Mazda 3 Instruction manual
Mazda 3 Workshop Manual –Engine + Wiring Diagrams + Diagnostic Trouble Codes
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Mazda 3 Workshop Manual –
Engine + Wiring Diagrams +
Diagnostic Trouble Codes
Contents
Mazda 3 Workshop Manual –Engine + Wiring Diagrams + Diagnostic Trouble Codes................................1
CONTROL SYSTEM WIRING DIAGRAM [Z6]....................................................................................23
MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [Z6].....25
OBD PENDING TROUBLE CODE [Z6]................................................................................................26
OBD FREEZE FRAME DATA [Z6] ........................................................................................................27
OBD ON-BOARD SYSTEM READINESS TEST [Z6].........................................................................28
OBD READ/CLEAR DIAGNOSTIC TEST RESULT [Z6] ...................................................................29
OBD PARAMETER IDENTIFICATION (PID) ACCESS [Z6] .............................................................30
ON-BOARD DIAGNOSTIC TEST [Z6]..................................................................................................31
DTC Reading Procedure.....................................................................................................................31
Pending Trouble Code Access Procedure.......................................................................................31
Freeze Frame PID Data Access Procedure.....................................................................................31
On-Board System Readiness Tests Access Procedure.................................................................32
PID/DATA Monitor and Record Procedure.......................................................................................32
Diagnostic Monitoring Test Results Access Procedure..................................................................33
AFTER REPAIR PROCEDURE [Z6].....................................................................................................34
OBD DRIVE MODE [Z6]..........................................................................................................................35
PCM Adaptive Memory Produce Drive Mode..................................................................................35
HO2S heater, HO2S, and TWC Repair Verification Drive Mode..................................................36
DTC TABLE [Z6].......................................................................................................................................38
DTC P0011 [Z6]........................................................................................................................................44
DTC P0012 [Z6]........................................................................................................................................47
DTC P0031 [Z6]........................................................................................................................................50
DTC P0032 [Z6]........................................................................................................................................54
DTC P0037 [Z6]........................................................................................................................................57
DTC P0038 [Z6]........................................................................................................................................61
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DTC P0102 [Z6]........................................................................................................................................64
DTC P0103 [Z6]........................................................................................................................................68
DTC P0111 [Z6]........................................................................................................................................72
DTC P0112 [Z6]........................................................................................................................................75
DTC P0113 [Z6]........................................................................................................................................78
DTC P0117 [Z6]........................................................................................................................................82
DTC P0118 [Z6]........................................................................................................................................84
DTC P0121 [Z6]........................................................................................................................................87
DTC P0122 [Z6]........................................................................................................................................91
DTC P0123 [Z6]........................................................................................................................................94
DTC P0125 [Z6]........................................................................................................................................97
DTC P0132 [Z6]........................................................................................................................................99
DTC P0133 [Z6]......................................................................................................................................101
DTC P0134 [Z6]......................................................................................................................................105
DTC P0138 [Z6]......................................................................................................................................109
DTC P0140 [Z6]......................................................................................................................................112
DTC P0300 [Z6]......................................................................................................................................115
DTC P0301, P0302, P0303, P0304 [Z6].............................................................................................121
DTC P0327 [Z6]......................................................................................................................................125
DTC P0328 [Z6]......................................................................................................................................127
DTC P0335 [Z6]......................................................................................................................................130
DTC P0340 [Z6]......................................................................................................................................133
DTC P0403 [Z6]......................................................................................................................................137
DTC P0420 [Z6]......................................................................................................................................142
DTC P0443 [Z6]......................................................................................................................................144
DTC P0480 [Z6]......................................................................................................................................147
DTC P0500 [Z6]......................................................................................................................................150
DTC P0505 [Z6]......................................................................................................................................151
DTC P0506 [Z6]......................................................................................................................................153
DTC P0507 [Z6]......................................................................................................................................158
DTC P0511 [Z6]......................................................................................................................................160
DTC P0550 [Z6]......................................................................................................................................163
DTC P0602 [Z6]......................................................................................................................................167
DTC P0610 [Z6]......................................................................................................................................168
