.3 engine mount bracket.
Tightening torque
7.013 N·m
{71.4132.5 kgf·cm, 62.0-115.0 in·lbf}
Note
• If the No.3 engine mount bracket remove to the engine
2. Hand-tighten the No.3 engine mount rubber and No.3 engine mount bracket.
3. Tighten the bolts and nuts in the order as shown in the figure.
Crankshaft Pulley Lock Bolt Installation Note
1. Install the SST to the camshaft as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Install the M6 x 1.0
bolt in by hand.
3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
4. Hold the crankshaft pulley using the SST .
5. Tighten the crankshaft pulley lock bolt in the order shown with the following 2 steps using the SST (49
D032 316) .
Tightening torque
(1) 96104 N·m
{9.810.6 kgf·m, 70.9-76.7 ft·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(2) 87°-93°
6. Remove the M6 x 1.0
bolt.
7. Remove the SST from the camshaft.
8. Remove the SST from the cylinder block lower blind plug.
9. Rotate the crankshaft clockwise two turns until the TDC position.
• If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.
10. Install the cylinder block lower blind plug.
Tightening torque
1822 N·m {1.9-2.2 kgf·m, 14-16 ft·lbf}
Cylinder Head Cover Installation Note
1. Apply silicone sealant to the mating faces as shown in the figure.
Caution
• Install the cylinder head cover within 10 min of applying the silicone sealant.
Thickness
4.0-6.0 mm {0.16-0.23 in}
2. Install the cylinder head cover with a new gasket.
3. Tighten the bolts in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
8.010.5 N·m
{81.6107.1 kgf·cm, 70.9-94.4 in·lbf}
CYLINDER HEAD GASKET REPLACEMENT [LF]
B3E011010271W02
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See Fuel Line Safety Procedure .)
1. Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [LF] .)
2. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
3. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
4. Disconnect the following parts.
(1) WU-TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)
(2) Radiator upper hose.
(3) Water hose.
(4) Heater hose.
(5) wiring harness.
5. To firmly support the engine, first set the engine jack and attachment to the oil pan.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the compression. (See COMPRESSION INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Camshaft
1 (See Camshaft Removal Note .)
(See Camshaft Installation Note .)
Cylinder head
2 (See Cylinder Head Removal Note .)
(See Cylinder Head Installation Note .)
3 Cylinder head gasket
Camshaft Removal Note
Note
• The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head they were removed from.
Do not mix the caps.
1. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure.
Cylinder Head Removal Note
1. Loosen the cylinder head bolts in 2-3 passes in the order shown in the figure.
Cylinder Head Installation Note
1. Measure the length of each cylinder head bolt.
• Replace any that exceeds maximum length.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Length L
145.2-145.8 mm {5.72-5.74 in}
Maximum
146.5 mm {5.78 in}
2. Tighten the cylinder head bolts in the order shown with the following 5 steps using the SST (49 D032
316) .
Tightening torque
(1) 311 N·m
{0.4-1.1 kgf·m, 27.6-97.3 in·lbf}
(2) 1317 N·m
{1.41.7 kgf·m, 9.59-12.5 ft·lbf}
(3) 4347 N·m
{4.44.7 kgf·m, 31.8-34.6 ft·lbf}
(4) 88°-92°
(5) 88°-92°
Camshaft Installation Note
1. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.
2. Temporarily tighten the camshaft bearing caps evenly in 2-3 passes.
3. Tighten the camshaft cap bolts in the order shown with the following two steps.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tighten torque
(1) 5.09.0 N·m
{51.091.7 kgf·cm, 44.3-79.6 in·lbf}
(2) 14.017.0 N·m
{1.51.7 kgf·m, 10.4-12.5 ft·lbf}
FRONT OIL SEAL REPLACEMENT [LF]
B3E011010602W02
1. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the plug hole plate bracket.
3. Remove the battery cover (See BATTERY REMOVAL/INSTALLATION [LF] .)
4. Disconnect the negative battery cable.
5. Disconnect the wiring harness.
6. Remove the following parts.
(1) Ignition coils (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(2) Cylinder head cover. (See Cylinder Head Cover Installation Note .)
(3) Drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
(4) Front wheel and tire (RH) (See GENERAL PROCEDURES (SUSPENSION) .)
(5) Under cover and splash shield.
(6) Crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [LF] .)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Crankshaft pulley lock bolt
1 (See Crankshaft Pulley Lock Bolt Removal Note .)
(See Crankshaft Pulley Lock Bolt Installation Note .)
2 Crankshaft pulley
Front oil seal
3 (See Front Oil Seal Removal Note .)
(See Front Oil Seal Installation Note .)
Crankshaft Pulley Lock Bolt Removal Note
1. Remove the cylinder block lower blind plug.
2. Install the SST .
3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Hold the crankshaft pulley using the SSTs .
Front Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver wrapped with a rag.
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a hammer.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Crankshaft Pulley Lock Bolt
Installation Note
1. Install the SST on the camshaft as shown in the figure.
2. Install the M6 x 1.0
bolt in by hand.
3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
4. Hold the crankshaft pulley using the SSTs .
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Tighten the crankshaft pulley lock bolt in the order shown following 2 steps using the SST (49 D032
316) .
Tightening torque
(1) 96104 N·m
{9.810.6 kgf·m, 70.9-76.7 ft·lbf}
(2) 87°-93°
6. Remove the M6 x 1.0
bolt.
7. Remove the SST from the camshaft.
8. Remove the SST from the cylinder block lower blind plug.
9. Rotate the crankshaft clockwise 2 turns until the TDC position.
• If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.
10. Install the cylinder block lower blind plug.
Tightening torque
1822 N·m {1.9-2.2 kgf·m, 14-16 ft·lbf}
REAR OIL SEAL REPLACEMENT [LF]
B3E011011399W02
1. Remove the manual transaxle (See CLUTCH UNIT REMOVAL/INSTALLATION .)
2. Remove the flywheel (See CLUTCH UNIT REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
1 Bolt
2
Rear oil seal
(See Rear Oil Seal Installation Note .)
Rear Oil Seal Installation Note
1. Apply silicone sealant to the mating faces as shown in the figure.
Thickness
4.0-6.0 mm {0.16-0.23 in}
2. Apply clean engine oil to the new oil seal lip.
3. Install the rear oil seal using the installer as shown in the figure.
4. Tighten the rear oil seal bolts in the order as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
8.011.5 N·m
{81.6117.2 kgf·cm, 70.9-101.7 in·lbf}
ENGINE REMOVAL/INSTALLATION [LF]
B3E011001001W04
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedure". (See Fuel Line Safety Procedure .)
1. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the air hose and air cleaner component (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [LF] .)
3. Remove the battery cover, battery duct, battery clamp, battery and battery tray (See BATTERY
REMOVAL/INSTALLATION [LF] .)
4. Disconnect the fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
5. Remove the following parts.
(1) Accelerator cable and bracket.
(2) Front wheels and tires (See GENERAL PROCEDURES (SUSPENSION) .)
(3) Under cover and splash shields.
(4) A/C drive belt (See DRIVE BELT REPLACEMENT [LF] .)
(5) A/C compressor with the pipes still connected.
Note
• Secure the A/C compressor using wire or rope so that it is out of the way.
6. Drain the transaxle oil (MTX) (See TRANSAXLE OIL REPLACEMENT [F35M-R] .)
7. Drain the engine coolant (See ENGINE COOLANT REPLACEMENT .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8. Disconnect the brake vacuum hose.
9. Remove the following parts.
(1) Member (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
(2) Front crossmember, front stabilizer, lower arm, steering gear and No.1 engine mount rubber component (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION .)
(3) Drive shafts (See DRIVE SHAFT REMOVAL/INSTALLATION .)
(4) Coolant reserve tank with the hose still connected.
(5) Cooling fan component (See RADIATOR REMOVAL/INSTALLATION .)
(6) Shift cable (MTX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G35M-R] .)
(7) Clutch release cylinder with the pipe still connected (MTX) (See CLUTCH RELEASE
CYLINDER REMOVAL/INSTALLATION .)
10. Disconnect the heater hose.
11. Disconnect the Upper and lower radiator hose.
12. Disconnect the Main silencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)
13. Remove in the order indicated in the table.
14. Install in the reverse order of removal.
Caution
• Do not tighten the No.1 engine mount rubber installation bolt before tightening the No.4 engine mount rubber installation bolt. (See No.3 Engine Mount and No.4 Engine Mount Rubber
Installation Note .)
15. Start the engine. And inspect and adjust them if necessary.
16. Inspect the following and adjust them if necessary.
• Front wheel alignment (See FRONT WHEEL ALIGNMENT .)
• Puller and belt for runout and contact.
• Leakage of engine oil, engine coolant, MT oil, and fuel.
• Ignition timing and idle speed. Verify the amount of CO, HC. (See ENGINE TUNE-UP [LF] .)
• Engine-driven accessories operation.
Note
• If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no abnormality.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Main fuse block connector
(See Main Fuse Block Connector Removal Note .)
2
No.1 engine mount rubber
(See No.1 Engine Mount Rubber Installation Note .)
No.3 Engine mount
3 (See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note .)
(See No.3 Engine Mount and No.4 Engine Mount Rubber Installation Note .)
4 Battery bracket
5 No.4 Engine mount rubber
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note .)
(See No.3 Engine Mount and No.4 Engine Mount Rubber Installation Note .)
6 Engine, transaxle
Main Fuse Block Connector Removal Note
1. Release the tab in the order shown in the figure.
2. Pull the lock lever up and remove the connector.
No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note
1. Secure the engine and the transaxle using an engine jack and attachment as shown in the figure.
No.3 Engine Mount and No.4 Engine Mount Rubber Installation Note
1. Secure the engine and the transaxle using an engine jack and attachment as shown in the figure.
2. Install the No.1 engine mount rubber and No.4 engine mount rubber.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Note
• Do not tighten the bolt and nut for the No.1 engine mount rubber and No.4 engine mount rubber during this step.
3. Tighten the No.4 engine mount rubber installation bolt as shown in the figure.
Tightening torque
66.693.1 N·m
{6.89.4 kgf·m, 49.2-68.6 ft·lbf}
4. Tighten the No.4 engine mount rubber and battery bracket bolts and nuts in the order as shown in the figure.
Tightening torque
(1) 44.061.0 N·m
{4.56.2 kgf·m, 32.5-44.9 ft·lbf}
(2) 6.99.8 N·m
{70.499.9 kgf·cm, 61.1-86.7 in·lbf}
5. Tighten the No.3 engine mount bracket stud bolts.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Tightening torque
7.013 N·m
{71.4132.5 kgf·cm, 62.0-115.0 in·lbf}
6. Tighten the No.3 engine joint bracket bolts and nuts in the order as shown in the figure.
Tightening torque
74.5104.9 N·m
{7.6010.6 kgf·m, 55.0-77.3 ft·lbf}
No.1 Engine Mount Rubber Installation Note
1. Remove the engine jack and attachment.
2. Tighten the No.1 engine mount rubber installation bolts as shown in the figure.
Tightening torque
93.1116.6 N·m
{9.5011.88 kgf·m, 68.7-85.9 ft·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ENGINE DISASSEMBLY/ASSEMBLY [LF]
B3E011001001W05
1. Disconnect the engine and manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION
[F35M-R] .)
2. Remove the following part:
(1) the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
(2) the generator. (See GENERATOR REMOVAL/INSTALLATION [LF] .)
(3) the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(4) the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [LF] .)
3. Assemble in the reverse order of disassembly.
PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]
B3E011000149W01
1. Remove the plug hole plate.
Note
• Lift off and remove the plug hole plate from the installation areas as shown in the figure.
2. Install the plug hole plate.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ENGINE TUNE-UP [LF]
B3E011001001W06
Engine Tune-up Preparation
1. Turn off all electrical loads.
2. Warm up the engine as follows.
(1) Start the engine.
(2) Maintain the engine speed 2,500-3,000 rpm until the cooling fans start to operate.
(3) Release the accelerator pedal.
(4) Wait until the cooling fans stop.
3. Connect the SST (WDS or equivalent) to the DLC-2.
Ignition Timing Inspection
Note
• Ignition timing is not adjustable.
• Ignition timing verification requires WDS or equivalent.
1. Verify that the ignition timing (WDS: SPARKADV PID) is within the specification using WDS or equivalent.
Ignition timing
Approx. BTDC 8°
2. Verify that ignition timing advances when the engine speed increases gradually.
Idle Speed Inspection
Note
• Idle speed is not adjustable.
• Idle speed verification requires WDS or equivalent.
1. Verify that the idle speed (WDS: RPM PID) is within the specification using WDS or equivalent.
Idle speed
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Condition Engine speed (rpm)* 1
No load
Electrical loads* 2 ON
(38-48A)
600-700
650-750
Electrical loads* 2 ON
(Above 42A)
700-800
A/C ON and refrigerant pressure switch (middle) OFF 700-800
A/C ON and refrigerant pressure switch (middle) ON 700-800
*1 :
Excludes temporary idle speed drop just after the electrical loads are turned on.
*2 :
Alternator generating current value.
Idle Mixture Inspection
1. Verify that the idle speed and ignition timing are within the specification. (See Idle Speed Inspection .)
(See Ignition Timing Inspection .)
2. Insert an exhaust gas analyzer to the tailpipe.
3. Verify that the CO and HC concentrations are within the regulation.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
LUBRICATION
LUBRICATION SYSTEM LOCATION INDEX [Z6]
B3E011101003W01
1
Oil pressure switch
(See OIL PRESSURE INSPECTION [Z6] .)
2
Oil filter
(See OIL FILTER REPLACEMENT [Z6] .)
3
Oil pan
(See OIL PAN REMOVAL/INSTALLATION [Z6] .)
4
Oil strainer
(See OIL PAN REMOVAL/INSTALLATION [Z6] .)
Oil pump
5
(See OIL PUMP REMOVAL/INSTALLATION [Z6] .)
(See OIL PUMP DISASSEMBLY/ASSEMBLY [Z6] .)
(See OIL PUMP INSPECTION [Z6] .)
LUBRICATION SYSTEM LOCATION INDEX [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E011101003W02
1
Oil pressure switch
(See OIL PRESSURE INSPECTION [LF] .)
2
Oil filter
(See OIL FILTER REPLACEMENT [LF] .)
3
Oil pan
(See OIL PAN REMOVAL/INSTALLATION [LF] .)
4
Oil strainer
(See OIL PUMP REMOVAL/INSTALLATION [LF] .)
5
Oil pump component
(See OIL PUMP REMOVAL/INSTALLATION [LF] .)
OIL PRESSURE INSPECTION [Z6]
B3E011101003W03
Warning
• Continuous exposure with used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove the oil pressure switch.
5. Screw the SST into the oil pressure switch installation hole.
6. Warm up the engine to normal operating temperature.
7. Run the engine at the specified speed, and note the gauge readings.
• If not within the specification, inspect for the cause and repair or replace if necessary.
Note
• The oil pressure can vary with oil viscosity and temperature.
Oil pressure [oil temperature: 100°C {212°F}] (approx. quantity)
330380 kPa {3.36-3.87 kgf/cm 2 , 47.8-55.0 psi} min [3,000 rpm]
8. Stop the engine and wait until it is cool.
9. Remove the SST .
Caution
• Be sure there is no sealant between 1.0-2.0 mm {0.04-0.07 in} from the end of the oil pressure switch to prevent a possible operation malfunction.
10. Apply silicone sealant to the oil pressure switch threads.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
11. Install the oil pressure switch.
Tightening torque
1217 Nm {1.21.8 kgf·m, 9-13 ft·lbf}
12. Install the under cover.
13. Connect the negative battery cable.
14. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
15. Start the engine and inspect for oil leakage.
• If the oil leaks, specify the malfunctioning part and repair or replace it.
OIL PRESSURE INSPECTION [LF]
B3E011101003W04
Warning
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove the oil pressure switch.
5. Screw the SST into the oil pressure switch installation hole.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6. Warm up the engine to normal operating temperature.
7. Run the engine at the specified speed, and note the gauge readings.
• If the pressure is not as specified, inspect for the cause and repair or replace if necessary.
Note
• The oil pressure can vary with oil viscosity and temperature.
Oil pressure [oil temperature: 100°C {212°F}] (approx. quantity)
234-521 kPa {2.39-5.31 kgf/cm 2 , 33.9-75.5 psi} min [3,000rpm]
8. Stop the engine and wait until it is cool.
9. Remove the SST .
Caution
• Be sure there is no sealant between 1.0-2.0 mm {0.04-0.07 in} from the end of the oil pressure switch to prevent a possible operation malfunction.
10. Apply silicone sealant to the oil pressure switch threads as shown.
11. Install the oil pressure switch.
Tightening torque
1218 N·m {1.2-1.8 kgf·m, 9-13 ft·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12. Install the under cover.
13. Connect the negative battery cable.
14. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
15. Start the engine and inspect for oil leakage.
• If the oil leaks, specify the malfunctioning part and repair or replace it.
ENGINE OIL LEVEL INSPECTION [Z6]
B3E011114001W01
1. Position the vehicle on level ground.
2. Warm up the engine.
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick and verify that the oil level is between the F and L marks on the dipstick.
• If the oil level is below the L mark, add engine oil.
ENGINE OIL LEVEL INSPECTION [LF]
B3E011114001W02
1. Position the vehicle on level ground.
2. Warm up the engine.
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick and verify that the oil level is between the MAX and MIN marks on the dipstick.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If the oil level is below the MIN mark, add engine oil.
ENGINE OIL REPLACEMENT [Z6]
B3E011114001W03
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
Caution
• In case you spill engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.
1. Position the vehicle on level ground.
2. Remove the oil filler cap.
3. Remove the oil pan drain plug.
4. Drain the engine oil into a container.
5. Install the oil pan drain plug with a new washer.
Oil pan drain plug tightening torque
3041 N·m {3.1-4.1 kgf·m, 23-30 ft·lbf}
Note
• The amount of residual oil in the engine can vary according to factors such as the replacement method, oil temperature. Verify the oil level after engine oil replacement.
6. Refill the engine with the type and amount of engine oil specified in the table.
Recommended engine oil
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Item
Grade
Viscosity
(SAE)
Europe
API SL, ACEA A3
5W-30 10W-40
Remarks Mazda genuine
Dexelia oil e.g.
Oil capacity (approx. quantity)
L {US qt, Imp qt}
Item Specifications
Oil replacement 3.7 {3.9, 3.3}
Oil and oil filter replacement 3.9 {4.1, 3.4}
Total (dry engine) 4.2 {4.4, 3.7}
Specifications
Except Europe
API SG, SH, SJ, SL, ILSAC GF-2, GF-3
5W-
20
40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 20W-40,
15W-40, 20W-50, 15W-50, 5W-20, 5W-30
-
7. Install the oil filler cap.
8. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.
9. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [Z6] .)
ENGINE OIL REPLACEMENT [LF]
B3E011114001W04
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
Caution
• In case you spill engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.
1. Position the vehicle on level ground.
2. Remove the oil filler cap.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Remove the oil pan drain plug.
4. Drain the engine oil into a container.
5. Install the oil pan drain plug with a new washer.
Oil pan drain plug tightening torque
3041 N·m {3.1-4.1 kgf·m, 23-30 ft·lbf}
Note
• The amount of residual oil in the engine can vary according to factors such as the replacement method, oil temperature. Verify the oil level after engine oil replacement.
6. Refill the engine with the type and amount of engine oil specified in the table.
Recommended engine oil
Item
Grade
Viscosity
(SAE)
Europe
API SL, ACEA A3
5W-30 10W-40
Remarks Mazda genuine
Dexelia oil e.g.
Oil capacity (approx. quantity)
L {US qt, Imp qt}
Item Specifications
Oil replacement 3.9 {4.1, 3.4}
Oil and oil filter replacement 4.3 {4.5, 3.8}
Total (dry engine) 4.6 {4.9, 4.0}
Specifications
Except Europe
API SG, SH, SJ, SL, ILSAC GF-2, GF-3
5W-
20
40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 20W-40,
15W-40, 20W-50, 15W-50, 5W-20, 5W-30
-
7. Install the oil filler cap.
8. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.
9. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [LF] .)
OIL FILTER REPLACEMENT [Z6]
B3E011114300W01
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
Caution
• In case you spill engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.
1. Remove the under cover.
2. Remove the oil filter using the SST .
3. Use a clean rag to wipe off the mounting surface on the cylinder block.
4. Apply clean oil to the O-ring of a new oil filter.
5. Install the oil filter using the SST with specified tightening torque.
Tightening torque
11.715.7 N·m {1.2-1.6 kgf·m, 8.7-11.5 ft·lbf}
6. Fill with the specified amount of engine oil. (See ENGINE OIL REPLACEMENT [Z6] .)
7. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.
8. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9. Install the under cover.
OIL FILTER REPLACEMENT [LF]
B3E011114300W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
Caution
• In case you spill engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.
1. Remove the under cover.
2. Remove the oil filter using a commercially available, cap-type oil filter wrench ( 76 mm {3.0 in} diameter, 15 sided ).
3. Use a clean rag to wipe off the mounting surface.
4. Apply clean engine oil to the gasket of a new oil filter.
5. Tighten the oil filter using cap-type oil filter wrench with specified tightening torque.
Tightening torque
1520 N·m {1.6-2.0 kgf·m, 11-14 ft·lbf}
6. Fill with the specified amount of engine oil. (See ENGINE OIL REPLACEMENT [LF] .)
7. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.
8. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9. Install the under cover.
OIL PAN REMOVAL/INSTALLATION [Z6]
B3E011110040W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Drain the engine oil. (See ENGINE OIL REPLACEMENT [Z6] .)
5. Remove in the order indicated in the table.
Oil pan
1 (See Oil Pan Removal Note .)
(See Oil Pan Installation Note .)
2 Oil strainer
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3 O-ring
6. Install in the reverse order of removal.
7. Add engine oil. (See ENGINE OIL REPLACEMENT [Z6] .)
8. Start the engine and confirm that there is no oil leakage from areas worked on.
• If there is oil leakage, find the cause and repair or replace the applicable part.
9. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [Z6] .)
10. Install the under cover.
Oil Pan Removal Note
1. Remove the oil pan using the separator tool.
Oil Pan Installation Note
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan within 5 min after applying the silicone sealant.
• Using bolts with the seal adhering could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing and oil pan.
2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
3. Apply silicone sealant to the areas shown in th figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Thickness
2.06.0 mm {0.080.24 in}
4. Tighten the bolts in the order shown.
Tightening torque
7.810.8 N·m {80-110 kgf·cm, 69.1-95.5 in·lbf}
OIL PAN REMOVAL/INSTALLATION [LF]
B3E011110040W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Remove the front tire (RH).
5. Drain the engine oil. (See ENGINE OIL REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
7. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
8. Position the coolant reserve tank out of the way.
9. Remove the A/C compressor with the pipes still connected. (See A/C COMPRESSOR
REMOVAL/INSTALLATION [LF] .)
10. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
11. Position the accelerator cable bracket out of the way.
12. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [LF] .)
13. Remove the engine front cover. (See TIMING CHAIN REMOVAL/INSTALLATION [LF] .)
14. Remove in the order indicated in the table.
15. Install in the reverse order of removal.
16. Refill the engine with the specified type and amount of the engine oil. (See ENGINE OIL
REPLACEMENT [LF] .)
17. Start the engine and inspect for oil leakage.
• If the oil leaks, specify the malfunctioning part and repair or replace it.
18. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [LF] .)
19. Inspect for the ignition timing and idle speed. (See ENGINE TUNE-UP [LF] .)
1 Oil level gauge pipe
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2 O-ring
Oil pan
3 (See Oil Pan Removal Note .)
(See Oil Pan Installation Note .)
Oil Pan Removal Note
1. Remove the oil pan using the separator tool.
Oil Pan Installation Note
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan within 5 min after applying the silicone sealant.
• Using bolts with the seal adhering could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing and oil pan.
2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
3. Use a square ruler to align the oil pan and the cylinder block junction side on the engine front cover side.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown.
Thickness
2.5 mm {0.098 in}
5. Tighten the bolts in the order shown.
OIL PUMP REMOVAL/INSTALLATION [Z6]
B3E011119220W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
Downloaded from https://carmanualshub.com/ - automotive repair manuals website
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Position the coolant reserve tank out of the way.
6. Remove the power steering fluid tank with the hoses still connected.
7. Remove the power steering oil pump with the hoses and pipes still connected. (See POWER
STEERING OIL PUMP (Z6) REMOVAL/INSTALLATION .)
8. Disconnect the crankshaft position (CKP) sensor connector. (See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
9. Position the oil control valve (OCV) wiring harness out of the way.
10. Position the accelerator cable bracket out of the way.
11. Remove the following.
(1) Front tire (RH)
(2) Drive belt (See DRIVE BELT REPLACEMENT [Z6] .)
(3) Air cleaner case, PCM component, and fresh air duct (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
(4) Ignition coil (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
(5) Generator (See GENERATOR REMOVAL/INSTALLATION [Z6] .)
(6) Water pump (See WATER PUMP REMOVAL/INSTALLATION [Z6] .)
(7) Timing chain (See TIMING CHAIN REMOVAL/INSTALLATION [Z6] .)
12. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Oil pump
(See Oil Pump Installation Note .)
2 Oil pump gasket
13. Install in the reverse order of removal.
14. Add the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
15. Start the engine and inspect for oil leakage.
• If the oil leaks, specify the malfunctioning part and repair or replace it.
16. Inspect the oil pressure. (See OIL PRESSURE INSPECTION [Z6] .)
17. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [Z6] .)
18. Inspect for the ignition timing and idle speed. (See ENGINE TUNE-UP [Z6] .)
Oil Pump Installation Note
1. Install the oil pump gasket to the oil pump.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Install the oil pump and the oil pump gasket to the engine as a single unit.
OIL PUMP REMOVAL/INSTALLATION [LF]
B3E011119220W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
• Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Remove the front tire (RH).
5. Drain the engine oil. (See ENGINE OIL REPLACEMENT [LF] .)
6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
7. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)
8. Position the coolant reserve tank out of the way.
9. Remove the A/C compressor with the pipes still connected. (See A/C COMPRESSOR
REMOVAL/INSTALLATION [LF] .)
10. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
11. Remove the spark plug. (See SPARK PLUG REMOVAL/INSTALLATION [LF] .)
12. Position the accelerator cable bracket out of the way.
13. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [LF] .)
14. Remove the engine front cover. (See TIMING CHAIN REMOVAL/INSTALLATION [LF] .)
15. Remove the oil pan. (See OIL PAN REMOVAL/INSTALLATION [LF] .)
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Refill the engine with the specified type and amount of the engine oil. (See ENGINE OIL
REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
19. Start the engine and inspect for oil leakage.
• If the oil leaks, specify the faulty part and repair or replace it.
20. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [LF] .)
21. Inspect for the ignition timing and idle speed. (See ENGINE TUNE-UP [LF] .)
1 Oil strainer
2 Oil pump chain guide
3 Oil pump chain tensioner and spring component
4 Oil pump chain
5
Oil pump sprocket
(See Oil Pump Sprocket Removal/Installation Note .)
6
Oil pump
(See Oil Pump Installation Note .)
Oil Pump Sprocket Removal/Installation Note
1. Install the SST to the oil pump sprocket to stop the oil pump from rotating.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Oil Pump Installation Note
1. Tighten the oil pump bolts in two steps in the order indicated in the figure.
Tightening torque:
1) 810 N·m {82-101 kgf·cm, 71-88 in·lbf}
2) 2025 N·m {2.1-2.5 kgf·m, 15.2-18.4 ft·lbf}
OIL PUMP DISASSEMBLY/ASSEMBLY [Z6]
B3E011119220W03
Warning
• Continuous exposure with used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Disassemble in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Oil pump cover
2
Inner rotor, outer rotor
(See Inner Rotor, Outer Rotor Installation Note .)
3 Plunger plug
4 Plunger spring
5 Control plunger
6 Oil pump body
2. Assemble in the reverse order of disassembly.
Inner Rotor, Outer Rotor Installation Note
1. Align the punch marks of the inner and outer rotor and assemble.
OIL PUMP INSPECTION [Z6]
B3E011119220W04
Warning
• Continuous exposure with used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
1. Measure the clearance between the inner rotor and the outer rotor using a feeler gauge.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it exceeds the maximum specification, replace the inner rotor or the outer rotor, or the both.
Standard tip clearance
0.020.18 mm {0.00080.0070 in}
Maximum tip clearance
0.20 mm {0.0079 in}
2. Measure the clearance between the outer rotor and the body using a feeler gauge.
• If it exceeds the maximum specification, replace the outer rotor or oil pump body, or both.
Standard body clearance
0.090.175 mm {0.00360.0068 in}
Maximum body clearance
0.20 mm {0.0079 in}
3. Measure the side clearance using a feeler gauge.
• If it exceeds the maximum specification, replace the inner rotor or oil pump body, or both.
Standard side clearance
0.030.07 mm {0.00120.0027}
Maximum side clearance
0.09 mm {0.0035 in}
4. Measure the free length of the plunger spring using the vernier caliper.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it is less than the specification, replace the plunger spring.
Free length
45.94 mm {1.8087 in}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
COOLING SYSTEM
COOLING SYSTEM LOCATION INDEX [Z6]
B3E011201004W01
1
Cooling system cap
(See COOLING SYSTEM CAP INSPECTION .)
2
Radiator
(See RADIATOR REMOVAL/INSTALLATION .)
Thermostat
3 (See THERMOSTAT REMOVAL/INSTALLATION [Z6] .)
(See THERMOSTAT INSPECTION [Z6] .)
4
Water pump
(See WATER PUMP REMOVAL/INSTALLATION [Z6] .)
5
Cooling fan component
(See RADIATOR REMOVAL/INSTALLATION .)
6
Cooling fan motor component
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
COOLING SYSTEM LOCATION INDEX [LF]
B3E011201004W02
1
Cooling system cap
(See COOLING SYSTEM CAP INSPECTION .)
2
Radiator
(See RADIATOR REMOVAL/INSTALLATION .)
Thermostat
3 (See THERMOSTAT REMOVAL/INSTALLATION [LF] .)
(See THERMOSTAT INSPECTION [LF] .)
4
Water pump
(See WATER PUMP REMOVAL/INSTALLATION [LF] .)
5
Cooling fan component
(See RADIATOR REMOVAL/INSTALLATION .)
6
Cooling fan motor component
(See COOLING FAN MOTOR COMPONENT INSPECTION .)
COOLING SYSTEM SERVICE WARNINGS
B3E011215001W01
Warning
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
ENGINE COOLANT LEVEL INSPECTION
B3E011215001W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
1. Verify that the engine coolant level in the coolant reserve tank installed on the shroud panel is between the MIN and MAX marks.
2. If the engine coolant level is below MIN mark, add engine coolant.
ENGINE COOLANT PROTECTION INSPECTION
B3E011215001W03
1. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer.
Caution
• The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will reduce the coolant's effectiveness.
2. Determine the coolant protection by referring to the graph shown.
• If the coolant protection is not proper, add water or coolant.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Warning
ENGINE COOLANT REPLACEMENT
B3E011215001W04
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will reduce the coolant's effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
1. Remove the cooling system cap.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Remove the under cover.
3. Remove the radiator drain plug and drain the engine coolant into a container.
4. Flush the cooling system with water until all traces of color are gone.
5. Let the system drain completely.
6. Tighten the radiator drain plug.
Tightening torque
1.2-1.5 N·m {13-15 kgf·cm, 11-13 in·lbf}
7. Referring to the following chart, select proper volume percentage of the water and coolant.
Antifreeze solution mixture percentage
Coolant protection
Volume percentage Gravity at 20 °C
Water Coolant
{68 °F}
Above -1 6 °C {3 °F} 65
Above 26 °C {-15°F} 55
Above 40 °C {-40 °F} 45
35
45
55
1.057
1.072
1.086
8. Refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
9. Fully install the cooling system cap.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Caution
• If the water temperature gauge rises too high, stop the engine and decrease the water temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
10. Start the engine and idle it until the thermometer indicator is in the center when the engine is at below
1,500 rpm .
11. After the engine warms up, perform the following steps verifying that engine coolant temperature does not increase too high using the thermometer.
(1) Run the engine at 2,500 rpm for 5 min .
(2) Run the engine at 3,000 rpm for 5 s , then idle.
(3) Repeat Step (2) approx. two times.
12. Stop the engine and wait until the coolant temperature decreases.
13. Check the coolant level.
• If It is low, refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
14. Inspect for coolant leakage.
• If the coolant leaks, specify the malfunctioning part and repair or replace it.
ENGINE COOLANT LEAKAGE INSPECTION
B3E011215001W05
Warning
• Never remove the cooling system cap while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
1. Inspect the engine coolant level.
2. Remove the cooling system cap.
3. Clean the installation parts of the cooling system cap and the upper radiator hose.
4. Install the SST and a radiator cap tester to the coolant reserve tank filler port.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Apply pressure using the radiator cap tester.
Caution
• Applying more than Z6: 100 kPa {1.0 kgf/cm 2 , 14.5 psi}, LF: 145 kPa {1.5 kgf/cm 2 , 21 psi} can damage the hoses, fittings, and other components, and cause leakage.
Pressure
Z6: 100 kPa {1.0 kgf/cm 2 , 14.5 psi} [1 min]
LF: 145 kPa {1.5 kgf/cm 2 , 21 psi} [1 min]
6. When pressurizing the coolant reserve tank, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage, therefore perform leakage inspection.
- If engine coolant leaks from the upper hose installation part, replace the upper hose and the clamp.
- If the engine coolant leaks from the main body of the radiator (caulked part), replace the radiator.
COOLANT RESERVE TANK REMOVAL/INSTALLATION
B3E011215201W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Drain the engine coolant until the coolant reserve tank becomes empty. (See ENGINE COOLANT
REPLACEMENT .)
2. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Hose
2 Coolant reserve tank
3. Install in the reverse order of removal.
4. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
COOLING SYSTEM CAP INSPECTION
B3E011215201W02
Warning
• Never remove the cooling system cap while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
• When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
1. Clean the cooling system cap and the sealed part.
2. Inspect the crack or turn over on the sealed part of the cooling system cap.
• If there is malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the radiator cap tester.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure holds for 10 s .
• If the pressure is not held stable within the specification, replace the cooling system cap.
Pressure
Z6: 90-110 kPa
{0.92-1.12 kgf/cm 2 , 13.1-15.9 psi}
LF: 135-155 kPa
{1.38-1.58 kgf/cm 2 , 19.6-22.4 psi}
RADIATOR REMOVAL/INSTALLATION
B3E011215200W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .) (See BATTERY
REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Disconnect the coolant reservoir hose from the radiator.
6. Position the front wiring harnesses out of the way.
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
10. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Fan control module connector
2
Cooling fan component
(See Cooling Fan Component Installation Note .)
3 Radiator lower hose
4 Radiator upper hose
5 Radiator mount
Radiator
6 (See Radiator Removal Note .)
(See Radiator Installation Note .)
Radiator Removal Note
1. Remove the oil cooler from the radiator with the hoses still connected by pulling the radiator tabs outward. (ATX)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tab to unlock the tab B on the condenser.
3. Remove rubber mount A from the mount installation hole.
4. Tilt the radiator to the engine side.
5. Remove rubber mount B from the mount installation hole.
6. Remove the radiator from below.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Radiator Installation Note
1. Install the condenser to the radiator by aligning lower side tab B with the radiator side tab, install upper tab B, then install lower side tab B.
2. Install the oil cooler by inserting oil cooler bracket to the radiator tab on the radiator. (ATX)
3. Install the radiator.
Cooling Fan Component Installation Note
1. Insert tab A to the radiator to install the cooling fan component.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
THERMOSTAT REMOVAL/INSTALLATION [Z6]
B3E011215171W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Disconnect the lower radiator hose from the thermostat.
6. Remove in the order indicated in the table.
1 Thermostat cover
2
Thermostat
(See Thermostat Installation Note .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7. Install in the reverse order of removal.
8. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
9. Inspect the system for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
Thermostat Installation Note
1. Install the thermostat into the thermostat case with the jiggle pin at the top.
THERMOSTAT REMOVAL/INSTALLATION [LF]
B3E011215171W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Position the coolant reserve tank out of the way.
6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
7. Position the drive belt out of the way. (See DRIVE BELT REPLACEMENT [LF] .)
8. Remove the drive belt tensioner. (See TIMING CHAIN REMOVAL/INSTALLATION [LF] .)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
12. Inspect for the engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
13.
1 Hose
2 Lower radiator hose
3 Thermostat component
4 Gasket
THERMOSTAT INSPECTION [Z6]
B3E011215171W03
1. Inspect the thermostat for the following.
Warning
• During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water.
• The valve should not open under normal temperature.
• Opening temperature and valve lift
- If there is malfunction, replace the thermostat.
Item Specification
Initial-opening temperature (°C {°F}) 80-84 {176-183}
Full-open temperature (°C {°F}) 95 {203}
Full-open lift (mm {in}) 8.5 {0.33} or more
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
THERMOSTAT INSPECTION [LF]
B3E011215171W04
1. Inspect the thermostat for the following.
Warning
• During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water.
• The valve should not open under normal temperature.
• Opening temperature and valve lift
- If there is malfunction, replace the thermostat.
Item Specification
Initial-opening temperature (°C {°F}) 80-84 {176-183}
Full-open temperature
Full-open lift
(°C {°F}) 97 {207}
(mm {in}) 8.0 {0.31} or more
WATER PUMP REMOVAL/INSTALLATION [Z6]
B3E011215010W01
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Position the coolant reserve tank out of the way.
6. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
7. Position the power steering fluid tank out of the way.
8. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [Z6] .)
9. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Water pump component
2 O-ring
10. Install in the reverse order of removal.
11. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
WATER PUMP REMOVAL/INSTALLATION [LF]
B3E011215010W02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Position the coolant reserve tank out of the way.
6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See DRIVE BELT
REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)
11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)
1 Water pump pulley
2 Water pump
3 O-ring
COOLING FAN MOTOR COMPONENT INSPECTION
B3E011215025W01
1. Verify that battery voltage is 12.4 V or more.
• If it cannot be verified, charge the battery or contact an external power supply to the vehicle.
2. Connect the WDS or equivalent to the DLC-2.
3. Turn the ignition switch to the ON position.
Note
• The cooling fan does not operate if the duty value of the fan control signal is 10 % or less, or 95
% or more.
• The range of the duty value of the fan control signal which the simulation function can control is 10 %-90%.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Due to the cooling fan protection function, there is a time lag until the fan control signal reaches the specified duty value. (Example: If a fan control signal with a 90 % duty value is input while the cooling fan is stopped, it takes approx. 14 s until the fan speed increases and stabilizes.)
4. Using the "FAN DUTY" simulation function, input fan control signals with duty values of 20 %, 40 %, 60
%, and 80 % at 30 s intervals and verify that the cooling fan operation speed increases.
• If the cooling fan does not operate, inspect the following:
- Open or short circuit in fan control module power supply
- Open or short circuit in fan control module ground
- Open or short circuit in the wiring harness between fan control module terminal B and PCM terminal 1AP (Z6)/ 1W (LF).
• If the wiring harnesses and connectors are normal, inspect the cooling fan component.
• If the cooling fan operation speed does not increase, replace the cooling fan component.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INTAKE-AIR SYSTEM[Z6]
INTAKE-AIR SYSTEM LOCATION INDEX [Z6]
B3E011300113W01
1
Air cleaner
(See AIR CLEANER ELEMENT INSPECTION [Z6] .)
IAC solenoid valve
2 (See IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION [Z6] .)
(See IDLE AIR CONTROL (IAC) VALVE INSPECTION [Z6] .)
Variable intake-air shutter valve actuator
3 (See VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6] .)
(See VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [Z6] .)
Variable tumble shutter valve actuator
4 (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6] .)
(See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5
Accelerator pedal
(See ACCELERATOR PEDAL REMOVAL/INSTALLATION [Z6] .)
6
Accelerator cable
(See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6] .)
7
Intake-air system
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
INTAKE-AIR SYSTEM DIAGRAM [Z6]
B3E011300113W02
INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM [Z6]
B3E011300113W03
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INTAKE-AIR SYSTEM MANIFOLD VACUUM
INSPECTION [Z6]
B3E011300113W04
1.• Verify that the intake air hoses are installed securely.
2. Warm up the engine.
3. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoid valve side) and install the vacuum gauge.
4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.
• If not within the specification, perform the following inspections.
- Accelerator cable play
- Compression pressure (See COMPRESSION INSPECTION [Z6] .)
- Air suction (installation areas of throttle body, fuel injector, PCV valve, intake manifold)
Note
• If any air suction exists, the change in engine speed can be made apparent by spraying the penetrant lubricating spray on the applicable part.
Standard
ATX: -71.0 kPa {-533 mmHg, -21.0 inHg} or more
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MTX: -72.0 kPa {-541 mmHg, -21.3 inHg} or more
5. After measuring the intake manifold vacuum, install the vacuum hose to the purge solenoid valve as shown in the figure.
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6]
B3E011300113W05
Warning
• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION .)
Caution
• The PCM is built into the air cleaner cover. Applying excessive pressure to the cover could damage the PCM. Be careful not to put your hands on the PCM during the removal/installation.
• Removing the PCM from the air cleaner could damage the sealing or the circuitry. Do not remove the PCM from the air cleaner.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 PCM connector cover
2
PCM connector
(See PCM Connector Installation Note .)
3 Air cleaner cover
4 Air cleaner element
5 Air cleaner case
6 Fresh-air duct cover
7
Strap
(See Strap Installation Note .)
8
Fresh-air duct
(See Fresh-air Duct Installation Note .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
9
Air hose
(See Air Hose Installation Note .)
10
Throttle body
(See Throttle Body Removal Note .)
11
EGR pipe (Intake manifold side)
(See EGR Pipe Installation Note .)
12
Fuel distributor
(See FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .)
13
Intake manifold
(See Intake Manifold Removal Note .)
Throttle Body Removal Note
1. Remove the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [Z6] .)
2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
Intake Manifold Removal Note
1. Disconnect the engine coolant hose from the engine coolant pipe as shown in the figure.
2. Remove the accelerator cable bracket from the intake manifold.
EGR Pipe Installation Note
1. Install the EGR pipe installation bolts and the nut in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Air Hose Installation Note
1. Align the alignment marks on the throttle body and the air hose.
Fresh-air Duct Installation Note
Note
• Before installing the fresh-air duct, verify that the rubber mounts on the battery support bracket have not fallen off.
• When inserting the fresh-air duct into the rubber mounts, applying soapy water aids the operation.