DTC P0660 [Z6]......................................................................................................................................169
DTC P0668 [Z6]......................................................................................................................................173
DTC P0669 [Z6]......................................................................................................................................175
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DTC P0703 [Z6]......................................................................................................................................176
DTC P0704 [Z6]......................................................................................................................................179
DTC P0850 [Z6]......................................................................................................................................182
DTC P1260 [Z6]......................................................................................................................................185
DTC P2006 [Z6]......................................................................................................................................186
DTC P2008 [Z6]......................................................................................................................................188
DTC P2088 [Z6]......................................................................................................................................192
DTC P2089 [Z6]......................................................................................................................................195
DTC P2096 [Z6]......................................................................................................................................197
DTC P2097 [Z6]......................................................................................................................................202
DTC P2177 [Z6]......................................................................................................................................206
DTC P2178 [Z6]......................................................................................................................................210
DTC P2187 [Z6]......................................................................................................................................214
DTC P2188 [Z6]......................................................................................................................................218
DTC P2195 [Z6]......................................................................................................................................222
DTC P2196 [Z6]......................................................................................................................................226
DTC P2228 [Z6]......................................................................................................................................229
DTC P2229 [Z6]......................................................................................................................................232
DTC P2502 [Z6]......................................................................................................................................234
DTC P2503 [Z6]......................................................................................................................................237
DTC P2504 [Z6]......................................................................................................................................240
DTC P2507 [Z6]......................................................................................................................................243
ON-BOARD DIAGNOSTIC[ENGINE CONTROL SYSTEM (LF)].......................................................................246
CONTROL SYSTEM WIRING DIAGRAM [LF]..................................................................................246
MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [LF]...248
OBD PENDING TROUBLE CODE [LF]..............................................................................................249
OBD FREEZE FRAME DATA [LF] ......................................................................................................250
OBD ON-BOARD SYSTEM READINESS TEST [LF].......................................................................250
OBD READ/CLEAR DIAGNOSTIC TEST RESULT [LF] .................................................................250
OBD PARAMETER IDENTIFICATION (PID) ACCESS [LF] ...........................................................250
ON-BOARD DIAGNOSTIC TEST [LF]................................................................................................250
DTC Reading Procedure...................................................................................................................250
Pending Trouble Code Access Procedure.....................................................................................251
Freeze Frame PID Data Access Procedure...................................................................................251
On-Board System Readiness Tests Access Procedure...............................................................252
PID/DATA Monitor and Record Procedure.....................................................................................252
Diagnostic Monitoring Test Results Access Procedure................................................................252
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AFTER REPAIR PROCEDURE [LF]...................................................................................................253
OBD DRIVE MODE [LF]........................................................................................................................253
Mode 1 (PCM Adaptive Memory Produce Drive Mode)...............................................................254
Mode 3 (HO2S heater, HO2S, and TWC Repair Verification Drive Mode)...............................254
DTC TABLE [LF].....................................................................................................................................255
DTC P0031 [LF]......................................................................................................................................259
DTC P0032 [LF]......................................................................................................................................262
DTC P0037 [LF]......................................................................................................................................264
DTC P0038 [LF]......................................................................................................................................267
DTC P0101 [LF]......................................................................................................................................270
DTC P0102 [LF]......................................................................................................................................273
DTC P0103 [LF]......................................................................................................................................276
DTC P0107 [LF]......................................................................................................................................278
DTC P0108 [LF]......................................................................................................................................281
DTC P0111 [LF]......................................................................................................................................284
DTC P0112 [LF]......................................................................................................................................286
DTC P0113 [LF]......................................................................................................................................288
DTC P0117 [LF]......................................................................................................................................291
DTC P0118 [LF]......................................................................................................................................293
DTC P0121 [LF]......................................................................................................................................296
DTC P0122 [LF]......................................................................................................................................300
DTC P0123 [LF]......................................................................................................................................303
DTC P0125 [LF]......................................................................................................................................306
DTC P0132 [LF]......................................................................................................................................308
DTC P0133 [LF]......................................................................................................................................310
DTC P0134 [LF]......................................................................................................................................314
DTC P0138 [LF]......................................................................................................................................318
DTC P0140 [LF]......................................................................................................................................320
DTC P0300 [LF]......................................................................................................................................324
DTC P0301, P0302, P0303, P0304 [LF].............................................................................................329
DTC P0327 [LF]......................................................................................................................................332
DTC P0328 [LF]......................................................................................................................................335
DTC P0335 [LF]......................................................................................................................................337
DTC P0340 [LF]......................................................................................................................................341
DTC P0403 [LF]......................................................................................................................................345
DTC P0420 [LF]......................................................................................................................................349
DTC P0443 [LF]......................................................................................................................................351
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DTC P0480 [LF]......................................................................................................................................354
DTC P0500 [LF]......................................................................................................................................357
DTC P0505 [LF]......................................................................................................................................358
DTC P0506 [LF]......................................................................................................................................360
DTC P0507 [LF]......................................................................................................................................363
DTC P0511 [LF]......................................................................................................................................365
DTC P0602 [LF]......................................................................................................................................369
DTC P0610 [LF]......................................................................................................................................370
DTC P0661 [LF]......................................................................................................................................371
DTC P0662 [LF]......................................................................................................................................374
DTC P0703 [LF]......................................................................................................................................376
DTC P0704 [LF]......................................................................................................................................380
DTC P0850 [LF]......................................................................................................................................383
DTC P1260 [LF]......................................................................................................................................387
DTC P2006 [LF]......................................................................................................................................388
DTC P2009 [LF]......................................................................................................................................392
DTC P2010 [LF]......................................................................................................................................394
DTC P2096 [LF]......................................................................................................................................397
DTC P2097 [LF]......................................................................................................................................401
DTC P2177 [LF]......................................................................................................................................405
DTC P2178 [LF]......................................................................................................................................409
DTC P2187 [LF]......................................................................................................................................412
DTC P2188 [LF]......................................................................................................................................416
DTC P2195 [LF]......................................................................................................................................419
DTC P2196 [LF]......................................................................................................................................423
DTC P2228 [LF]......................................................................................................................................425
DTC P2229 [LF]......................................................................................................................................428
DTC P2502 [LF]......................................................................................................................................431
DTC P2503 [LF]......................................................................................................................................433
DTC P2504 [LF]......................................................................................................................................435
DTC P2507 [LF]......................................................................................................................................437
SYMPTOM TROUBLESHOOTING[ENGINE CONTROL SYSTEM (Z6)] ...........................................................440
ENGINE SYMPTOM TROUBLESHOOTING [Z6].............................................................................440
QUICK DIAGNOSIS CHART [Z6]........................................................................................................442
NO.1 MELTING OF MAIN OR OTHER FUSES [Z6] ........................................................................445
NO.2 MIL ILLUMINATES [Z6] ..............................................................................................................447
NO.3 WILL NOT CRANK [Z6] ..............................................................................................................448
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NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [Z6]..................451
NO.5 ENGINE STALLS-AFTER START/AT IDLE [Z6] ....................................................................455
NO.6 CRANKS NORMALLY BUT WILL NOT START [Z6] .............................................................461
NO.7 SLOW RETURN TO IDLE [Z6]..................................................................................................468
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [Z6]........................................................................469
NO.9 FAST IDLE/RUNS ON [Z6].........................................................................................................475
NO.10 LOW IDLE/STALLS DURING DECELERATION [Z6]..........................................................477
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES [Z6]............................................................................................480
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [Z6].................................................486