1. Verify that two rubber mounts are installed on the battery support bracket.
2. Install the fresh-air duct into the rubber mounts.
Strap Installation Note
1. Using the strap, secure the shroud panel and the fresh-air duct as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
PCM Connector Installation Note
1. Insert the PCM connector fully into the air cleaner and push the lever until a click is heard.
AIR CLEANER ELEMENT INSPECTION [Z6]
B3E011313300W01
1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
2. Inspect the following items:
• If there is any abnormality, clean or replace the air cleaner element.
- Has the replacement interval come?
- Is the air cleaner element soiled, damaged, or bent?
- Are the air cleaner case and the air cleaner element correctly sealed?
- Is the correct air cleaner element installed?
IDLE AIR CONTROL (IAC) VALVE
REMOVAL/INSTALLATION [Z6]
B3E011320661W01
1. Remove the under cover.
2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
3. Disconnect the negative battery cable.
4. Remove the IAC valve.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Install in the reverse order of removal.
IDLE AIR CONTROL (IAC) VALVE INSPECTION [Z6]
B3E011320661W02
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the IAC valve connector.
3. Measure the resistance between IAC valve terminals A and B.
• If within the specification, carry out the "Circuit Open/Short Inspection".
• If not within the specification, replace the IAC valve.
Resistance
8.810.6 ohms [24°C {75 °F}]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- IAC valve terminal A and PCM terminal 2X
- IAC valve terminal B and PCM terminal 2AB
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- IAC valve terminal A and body GND
- IAC valve terminal B and power supply
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR
REMOVAL/INSTALLATION [Z6]
B3E011320130W01
Caution
• Be careful of the following after removing the actuator to prevent abnormal gear wear and gear lock which could result in shutter valve malfunction.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Do not pull out the intake manifold side gear.
- Do not allow foreign material to contact the intake manifold side gear.
- Keep the inside of the actuator away from foreign material.
• Improper installation of the actuator and retainer will cause gear lock and might result in shutter valve malfunction. To prevent this, install the actuator and shutter valve as described in the following procedure:
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
Variable intake-air shutter valve actuator
1 (See Variable Intake-air Shutter Valve Actuator Removal Note .)
(See Variable Intake-air Shutter Valve Actuator Installation Note .)
Retainer
2 (See Retainer Removal Note .)
(See Retainer Installation Note .)
3. Install in the reverse order of removal.
Variable Intake-air Shutter Valve Actuator Removal Note
1. After removing the actuator, cover it with a plastic sheet to prevent foreign material from entering the inside of the actuator.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Retainer Removal Note
1. After removing the retainer, cover it with a plastic sheet to prevent foreign material from contacting the intake manifold side gear.
Retainer Installation Note
1. Install the retainer by positioning the projection on the intake manifold with the indentation on the retainer.
2. Be careful not to shift the retainer installation position.
Variable Intake-air Shutter Valve Actuator Installation Note
1. Verify that the retainer installation position has not shifted.
2. Verify that the gasket is installed.
3. Verify that intake manifold side gear and actuator side gear are engaged properly so that the actuator can be installed without any excessive force.
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR
INSPECTION [Z6]
B3E011320130W02
Operation Inspection
1. Disconnect the negative battery cable.
2. Remove the variable intake-air shutter valve actuator.
3. Connect the battery positive voltage to terminal A or B, and verify that the gear moves.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If there is no malfunction, carry out the "Circuit Open/Short Inspection".
• If there is any malfunction, replace the variable intake-air shutter valve actuator.
Terminal
Gear rotation direction
A B
B+ GND Counterclockwise
GND B+ Clockwise
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- Variable intake-air shutter valve actuator terminal A and PCM terminal 2AO
- Variable intake-air shutter valve actuator terminal B and PCM terminal 2AS
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- Variable intake-air shutter valve actuator terminal A and power supply
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Variable intake-air shutter valve actuator terminal A and body GND
- Variable intake-air shutter valve actuator terminal B and power supply
- Variable intake-air shutter valve actuator terminal B and body GND
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR
REMOVAL/INSTALLATION [Z6]
B3E011320130W03
Caution
• Be careful of the following after removing the actuator to prevent abnormal gear wear and gear lock which could result in shutter valve malfunction.
- Do not pull out the intake manifold side gear.
- Do not allow foreign material to contact the intake manifold side gear.
- Keep the inside of the actuator away from foreign material.
• Improper installation of the actuator and retainer will cause gear lock and might result in shutter valve malfunction. To prevent this, install the actuator and shutter valve as described in the following procedure:
1. Disconnect the negative battery cable.
2. Remove the following parts for easier access.
• Air cleaner (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
• Fresh-air duct
• Battery
3. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Variable tumble shutter valve actuator
1 (See Variable Tumble Shutter Valve Actuator Removal Note )
(See Variable Tumble Shutter Valve Actuator Installation Note )
Retainer
2 (See Retainer Removal Note )
(See Retainer Installation Note )
4. Install in the reverse order of removal.
Variable Tumble Shutter Valve Actuator Removal Note
1. After removing the actuator, cover it with a plastic sheet to prevent foreign material from entering the inside of the actuator.
Retainer Removal Note
1. After removing the retainer, cover it with a plastic sheet to prevent foreign material from contacting the intake manifold side gear.
Retainer Installation Note
1. Install the retainer by positioning the projection on the intake manifold with the indentation on the retainer.
2. Be careful not to shift the retainer installation position.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Variable Tumble Shutter Valve Actuator Installation Note
1. Verify that the retainer installation position has not shifted.
2. Verify that the gasket is installed.
3. Verify that intake manifold side gear and actuator side gear are engaged properly so that the actuator can be installed without any excessive force.
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR
INSPECTION [Z6]
B3E011320130W04
Operation Inspection
1. Disconnect the negative battery cable.
2. Remove the variable tumble shutter valve actuator.
3. Connect the battery positive voltage to terminal A or B, and verify that the gear moves.
• If there is no malfunction, carry out the "Circuit Open/Short Inspection".
• If there is any malfunction, replace the variable tumble shutter valve actuator.
Terminal
Gear rotation direction
A B
B+ GND Counterclockwise
GND B+ Clockwise
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- Variable tumble shutter valve actuator terminal A and PCM terminal 2AJ
- Variable tumble shutter valve actuator terminal B and PCM terminal 2AF
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- Variable tumble shutter valve actuator terminal A and power supply
- Variable tumble shutter valve actuator terminal A and body GND
- Variable tumble shutter valve actuator terminal B and power supply
- Variable tumble shutter valve actuator terminal B and body GND
ACCELERATOR PEDAL REMOVAL/INSTALLATION
[Z6]
B3E011341600W01
1. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Accelerator pedal
2 Accelerator cable
2. Install in the reverse order of removal.
3. Adjust the accelerator cable. (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6] .)
ACCELERATOR CABLE INSPECTION/ADJUSTMENT
[Z6]
B3E011341660W01
1. Verify that the throttle valve is fully closed.
2. Move the accelerator cable in the directions of A and B, and verify that the accelerator cable play is within the specification.
• If not within the specification, adjust the cable play using locknut C.
Standard
1.0-3.0 mm {0.04-0.11 in}
Tightening torque
9.814.7 N·m {100-149 kgf·cm, 86.8-130 in·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INTAKE-AIR SYSTEM[LF]
INTAKE-AIR SYSTEM LOCATION INDEX [LF]
B3E011300113W06
1
Air cleaner
(See AIR CLEANER ELEMENT INSPECTION [LF] .)
2
IAC solenoid valve
(See IDLE AIR CONTROL (IAC) VALVE INSPECTION [LF] .)
3
Variable intake-air solenoid valve
(See VARIABLE INTAKE-AIR SOLENOID VALVE INSPECTION [LF] .)
4
Variable tumble solenoid valve
(See VARIABLE TUMBLE SOLENOID VALVE INSPECTION [LF] .)
5
Variable intake-air shutter valve actuator
(See VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
Variable tumble shutter valve actuator
(See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF] .)
7
Accelerator pedal
(See ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF] .)
8
Accelerator cable
(See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [LF] .)
9
Intake-air system
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
INTAKE-AIR SYSTEM DIAGRAM [LF]
B3E011300113W07
INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM [LF]
B3E011300113W08
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INTAKE-AIR SYSTEM MANIFOLD VACUUM
INSPECTION [LF]
B3E011300113W09
1.• Verify that the intake air hoses are installed securely.
2. Warm up the engine.
3. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (intake manifold side) and install the vacuum gauge.
4. Using the vacuum gauge, measure the intake manifold vacuum in the idling condition (no load).
• If not within the specification, perform the following inspections.
- Accelerator cable play
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- Compression pressure (See COMPRESSION INSPECTION [LF] .)
- Air suction (throttle body, fuel injector, PCV valve, intake manifold)
Note
• If any air suction exists, the change in engine speed can be made apparent by spraying penetrant lubricating spray on the applicable part.
Standard
-60.0 kPa {-451 mmHg, -17.8 inHg} or more
5. After measuring the intake manifold vacuum, install the vacuum hose to the intake manifold as shown in the figure.
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]
B3E011300113W10
Warning
• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE
PRECAUTIONS". (See BEFORE SERVICE PRECAUTION .)
1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the battery cover and battery duct. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Remove the under cover.
4. Disconnect the negative battery cable.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the "AFTER SERVICE PRECAUTIONS". (See AFTER SERVICE PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Intake-air cover
2
Air hose
(See Air Hose Installation Note .)
3 Air cleaner cover
4 Resonance chamber (Air cleaner side)
5 Air cleaner element
6
Strap
(See Strap Installation Note .)
7
Air cleaner case
(See Air Cleaner Case Installation Note .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8
Fresh-air duct
(See Fresh-air Duct Removal Note .)
9 Throttle body
10 Variable intake air solenoid valve
11 Variable tumble solenoid valve
12
Fuel distributor
(See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)
13 IAC solenoid valve
14
Intake manifold
(See Intake Manifold Removal Note .)
15 EGR pipe gasket
Fresh-air Duct Removal Note
1. Remove the front bumper before removing the fresh-air duct. (See FRONT BUMPER
REMOVAL/INSTALLATION .)
Intake Manifold Removal Note
1. Remove the dipstick pipe. (See OIL PAN REMOVAL/INSTALLATION [LF] .)
2. Remove the accelerator cable bracket from the intake manifold.
Air Cleaner Case Installation Note
Note
• Before installing the air cleaner case, verify that the rubber mounts on the battery support bracket have not fallen off.
• When inserting the air cleaner case into the rubber mounts, applying soapy water aids the operation.
1. Verify that two rubber mounts are installed on the battery support bracket.
2. Install the air cleaner case into the rubber mounts.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Strap Installation Note
1. Using the strap, secure the shroud panel and the air cleaner case as shown in the figure.
Air Hose Installation Note
1. Align the alignment marks on the throttle body and the air hose.
AIR CLEANER ELEMENT INSPECTION [LF]
B3E011313300W02
1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
2. Inspect the following items:
• If there is any malfunction, clean or replace the air cleaner element.
• If the replacement interval has come, replace the air cleaner element.
- Is the air cleaner element soiled, damaged, or bent?
- Are the air cleaner case and the air cleaner element correctly sealed?
- Is the correct air cleaner element installed?
IDLE AIR CONTROL (IAC) VALVE INSPECTION [LF]
B3E011320661W03
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Perform the following inspection only when directed.
Operation Test
1. Carry out the "Idle Air Control Inspection". (See Idle Air Control System Inspection .)
• If not as specified, perform the further inspection for the IAC valve.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the IAC valve connector.
3. Measure the resistance between the IAC valve terminals using an ohmmeter.
• If not as specified, replace the IAC valve. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [LF] .)
• If as specified but the Operation Test is failed, carry out the "Circuit Open/Short Inspection".
Specification
Ambient temperature (°C {°F}) Resistance (ohms)
23 {73} 8.8-10.6
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See PCM
REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harnesses for open or short (continuity check).
Open circuit
• If there is no continuity, the circuit is open.
Repair or replace the wiring harness.
- IAC valve terminal A and PCM terminal 2E
- IAC valve terminal B and PCM terminal 2F
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- IAC valve terminal A and power supply
- IAC valve terminal A and GND
- IAC valve terminal B and power supply
- IAC valve terminal B and GND
VARIABLE INTAKE-AIR SOLENOID VALVE
INSPECTION [LF]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E011318740W01
1. Remove the variable intake-air solenoid valve. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [LF] .)
2. Inspect airflow between the ports under the following conditions.
• If not as specified, replace the variable intake-air solenoid valve.
• If as specified, carry out the "Circuit Open/Short Inspection".
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See PCM
REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harness for open or short (continuity check).
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- Variable intake-air solenoid valve terminal A and PCM terminal 2AJ
- Variable intake-air solenoid valve terminal B and main relay terminal
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- Variable intake-air solenoid valve terminal B and body GND
- Variable intake-air solenoid valve terminal A and power supply
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR
INSPECTION [LF]
B3E011320130W05
1. Remove the air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
2. Disconnect the vacuum hose from the variable intake-air shutter valve actuator.
3. Connect a vacuum pump to the variable intake-air shutter valve actuator.
4. Apply vacuum and verify that the rod moves.
• If the rod dose not move, replace the intake manifold.
Vacuum kPa {mmHg, inHg}
Rod movement
Below -2.7 {-21, -0.9 } Not operate
Above -33.4 {-251, -9.89 } Fully pulled
VARIABLE TUMBLE SOLENOID VALVE INSPECTION
[LF]
B3E011318740W02
1. Remove the variable tumble solenoid valve. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[LF] .)
2. Inspect airflow between the ports under the following conditions.
• If not as specified, replace the variable tumble solenoid valve.
• If as specified, carry out the "Circuit Open/Short Inspection".
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See PCM
REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harness for open or short (continuity check).
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- Variable tumble solenoid valve terminal B and PCM terminal 2AI
- Variable tumble solenoid valve terminal A and main relay terminal A
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- Variable tumble solenoid valve terminal A and body GND
- Variable tumble solenoid valve terminal B and power supply
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR
INSPECTION [LF]
B3E011320130W06
1. Remove the air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
2. Disconnect the vacuum hose from the variable tumble shutter valve actuator.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Connect a vacuum pump to the variable tumble shutter valve actuator.
4. Apply vacuum and verify that the rod moves.
• If the rod dose not move, replace the intake manifold.
Vacuum kPa {mmHg, inHg}
Rod movement
Below -2.7 {-21, -0.9 } No operate
Above -33.4 {-251, -9.89 } Fully pulled
ACCELERATOR PEDAL REMOVAL/INSTALLATION
[LF]
B3E011341600W02
1. Remove in the order indicated in the table.
1 Accelerator pedal
2 Accelerator cable
2. Install in the reverse order of removal.
3. Adjust the accelerator cable. (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ACCELERATOR CABLE INSPECTION/ADJUSTMENT
[LF]
B3E011341660W02
1. Verify that the throttle valve is fully closed.
2. Move the accelerator cable in the directions of A and B, and verify that the accelerator cable play is within the specification.
• If not within the specification, adjust the cable play using locknut C.
Standard
1.0-3.0 mm {0.04-0.11 in}
Tightening torque
9.814.7 N·m {100-149 kgf·cm, 86.8-130 in·lbf}
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
FUEL SYSTEM
FUEL SYSTEM LOCATION INDEX
B3E011401006W01
Engine Compartment Side
LF
Fuel injector
1 (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)
(See FUEL INJECTOR INSPECTION .)
2
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3 Fuel pump relay
Z6
Fuel injector
1 (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .)
(See FUEL INJECTOR INSPECTION .)
2
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
3 Fuel pump relay
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel Tank Side
Fuel tank
1 (See FUEL TANK REMOVAL/INSTALLATION .)
(See FUEL TANK INSPECTION .)
Fuel pump unit
2
(See FUEL PUMP UNIT REMOVAL/INSTALLATION .)
(See FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .)
(See FUEL PUMP UNIT INSPECTION .)
3
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
FUEL SYSTEM FLOW DIAGRAM
B3E011401006W02
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Fuel-filler cap
2 Fuel filter (high-pressure)
3 Pressure regulator
4 Fuel pump unit
5 Fuel pump
6 Fuel filter (low-pressure)
7 Fuel tank
8 Fuel injector
9 Fuel flow
BEFORE SERVICE PRECAUTION
B3E011401006W03
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".
Caution
• If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel Line Safety Procedure
1. Remove the fuel-filler cap to release the pressure inside the fuel tank.
2. Remove the fuel pump relay.
3. Start the engine.
4. After the engine stalls, crank the engine several times .
5. Turn the ignition switch to the LOCK position.
6. Install the fuel pump relay.
AFTER SERVICE PRECAUTION
B3E011401006W04
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Inspection".
Fuel Leakage Inspection
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, complete the following inspection with the engine stopped.
1. Connect the WDS or equivalent to the DLC-2.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Turn the ignition switch to the ON position.
3. Using the simulation function "FP", start the fuel pump.
4. Verify that there is no fuel leakage from the pressurized parts.
• If there is leakage, replace the fuel hoses and clips.
• If there is damage on the seal on the fuel pipe side, replace the fuel pipe.
Standard
There shall be no leakage after 5 min.
5. After reinstallation, repeat step 2-3 in the fuel leakage inspection.
FUEL LINE PRESSURE INSPECTION
B3E011401006W05
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
3. Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION .)
4. Turn the lever of the SST parallel to the hose as shown in the figure.
LF
Z6
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Insert the SST quick release connector into the fuel pipe until a click is heard.
6. Verify that the quick release connector is firmly connected by pulling it by hand.
7. Connect the negative battery cable.
8. Connect the WDS or equivalent to the DLC-2.
9. Turn the ignition switch to the ON position.
10. Using the simulation function "FP", start the fuel pump.
11. Operate the fuel pump for 10 s .
12. Measure the fuel line pressure.
• If not within the specification, inspect the following:
If it less than the specification:
- Fuel pump unit
- Fuel line leakage
If it exceeds the specification:
- Fuel line clogging
Fuel pressure
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
350-410 kPa {3.57-4.18 kgf/cm 2 , 50.8-59.4 psi}
13. Stop the fuel pump.
14. Measure the fuel hold pressure after 5 min .
• If not within the specification, inspect the following:
- Fuel line for clogging or leakage
Fuel hold pressure
250 kPa {2.55 kgf/cm 2 , 36.2 psi} or more
15. Disconnect the SST .
16. Connect the quick release connector. (See QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION .)
17. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
FUEL TANK REMOVAL/INSTALLATION
B3E011442110W01
Warning
• Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
1. Park the vehicle on a level surface.
2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
Warning
• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.
3. Drain the fuel from the fuel tank using the following procedure:
(1) Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION .)
(2) Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(3) Connect the WDS or equivalent to the DLC-2.
(4) Turn the ignition switch to the ON position.
(5) Using the simulation function "FP", start the fuel pump.
Caution
• The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.
(6) When essentially no fuel is being discharged from the hose, turn the ignition switch to the
LOCK position.
(7) Disconnect the negative battery cable.
4. Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION .)
5. Remove the service hole cover.
6. Disconnect the fuel pump unit connector.
7. Remove the charcoal canister protector. (See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
8. Lower the main silencer so that the insulator can be removed. (See EXHAUST SYSTEM
REMOVAL/INSTALLATION [LF] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
9. Remove the rear under cover (LH).
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Inspect all parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Insulator
2
Quick release connector (fuel tank front)
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
3
Quick release connector (on rollover valve)
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
4
Quick release connector (on charcoal canister, purge solenoid valve side)
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
5
Charcoal canister
(See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
6
Joint hose
(See Joint Hose Installation Note .)
7
Breather hose
(See Breather Hose Installation Note .)
8 Strap
9 Fuel tank
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10 Fuel-filler cap
11
Fuel-filler pipe
(See Fuel-filler Pipe Removal Note .)
Fuel-filler Pipe Removal Note
1. Remove the rear tire (RH).
2. Remove the rear mudguard (RH).
3. Support the rear crossmember using a transmission jack.
4. Remove the rear shock absorber (RH) lower bolts. (See REAR SHOCK ABSORBER
REMOVAL/INSTALLATION .)
5. Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember 30 mm
{1.2 in} . (See REAR CROSSMEMBER REMOVAL/INSTALLATION .)
6. Remove the fuel-filler pipe.
Joint Hose Installation Note
1. Install the joint hose and clamp as shown in the figure.
Breather Hose Installation Note
1. Install the breather hose and clamp as shown in the figure.
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FUEL TANK INSPECTION
B3E011442110W02
Note
• The two rollover valves built into the fuel tank and check valves (two-way) built into the rollover valves are inspected in this inspection.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
3. Remove the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION .)
4. Perform the following procedure to verify the fuel tank airtightness.
(1) Plug the fuel pump unit pipe, ports B and C.
(2) Apply a pressure of 3 kPa {22 mmHg, 0.8 inHg} to port A and wait for a while.
(3) Verify that there is no air leakage from the fuel tank.
5. Plug the fuel pump unit pipe and port B.
6. Level the fuel tank.
7. Apply a pressure of 3 kPa {22 mmHg, 0.8 inHg} to port A and wait for a while.
8. With the pressure still applied, verify that there is airflow from port C and the pressure is 0-3 kPa {0-22 mmHg, 0-0.8 inHg} .
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• If there is no airflow, replace the fuel tank.
9. Apply a pressure of -0.5 kPa {-3.7 mmHg, -0.1 inHg} to port A and wait for a while.
10. With the pressure still applied, verify that there is airflow from port C and the pressure is 0- -0.5 kPa
{0- -3.7 mmHg, 0- -0.1 inHg}.
• If there is no airflow, replace the fuel tank.
• If there is airflow, place the fuel tank upside down.
11. Apply a pressure of 3 kPa {22 mmHg, 0.8 inHg} to port A and wait for a while.
12. With the pressure still applied, verify that there is no airflow from port C.
• If there is airflow, replace the fuel tank.
NONRETURN VALVE INSPECTION
B3E011442270W01
1. Remove the fuel-filler pipe. (See FUEL TANK REMOVAL/INSTALLATION .)
2. Move the valve and verify that the valve opens to 90 °.
• If it does not open, replace the fuel-filler pipe.
3. Verify that the nonreturn valve returns to the normal position by spring force.
• If it does not return, replace the fuel-filler pipe.
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FUEL PUMP UNIT REMOVAL/INSTALLATION
B3E011413350W01
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE
PRECAUTION".
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always complete the "Fuel Leak
Inspection After Fuel Pump Unit Installation".
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
3. Remove the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION .)
4. Remove in the order indicated in the table.
1
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
Fuel pump cap
2 (See Fuel Pump Cap Removal Note .)
(See Fuel Pump Cap Installation Note .)
3 Fuel pump unit
5. Install in the reverse order of removal.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
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Fuel Pump Cap Removal Note
Caution
• The fuel pump cap could be damaged if the SST is used with any gap between the cap and the
SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.
1. Remove the fuel pump cap using the SST .
Fuel Pump Cap Installation Note
Note
• The fuel pump unit will rotate and cannot be secured in the specified position if there is any gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.
1. Align the fuel tank and fuel pump unit alignment marks as shown in the figure.
2. Set the SST as shown in the figure.
3. Using the SST , tighten the fuel pump cap within the specified tightening torque without shifting the alignment marks.
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• If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.
• If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.
Fuel pump cap tightening torque
8090 N·m {8.2-9.1 kgf·m, 59-66 ft·lbf}
Fuel Leakage Inspection After Pump Unit Installation
1. Before installing the fuel tank, verify that there is no leakage when a pressure of +5.9 kPa {+44 mmHg,
+1.7 inHg} is applied to the fuel tank.
2. Install the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION .)
3. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
4. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the fuel pump unit.
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY
B3E011413350W02
Note
• The fuel pump unit cannot be disassembled.
FUEL PUMP UNIT INSPECTION
B3E011413350W03
Fuel Pump Operation Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Remove the fuel-filler cap.
3. Turn the ignition switch to the ON position.
4. Using the simulation function "FP", verify that operation sound is heard from the fuel pump when "FP" is turned from OFF to ON.
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• If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-side connector terminal A.
- If as specified, inspect the following:
• Fuel pump continuity
- If not within the specification, inspect the following:
• Fuel pump relay
• Wiring harnesses and connectors between main relay-fuel pump relay-fuel pump
Standard
B+ (Ignition switch at ON)
Continuity Inspection
1. Disconnect the negative battery cable.
2. Disconnect the fuel pump unit connector.
3. Inspect for continuity between fuel pump unit terminals A-E.
• If there is continuity, perform the "Circuit Open/Short Inspection".
• If there is no continuity, replace the fuel pump.
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for an open or short circuit (continuity check).
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Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
- Fuel pump unit terminal A and fuel pump relay terminal D
- Fuel pump unit terminal E and body GND
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
- Fuel pump unit terminal A and body GND
- Fuel pump unit terminal E and power supply
Fuel Static Pressure Inspection
Note
• The fuel static pressure inspection cannot be performed because the pressure regulator is integrated with the fuel pump unit.
QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION
B3E011442692W01
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE
PRECAUTION".
Quick Release Connector Type
Caution
• There are four types of quick release connectors. Verify the type and location, and install/remove properly.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Engine compartment side
2 Fuel tank side
3 Only on LF
4 Only on Z6
Type A Removal
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
Caution
• The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper.
Note
• The fuel hose can be removed by pushing it to the pipe side to release the lock.
2. Rotate the release tab on the quick release connector to the stopper position.
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3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
Type B Removal
Note
• Use the SST .
• For the purge solenoid valve-side of the charcoal canister, do not use the SST because it cannot be accessed easily.
Using the SST
1. Follow " BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION .)
2. Insert the SST into the quick release connector.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
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4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
Without using the SST
Caution
• When releasing the retainer locks, take extreme care not to damage the charcoal canister and pipe.
1. Follow " BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION .)
2. Release the locks between the retainer and pipe by pressing each retainer lock one by one using a flathead screwdriver or a similar tool.
3. Pull out the hose straight from the pipe and disconnect it.
• The retainer remains on the charcoal canister pipe.
4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
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Type C Removal
1. Follow " BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION .)
2. Push the release tab on the retainer to unlock.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
Type D Removal
1. Follow " BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION .)
2. Move the retainer upward using a small flathead screwdriver or a similar tool.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
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4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.
Type A Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
3. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
Note
• If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely.
5. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Type B Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
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• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.
Using the SST
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
4. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Without using the SST
Caution
• Be sure to replace the retainer with a new one to prevent gas leakage.
• To prevent evaporative gas leakage, be sure not to damage the connecting part between the charcoal canister and pipe, and the locks between the quick release connector and retainer. If any of them are damaged, replace the charcoal canister or hose with a new one.
1. Remove the retainer remaining on the charcoal canister pipe.
2. Install a new retainer to the quick release connector.
3. Reconnect the hose straight to the pipe until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
5. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Type C Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes completely engaged with the fuel pipe.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the resin pipe end while pressing the end with a finger.
• If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.
3. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
5. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Type D Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
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2. When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the resin pipe end while pressing the end with a finger.
• If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.
3. Insert the fuel pipe straight to the end of the quick release connector.
4. Push down the retainer using a finger.
• If the retainer cannot be pushed down, push the fuel pipe further to the quick release connector.
5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
FUEL INJECTOR REMOVAL/INSTALLATION [LF]
B3E011413250W01
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Remove the plug hole plate.
3. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
4. Disconnect the negative battery cable.
5. Disconnect the fuel injector connector.
6. Remove in the order indicated in the table.
1
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
2 Fuel distributor
3
Injector clip
(See Fuel Injector Removal Note [LF] .)
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4
Fuel injector
(See Fuel Injector Installation Note [LF] .)
7. Install in the reverse order of removal.
8. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Fuel Injector Removal Note [LF]
Caution
• Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the injector to rotate. Therefore, always replace the clip when the injector is removed.
1. Insert a flathead screwdriver between the injector cup and clip finger.
Note
• When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.
2. Push the clip finger outward using a flathead screwdriver.
3. Remove the injector with the clip.
4. Remove the clip from the fuel injector using the following procedure:
Note
• The clip will not be reused.
(1) Hold the clip using pliers.
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(2) Pull the clip parallel to the injector groove and remove it from the injector.
Fuel Injector Installation Note [LF]
1. Verify that the O-ring is not damaged.
• If there is any damage, replace the O-ring.
2. Apply a small amount of clean oil to the injector groove and the O-ring.
3. Temporarily attach a new clip to the injector groove.
Note
• When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.
4. Hold the injector firmly and push the clip into the injector until the clip stops sliding.
5. Verify that the injector connector position is correct.
6. Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.
7. Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.
FUEL INJECTOR REMOVAL/INSTALLATION [Z6]
B3E011413250W02
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
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2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
3. Disconnect the negative battery cable.
4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
5. Disconnect the fuel injector connector.
6. Remove in the order indicated in the table.
1
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
2 Fuel distributor
Injector clip
3 (See Injector Clip Removal Note [Z6] .)
(See Injector Clip Installation Note [Z6] .)
4
Fuel injector
(See Fuel Injector Installation Note [Z6] .)
5 Insulator
7. Install in the reverse order of removal.
8. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Injector Clip Removal Note [Z6]
Caution
• If the injector port flange or fuel distributor coated part is damaged, it might cause fuel leakage.
To prevent damage, carefully remove the injector clip.
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• Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. Make sure to replace with a new injector clip after removing it.
1. Detach one side of the injector clip from the injector port flange.
2. While holding one side of the injector clip removed in Step 1 to prevent it shifting, release the other side of injector clip.
3. Detach the injector clip by sliding it in the axial direction of the fuel injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel Injector Installation Note [Z6]
1. Apply a small amount of clean oil to a new O-ring.
Caution
• A damaged O-ring could cause fuel leakage. Be careful not to damage the O-ring when installing the fuel injector.
• If there is foreign material on the fuel injector connecting part, it might damage the fuel injector and fuel distributor. To prevent this, clean the connecting part before connecting the fuel injector.
2. Install the fuel injector straight to the injector port.
3. Verify that the fuel injector rotates smoothly.
• If it does not rotate smoothly, reinstall the fuel injector.
Injector Clip Installation Note [Z6]
1. Install a new injector clip to the fuel injector and insert the supporting part completely to the lower part of the injector connector.
2. Insert the injector port flange into the injector clip groove, sliding the injector clip along the fuel injector with the injector clip groove and injector port flange parallel.
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1
2
3
3. Verify that the injector port flange is completely inserted into the groove.
FUEL INJECTOR INSPECTION
B3E011413250W03
Fuel Injector Operation Inspection
Warning
• To prevent serious injury or damage, always perform diagnosis while referring to the warnings and cautions in each procedure when inspecting or repairing the fuel system.
STEP INSPECTION RESULT ACTION
Yes
Is there fuel injector operation sound from each cylinder when the engine is cranked? (Use a soundscope or equivalent tool.)
No
Is the main relay operation normal?
Yes
No
Remove the fuel injector where the operation sound cannot be verified, install it to the connector where the operation sound is verified, and then crank the engine again.
Yes
Is there operation sound?
No
The fuel injector operation system is normal.
If the operation sound cannot be verified at all cylinders, go to Step 2.
If the operation sound cannot be verified at specific cylinders, go to
Step 3.
Inspect the following:
• Wiring harnesses and connectors related to fuel injector power supply system
• PCM connector
• Fuel injector ground and related wiring harnesses and connectors
Replace the main relay.
Inspect for open or short circuit in the wiring harnesses and connectors, and repair or replace the malfunctioning part.
Replace the fuel injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel Cut Control Inspection
1. Connect the WDS or equivalent to the DLC-2.
2. Warm up the engine and idle it.
3. Turn off all the electrical loads and the A/C switch.
4. Using "RPM" of the PID/data monitor function, verify the engine speed.
5. Using a soundscope or a screwdriver, verify the operation sound of the fuel injector at all cylinders.
(1) Open the throttle valve and increase the engine speed to 4,000 rpm .
(2) Close the throttle valve instantaneously and verify that the fuel injector operation sound stops until the engine speed decreases to approx. 1,200 rpm and the sound is heard when the engine speed is approx. 1,200 rpm or less.
• If the sound does not stop at all cylinders, inspect the following:
- PCM input signal circuit (sensor, wiring harness)
• Throttle opening signal (TP sensor)
• If the sound does not stop at specific cylinders, inspect the following:
- Corresponding fuel injector and related wiring harnesses and connectors
• If the operation sound stops at all cylinders but the engine speed at which the operation sound recovers is not within the specification, inspect the following:
- PCM input signal circuit (sensor, wiring harness)
• Load/no load detection signal (neutral/CPP switch (MTX), TR switch (ATX))
• Water temperature signal (ECT sensor)
6. Place the vehicle on a chassis dynamometer.
7. Inspect the following using the WDS or equivalent.
(1) Verify the injector actuation time using the PID/data monitor function.
(2) Depress the accelerator pedal and increase the engine speed to 4,000 rpm . (Loaded range)
(3) With the accelerator pedal released (without depressing the brake pedal), verify that the injector actuation time of 0 ms is indicated until the engine speed decreases to approx. 1,200 rpm , and then the actuation time 2-5 ms is indicated when the engine speed decreases to approx. 1,000 rpm or less .
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it cannot be verified, inspect the PCM input signal circuit.
- Load/no load detection signal (neutral/CPP switch (MTX), TR switch (ATX))
Resistance Inspection
1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable.
3. Disconnect the fuel injector connector.
4. Inspect the resistance between fuel injector terminals A and B using a tester.
LF
Z6
• If within the specification, perform the "Circuit Open/Short Inspection".
• If not within the specification, replace the fuel injector.
Standard
LF: 11.4-12.6 ohms [ 20 °C {68 °F}]
Z6: Approx. 13.8 ohms [20 °C {68 °F}]
Circuit Open/Short Inspection [LF]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
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Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
- Fuel injector No.1 terminal A and PCM terminal 2BB
- Fuel injector No.2 terminal A and PCM terminal 2BC
- Fuel injector No.3 terminal A and PCM terminal 2BD
- Fuel injector No.4 terminal A and PCM terminal 2AZ
- Fuel injector No.1 terminal B and main relay terminal A
- Fuel injector No.2 terminal B and main relay terminal A
- Fuel injector No.3 terminal B and main relay terminal A
- Fuel injector No.4 terminal B and main relay terminal A
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
- Fuel injector No.1 terminal A and body GND
- Fuel injector No.2 terminal A and body GND
- Fuel injector No.3 terminal A and body GND
- Fuel injector No.4 terminal A and body GND
Circuit Open/Short Inspection [Z6]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [Z6] .)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
- Fuel injector No.1 terminal A and PCM terminal 2E
- Fuel injector No.2 terminal A and PCM terminal 2F
- Fuel injector No.3 terminal A and PCM terminal 2G
- Fuel injector No.4 terminal A and PCM terminal 2L
- Fuel injector No.1 terminal B and PCM terminal 2B
- Fuel injector No.1 terminal B and PCM terminal 2C
- Fuel injector No.1 terminal B and PCM terminal 2D
- Fuel injector No.1 terminal B and PCM terminal 2H
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
- Fuel injector No.1 terminal A and body GND
- Fuel injector No.2 terminal A and body GND
- Fuel injector No.3 terminal A and body GND
- Fuel injector No.4 terminal A and body GND
Leakage Inspection
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR
REMOVAL/INSTALLATION [LF] .) (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .)
4. Fix the fuel injector to the fuel distributor with a wire or the equivalent.
LF
Z6
5. Connect the fuel hose.
6. Connect the negative battery cable.
7. Connect the WDS or equivalent to the DLC-2.
8. Turn the ignition switch to the ON position.
9. Using the simulation function "FP", start the fuel pump.
10. Tilt the fuel injector at an angle of 60 ° to inspect for leakage.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
LF
Z6
• If not within the specification, replace the fuel injector.
Standard
1 drop or less/2 min
11. Turn the ignition switch to the LOCK position and stop the fuel pump.
12. Remove the wire or the equivalent securing the fuel injector.
13. Install the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .) (See FUEL
INJECTOR REMOVAL/INSTALLATION [Z6] .)
14. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Injection Volume Inspection [LF]
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
3. Remove the PCM.
4. Connect the PCM connector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR
REMOVAL/INSTALLATION [LF] .)
6. Fix the fuel injector to the fuel distributor with a wire or the equivalent.
7. Connect the corresponding fuel injector connector.
8. Connect the negative battery cable.
9. Connect the WDS or equivalent to the DLC-2.
10. Turn the ignition switch to the ON position.
11. Using the simulation function "FP", start the fuel pump.
12. Ground the following PCM terminals using a jumper wire and measure the injection volume of each fuel injector.
• If not within the specification, replace the fuel injector.
Standard
46-66 ml {44-66 cc, 2.8-4.0 cu in}/15 s
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel injector No.
PCM terminal
1
2
3
4
2BB
2BC
2BD
2AZ
13. Turn the ignition switch is to the LOCK position and stop the fuel pump.
14. Remove the wire or the equivalent securing the fuel injector.
15. Install the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)
16. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Injection volume Inspection [Z6]
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
2. Disconnect the negative battery cable.
3. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR
REMOVAL/INSTALLATION [Z6] .)
4. Fix the fuel injector to the fuel distributor with a wire or the equivalent.
5. Connect the SST to the corresponding fuel injector and battery.
6. Connect the negative battery cable.
7. Connect the WDS or equivalent to the DLC-2.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
8. Turn the ignition switch to the ON position.
9. Using the simulation function "FP", start the fuel pump.
10. Measure the fuel injection volume.
• If not within the specification, replace the fuel injector.
Standard
64-84 ml {64-84 cc, 3.9-5.1 cu in}/15 s
11. Turn the ignition switch to the LOCK position and stop the fuel pump.
12. Remove the wire or the equivalent securing the fuel injector.
13. Install the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .)
14. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION .)
Atomization Inspection
1. Inspect the atomization status.
• If not normal, replace the fuel injector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
EXHAUST SYSTEM[Z6]
EXHAUST SYSTEM INSPECTION [Z6]
B3E011500115W01
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If there is leakage, repair or replace the appropriate component.
EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6]
B3E011500115W02
Warning
• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Rear tunnel member
2 Front tunnel member
3 Main silencer
4
Rear heated oxygen sensor
(See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] .)
5
Front heated oxygen sensor
(See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6
EGR pipe (Exhaust manifold side)
(See EGR Pipe Installation Note .)
7 Member
8 Exhaust manifold bracket
9 Clip
WU-TWC
10 (See Exhaust Manifold/Exhaust Manifold Insulator Removal Note .)
(See Exhaust Manifold Installation Note .)
11
Exhaust manifold insulator
(See Exhaust Manifold/Exhaust Manifold Insulator Removal Note .)
12 Exhaust manifold gasket
Exhaust Manifold/Exhaust Manifold Insulator Removal Note
Caution
• Over bending of the exhaust flexible pipe may cause damage resulting in failure.
Note
• When removing the exhaust manifold, move the exhaust manifold insulator slightly out of the way, loosen the nuts, then remove the exhaust manifold together with the insulator. Refer to the following procedure.
1. Remove the front wheels and tires.
2. Remove the air cleaner cover and the air cleaner case. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
3. Remove the EGR pipe (Intake manifold side). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[Z6] .)
4. Remove the EGR valve component. (See EGR VALVE REMOVAL/INSTALLATION [Z6] .)
5. Disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION .)
6. Disconnect the pressure hose and the return hose. (See STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION .)
7. Remove the No.1 engine mount rubber. (See ENGINE REMOVAL/INSTALLATION [Z6] .)
8. Loosen the exhaust manifold insulator bolts.
9. Move the exhaust manifold insulator slightly out of the way and loosen the exhaust manifold nuts.
10. Remove the installation bolts of the front stabilizer and front crossmember component. (See FRONT
CROSSMEMBER REMOVAL/INSTALLATION .)
11. Loosen the front crossmember component installation bolts and lower the front crossmember component approx. 100 mm {3.94 in} . (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
12. Support the flexible pipe with a support wrap or splint as shown in the figure.
13. Remove the exhaust manifold together with the insulator by lowering it to the underside of the vehicle.
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in the order shown in the figure.
EGR Pipe Installation Note
1. Tighten the EGR pipe bolts and nuts in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
EXHAUST SYSTEM[LF]
EXHAUST SYSTEM INSPECTION [LF]
B3E011500115W03
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If there is leakage, repair or replace the appropriate component.
EXHAUST SYSTEM REMOVAL/INSTALLATION [LF]
B3E011500115W04
Warning
• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.
1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
2. Remove the battery cover and battery duct. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the negative battery cable.
4. Remove the under cover.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Rear tunnel member
2 Front tunnel member
3
Main silencer
(See Main Silencer Removal Note .)
4
Rear heated oxygen sensor
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [LF] .)
5
Front heated oxygen sensor
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [LF] .)
6 Member
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7 Exhaust manifold bracket
WU-TWC
8 (See Exhaust Manifold Removal Note .)
(See Exhaust Manifold Installation Note .)
9 Exhaust manifold insulator
10 Exhaust manifold gasket
Main Silencer Removal Note
1. Loosen the lower shock absorber bolt and rear crossmember component installation bolt, and lower the rear crossmember component approx. 70 mm {2.8 in} . (See REAR CROSSMEMBER
REMOVAL/INSTALLATION .)
Exhaust Manifold Removal Note
Caution
• Over bending of the exhaust flexible pipe may cause damage resulting in failure.
1. Remove the front wheels and tires.
2. Disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION .)
3. Remove the No.1 engine mount rubber. (See ENGINE REMOVAL/INSTALLATION [LF] .)
4. Loosen the exhaust manifold bolts.
5. Remove the installation bolts of the front stabilizer and front crossmember component. (See FRONT
CROSSMEMBER REMOVAL/INSTALLATION .)
6. Loosen the front crossmember component installation bolts and lower the front crossmember component approx. 100 mm {3.94 in} . (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
7. Support the flexible pipe with a support wrap or splint as shown in the figure.
8. Remove the exhaust manifold by lowering it to the underside of the vehicle.
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in the order shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
EMISSION SYSTEM
EMISSION SYSTEM LOCATION INDEX
B3E011601074W01
Engine Compartment Side
LF
1
Positive crankcase ventilation (PCV) valve
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .)
EGR valve
2 (See EGR VALVE REMOVAL/INSTALLATION [LF] .)
(See EGR VALVE INSPECTION .)
Purge solenoid valve
3 (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [LF] .)
(See PURGE SOLENOID VALVE INSPECTION .)
Z6
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Positive crankcase ventilation (PCV) valve
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .)
EGR valve
2 (See EGR VALVE REMOVAL/INSTALLATION [Z6] .)