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [Z6] ......................................................492
NO.14 POOR FUEL ECONOMY [Z6] .................................................................................................494
NO.15 EMISSION COMPLIANCE [Z6]...............................................................................................497
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [Z6]..........................................................................500
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [Z6]....................................................501
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [Z6]..........................................................504
NO.19 EXHAUST SMOKE [Z6]............................................................................................................505
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [Z6] ..............................................................508
NO.21 ENGINE NOISE [Z6].................................................................................................................510
NO.22 VIBRATION CONCERNS (ENGINE) [Z6]..............................................................................512
NO.23 A/C DOES NOT WORK SUFFICIENTLY [Z6].......................................................................512
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
NO.26 EXHAUST SULPHUR SMELL [Z6].........................................................................................517
NO.27 SPARK PLUG CONDITION [Z6].............................................................................................519
INTERMITTENT CONCERN TROUBLESHOOTING [Z6]...............................................................524
Vibration Method.................................................................................................................................524
Inspection Method for Switch Connectors or Wiring Harnesses.................................................524
Inspection Method for Sensor Connectors or Wiring Harnesses................................................525
Inspection Method for Sensors.........................................................................................................525
Inspection Method for Actuators or Relays ....................................................................................526
Water Sprinkling Method...................................................................................................................526
ENGINE CONTROL SYSTEM OPERATION INSPECTION [Z6]...................................................527
Main Relay Operation Inspection.....................................................................................................527
Intake Manifold Vacuum Inspection.................................................................................................527
Idle Air Control System Inspection...................................................................................................528
Engine coolant temperature compensation inspection.............................................................528
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Load compensation inspection.....................................................................................................528
Variable Intake-air Control Operation Inspection ..........................................................................529
Variable Tumble Control Operation Inspection..............................................................................530
Fuel Injector Operation Inspection...................................................................................................530
Fuel Cut Control System Inspection................................................................................................531
Fuel Pump Operation Inspection......................................................................................................532
Fuel Pump Control System Inspection............................................................................................532
Spark Test ...........................................................................................................................................532
EGR Control System Inspection ......................................................................................................533
Purge Control System Inspection ....................................................................................................534
A/C Cut-off Control System Inspection...........................................................................................535
Cooling Fan Motor Operation Inspection........................................................................................536
Variable Valve Timing Control System Operation Inspection......................................................537
When idling cannot be continued.................................................................................................537
When idling can be continued ......................................................................................................537
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (LF)]...........................................................539
ENGINE SYMPTOM TROUBLESHOOTING [LF].............................................................................539
QUICK DIAGNOSTIC CHART [LF].....................................................................................................540
NO.1 MELTING OF MAIN OR OTHER FUSES [LF] ........................................................................544
NO.2 MIL ILLUMINATES [LF]..............................................................................................................546
NO.3 WILL NOT CRANK [LF] ..............................................................................................................547
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [LF]..................550
NO.5 ENGINE STALLS-AFTER START/AT IDLE [LF] ....................................................................554
NO.6 CRANKS NORMALLY BUT WILL NOT START [LF] .............................................................560
NO.7 SLOW RETURN TO IDLE [LF]..................................................................................................566
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [LF]........................................................................567
NO.9 FAST IDLE/RUNS ON [LF].........................................................................................................573
NO.10 LOW IDLE/STALLS DURING DECELERATION [LF]..........................................................574
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES [LF]............................................................................................577
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [LF].................................................583
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [LF] ......................................................588
NO.14 POOR FUEL ECONOMY [LF] .................................................................................................590
NO.15 EMISSION COMPLIANCE [LF]...............................................................................................593
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [LF]..........................................................................596
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [LF]....................................................597
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [LF]..........................................................600
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NO.19 EXHAUST SMOKE [LF]............................................................................................................601
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [LF] ..............................................................604
NO.21 ENGINE NOISE [LF].................................................................................................................606
NO.22 VIBRATION CONCERNS (ENGINE) [LF]..............................................................................608
NO.23 A/C DOES NOT WORK SUFFICIENTLY [LF].......................................................................609
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
NO.26 EXHAUST SULPHUR SMELL [LF].........................................................................................613
NO.27 SPARK PLUG CONDITION [LF].............................................................................................615