(See EGR VALVE INSPECTION .)
Purge solenoid valve
3 (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [Z6] .)
(See PURGE SOLENOID VALVE INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Fuel Tank Side
Charcoal canister
1 (See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
(See CHARCOAL CANISTER INSPECTION .)
Rollover valve
2 (See ROLLOVER VALVE REMOVAL/INSTALLATION .)
(See ROLLOVER VALVE INSPECTION .)
EMISSION SYSTEM DIAGRAM
B3E011601074W02
LF
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Z6
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
INSPECTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E011613890W01
1. Remove the intake manifold.
2. Remove the PCV valve.
3. Verify that there is no airflow when pressure is applied to port A.
• If there is airflow, replace the PCV valve.
4. Verify that there is airflow when vacuum is applied to port A.
• If there is no airflow, replace the PCV valve.
PURGE SOLENOID VALVE REMOVAL/INSTALLATION
[LF]
B3E011618740W01
1. Remove the plug hole plate.
2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the negative battery cable.
4. Remove using the following procedure:
Caution
• Do not disconnect the purge solenoid valve and evaporative hose except when replacing the purge solenoid valve because it may cause evaporative gas leakage. When it is necessary to remove the purge solenoid valve for removing/installing other parts, disconnect the valve at the quick release connector.
(1) Disconnect the evaporative hose at the charcoal canister side. (See Evaporative Hose
Installation Note .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(2) Pull the vacuum tube from the intake manifold.
5. Install in the reverse order of removal.
Evaporative Hose Installation Note
1. Install the evaporative hose and clamp as shown in the figure.
PURGE SOLENOID VALVE REMOVAL/INSTALLATION
[Z6]
B3E011618740W02
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Remove in the order indicated in the table.
1 Purge solenoid valve
4. Install in the reverse order of removal.
PURGE SOLENOID VALVE INSPECTION
B3E011618740W03
Evaporative Purge Control Inspection
Without using WDS or equivalent
1. Warm up the engine and idle it.
2. Disconnect the vacuum hose which is connected to the charcoal canister from purge solenoid valve.
3. Place your finger onto the purge solenoid valve as shown in the figure and verify that vacuum is applied.
LF
Z6
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If vacuum is not applied, inspect the following:
- PCM output signal circuit (wiring harness, connector)
• Evaporative purge control signal
- Purge solenoid valve
4. Run the vehicle on the chassis dynamometer and maintain the engine speed at approx. 2,000 rpm .
5. Verify that vacuum is applied after approx. 30 s .
• If the vacuum is not verified, inspect the following:
- PCM input signal circuit (sensor, switch, wiring harness)
• Intake air temperature signal (intake air temperature sensor)
• Evaporative purge control signal (purge solenoid valve)
• Throttle opening signal (throttle position sensor)
• Load/no load identification signal
Neutral switch/Clutch switch (MTX)/Transaxle range switch (ATX)
- Purge solenoid valve
Using WDS or equivalent
1. Connect the WDS or equivalent to the DLC-2.
2. Warm up the engine and idle it.
3. Disconnect the vacuum hose which is connected to the charcoal canister from purge solenoid valve.
4. Place your finger onto the purge solenoid valve as shown in the figure and verify that vacuum is applied.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
LF
Z6
• If vacuum is not applied, inspect the following:
- PID: EVAPCP
- Purge solenoid valve
5. Disconnect the vacuum hose.
6. Using the "EVAPCP" simulation function, set the present 0% duty value of the purge solenoid valve to the 100% duty value and verify that the engine idles roughly or stalls.
• If the idle status does not change, inspect the following:
(1) Turn the ignition switch to the ON position.
(2) Using the "EVAPCP" simulation function, set the present 0% duty value of the purge solenoid valve to the 50% duty value and verify purge solenoid valve operation sound.
• If the operation sound is verified, inspect the following:
- Disconnection and damage of the vacuum hose (intake manifold-purge solenoid valve-charcoal canister)
• If the operation sound is not verified, inspect the following:
- Purge solenoid valve
- Wiring harness and connector open circuit (main relay-purge solenoid valve-PCM)
Airflow Inspection
1. Disconnect the negative battery cable.
2. Remove the purge solenoid valve.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Verify that the airflow is as indicated in the table.
LF
Z6
• If as specified in the table, perform the "Circuit Open/Short Inspection".
• If not as specified in the table, inspect the purge solenoid valve.
Measured condition Continuity between A-B
When voltage is applied between terminals A and B No airflow
When voltage is not applied between terminals A and B Airflow detected
Circuit Open/Short Inspection [LF]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harness for an open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
- Purge solenoid valve terminal A and PCM terminal 2AN
- Purge solenoid valve terminal B and main relay terminal A
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
- Purge solenoid valve terminal A and body GND
Circuit Open/Short Inspection [Z6]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [Z6] .)
2. Inspect the following wiring harness for an open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
- Purge solenoid valve terminal A and PCM terminal 2T
- Purge solenoid valve terminal B and PCM terminal 2AV
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
- Purge solenoid valve terminal A and body GND
- Purge solenoid valve terminal B and power supply
EGR VALVE REMOVAL/INSTALLATION [LF]
B3E011620300W01
1. Remove the plug hole plate.
2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the negative battery cable.
4. Disconnect the EGR valve connector.
5. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Water hose
(See Water Hose Removal Note [LF] .)
2
EGR valve
(See EGR Valve Removal Note [LF] .)
6. Install in the reverse order of removal.
Water Hose Removal Note [LF]
1. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT .)
EGR Valve Removal Note [LF]
1. Remove the air cleaner and air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)
2. Remove the radiator hose (upper). (See RADIATOR REMOVAL/INSTALLATION .)
EGR VALVE REMOVAL/INSTALLATION [Z6]
B3E011620300W02
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Disconnect the EGR valve connector.
4. Remove in the order indicated in the table.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
EGR pipe (Exhaust manifold side)
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] .)
2 EGR valve
5. Install in the reverse order of removal.
EGR VALVE INSPECTION
EGR Control Inspection
Without using WDS or equivalent
1. Inspect the following:
• EGR pipe clogging
• PCM terminal voltage
- EGR valve signal
- Vehicle speed signal
- Throttle opening signal
- Engine coolant temperature signal
• EGR valve (If it is stuck or not moving smoothly, replace it with a new one.)
Using WDS or equivalent
1. Connect the WDS or equivalent to the DLC-2.
B3E011620300W03
2. Start the engine.
3. Using the "SEGRP" simulation function, operate with Steps 0 (idling) to 52 and verify that the engine speed becomes unstable or the engine stalls.
• If the engine speed does not change, perform the following procedure:
(1) Stop the engine.
(2) Remove the EGR valve.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(3) Connect the EGR valve connector.
(4) Turn the ignition switch to the ON position.
(5) Using the "SEGRP" simulation function, verify that it operates with Steps 0 (idling) to 52 .
• If the EGR valve operates, inspect the following:
- EGR pipe clogging
• If the EGR valve does not operate, inspect the following:
- PCM terminal voltage
• EGR valve signal
- EGR valve (If it is stuck or not moving smoothly, replace it with a new one.)
4. Warm up the engine to normal operating temperature.
5. Place the vehicle on the chassis dynamometer.
6. Monitor the following signals using the PID/data monitor.
• EGR valve step number (SEGRP)
• Engine speed (RPM)
• Vehicle speed (VSS)
• Throttle position (TP)
• Engine coolant temperature (ECT)
7. Verify that the EGR valve step number is 0 during idle.
8. Verify that the EGR valve step number increases when the accelerator pedal is depressed to increase the vehicle speed.
• If it does not increase, inspect the following using the PID/data monitor.
- Vehicle speed (VSS)
- Throttle position (TP)
- Engine coolant temperature (ECT)
9. Stop the vehicle and verify that the EGR valve step number is 0 during idle.
On-vehicle Inspection
1. Verify that the buzzing sound (valve operation sound) is heard from the EGR valve when engine cranking.
• If the buzzing sound is not heard, perform the resistance inspection.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the EGR valve connector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Measure the resistance between the EGR valve terminals.
• If within the specification, perform out the "Circuit Open/Short Inspection".
• If not within the specification, replace the EGR valve.
Standard
Terminal
Resistance (ohm)
LF Z6
C-E
C-A
D-B
D-F
12-16 20-24
Circuit Open/Short Inspection [LF]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
Open circuit
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- EGR valve terminal A and PCM terminal 2AR
- EGR valve terminal B and PCM terminal 2AY
- EGR valve terminal E and PCM terminal 2AU
- EGR valve terminal F and PCM terminal 2AV
- EGR valve terminal C and main relay terminal A
- EGR valve terminal D and main relay terminal A
Short circuit
• If there is continuity, the circuit is short. Repair or replace the wiring harness.
- EGR valve terminal A and body GND
- EGR valve terminal B and body GND
- EGR valve terminal E and body GND
- EGR valve terminal F and body GND
Circuit Open/Short Inspection [Z6]
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [Z6] .)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- EGR valve terminal A and PCM terminal 2V
- EGR valve terminal B and PCM terminal 2R
- EGR valve terminal C and PCM terminal 2BG
- EGR valve terminal D and PCM terminal 2BG
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- EGR valve terminal E and PCM terminal 2Z
- EGR valve terminal F and PCM terminal 2N
Short circuit
• If there is continuity, the circuit is short. Repair or replace the wiring harness.
- EGR valve terminal A and body GND
- EGR valve terminal B and body GND
- EGR valve terminal E and body GND
- EGR valve terminal F and body GND
CHARCOAL CANISTER REMOVAL/INSTALLATION
B3E011613970W01
1. Remove the charcoal canister protector.
2. Remove in the order indicated in the table.
1
Evaporative hose
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
2 Charcoal canister
3. Install in the reverse order of removal.
CHARCOAL CANISTER INSPECTION
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1. Remove the charcoal canister.
2. Plug the atmosphere side and purge solenoid valve side of the charcoal canister.
B3E011613970W02
3. Inspect for air leakage when blowing air by mouth from the fuel tank side.
• If air leaks, replace the charcoal canister.
ROLLOVER VALVE REMOVAL/INSTALLATION
B3E011642720W01
Note
• The rollover valve cannot be removed as it is built into the fuel tank.
ROLLOVER VALVE INSPECTION
B3E011642720W02
Note
• The rollover valve cannot be disassembled and inspected as it is built into the fuel tank.
1. Perform the fuel tank inspection. (See FUEL TANK INSPECTION .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
CHARGING SYSTEM
CHARGING SYSTEM LOCATION INDEX [Z6]
B3E011701098W01
Battery
1
(See BATTERY REMOVAL/INSTALLATION [Z6] .)
(See BATTERY INSPECTION .)
(See BATTERY RECHARGING .)
Generator
2 (See GENERATOR REMOVAL/INSTALLATION [Z6] .)
(See GENERATOR INSPECTION .)
CHARGING SYSTEM LOCATION INDEX [LF]
B3E011701098W02
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Battery
1
(See BATTERY REMOVAL/INSTALLATION [LF] .)
(See BATTERY INSPECTION .)
(See BATTERY RECHARGING .)
Generator
2 (See GENERATOR REMOVAL/INSTALLATION [LF] .)
(See GENERATOR INSPECTION .)
BATTERY REMOVAL/INSTALLATION [Z6]
B3E011718520W01
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Battery cover
(See Battery Cover Installation Note .)
2 Negative battery cable
3 Positive battery cable
4
Battery box
(See Battery Box Installation Note .)
5 Battery clamp
6 Battery
7 Battery tray
Battery Box Installation Note
1. Assemble with the battery box hooks E aligned with the battery tray holes at two points.
Battery Cover Installation Note
1. Install with the battery cover hooks A aligned with the battery tray holes at two points.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Install with the battery cover hooks D aligned with the battery tray flange at two points.
3. Set the battery cover to the battery tray hooks C at two points.
BATTERY REMOVAL/INSTALLATION [LF]
B3E011718520W02
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1
Battery cover
(See Battery Cover Installation Note .)
2 Negative battery cable
3 Positive battery cable
4
Battery duct
(See Battery Duct Installation Note .)
5
Battery box
(See Battery Box Installation Note .)
6 Battery clamp
7 Battery
8
PCM cover
(See PCM Cover Installation Note .)
9 Connectors
10 Battery tray and PCM component
PCM Cover Installation Note
1. Install with the PCM cover hooks B aligned with the PCM box holes.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Install the PCM cover to the PCM box hook.
Battery Box Installation Note
1. Assemble with the battery box hooks E aligned with the battery tray holes at two points.
Battery Duct Installation Note
1. Match the mark of the shroud panel and notch in the battery duct, and install the battery duct to the shroud panel.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Battery Cover Installation Note
1. Install the battery duct between the battery cover and the battery box.
2. Install with the battery cover hooks A aligned with the battery tray holes at two points.
3. Install with the battery cover hooks D aligned with the battery tray flange at two points.
4. Set the battery cover to the battery tray hooks C at two points.
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1 Measure the battery positive voltage.
2 Quick charge for 30 min and recheck voltage.
3
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
BATTERY INSPECTION
B3E011718520W03
Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt medical attention.
Electrolyte gravity
1. Measure the electrolyte gravity using a hydrometer.
• If it is less than the specification, recharge the battery. (See BATTERY RECHARGING .)
Standard electrolyte gravity
1.221.29 [20 °C {68 °F}]
Battery voltage
1. Inspect the battery as follows:
Step Inspection
Using the battery load tester, apply load current (see load test chart) and record battery voltage after 15 s. Is voltage more than specification?
Action
12.4 V or more
Go to Step 3.
Less than
12.4 V
Go to the next step.
12.4 V or more
Go to the next step.
Less than
12.4 V
Replace the battery.
Yes Normal
No
Replace the battery.
Load test chart
Battery Current load (A)
50D20L 150
75D26L 195
80D26L 195
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Standard specification
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39}
10 {50}
9.3
9.4
16 {61}
21 {70}
Back-up current
9.5
9.6
1. Verify that the ignition switch is off and that the key has been removed.
2. Disconnect the negative battery cable.
3. Measure the back-up current between the negative battery terminal and the negative battery cable.
• If not within the specification, measure the back-up current while removing the fuses one by one from the inside of the main fuse block and the inside of the fuse block.
Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.
Standard current
20 mA max.
4. Inspect and repair wiring harnesses and connectors of the fuse where the current decreased.
BATTERY RECHARGING
B3E011718520W04
Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage.
Caution
• Do not quick charge for over 30 min. It will damage the battery.
1. Remove the battery and then place it in a pan of water.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2. Connect a battery charger to the battery and adjust the charging current as follows.
Standard specification
Battery type
(5-h rate)
Recharge current (A)
Quick charge
(A/30 min)
50D20L (40) 4.0-5.0
75D26L (52) 5.0-6.0
80D26L (55) 5.5-6.5
25
35
35
3. After the battery is recharged, verify that the voltage is within the specification and remains at the same value for 1 h or more after the recharging was completed.
• If not within the specification, replace the battery.
Standard voltage
12.4 V or more
GENERATOR REMOVAL/INSTALLATION [Z6]
B3E011718300W01
Warning
• When the battery cables are connected, touching the vehicle body with generator terminal B generates sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6] .)
5. Position the coolant reserve tank out of the way.
6. Position the power steering fluid tank out of the way.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
1 Terminal B cable
2 Generator connector
3
Generator
(See Generator Removal Note .)
Generator Removal Note
1. Remove bolt A with the generator since there is not enough space.
GENERATOR REMOVAL/INSTALLATION [LF]
B3E011718300W02
Warning
• When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the battery negative cables before performing the following operation.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield as a single unit.
4. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
5. Position the drive belt out of the way. (See DRIVE BELT REPLACEMENT [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6. Position the coolant reserve tank out of the way.
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
1 B terminal cable
2 Generator connector
3
Generator
(See Generator Installation Note .)
Generator Installation Note
1. Match the generator fixing hole and engine side hole, then temporarily tighten the generator installation bolts in the order A, B, C, and D.
2. Securely tighten the generator installation bolts in the order A, B, C, and D.
GENERATOR INSPECTION
B3E011718300W03
Caution
• Do not apply direct battery positive voltage to the generator terminal D, otherwise it could cause damage to the internal parts (power transistor) of the generator.
Generator warning light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [Z6] .)
(See DRIVE BELT INSPECTION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. With the ignition switch at ON, verify that the generator warning light illuminates.
• If it does not illuminate, inspect the generator warning light and the wiring harness.
- If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes off after the engine is started.
• If it does not goes out, check if any one of the following DTCs in the on-board diagnostic system are displayed: P0112, P0113, P2502, P2503, P2504. (See DTC TABLE [Z6] .) (See DTC TABLE
[LF] .)
Generator
Voltage
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [Z6] .)
(See DRIVE BELT INSPECTION [LF] .)
3. Turn off all electrical loads.
4. Start the engine and verify that the generator rotates smoothly without any noise while the engine is running.
5. Measure the voltage at each terminal using a tester.
Standard specification
Terminal IG-ON (V) Idle (V) [20°C {68 °F}]
B
P
B+ 13.0-15.0
Approx. 1.0 or less Approx. 3.0-8.0
D Approx. 0 *
* :
Turn the following electrical loads on and verify that the voltage reading increases.
• Headlights
• Blower motor
• Rear defroster
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Current
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [Z6] .)
(See DRIVE BELT INSPECTION [LF] .)
3. Disconnect the negative battery cable.
4. Connect a tester capable of reading 120 A or above between generator terminal B and the wiring harness.
5. Connect the negative battery cable.
6. Turn off all electrical loads.
7. Start the engine.
8. Increase engine speed from 2,000-2,500 rpm .
9. Turn the following electrical loads on and verify that the current reading increases.
• Headlights
• Blower motor
• Rear window defroster
Note
• Current required for generating power varies with electrical loads applied.
Reference value
Current possible for power generation (differs according to load)
[Conditions] ambient temperature 20 ° C {68 ° F}, voltage 13.0-15.0 V, engine warm
Engine speed (rpm)
Terminal B current (A)
Z6 LF
1,000 0*-65 0*-80
2,000 0*-85 0*-95
* :
The lower limit must be more than 0 A.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
IGNITION SYSTEM
IGNITION SYSTEM LOCATION INDEX [Z6]
B3E011801009W01
Ignition coil
1 (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
(See IGNITION COIL INSPECTION [Z6] .)
Spark plug
2 (See SPARK PLUG REMOVAL/INSTALLATION [Z6] .)
(See SPARK PLUG INSPECTION .)
IGNITION SYSTEM LOCATION INDEX [LF]
B3E011801009W02
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Ignition coil
1 (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
(See IGNITION COIL INSPECTION [LF] .)
Spark plug
2 (See SPARK PLUG REMOVAL/INSTALLATION [LF] .)
(See SPARK PLUG INSPECTION .)
IGNITION COIL REMOVAL/INSTALLATION [Z6]
B3E011801009W03
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Connector
2 Ignition coil
IGNITION COIL REMOVAL/INSTALLATION [LF]
B3E011801009W04
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the plug hole plate.
(See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Connector
2 Ignition coil
IGNITION COIL INSPECTION [Z6]
B3E011801009W05
IGNITION COIL WITH BUILT-IN POWER SWITCH INSPECTION
1. Remove the ignition coil connector.
2. Measure the resistance between each terminal on the ignition coil connector.
• If the measurement corresponds to the table, replace the ignition coil.
Item
Tester Connection Position
Positive Negative
Condition
C B
∞ or 0 ohm is not normal
Terminal A
A
B
C 0 to several kilohm (continuity) is not normal
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
IGNITION COIL INSPECTION [LF]
B3E011801009W06
Primary Coil Winding
1. Disconnect the ignition coil connector.
2. Measure the resistance between the following terminals using an ohmmeter:
• A and B
- If not as specified, replace the ignition coil.
Resistance (Reference)
0.451.15 ohms [25 °C {77 °F}]
Secondary Coil Winding
1. Disconnect the ignition coil connector.
2. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Measure the resistance between the following using an ohmmeter.
• Terminal A to coil boot socket
- If not as specified, replace the ignition coil.
Resistance (Reference)
5.06.0 kilohms [25 °C {77 °F}]
Insulation Resistance of Case
1. Disconnect the ignition coil connector.
2. Measure the insulation resistance from terminal A to ignition coil case using an ohmmeter.
• If not as specified, replace the ignition coil.
Resistance (Reference)
Above 10 megohms [25 °C {77 °F}]
SPARK PLUG REMOVAL/INSTALLATION [Z6]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E011801009W07
Caution
• If a spark plug that is not as specified is installed, sealing performance will be deteriorated.
Install only the specified spark plug when replacing.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [Z6] .)
5. Remove the spark plugs using a plug-wrench.
6. Install in the reverse order of removal.
Tightening torque
1422 N·m {1.52.3 kgf·m, 1116 ft·lbf}
SPARK PLUG REMOVAL/INSTALLATION [LF]
B3E011801009W08
Caution
• If a spark plug that is not as specified is installed, sealing performance will be deteriorated.
Install only the specified spark plug when replacing.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)
4. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)
5. Remove the spark plugs using a plug-wrench.
6. Install in the reverse order of removal.
Tightening torque
1014 N·m {1.1-1.4kgf·m, 8-10 ft·lbf}
SPARK PLUG INSPECTION
B3E011801009W09
Specification
Item Engine
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Z6 LF
Type
NGK ITR6F13
DENSO
SK16PR-E11
-
Plug Gap Inspection
Caution
• To avoid possible damage to the tip, do not adjust the plug gap.
• To prevent damaging the tip, use wire type plug gap gauge when inspecting the plug gap.
1. Measure the spark plug gap using the wire type plug gap gauge.
• If it is more than the maximum specification, replace the spark plug.
Standard plug gap
Z6: 1.0-1.1 mm {0.039-0.043 in}
LF: 1.25-1.35 mm {0.049-0.053 in}
Cleaning
Caution
• To avoid possible damage to the tip, do not use a wire brush to clean the plug.
Note
• To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.
Visual inspection
1. Inspect the following items:
• If there is any malfunction, replace the spark plug.
- Insulator breakage
- Worn electrode
- Damaged gasket
- Badly burned insulator (sparking side)
Resistance Inspection
1. Measure the resistance of the spark plug using a tester as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If not within the specification, replace the spark plug.
Resistance
3.07.5 kilohms [25°C {77 °F}]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
STARTING SYSTEM
STARTING SYSTEM LOCATION INDEX [Z6]
B3E011918400W01
Starter
1 (See STARTER REMOVAL/INSTALLATION [Z6] .)
(See STARTER INSPECTION .)
STARTING SYSTEM LOCATION INDEX [LF]
B3E011918400W02
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Starter
1 (See STARTER REMOVAL/INSTALLATION [LF] .)
(See STARTER INSPECTION .)
STARTER REMOVAL/INSTALLATION [Z6]
B3E011918400W03
Warning
• When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Terminal B cable
2 Terminal S connector
3 Wiring harness clip
4 Starter
STARTER REMOVAL/INSTALLATION [LF]
B3E011918400W04
Warning
• When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove the clutch release cylinder. (MTX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION
[F35M-R] .)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1 Terminal B cable
2 Terminal S connector
3 Wiring harness bracket
4 Starter
STARTER INSPECTION
B3E011918400W05
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
• If the starter does not operate, inspect the following:
- Remove the starter, and inspect the starter unit.
- Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch (ATX).
No-load test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as shown in the figure.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Operate the starter and verify that it rotates smoothly.
• If the starter does not rotate smoothly, inspect the starter unit.
4. Measure the voltage and current while the starter is operating.
• If not within the specification, replace the starter.
Standard current
Item
Voltage (V) Current (A)
11 90 or less
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
CONTROL SYSTEM[Z6]
CONTROL SYSTEM LOCATION INDEX [Z6]
B3E014018880W04
PCM
1
(See PCM REMOVAL/INSTALLATION [Z6] )
(See PCM INSPECTION [Z6] )
(See PCM CONFIGURATION [Z6] )
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2
Neutral switch
(See NEUTRAL SWITCH INSPECTION [Z6] )
3
CPP switch (MTX)
(See CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [Z6] )
4
PSP switch
(See POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [Z6] )
ECT sensor
5 (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6] )
(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [Z6] )
IAT sensor
6
(See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] )
(See INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [Z6] )
CKP sensor
7 (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6] )
(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [Z6] )
CMP sensor
8 (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [Z6] )
(See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [Z6] )
TP sensor
9 (See THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION [Z6] )
(See THROTTLE POSITION (TP) SENSOR INSPECTION [Z6] )
MAF sensor
10
(See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
REMOVAL/INSTALLATION [Z6] )
(See MASS AIR FLOW (MAF) SENSOR INSPECTION [Z6] )
Front HO2S
11 (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] )
(See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6] )
Rear HO2S
12 (See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] )
(See REAR HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6] )
13 BARO sensor
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
(See BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION [Z6] )
KS
14 (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [Z6] )
(See KNOCK SENSOR (KS) INSPECTION [Z6] )
CONTROL SYSTEM DIAGRAM [Z6]
B3E014018880W05
CONTROL SYSTEM WIRING DIAGRAM [Z6]
B3E014018880W06
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
PCM REMOVAL/INSTALLATION [Z6]
B3E014018880W07
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Note
• The PCM is integrated with the air cleaner cover and cannot be removed.
1. When replacing the PCM, perform the following:
• PCM configuration (See PCM CONFIGURATION [Z6] .)
2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
3. Disconnect the negative battery cable.
4. Remove the air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
5. When replacing the PCM on the vehicles, perform the following:
• PCM parameter reset (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING .)
6. Install in the reverse order of removal.
PCM INSPECTION [Z6]
B3E014018880W08
Not Using the WDS or Equivalent
Note
• The PCM terminal voltage can vary with conditions when measuring and changes due to age deterioration on the vehicle, causing false diagnosis. Therefore a comprehensive inspection of the input and output systems, and the PCM is necessary to determine where the malfunction occurs.
PCM terminal voltage table (Reference)
Terminal voltage table (Reference)
Terminal Signal name Connected to Measurement condition
1A
1B
-
-
-
-
-
-
-
-
Voltage
(V)
-
-
Inspection item(s)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1H
1I
1J
1L
1M
1N
1C
1D
1E
1F
1G *1
1K *1
1O *1
1P
1Q
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Internal GND
Input/turbine speed sensor shield wire
Under any condition
-
-
-
-
-
-
-
-
-
-
-
-
-
1.0 or less
• Related wiring harness
-
-
-
-
-
-
Input/turbine speed sensor
(-)
Input/turbine speed sensor
(See Inspection Using An Oscilloscope
(Reference) .)
-
-
-
-
-
-
-
-
-
Input/turbine speed sensor
(+)
Input/turbine speed sensor
(See Inspection Using An Oscilloscope
(Reference) .)
*3 CPP switch
CPP switch
Ignition switch is turned to the ON position.
Clutch pedal depressed
Clutch pedal released
1.0 or less • CPP switch
B+
• Related wiring harness
*1 Manual up
Up switch
Ignition switch is turned to the ON position.
Detects up-shift operation of selector lever in M range
1.0 or less
• Selector lever
• Related wiring harness
Others B+
Refrigerant pressure
(low, high)
Refrigerant pressure switch than the specification or less than the specification.
(low pressure
Refrigerant pressure is more
(Refrigerant pressure switch switch, high pressure switch)
(low pressure switch, high pressure switch) is off.)
Others
B+
• Refrigerant pressure switch
(low pressure switch, high pressure switch)
1.0 or less
• Related wiring harness
-
-
-
• Input/turbine speed sensor
• Related wiring harness
-
-
-
• Input/turbine speed sensor
• Related wiring harness
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1R
1S
1T
1U
1V
1W
1X *1
1Y
1Z
1AA
1AB
-
CAN_L
Instrument cluster, ABS
HU/CM, DSC
HU/CM, DLC-2
Because this terminal is for CAN, good/no good judgment by terminal voltage is not possible.
-
-
Refrigerant pressure
(middle)
Brake switch
Refrigerant pressure switch
(middle)
Brake switch
Idle
Refrigerant pressure is 1.52
MPa {15.5 kgf/cm 2 , 221 psi} or more
Refrigerant pressure is 12.3
1.0 or less • Refrigerant pressure switch
(middle)
• Related wiring harness
MPa {125 kgf/cm 2 ,
1783 psi} or less
B+
Brake pedal depressed
Brake pedal released
B+ • Brake switch
1.0 or less
• Related wiring harness
-
-
-
CAN_H
Selector lever position
Instrument cluster, ABS
HU/CM, DSC
HU/CM, DLC-2
Because this terminal is for CAN, good/no good judgment by terminal voltage is not possible.
-
P position
Approx.
4.6
Approx.
3.9
TR switch
R position
Ignition switch is turned to the ON position.
N position
D range
Approx.
3.2
Approx.
2.5
• TR switch
• Related wiring harness
*3 Neutral switch
-
-
-
Neutral switch
-
-
-
Ignition switch is turned to the ON position.
M range
Neutral
Except above
-
-
Approx.
2.5
-
-
-
1.0 or less
• Neutral switch
B+
• Related wiring harness
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1AC
*1 Manual down
Fuel pump control
Down switch
Fuel pump relay
Ignition switch is turned to the ON position.
Detects down-shift operation of
1.0 or less selector lever in M range
• Selector lever
• Related wiring harness
Others B+
Immediately after ignition switch is turned to the ON position.
1.0 or less
• Fuel pump relay
• Related wiring harness
1AD
1AE
1AF
1AG
1AH
1AI
1AJ
1AL
1AK
*1
1AM
*1
-
-
-
-
-
Pressure control solenoid (+)
-
P or N position
Shift solenoid
D
Shift solenoid D
Except above
Starter relay control
The A/C cutoff control.
-
-
-
-
Pressure control solenoid
Starter relay
A/C relay
(See Inspection Using An Oscilloscope
-
-
(Reference) .)
Cranking
The A/C is operating.
The A/C is not operating.
-
-
-
-
• Pressure control solenoid
• Related wiring harness
-
-
-
B+ • Shift solenoid
D
1.0 or less
• Related wiring harness
• Starter relay
1.0 or less • Related wiring harness
1.0 or less • A/C relay
B+
• Related wiring harness
-
1AN *1 Internal GND
1AO
1AP
-
Fan control
-
-
TFT sensor, TR switch
Under any condition
-
CTP
-
-
1.0 or less
• Related wiring harness
-
B+
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1AQ *1
1AR
1AS
1AT
1AU
1AV
1AW
1AX
*1
*1
*1
M range switch
-
-
ATF temperature
Fan control
-
module
M range switch
Ignition switch is turned to the ON position.
Shift solenoid
E
Shift solenoid E
TFT sensor
Test mode
-
is on.
*2
WOT
Except above
During TCC operation
Except above
Ignition switch is turned to the ON position.
M range
1.0 or less
• Fan control module
• Related wiring harness
1.0 or less
B+
• Selector lever
• Related wiring harness
B+ • Shift solenoid E
1.0 or less
• Related wiring harness
-
-
TFT is 20 °C {68
°F}
Approx.
3.3
TFT is 40 °C {104
°F}
Approx.
2.4
TFT is 60 °C {140
°F}
Approx.
1.5
• TFT sensor
• Related wiring harness
Pressure control solenoid (-)
Pressure control solenoid
(See Inspection Using An Oscilloscope
(Reference) .)
• Pressure control solenoid
• Related wiring harness
Main relay
Back-up power supply
Main relay
Battery
Ignition switch is off.
Ignition switch is turned to the
ON position.
B+ • Main relay
1.0 or less
• Related wiring harness
Under any condition B+
• Battery
• Related wiring harness
1AY *1
Vehicle speed
1AZ *1
1BA
1BB
-
Main relay
-
Ignition switch is off.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1BC
1BD
1BE
1BF
1BG *1
1BH
2A
2B
2C
2D
*1
*1
*1
Battery voltage
VSS power supply
VSS
Ignition switch is turned to the
ON position.
B+
Ignition switch is turned to the
ON position.
B+
• Battery
• Related wiring harness
• Related wiring harness
Shift solenoid
C
Ignition switch
Battery voltage
Battery voltage
Shift solenoid C
Main relay
(See Inspection Using An Oscilloscope
(Reference) .)
• Shift solenoid
C
• Related wiring harness
Ignition switch is off.
Ignition switch
Ignition switch is turned to the
ON position.
1.0 or less • Ignition switch
B+
• Related wiring harness
Main relay
Ignition switch is off
Ignition switch is turned to the
ON position.
1.0 or less • Main relay
• Battery
B+ • Related wiring harness
Ignition switch is off.
Ignition switch is turned to the
ON position.
1.0 or less • Main relay
• Battery
B+ • Related wiring harness
Shift solenoid
B
Ignition coil power supply
Fuel injection control
Fuel injection control
Fuel injection control
Shift solenoid B
Ignition coil
Fuel injector
No.1
Fuel injector
No.2
Fuel injector
No.3
(See Inspection Using An Oscilloscope
(Reference) .)
Ignition switch is turned to the
ON position.
B+
(See Inspection Using An Oscilloscope
(Reference) .)
(See Inspection Using An Oscilloscope
(Reference) .)
(See Inspection Using An Oscilloscope
(Reference) .)
• Shift solenoid B
• Related wiring harness
• Related wiring harness
• Fuel injector
No.1
• Related wiring harness
• Fuel injector
No.2
• Related wiring harness
• Fuel injector
No.3
• Related wiring harness
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2E
2F
2G
Fuel injector
No.1 power supply
Fuel injector
No.1
Fuel injector
No.2 power supply
Fuel injector
No.2
Fuel injector
No.3 power supply
Fuel injector
No.3
Ignition switch is turned to the
ON position.
B+
Ignition switch is turned to the
ON position.
B+
Ignition switch is turned to the
ON position.
B+
• Related wiring harness
• Related wiring harness
• Related wiring harness
2H
2I
Fuel injection control
Fuel injector
No.4
-
2J ECT ECT sensor
Ignition switch is turned to the ON position.
2K Rear HO2S Rear HO2S Idle
2L
2M ESA control
Ignition coil
No.4
• Related wiring harness
2N
2O
2P CKP
-
CKP sensor
2Q ESA control
Ignition coil
No.3
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2R
2S
2T
2U
2V
2W
2X
2Y
EGR control EGR valve Idle (EGR control operating) B+
• Related wiring harness
• EGR valve
• Related wiring harness
BARO sensor
Altitude:0 m {0 ft}) 2.3-2.8
*4
Altitude:500 m
{1,640 ft}
2.2-2.8
*4
BARO sensor
Ignition switch is turned to the ON position.
Altitude:1,000 m
{3,281 ft}
2.1-2.8
*4
Altitude:1,500 m
{4921 ft}
2.0-2.8
*4
• BARO sensor
• Related wiring harnesses
Altitude: 2,000 m
{6,562 ft}
1.9-2.7
*4
Altitude: 2,500 m
{8,202 ft}
1.8-2.6
*4
Input/output device power supply
CKP sensor,
CMP sensor, front HO2S, rear HO2S, purge solenoid valve
Ignition switch is turned to the
ON position.
B+
• Related wiring harness
ESA control
EGR control
Constant voltage (vref)
IAC (+)
ESA control
Ignition coil
No.2
EGR valve
TP sensor,
BARO sensor
IAC valve
Ignition coil
No.1
(See Inspection Using An Oscilloscope
(Reference) .)
Idle (EGR control operating)
Ignition switch is turned to the
ON position.
Approx.
5.0
(See Inspection Using An Oscilloscope
(Reference) .)
(See Inspection Using An Oscilloscope
(Reference) .)
B+
• Ignition coil
No.2
• Related wiring harness
• EGR valve
• Related wiring harness
• TP sensor
• BARO sensor
• Related wiring harness
• IAC valve
• Related wiring harness
• Ignition coil
No.1
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2Z
2AA
2AB
EGR control
TP
IAC (-)
EGR valve
TP sensor
IAC valve
• Related wiring harness
• EGR valve
Idle (EGR control operating) 1.0 or less
• Related wiring harness
CTP 0.3-1.0
Ignition switch is turned to the ON position.
WOT 3.1-4.5
• TP sensor
• Related wiring harness
(See Inspection Using An Oscilloscope
(Reference) .)
• IAC valve
• Related wiring harness
2AC PSP switch PSP switch
2AD
2AE
-
Internal GND TP sensor
2AF
Variable tumble control
(open)
2AG
2AH
2AI
2AJ
Variable valve timing control (-)
OCV
-
Front HO2S
Variable tumble control
(close)
Front HO2S
(See Inspection Using An Oscilloscope
(Reference) .)
• Front HO2S
• Related wiring harness
When the ignition
Variable tumble shutter valve actuator
The engine is cold.
Except above switch turned to the ON position.
B+ *5
1.0 or less
• Variable tumble shutter valve actuator
• Related wiring harness
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2AK
2AL
2AM
Variable valve timing control (+)
OCV
-
(See Inspection Using An Oscilloscope
(Reference) .)
-
Front HO2S heater control
Front HO2S heater
(See Inspection Using An Oscilloscope
(Reference) .)
2AN
Generator control
Generator
(terminal D)
(See Inspection Using An Oscilloscope
(Reference) .)
2AO
Variable intake-air control
(open)
2AP -
2AQ IAT
2AR
2AS
2AT
2AU
Generator output voltage
Variable intake-air control
(close)
Rear HO2S
Variable intakeair shutter valve actuator
Rear HO2S
When the ignition switch is turned to the ON position.
When the engine speed is decreased gradually and reaches 4,100 rpm.
Except above
B+ *5
1.0 or less
• Variable intakeair shutter valve actuator
• Related wiring harness
After fixed period of time from engine start
Engine speed is 2,700 or more.
1.0 or less
• Rear HO2S
B+
• Related wiring harness
MAF MAF sensor
Ignition switch is turned to the
ON position.
Approx.
0.7
Idle
Approx.
1.3
• MAF sensor
• Related wiring harness
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
2AV
2AW
Purge control
Purge solenoid valve
(See Inspection Using An Oscilloscope
(Reference) .)
-
• Purge solenoid valve
• Related wiring harness
-
2AX Internal GND
ECT sensor, front HO2S, rear HO2S,
BARO sensor
Under any condition 1.0 or less
• Related wiring harness
2AY
2AZ
Internal GND IAT sensor
GND GND
Under any condition
Under any condition
1.0 or less
• Related wiring harness
1.0 or less
• Related wiring harness
2BA
2BB
2BC
2BD
2BE
2BF
2BG
2BH
Knocking Knock sensor
Ignition switch is turned to the
ON position. (Use digital type voltmeter, because measurement voltage will be detected less than true voltage when using analog type voltmeter)
Approx.
2.4
• Knock sensor
• Related wiring harness
CMP
Internal GND
GND
CMP sensor
MAF sensor
GND
(See Inspection Using An Oscilloscope
(Reference) .)
Under any condition
Under any condition
• CMP sensor
• Related wiring harness
1.0 or less
• Related wiring harness
1.0 or less
• Related wiring harness
Internal GND
Internal GND
Power supply
GND
HO2S shield wire
CKP sensor,
CMP sensor
MAF sensor,
EGR valve
GND
Under any condition
Under any condition
Under any condition
Under any condition
1.0 or less
• Related wiring harness
1.0 or less
• Related wiring harness
B+
• Related wiring harness
1.0 or less
• Related wiring harness
*1 :
ATX
*2 :
Turn the test mode on using the WDS simulation test.
*3 :
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
MTX
*4 :
The voltage may vary excessively depending on the weather or battery conditions.
*5 :
The voltage changes for a specified time.
Inspection Using An Oscilloscope (Reference)
Input/turbine speed sensor (-) signal
PCM terminals
• 1K (+)-Negative battery terminal (-)
Oscilloscope setting
• 500 mV/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
Input/turbine speed sensor (+) signal
PCM terminals
• 1O (+)-Negative battery terminal (-)
Oscilloscope setting
• 500 mV/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Idle after warm-up
Vehicle speed output signal
PCM terminals
• 1Z (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 20 ms/DIV (X), DC range
Vehicle condition
• Vehicle speed is 20 km/h {12 mph}.
Pressure control solenoid (+) signal
PCM terminals
• 1AF (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• All of the following conditions are met.
- Ignition switch is turned to the ON position. (engine off)
- P or N position
- CTP
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Pressure control solenoid (-) signal
PCM terminals
• 1AV (+)-Negative battery terminal (-)
Oscilloscope setting
• 200 mV/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• All of the following conditions are met.
- Ignition switch is turned to the ON position. (engine off)
- P or N position
- CTP
Vehicle speed signal (ATX)
PCM terminals
• 1AY (+)-Negative battery terminal (-)
Oscilloscope setting
• 1 V/DIV (Y), 2.5 ms/DIV (X), DC range
Vehicle condition
• Vehicle speed is 32 km/h {20 mph}.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Shift solenoid A signal
PCM terminals
• 1AZ (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 5 ms/DIV (X), DC range
Vehicle condition
• 4GR
Shift solenoid C signal
PCM terminals
• 1BD (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 5 ms/DIV (X), DC range
Vehicle condition
• 1GR or 2GR
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Shift solenoid B signal
PCM terminals
• 1BH (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 5 ms/DIV (X), DC range
Vehicle condition
• 1GR (except L range (HOLD))
Fuel injection control signal
PCM terminals
• No.1: 2B (+)-Negative battery terminal (-)
• No.2: 2C (+)-Negative battery terminal (-)
• No.3: 2D (+)-Negative battery terminal (-)
• No.4: 2H (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 10 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ESA control signal
PCM terminals
• No.1: 2Y (+)-Negative battery terminal (-)
• No.2: 2U (+)-Negative battery terminal (-)
• No.3: 2Q (+)-Negative battery terminal (-)
• No.4: 2M (+)-Negative battery terminal (-)
Oscilloscope setting
• 0.5 V/DIV (Y), 40 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
CKP signal
PCM terminals
• 2P (+)-Negative battery terminal (-)
Oscilloscope setting
• 1 V/DIV (Y), 10 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
IAC (+) signal
PCM terminals
• 2X (+)-Negative battery terminal (-)
Oscilloscope setting
• 2 V/DIV (Y), 2 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
IAC (-) signal
PCM terminals
• 2AB (+)-Negative battery terminal (-)
Oscilloscope setting
• 2 V/DIV (Y), 2 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Oxygen concentration signal
PCM terminals
• 2AI (+)-Negative battery terminal (-)
Oscilloscope setting
• 0.2 V/DIV (Y), 1 s/DIV (X), DC range
Vehicle condition
• Idle after warm-up
Variable valve timing control (+) signal
PCM terminals
• 2AK (+)-Negative battery terminal (-)
Oscilloscope setting
• 5 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
HO2S heater signal
PCM terminals
• 2AM (+)-Negative battery terminal (-)
Oscilloscope setting
• 2 V/DIV (Y), 0.1 s/DIV (X), DC range
Vehicle condition
• Idle after warm-up
Generator control signal
PCM terminals
• 2AN (+)-Negative battery terminal (-)
Oscilloscope setting
• 0.5 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Generator output voltage signal
PCM terminals
• 2AR (+)-Negative battery terminal (-)
Oscilloscope setting
• 2 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
Purge control signal
PCM terminals
• 2AV (+)-Negative battery terminal (-)
Oscilloscope setting
• 2 V/DIV (Y), 0.1 s/DIV (X), DC range
Vehicle condition
• Idle after warm-up
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
CMP signal
PCM terminals
• 2BB (+)-Negative battery terminal (-)
Oscilloscope setting
• 1 V/DIV (Y), 20 ms/DIV (X), DC range
Vehicle condition
• Idle after warm-up
Using the WDS or Equivalent
Note
• PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.