INTERMITTENT CONCERN TROUBLESHOOTING [LF]...............................................................620
Vibration Method.................................................................................................................................620
Inspection Method for Switch Connectors or Wiring Harnesses.................................................620
Inspection Method for Sensor Connectors or Wiring Harnesses................................................621
Inspection Method for Sensors.........................................................................................................621
Inspection Method for Actuators or Relays ....................................................................................622
Water Sprinkling Method...................................................................................................................622
ENGINE CONTROL SYSTEM OPERATION INSPECTION [LF]...................................................623
Main Relay Operation Inspection.....................................................................................................623
Intake Manifold Vacuum Inspection.................................................................................................623
Idle Air Control System Inspection...................................................................................................624
Engine coolant temperature compensation inspection.............................................................624
Load compensation inspection.....................................................................................................624
Variable Intake-air Control Operation Inspection ..........................................................................625
Variable Tumble Control Operation Inspection..............................................................................626
Fuel Injector Operation Inspection...................................................................................................627
Fuel Cut Control System Inspection................................................................................................627
Fuel Pump Operation Inspection......................................................................................................628
Fuel Pump Control System Inspection............................................................................................628
Spark Test ...........................................................................................................................................629
EGR Control System Inspection ......................................................................................................630
Purge Control System Inspection ....................................................................................................631
A/C Cut-off Control System Inspection...........................................................................................631
Cooling Fan Motor Operation Inspection........................................................................................632
MECHANICAL[Z6] ......................................................................................................................................634
ENGINE LOCATION INDEX [Z6].........................................................................................................634
DRIVE BELT INSPECTION [Z6]..........................................................................................................635
DRIVE BELT REPLACEMENT [Z6] ....................................................................................................636
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DRIVE BELT AUTO TENSIONER INSPECTION [Z6] .....................................................................636
VALVE CLEARANCE INSPECTION [Z6]...........................................................................................637
VALVE CLEARANCE ADJUSTMENT [Z6].........................................................................................638
COMPRESSION INSPECTION [Z6]...................................................................................................645
TIMING CHAIN REMOVAL/INSTALLATION [Z6].............................................................................646
Crankshaft Pulley Installation Bolt Removal Note.........................................................................649
No.3 Engine Mount Removal Note..................................................................................................649
Engine Front Cover Removal Note..................................................................................................649
Chain Tensioner Removal Note.......................................................................................................650
Timing Chain Removal Note.............................................................................................................651
Timing Chain Installation Note..........................................................................................................651
Engine Front Cover Installation Note ..............................................................................................652
No.3 Engine Mount Installation Note...............................................................................................654
Crankshaft Pulley Installation Bolt Installation Note......................................................................655
Cylinder Head Cover Installation Note............................................................................................655
CYLINDER HEAD GASKET REPLACEMENT [Z6]..........................................................................656
Camshaft Cap Removal Note...........................................................................................................657
Cylinder Head Removal Note...........................................................................................................658
Cylinder Head Installation Note........................................................................................................658
Camshaft Cap Installation Note........................................................................................................659
FRONT OIL SEAL REPLACEMENT [Z6]...........................................................................................659
Crankshaft Pulley Installation Bolt Removal Note.........................................................................660
Front Oil Seal Removal Note............................................................................................................661
Front Oil Seal Installation Note.........................................................................................................661
Crankshaft Pulley Installation Bolt Installation Note......................................................................662
REAR OIL SEAL REPLACEMENT [Z6]..............................................................................................662
ENGINE REMOVAL/INSTALLATION [Z6].........................................................................................663
Main Fuse Block Connector Removal Note ...................................................................................666
No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note................................................667
No.4 Engine Mount Rubber Installation Note.................................................................................667
No.3 Engine Mount Installation Note...............................................................................................668
ENGINE DISASSEMBLY/ASSEMBLY [Z6]........................................................................................669
VARIABLE VALVE TIMING ACTUATOR INSPECTION [Z6]..........................................................670
VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [Z6].................................671
OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [Z6] ...................................................672
OIL CONTROL VALVE (OCV) INSPECTION [Z6]............................................................................675
Coil resistance inspection..................................................................................................................675
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Spool Valve Operation Inspection....................................................................................................676
ENGINE TUNE-UP [Z6].........................................................................................................................677
Engine Tune-up Preparation.............................................................................................................677
Ignition Timing Inspection .................................................................................................................678
Idle Speed Inspection........................................................................................................................680
Idle Mixture Inspection.......................................................................................................................681
MECHANICAL.............................................................................................................................................682
ENGINE LOCATION INDEX [LF].........................................................................................................682
DRIVE BELT INSPECTION [LF]..........................................................................................................683
Generator Drive Belt ..........................................................................................................................683
A/C Drive Belt......................................................................................................................................684
DRIVE BELT REPLACEMENT [LF] ....................................................................................................684
A/C Drive belt......................................................................................................................................684
Generator Drive Belt ..........................................................................................................................686
DRIVE BELT AUTO TENSIONER INSPECTION [LF] .....................................................................687
VALVE CLEARANCE INSPECTION [LF]...........................................................................................687
VALVE CLEARANCE ADJUSTMENT [LF].........................................................................................688
COMPRESSION INSPECTION [LF]...................................................................................................694
TIMING CHAIN REMOVAL/INSTALLATION [LF].............................................................................696
Crankshaft Pulley Lock Bolt Removal Note....................................................................................699
No.3 Engine Mount Removal Note..................................................................................................700
Engine Front Cover Removal Note..................................................................................................700
Chain Tensioner Removal Note.......................................................................................................701
Oil Pump Sprocket Removal Note...................................................................................................701
Oil Pump Sprocket Installation Note................................................................................................701
Timing Chain Installation Note..........................................................................................................702
Engine Front Cover Installation Note ..............................................................................................702
Front Oil Seal Installation Note.........................................................................................................703
No.3 Engine Mount Rubber and No.3 Engine Mount Bracket Installation Note.......................704
Crankshaft Pulley Lock Bolt Installation Note................................................................................704
Cylinder Head Cover Installation Note............................................................................................706
CYLINDER HEAD GASKET REPLACEMENT [LF]..........................................................................707
Camshaft Removal Note...................................................................................................................709
Cylinder Head Removal Note...........................................................................................................709
Cylinder Head Installation Note........................................................................................................709
Camshaft Installation Note................................................................................................................710
FRONT OIL SEAL REPLACEMENT [LF]...........................................................................................711
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Crankshaft Pulley Lock Bolt Removal Note....................................................................................712
Front Oil Seal Removal Note............................................................................................................713
Front Oil Seal Installation Note.........................................................................................................713
Crankshaft Pulley Lock Bolt Installation Note................................................................................714
REAR OIL SEAL REPLACEMENT [LF]..............................................................................................715
Rear Oil Seal Installation Note.........................................................................................................716
ENGINE REMOVAL/INSTALLATION [LF].........................................................................................717
Main Fuse Block Connector Removal Note ...................................................................................720
No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note.........................................720
No.3 Engine Mount and No.4 Engine Mount Rubber Installation Note......................................720
No.1 Engine Mount Rubber Installation Note.................................................................................722
ENGINE DISASSEMBLY/ASSEMBLY [LF]........................................................................................723
PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]....................................................................723
ENGINE TUNE-UP [LF].........................................................................................................................724
Engine Tune-up Preparation.............................................................................................................724
Ignition Timing Inspection .................................................................................................................724
Idle Speed Inspection........................................................................................................................724
Idle Mixture Inspection.......................................................................................................................725
LUBRICATION.............................................................................................................................................726
LUBRICATION SYSTEM LOCATION INDEX [Z6]............................................................................726
LUBRICATION SYSTEM LOCATION INDEX [LF]............................................................................726
OIL PRESSURE INSPECTION [Z6]....................................................................................................727
OIL PRESSURE INSPECTION [LF]....................................................................................................729
ENGINE OIL LEVEL INSPECTION [Z6].............................................................................................731
ENGINE OIL LEVEL INSPECTION [LF].............................................................................................731
ENGINE OIL REPLACEMENT [Z6].....................................................................................................732
ENGINE OIL REPLACEMENT [LF].....................................................................................................733
OIL FILTER REPLACEMENT [Z6] ......................................................................................................734
OIL FILTER REPLACEMENT [LF] ......................................................................................................736
OIL PAN REMOVAL/INSTALLATION [Z6].........................................................................................737
Oil Pan Removal Note.......................................................................................................................738
Oil Pan Installation Note....................................................................................................................738