- CMP sensor (See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [Z6] .)
- Main relay (See RELAY INSPECTION .)
1. Connect the WDS or equivalent to the DLC-2.
2. Turn the ignition switch to the ON position.
3. Measure the PID value.
• If PID value is not within the specification, follow the instructions in Action column.
Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.
• The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION
INSPECTION are as follows.
- ACCS, ALTF, ARPMDES, EVAPCP, FAN_DUTY, FP, FUELPW1, GENVDSD, HTR11, HTR12,
IAC, IMRC, IMTV, INJ_1, INJ_2, INJ_3, INJ_4, SEGRP, test, VT ACT1, VT DUTY1
Item (definition) Unit/Condition
Condition/Specification
(Reference)
Inspection item(s)
PCM terminal
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
AC_REQ
(Refrigerant pressure switch
(low pressure switch, high pressure switch))
ACCS
(A/C relay)
ALTF
(Generator field coil control duty value)
ALTT V
(Generator output voltage)
ARPMDES speed)
(Target engine
On/Off
On/Off
%
V
RPM
• Refrigerant pressure is more than the specification or less than the specification.
(Refrigerant pressure switch
(low pressure switch, high pressure switch) is off.): Off
• Refrigerant pressure switch (low pressure switch, high pressure switch)
1Q
• Others: On
• A/C is operating: On
• A/C is not operating: Off
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
PCM_T, RPM,
1AL
TP, TR,
AC_REQ,
COLP
• The following PIDs
• Ignition switch is turned to the ON position: 0%
• Idling, E/L is operating: Duty value increases.
- ECT, IAT,
RPM, VSS,
ALTT V,
VPWR
• Generator
• Ignition switch is turned to the ON position: Approx. 1.0 V or less
• Idling (no electrical load):
Approx. 14 V (This is an internal calculation value and differs from the terminal voltage.)
• Generator
2AN
2AR
MTX (neutral position)
• No load: 690 RPM
• E/L on *4 (34-42 A): 700 RPM
• The following PIDs
• E/L on *4 (42 A or more): 750
RPM
• A/C on *5 (low load): 700
RPM
• A/C on *5 (high load): 750
RPM
• P/S on: 750 RPM
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
-
MAF, BARO,
VSS,
AC_REQ,
COLP
ATX (N range)
• IAC valve
• No load: 750 RPM
• E/L on *4 (34-42 A): 750 RPM
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
BARO
(Barometric pressure)
BOO
(Brake switch) kPa Bar psi
V
On/Off
• E/L on *4 (42 A or more): 750
RPM
• A/C on *5 (low load): 750
RPM
• A/C on
*5 (high load): 750
RPM
• P/S on: 750 RPM
• Ignition switch is turned to the ON position: Indicate the atmospheric pressure
• Ignition switch is turned to the ON position
- Altitude: 0 m {0 ft}:
2.3-2.8
*1
- Altitude:500 m
{1,640 ft}: 2.2-2.8
*1
- Altitude:1,000 m
{3,281 ft}: 2.1-2.8
*1
- Altitude:1,500 m
{4921 ft}: 2.0-2.8
*1
- Altitude: 2,000 m
{6,562 ft}: 1.9-2.7
*1
- Altitude: 2,500 m
{8,202 ft}: 1.8-2.6
*1
• BARO sensor
• Brake pedal is depressed:
On
• Brake pedal is released: Off
• Brake switch
CATT11_DSD
(Estimated catalytic converter temperature)
CHRGLP
(Generator warning light)
°C
On/Off
COLP
(Refrigerant pressure switch
(medium pressure switch))
On/Off
°F
• Idling after warm up: approx.
440 °C {824 °F}
• Ignition switch is turned to the ON position: On
• Idling: Off
• The following PIDs
- BARO, ECT,
IAT, MAF,
RPM
• Generator warning light
2S
1V
-
-
• Refrigerant pressure is 1.52
MPa {15.5 kgf/cm 2 , 221 psi} or more: On
• Refrigerant pressure is 12.3
MPa {125 kgf/cm 2 , 1783 psi} or less: Off
• Refrigerant pressure switch (mediumpressure switch)
1U
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
CPP *2
(Clutch pedal position)
On/Off
• Clutch pedal is depressed:
On
• Clutch pedal is released: Off
• CPP switch 1P
CPP/PNP *2
(Shift lever position)
Drive/Neutral
DTCCNT
(Number of DTC detected)
No unit
• Neutral: Neutral
• Other than neutral: Drive
• Number of DTCs stored
• Neutral switch
-
DWN SW *3
ECT
(Engine coolant temperature)
V
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
°C °F
• Ignition switch is turned to the ON position: Indicate the
ECT
• ECT is 20 °C {68 °F}:
Approx. 3.0 V
• ECT is 60 °C {140 °F}:
Approx. 1.4 V
• ECT is 80 °C {176 °F}:
Approx. 0.9 V
• ECT sensor
EQ_RAT_DSD
(Theoretical air/fuel ratio coefficient to calculate target air/fuel ratio)
No unit
• Idling after warm-up:
Approx.1
• Front HO2S
EVAPCP
FP
(Fuel pump relay)
(Purge solenoid valve duty value)
FAN_DUTY
(Fan control duty value)
%
%
On/Off
1AB
-
-
2J
• Ignition switch is turned to the ON position: 0 %
• Increase the engine speed:
Duty value rises
• The following PIDs
- ECT, IAT,
RPM, TP,
MAF, O2S11,
BOO, VPWR
2AV
• When all of following condition are met: 90 %
- Test mode On
- WOP
• Immediately after ignition switch is turned to the ON position: On
• Ignition switch is turned to the ON position: Off
• Idling: On
• The following PIDs
- test, TP
• Fuel pump relay
-
1AC
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Cranking: On
FUELPW
FUELSYS
(Fuel system status)
(Fuel injector duration) ms
OL/CL/OL Drive/OL
Fault/CL Fault
• Idling: Approx. 2.0 ms
• Idling after warm-up: CL
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
2B, 2C,
2D, 2H
O2S12,
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
-
O2S12,
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
GEAR
GENVDSD
(Target generator voltage)
HTR11
(Front HO2S heater control)
HTR12
(Rear HO2S heater control)
IAC
*3
(IAC duty value)
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
V
• Ignition switch is turned to the ON position: Approx. 1.0 V or less
• The following PIDs
- ECT, IAT,
• Idling (no electrical load):
Approx. 14 V (This is an internal calculation value and differs from the terminal voltage.)
RPM, VSS,
ALTT V,
VPWR
• Generator
-
On/Off
On/Off
%
• Ignition switch is turned to the ON position: Off
• When the vehicle is driving at engine speed less than
4,300 rpm: On
• The following PIDs
- ECT, IAT,
RPM, TP,
MAF, BARO,
VPWR
2AM
• After fixed period of time from engine start: On
• Engine speed is 2,700 or more: Off
• Ignition switch is turned to the ON position: 0 %
• The following PIDs
- ECT, IAT,
RPM, TP,
MAF, BARO,
VPWR
2AT
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
2X, 2AB
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
IAT
(Intake air temperature)
IMRC
(Variable tumble control)
IMTV
(Variable intakeair control)
INGEAR
(Gears are engaged.)
IVS
(CTP condition)
°C
V
%
On/Off
%
On/Off
On/Off
Idle/Off Idle
°F
• Idling (ECT is 88 °C {190 °F}, no load condition): Approx. 25
%
MAF, BARO,
VSS,
AC_REQ,
COLP
• Ignition switch is turned to the ON position: Indicate the
IAT
• IAT is 20°C {68°F}: Approx.
2.2 V
• IAT is 30°C {86°F}: Approx.
1.8 V
• IAT sensor 2AQ
• Cold start and 3,250 rpm or less: 12.5-50
• Hot start or 3,250 rpm or more: 12.5-42
• Cold start and 3,250 rpm or less: On
• Hot start or 3,250 rpm or more: Off
• The following PIDs
- ECT, RPM,
TP
2AF,
2AJ
• Engine speed is less than
4,100 rpm: 12.5-50
• Engine speed is 4,100 rpm or more: 12.5-42
• Engine speed is less than
4,100 rpm: On
• Engine speed is 4,100 rpm or more: Off
• The following PIDs
- RPM
MTX
• When the following conditions are satisfied: On
- Not neutral
- Clutch pedal released
• Except above: Off
• CPP switch
• Neutral switch
2AO,
2AS
1P, 1AB
ATX
• Driving range: On
• Except above: Off
• Idling: Idle
• Other than idling: Off Idle
• TR switch
• The following PIDs
- TP
-
-
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
KNOCKR
(Knocking retard)
MNL SW *3
°
• Ignition switch is turned to the ON position: 0 °
• Idling: 0 °
• KS 2BA
LINEDES
LOAD
*3
(Engine load)
LONGFT1
(Long term fuel trim)
%
LPS *3
• Idling (after warm-up):
Approx. -15-+15 %
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
O2S12,
-
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
MAF
(Mass air flow)
MIL
(Malfunction indicator lamp)
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
%
• Idling (after warm-up):
Approx. 23 %
• The following PIDs
- BARO, IAT,
MAF, RPM
g/s
V
On/Off
• Ignition switch is turned to the ON position: Approx. 0 g/s
• Idling: Approx. 2.7 g/s
• Ignition switch is turned to the ON position: Approx. 0.7 V
• MAF sensor
• Idling: Approx. 1.3 V
• Ignition switch is turned to the ON position: On
• Idling: Off
(If there is a malfunction in emission control related system: On)
• MIL
2AU
-
MIL_DIS
(Travelled distance since
MIL illuminated) km mile Indicate the travelled distance since the MIL illuminated
O2S11
(Front HO2S)
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
V
• Ignition switch is turned to the ON position: 1.0 V or less
• Idling (after warm-up):
Alternates between 0 and 1.0
V
• Front HO2S
2AI
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
O2S12
(Rear HO2S)
V
• Idling (after warm-up):
Alternates between 0 and 1.0
V
• Rear HO2S
2K
OP_SW_B *3
PCM_T
(PCM temperature sensor)
(See
V
PID/DATA MONITOR INSPECTION [FN4A-EL]
• Ignition switch is turned to the ON position: Indicate the
PCM temperature sensor output voltage
)
• PCM
PCM_T_Max
(Maximum PCM temperature)
V
• Ignition switch is turned to the ON position: Indicate the maximum PCM temperature sensor output voltage
• PCM
PSP
(PSP switch)
High/Low
• Steering wheel is in straight ahead position: Low
• Steering wheel is fully turned: High
• PSP switch
RFCFLAG
(PCM adaptive memory produce verification)
Learnt/Not Learnt
• Idling (after running PCM adaptive memory procedure drive mode): Learnt
• Right after the negative battery cable is disconnected
(before running PCM adaptive memory procedure drive mode): Not Learnt
• Perform "DRIVE
MODE".
RO2FT1
(Rear oxygen sensor fuel trim)
No unit
• Idling after warm-up: Approx.
-0.03-+0.03
• The following PID
- O2S12
RPM
(Engine speed)
SEGRP
(EGR control)
SEGRP DSD
(EGR valve position desired)
RPM
Step
%
-
-
2AC
-
2K
MTX
• Idling (no load), neutral position: 640-740 RPM
ATX
• Idling (no load), N range:
700-800 RPM
• CKP sensor 2P
• Ignition switch is turned to the ON position: 0 step
• Idling: 0 step
• Vehicle driving when engine speed is 1,000-4,700 rpm: 0-
52 step
• EGR valve
• Ignition switch is turned to the ON position: 0 %
• Idling: 0 %
• The following PID -
2N, 2R,
2V, 2Z
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
SHRTFT1
(Short term fuel trim (front))
SHRTFT11
(Short term fuel trim (front))
%
%
• Vehicle driving when engine speed is 1,000-4,700 rpm: 0-
100 %
• Idling (after warm-up): -25-
+25%
• Idling (after warm-up): -25-
+25%
- MAF, TP,
ECT, RPM,
VSS
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
O2S12,
-
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
2AI
O2S12,
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
SHRTFT12
(Short term fuel trim (rear))
%
SPARKADV
(Ignition timing)
SSA/SS1 *3
° (BTDC)
• Idling after warm-up: Approx.
99 %
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
MAF, O2S11,
O2S12,
2K
BARO, VSS,
TR, BOO,
AC_REQ,
COLP, VPWR
• During test mode on at idling: BTDC 911 ° (BTDC)
• Idling: BTDC 6-18 ° (BTDC)
• The following PIDs
- CPP,
CPP/PNP,
PSP, ECT,
IAT, RPM, TP,
2BB
MAF,
KNOCKR, TR,
BOO,
AC_REQ,
COLP
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
SSB/SS2 *3 (See PID/DATA MONITOR INSPECTION [FN4A-EL] )
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
SSC/SS3 *3
TCS *3 test
(Test mode)
TFT *3
TFTV *3
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
On/Off
• During test mode: On
• Other than test mode: Off
-
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
TIRESIZE
(Tire revolution per mile)
No unit • Indicate the tire revolution per a mile
TP
(TP)
%
V
• CTP: Approx. 12 %
• WOT: Approx. 75 %
• CTP: 0.31.0 V
• WOT: 3.14.5 V
• TP sensor
TP REL
(Throttle position signal (relative value))
%
TPCT
(TP sensor voltage at CTP)
V
TR *3
TR_SENS *3
• CTP: Approx. 0 %
0.31.0 V
• WOT: Approx. 100 %
• TP sensor
• TP sensor
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
TSS *3
UP SW *3
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
(See PID/DATA MONITOR INSPECTION [FN4A-EL] )
VPWR
(Battery positive voltage)
V
• Ignition switch is turned to the ON position.: B+
• Idling: B+
• Battery
• Main relay
Vref
(Constant voltage)
V
VSS
(Vehicle speed)
KPH MPH
• Ignition switch is turned to the ON position.: Approx. 5 V
• Vehicle running: Indicate the vehicle speed
• Battery
• VSS
-
2AA
2AA
2AA
1AX,
1BB,
1BF
1BG *3
2W
*2 -
*3 1AY
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
VT ACT1
(Actual valve timing)
°
• Idling: 0 °
• Racing: 025 °
• The following PIDs
- ECT, RPM,
TP, MAF
• OCV
2AG,
2AK
VT DIFF1
(Difference between target valve timing and actual valve timing)
° • Idling: 0 °
• The following PIDs
- ECT, RPM,
TP, MAF
• OCV
-
VT DUTY1
(OCV control)
% • Idling: Approx. 10 %
• The following PIDs
- ECT, RPM,
TP, MAF
2AG,
2AK
The voltage may vary excessively depending on the weather or battery conditions.
*2 :
MTX
*1 :
*3 :
ATX
*4 :
Alternator generating current value
*5 :
A/C compressor pressure switch
PCM CONFIGURATION [Z6]
B3E014018880W09
1. Connect the WDS or equivalent to DLC-2.
2. Set up the WDS or equivalent (including the vehicle recognition).
3. Select "Module Programming".
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Select "Programmable Module Installation".
5. Select "PCM" and perform procedures according to directions on the WDS or equivalent screen.
Note
• If the PCM is replaced with a new one, the PCM stores DTC P0602 and illuminates the MIL even though no malfunction is detected. This means the PCM has not been configured yet.
6. Retrieve DTC's by the WDS or equivalent, then verify that there in no DTC present.
• If DTC is present, perform applicable DTC inspection. (See DTC TABLE [Z6] .)
NEUTRAL SWITCH INSPECTION [Z6]
B3E014017640W02
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Continuity Inspection
1. Remove the neutral switch.
2. Verify that the continuity between neutral switch terminals A and B is as indicated in the table.
• If not as indicated in the table, replace the neutral switch. (See NEUTRAL SWITCH
REMOVAL/INSTALLATION [F35M-R] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Neutral switch terminal A and PCM terminal 1AB
- Neutral switch terminal B and body GND
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Neutral switch terminal A and body GND
- Neutral switch terminal B and power supply
Note
CLUTCH PEDAL POSITION (CPP) SWITCH
INSPECTION [Z6]
B3E014018660W02
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Continuity Inspection
1. Remove the CPP switch.
2. Verify that the continuity between CPP switch terminals A and B is as indicated in the table.
• If not as indicated in the table, replace the CPP switch. (See CLUTCH PEDAL
REMOVAL/INSTALLATION .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- CPP switch terminal A and PCM terminal 1P
- CPP switch terminal B and body GND
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- CPP switch terminal A and body GND
- CPP switch terminal B and power supply
POWER STEERING PRESSURE (PSP) SWITCH
INSPECTION [Z6]
B3E014032230W01
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Continuity Inspection
1. Inspect the following items:
• Power steering fluid amount (See POWER STEERING FLUID INSPECTION .)
• Power steering-related inspection (See STEERING LOCATION INDEX .)
2. Disconnect the PSP switch connector.
3. Start the engine.
4. Verify that the continuity between PSP switch terminal A and body GND is as indicated in the table.
• If not as indicated in the table, replace the CPP switch. (See POWER STEERING OIL PUMP
(Z6) DISASSEMBLY/ASSEMBLY .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- PSP switch terminal A and PCM terminal 2AC
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- PSP switch terminal A and body GND
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL/INSTALLATION [Z6]
B3E014018840W04
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Perform the following procedure for easier access.
(1) Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
(2) Set the EGR pipe (intake manifold side) out of the way. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [Z6] .)
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
5. Install the SST to the ECT sensor.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
6. Remove the ECT sensor.
7. Replace the gasket.
8. Install in the reverse order of removal.
ECT sensor tightening torque
15.723.5 N·m {1.7-2.3 kgf·m, 12.3-16.6 ft·lbf}
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION [Z6]
B3E014018840W05
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Continuity Inspection
1. Disconnect the ECT sensor connector.
2. Remove the ECT sensor. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL/INSTALLATION [Z6] .)
3. Place the ECT sensor in the water and while increasing water temperature, measure the resistance between terminals A and B.
• If not within the specification, replace the ECT sensor. (See ENGINE COOLANT
TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
ECT sensor resistance
Water temperature (°C {°F}) Resistance (kilohm)
20 {68}
80 {176}
2.212.69
0.2870.349
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
ECT sensor characteristics graph (reference)
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- ECT sensor terminal A and PCM terminal 2J
- ECT sensor terminal B and PCM terminal 2AX
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
- ECT sensor terminal A and power supply
- ECT sensor terminal A and body GND
- ECT sensor terminal B and power supply
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
INTAKE AIR TEMPERATURE (IAT) SENSOR
INSPECTION [Z6]
B3E014018840W06
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Resistance Inspection
1. Disconnect the MAF/IAT sensor connector.
2. Verify that the resistance between terminals D and E is within the specification.
• If not within the specification, replace the MAF/IAT sensor. (See MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
IAT sensor resistance
Ambient temperature (°C {°F}) Resistance (kilohm)
-20 {-4} 13.618.4
20 {68}
60 {140}
2.212.69
0.4930.667
IAT sensor characteristics graph (reference)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- MAF/IAT sensor terminal D and PCM terminal 2AQ
- MAF/IAT sensor terminal E and PCM terminal 2AY
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- MAF/IAT sensor terminal D and power supply
- MAF/IAT sensor terminal D and body GND
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
- MAF/IAT sensor terminal E and power supply
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [Z6]
B3E014018220W01
Caution
• When replacing the CKP sensor, make sure there is no foreign material on it such as metal shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting from fluctuation in magnetic flux and cause a deterioration in engine control.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Perform the following procedure for easier access.
(1) Remove the under cover.
4. Remove the CKP sensor.
5. Install in the reverse order of removal.
CKP sensor tightening torque
7.810.8 N·m {80-110 kgf·cm, 70-94 in·lbf}
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION
[Z6]
B3E014018220W02
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Visual inspection
1. Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION [Z6] .)
2. Verify that there are no metal shavings on the sensor.
3. Install the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION
[Z6] .)
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 not within the specification, replace the plate. (See FRONT OIL SEAL REPLACEMENT [Z6] .)
Air gap
0.5-1.5 mm {0.02-0.05 in}
Voltage inspection
1. Idle the engine.
Caution
• Water 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.
2. Measure the output voltage using a oscilloscope.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If not within the specification, replace the CKP sensor. (See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
CKP sensor voltage
Terminal Voltage (V) Condition
A B+ Under any condition
4.8 or more High output*
B
0.8 or less Low output*
C 0 Under any condition
* :
Output voltage varies with camshaft rotation.
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- CKP sensor terminal A and PCM terminal 2T
- CKP sensor terminal B and PCM terminal 2P
- CKP sensor terminal C and PCM terminal 2BF
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- CKP sensor terminal A and body GND
- CKP sensor terminal B and power supply
- CKP sensor terminal B and body GND
- CKP sensor terminal C and power supply
Caution
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION [Z6]
B3E014018200W01
• When replacing the CKP sensor, make sure there is no foreign material on it such as metal shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting from fluctuation in magnetic flux and cause a deterioration in engine control.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the CMP sensor.
4. Verify that the O-ring is not damaged.
• If there is a damage, replace the CMP sensor.
5. Apply a small amount of clean oil to the O-ring and the head cover.
6. Install in the reverse order of removal.
CMP sensor tightening torque
7.810.8 N·m {80-110 kgf·cm, 70-94 in·lbf}
CAMSHAFT POSITION (CMP) SENSOR INSPECTION
[Z6]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
B3E014018200W02
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Visual inspection
1. Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION
[Z6] .)
2. Verify that there are no metal shavings on the sensor.
3. Install the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION
[Z6] .)
Voltage inspection
1. Idle the engine.
Caution
• Water 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.
2. Measure the output voltage using a oscilloscope.
• If not within the specification, replace the CMP sensor. (See CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
CMP sensor voltage
Terminal Voltage (V) Condition
A B+ Under any condition
B
4.8 or more High output*
0.8 or less Low output*
C 0 Under any condition
* :
Output voltage varies with camshaft rotation.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- CMP sensor terminal A and PCM terminal 2T
- CMP sensor terminal B and PCM terminal 2BB
- CMP sensor terminal C and PCM terminal 2BF
Short circuit
• If there is continuity, there is an short circuit. Repair or replace the wiring harness.
- CMP sensor terminal A and body GND
- CMP sensor terminal B and power supply
- CMP sensor terminal B and body GND
- CMP sensor terminal C and power supply
THROTTLE POSITION (TP) SENSOR
REMOVAL/INSTALLATION [Z6]
B3E014018910W03
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Perform the following procedure for easier access.
• Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
• Remove the air hose.
4. Remove the TP sensor.
5. Verify that the throttle valve is fully closed.
6. Install the TP sensor to the throttle body.
Tightening torque
1.62.4 N·m {17-24 kgf·cm, 15-21 in·lbf}
7. Verify that the throttle valve moves smoothly.
8. Connect the TP sensor connector.
9. Verify that the TP sensor output voltage (WDS PID: TP) is within the specification when it is open or closed. (See PCM INSPECTION [Z6] .)
• If not within the specification, inspect the TP sensor. (See THROTTLE POSITION (TP)
SENSOR INSPECTION [Z6] .)
THROTTLE POSITION (TP) SENSOR INSPECTION [Z6]
B3E014018910W04
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Resistance Inspection
1. Verify the following.
• Throttle valve closed status
• Accelerator cable play (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6] )
2. Disconnect the TP sensor connector.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Verify that the resistance between terminals B and C changes moderately corresponding to the throttle valve openings.
• If the resistance change is verified, go to the next step.
• If the resistance change is not verified, replace the TP sensor. (See THROTTLE POSITION
(TP) SENSOR REMOVAL/INSTALLATION [Z6] .)
4. Measure the resistance between terminals A and B.
• If not within the specification, replace the TP sensor. (See THROTTLE POSITION (TP)
SENSOR REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
TP sensor resistance
2.56.0 kilohms [25 °C {77 °F}]
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- TP sensor terminal A and PCM terminal 2W
- TP sensor terminal B and PCM terminal 2AE
- TP sensor terminal C and PCM terminal 2AA
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- TP sensor terminal A and body GND
- TP sensor terminal B and power supply
- TP sensor terminal C and power supply
- TP sensor terminal C and body GND
MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE
(IAT) SENSOR REMOVAL/INSTALLATION [Z6]
B3E014013215W02
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Perform the following procedure for easier access
(1) Remove the battery box. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
4. Remove the MAF/IAT sensor.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Install in the reverse order of removal.
MAF/IAT sensor tightening torque
0.550.82 N·m {5.7-8.3 kgf·cm, 4.9-7.2 in·lbf}
MASS AIR FLOW (MAF) SENSOR INSPECTION [Z6]
B3E014013215W03
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Visual inspection
1. Visually inspect the MAF sensor for the following:
• Damage, cracks
• Rusted sensor terminal
• Bent sensor terminal
- If there is any malfunction, replace the MAF/IAT sensor. (See MASS AIR FLOW (MAF)/INTAKE
AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [Z6] .)
Voltage Inspection
1. Remove the MAF/IAT sensor without disconnecting the MAF/IAT sensor connector.
2. Turn the ignition switch to the ON position.
3. As the air gradually approaches the MAF detection part of the MAF/IAT sensor, verify that the MAF sensor output voltage (WDS PID: MAF) varies.
• If it cannot be verified even though the related wiring harnesses have no malfunction, replace the MAF/IAT sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT)
SENSOR REMOVAL/INSTALLATION [Z6] .)
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit . Repair or replace the wiring harness.
- MAF/IAT sensor terminal A and PCM terminal 2BG
- MAF/IAT sensor terminal B and PCM terminal 2BC
- MAF/IAT sensor terminal C and PCM terminal 2AU
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- MAF/IAT sensor terminal A and power supply
- MAF/IAT sensor terminal A and body GND
- MAF/IAT sensor terminal B and power supply
- MAF/IAT sensor terminal C and power supply
- MAF/IAT sensor terminal C and body GND
FRONT HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [Z6]
B3E014018860W05
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Perform the following procedure for easier access.
(1) Remove the air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
4. Install the SST to the front HO2S.
5. Remove the front HO2S.
6. Install in the reverse order of removal.
Front HO2S tightening torque
29-49 N ·m {3.0-4.9 kgf·m, 22-35 ft·lbf}
FRONT HEATED OXYGEN SENSOR (HO2S)
INSPECTION [Z6]
B3E014018860W06
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Front Heated Oxygen Sensor (HO2S) Voltage Inspection
1. Warm up the engine to normal operating temperature.
2. Disconnect the front HO2S connector.
3. Connect the positive probe of the tester (digital type) to front HO2S terminal A, and the negative probe to front HO2S terminal B and measure the voltage.
4. Maintain the engine speed at 3,000 rpm until the voltage indicates approx. 0.5-0.7 V .
5. Verify that the voltage is as indicated in the table when the engine is raced repeatedly.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• If it cannot be verified, replace the front HO2S. (See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
Front HO2S Voltage Inspection
Engine condition Voltage (V)
Accelerated
Decelerated
0.5-1.0
0-0.5
Front Heated Oxygen Sensor (HO2S) Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Front HO2S terminal A and PCM terminal 2AI
- Front HO2S terminal B and PCM terminal 2AX
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Front HO2S terminal A and power supply
- Front HO2S terminal A and body GND
- Front HO2S terminal B and power supply
- Front HO2S terminal B and body GND
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Front Heated Oxygen Sensor (HO2S) Heater Resistance Inspection
1. Disconnect the front HO2S connector.
2. Measure the resistance between front HO2S terminals C and D.
• If not within the specification, replace the front HO2S. (See FRONT HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
Front HO2S heater resistance
5.06.8 ohms [20 °C {68 °F}]
Front Heated Oxygen Sensor (HO2S) Heater Circuit Open/Short
Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Front HO2S terminal C and PCM terminal 2T
- Front HO2S terminal D and PCM terminal 2AM
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Front HO2S terminal C and body GND
- Front HO2S terminal D and power supply
- Front HO2S terminal D and body GND
REAR HEATED OXYGEN SENSOR (HO2S)
REMOVAL/INSTALLATION [Z6]
B3E014018860W07
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Perform the following procedure for easier access.
(1) Remove the air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Install the SST to the rear HO2S.
5. Remove the rear HO2S.
6. Install in the reverse order of removal.
Front HO2S tightening torque
2949 N·m {3.0-4.9 kgf·m, 22-35 ft·lbf}
REAR HEATED OXYGEN SENSOR (HO2S)
INSPECTION [Z6]
B3E014018860W08
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Rear Heated Oxygen Sensor (HO2S) Voltage Inspection
1. Warm up the engine to normal operating temperature.
2. Disconnect the rear HO2S connector.
3. Connect the positive probe of the tester (digital type) to rear HO2S terminal A, and the negative probe to rear HO2S terminal B and measure the voltage.
4. Maintain the engine speed at 3,000 rpm until the voltage indicates approx. 0.5-0.7 V .
5. Verify that the voltage is as indicated in the table when the engine is raced repeatedly.
• If it cannot be verified, replace the rear HO2S. (See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
Rear HO2S Voltage Inspection
Engine condition Voltage (V)
Accelerated
Decelerated
0.5-1.0
0-0.5
Rear Heated Oxygen Sensor (HO2S) Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Rear HO2S terminal A and PCM terminal 2K
- Rear HO2S terminal B and PCM terminal 2AX
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Rear HO2S terminal A and power supply
- Rear HO2S terminal A and body GND
- Rear HO2S terminal B and power supply
- Rear HO2S terminal B and body GND
Rear Heated Oxygen Sensor (HO2S) Heater Resistance Inspection
1. Disconnect the rear HO2S connector.
2. Measure the resistance between rear HO2S terminals C and D.
• If not within the specification, replace the rear HO2S. (See FRONT HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Rear HO2S heater resistance
14.118.9 ohms [20 °C {68 °F}]
Rear Heated Oxygen Sensor (HO2S) Heater Circuit Open/Short
Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Rear HO2S terminal C and PCM terminal 2T
- Rear HO2S terminal D and PCM terminal 2AT
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Rear HO2S terminal C and body GND
- Rear HO2S terminal D and power supply
- Rear HO2S terminal D and body GND
BAROMETRIC PRESSURE (BARO) SENSOR
INSPECTION [Z6]
B3E014018210W03
Note
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
Voltage Inspection
1. Remove the BARO sensor with the connector still connected.
2. Remove the BARO sensor hose.
3. Turn the ignition switch to the ON position.
4. Verify that the BARO sensor output voltage (WDS PID: BARO) is within the specification. (See PCM
INSPECTION [Z6] .)
• If not within the specification even though the related wiring harnesses have no malfunction, replace the BARO sensor.
5. Install the vacuum pump to the BARO sensor.
6. Verify that the change in the BARO sensor output voltage (WDS PID: BARO) is within the specification when a vacuum of 30 kPa {0.30 kgf/cm 2 , 4.4 psi} is applied.
• If not within the specification, replace the BARO sensor.
BARO sensor output voltage variance
0.5-0.7 V
Note
• The voltage shown in the figure may vary excessively depending on the weather or battery conditions.
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- BARO sensor terminal C and PCM terminal 2W
- BARO sensor terminal A and PCM terminal 2AX
- BARO sensor terminal B and PCM terminal 2S
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- BARO sensor terminal C and body GND
- BARO sensor terminal A and body power supply
- BARO sensor terminal B and body GND
- BARO sensor terminal B and body power supply
KNOCK SENSOR (KS) REMOVAL/INSTALLATION [Z6]
B3E014018920W03
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6] .)
2. Disconnect the negative battery cable.
3. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
4. Install the SST to the KS.
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
5. Remove the KS.
6. Install in the reverse order of removal.
KS tightening torque
19.634.3 N·m {2.0-3.4 kgf·m, 14.5-24.5 ft·lbf}
KNOCK SENSOR (KS) INSPECTION [Z6]
B3E014018920W04
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure .)
1. Disconnect the KS connector.
2. Measure the resistance between KS terminal A and body GND.
• If not within the specification, replace the KS. (See KNOCK SENSOR (KS)
REMOVAL/INSTALLATION [Z6] .)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".
KS resistance
532588 kilohms [20 °C {68 °F}]
Circuit Open/Short Inspection
1. Remove the PCM connector cover.
2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6] .)
3. Inspect the following wiring harness for open or short circuit (continuity check).
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
- Knock sensor terminal A and PCM terminal 2BA
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
- Knock sensor terminal A and body GND
- Knock sensor terminal A and power supply
ENGINE TECHNICAL DATA
B3E015001001W01
Specifications
Item
Z6 LF
MECHANICAL
Valve clearance
[engine cold]
Compression pressure
(mm {in})
IN
EX
(kPa {kgf/cm 2 , psi}) [rpm]
Standard
0.27-0.33
{0.0107-
0.0129}
0.22-0.28
{0.0087-
0.0110}
0.27-0.33
{0.0107-
0.0129}
1,470 {14.99,
213.2} [250]
1.720
{17.54,
294.4} [300]
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Minimum
1,029 {10.49,
149.2} [250]
1.204
{12.28,
174.6} [300]
Maximum difference between cylinders
Standard
196.1 {2.0,
28.5}
196.1 {2.0,
28.5}
128.9-129.5
{5.075-5.098}
145.2-145.8
{5.72-5.74}
Cylinder head bolt length (mm {in})
Pushing distance of the front oil seal
Maximum
(mm {in})
130.2 {5.125} 146.5 {5.77}
0-0.5 {0-0.019}
(from the edge of the engine front cover)
Pushing distance of the rear oil seal
Oil control valve (OCV)
(mm {in})
0-0.5 {0-0.019}
(from the edge of the cylinder block)
-
Resistance (ohm) [20°C {68°F}] 6.9-7.9
-
ATX 700-800 -
Idle speed (rpm)
Ignition timing (test mode on)
MTX
(BTDC°)
640-740
9-11
N position 700-800 -
600-700
8
ATX
No load
D position 650-750 -
MTX
Neutral position
640-740 600-700
Idle-up speed
(rpm)
Electrical loads
ON *1
ATX
MTX
ATX
N position
D position
700-800 [34-42
A]
-
700-800
[Above 42 A]
650-750 [34-42
A]
-
670-770
[Above 42 A]
Neutral position
650-750 [34-42
A]
650-750 [38-
48 A]
700-800
[Above 42 A]
700-800
[Above 48 A]
N position 700-800 -
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
A/C
ON
Low load *2
MTX
High load *3
P/S ON
CO concentration
HC concentration
LUBRICATION SYSTEM
Oil pressure (approx. quantity)
[oil temperature: 100 °C {212 °F}]
(kPa {kgf/cm 2 , psi}) [rpm]
Oil capacity
Oil replacement
Oil and oil filter replacement
(approx. quantity)
Total (dry engine)
COOLING SYSTEM
D position 650-750
Neutral position
650-750
700-800
700-800
(L {US qt, Imp qt})
(L {US qt, Imp qt})
(L {US qt, Imp qt})
-
700-800
-
Within the regulation
330-380
{3.36-3.87,
47.8-55.0}
[3,000]
234-521
{2.39-5.31,
33.9-75.5}
[3,000]
3.7 {3.9, 3.3} 3.9 {4.1, 3.4}
3.9 {4.1, 3.4} 4.3 {4.5, 3.8}
4.2 {4.4, 3.7} 4.6 {4.9, 4.0}
Coolant capacity
Initial-opening temperature
Thermostat
Full-opening temperature
Full-open amount
(L {US qt, Imp qt})
Cooling system cap valve opening pressure (kPa {kgf/cm 2 , psi})
(°C {°F})
(°C {°F})
(mm {in})
With heater:
With heater:
6.0 {6.3, 5.3}
7.5 {7.9, 6.6}
Without heater:
Without heater:
5.5 {5.8, 4.8}
6.9 {7.3, 6.1}
90-110 {0.92-
1.12, 13.1-
15.9}
135-155
{1.38-1.58,
19.6-22.4}
80-84 {176-183}
95 {203} 97 {207}
8.5 {0.33} or more
8.0 {0.31} or more
FUEL SYSTEM
Fuel line pressure (kPa {kgf/cm 2 , psi})
Resistance
Fuel injector
Leakage amount
Fuel hold pressure
Fuel pressure
(ohm) [20°C {68°F}]
(drop/2 min)
250 {2.55, 36.2} or more
350-410 {3.57-4.18, 50.8-
59.4}
Approx. 13.8
11.4-12.6
1 or less
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Injection volume (ml {cc, cu in}/15 s)
64-84 {64-84,
3.9-5.1}
46-66 {46-66,
2.8-4.0}
CHARGING SYSTEM
Electrolyte gravity
Back-up current* 4
Battery
Generator
Generated current
(Reference)
(mA)
Test load chart
(A)
Slow charge
(A)
Quick charge
(A/30 min.)
Standard voltage
(V)
Battery type
(5-hour rate)
50D20L (40)
75D26L (52)
80D26L (55) *5
50D20L (40)
Battery type
(5-hour rate)
75D26L (52)
80D26L (55) *5
50D20L (40)
Battery type
(5-hour rate)
75D26L (52)
80D26L (55) *5
B
Ignition switch
ON
Terminal P
Idle [20
°C {68
°F}]
Terminal P
D
D
B
Terminal B current
[Engine speed 1,000 rpm]
(A)
Terminal B current
[Engine speed 2,000 rpm]
IGNITION SYSTEM
Primary coil winding (ohm)
Ignition coil
Resistance
(Reference)
[25 °C {77 °F}]
Secondary coil winding
(kilohm)
Spark plug Type
0* 6 -65
0* 6 -85
-
-
0* 6 -80
0* 6 -95
0.45-1.15
5.0-6.0
Insulation resistance of case
(megohm) -
DENSO
Above 10
SK16PR-E11 -
1.221.29 [20 °C {68 °F}]
Max. 20
150
195
195
4.0-5.0
5.0-6.0
5.5-6.5
25
35
35
B+
-
-
Approx. 1.0 or less
Approx. 0
13.0-15.0
Approx. 3.0-8.0
* 7
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
NGK
Plug gap Standard
Resistance [25°C {77°F}]
STARTING SYSTEM
Voltage
Starter No load test
Current
(mm {in})
(kilohm)
-
1.0-1.1
3.0-7.5
(V)
(A)
11
90 or less
ITR6F13
1.25-1.35
Recommended engine oil
Item
Grade
Europe
API SL, ACEA A3
Specifications
Except Europe
API SG, SH, SJ, SL ILSAC GF-2, GF-3
Viscosity
(SAE)
5W-30 10W-40
5W-
20
40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 20W-40,
15W-40, 20W-50, 15W-50, 5W-20, 5W-30
Remarks Mazda genuine
Dexelia oil e.g.
* 1 :
Generator generating current value.
* 2 :
-
Refrigerant pressure switch (middle pressure switch) is off.
* 3 :
Refrigerant pressure switch (middle pressure switch) is on.
* 4 :
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is off and with the ignition key removed.
* 5 :
For intensely hot area.
* 6 :
The lower limit must be more than 0 A.
* 7 :
Turn the following electrical loads on and verify that the voltage reading increases.
• Headlights
• Blower motor
• Rear window defroster
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
SERVICE TOOLS
ENGINE SST [Z6]
B3E016001001W01
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting bracket
49 E017
5A0
2: -
Engine support set
1:49 S120
710
2: -
Coupling flange holder
1:49 G014
001
2: -
Oil filter wrench
1:49 UN30
3050
2:303-050
Engine lifting bracket
1:49 G011
103
2: -
Bolts
1:49 B015
0A0
2:-
Adapter set
1:49 H010
401
2: -
Oil seal installer
1:49 E033
101
2: -
Dust cover installer
1:49 H018
001
2: -
Knock sensor wrench
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1:49 L018
001
2: -
O2 sensor wrench
1:49 L018
901
2: -
Injector checker
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
1: -
2: -
WDS
1:49 N013
1A0C
2:-
Fuel pressure gauge set
1:49 D015
001
2: -
Box wrench
-
1:49 0187
280A
2: -
Oil pressure gauge
1: 49 F042
001
2: -
Wrench
ENGINE SST [LF]
B3E016001001W02
1: Mazda SST number
2: Global SST number
Example
1:49 JE01 061
2:303-507
Crankshaft TDC setting pin
49 E017
5A0
2: -
1:49 H010
401
2: -
1:49 G032
354
2: -
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1:49 0187
280A
2: -
Oil pressure gauge
1:49 B015
0A0
2:-
Adapter set
1:49 N013
1A0C
2:-
Fuel pressure gauge set
Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
Engine support set
1:49 JE01
061
2:303-507
Crankshaft
TDC setting pin
Oil seal installer
1:49 UN20
5072
2:205-072
Holder
Adjusting wrench
1:49 B011
105
2: -
Adapter
1:49 D032
316
2: -
Protractor
1:49 JE01
054
2: -
Camshaft
Alignment
Timing Tool
(Europe)
1:49 UN30
3376
2: 303-376
Camshaft
Alignment
Timing Tool
(Except
Europe)
1:49 E019
001
2: -
Adapter
1:49 D015
001
2: -
Box wrench
1:49 L018
001
2: -
O2 sensor wrench
1: -
2: -
WDS
1: 49 F042
-
001
2: -
Wrench
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Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Key Features
- Comprehensive engine wiring diagrams for easy troubleshooting
- Detailed diagnostic trouble codes (DTCs) for quick issue identification
- OBD freeze frame data capture for in-depth analysis
- On-board system readiness tests for emissions compliance
- PID/data monitor and record for real-time performance tracking
- After-repair procedure guide for proper post-maintenance verification
- OBD drive mode for adaptive memory production and repair verification
Questions & Answers
Y Y E
How do I replace my knock sensor?
Related manuals
Frequently Answers and Questions
How do I access the OBD freeze frame data?
What is the purpose of the OBD drive mode?
How do I read diagnostic monitoring test results?
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