OIL PAN REMOVAL/INSTALLATION [LF].........................................................................................739
Oil Pan Removal Note.......................................................................................................................741
Oil Pan Installation Note....................................................................................................................741
OIL PUMP REMOVAL/INSTALLATION [Z6]......................................................................................742
Oil Pump Installation Note.................................................................................................................744
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OIL PUMP REMOVAL/INSTALLATION [LF]......................................................................................745
Oil Pump Sprocket Removal/Installation Note...............................................................................746
Oil Pump Installation Note.................................................................................................................747
OIL PUMP DISASSEMBLY/ASSEMBLY [Z6]....................................................................................747
Inner Rotor, Outer Rotor Installation Note......................................................................................748
OIL PUMP INSPECTION [Z6]..............................................................................................................748
COOLING SYSTEM......................................................................................................................................751
COOLING SYSTEM LOCATION INDEX [Z6]....................................................................................751
COOLING SYSTEM LOCATION INDEX [LF]....................................................................................752
COOLING SYSTEM SERVICE WARNINGS.....................................................................................752
ENGINE COOLANT LEVEL INSPECTION........................................................................................753
ENGINE COOLANT PROTECTION INSPECTION ..........................................................................753
ENGINE COOLANT REPLACEMENT................................................................................................754
ENGINE COOLANT LEAKAGE INSPECTION..................................................................................756
COOLANT RESERVE TANK REMOVAL/INSTALLATION .............................................................757
COOLING SYSTEM CAP INSPECTION............................................................................................758
RADIATOR REMOVAL/INSTALLATION............................................................................................759
Radiator Removal Note.....................................................................................................................760
Radiator Installation Note..................................................................................................................762
Cooling Fan Component Installation Note......................................................................................762
THERMOSTAT REMOVAL/INSTALLATION [Z6].............................................................................763
Thermostat Installation Note.............................................................................................................764
THERMOSTAT REMOVAL/INSTALLATION [LF].............................................................................764
THERMOSTAT INSPECTION [Z6]......................................................................................................765
THERMOSTAT INSPECTION [LF]......................................................................................................766
WATER PUMP REMOVAL/INSTALLATION [Z6]..............................................................................766
WATER PUMP REMOVAL/INSTALLATION [LF]..............................................................................767
COOLING FAN MOTOR COMPONENT INSPECTION...................................................................768
INTAKE-AIR SYSTEM[Z6]............................................................................................................................770
INTAKE-AIR SYSTEM LOCATION INDEX [Z6]................................................................................770
INTAKE-AIR SYSTEM DIAGRAM [Z6]...............................................................................................771
INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM [Z6]...............................................................771
INTAKE-AIR SYSTEM MANIFOLD VACUUM INSPECTION [Z6].................................................772
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].................................................................773
Throttle Body Removal Note.............................................................................................................775
Intake Manifold Removal Note.........................................................................................................775
EGR Pipe Installation Note...............................................................................................................775
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Air Hose Installation Note..................................................................................................................776
Fresh-air Duct Installation Note........................................................................................................776
Strap Installation Note .......................................................................................................................776
PCM Connector Installation Note.....................................................................................................777
AIR CLEANER ELEMENT INSPECTION [Z6]...................................................................................777
IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION [Z6]...........................................777
IDLE AIR CONTROL (IAC) VALVE INSPECTION [Z6]....................................................................778
Resistance Inspection........................................................................................................................778
Circuit Open/Short Inspection...........................................................................................................779
Open circuit .....................................................................................................................................779
Short circuit......................................................................................................................................779
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6].....779
Variable Intake-air Shutter Valve Actuator Removal Note...........................................................780
Retainer Removal Note.....................................................................................................................781
Retainer Installation Note..................................................................................................................781
Variable Intake-air Shutter Valve Actuator Installation Note........................................................781
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [Z6].............................781
Operation Inspection..........................................................................................................................781
Circuit Open/Short Inspection...........................................................................................................782
Open circuit .....................................................................................................................................782
Short circuit......................................................................................................................................782
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [Z6]...........783
Variable Tumble Shutter Valve Actuator Removal Note..............................................................784
Retainer Removal Note.....................................................................................................................784
Retainer Installation Note..................................................................................................................784
Variable Tumble Shutter Valve Actuator Installation Note...........................................................785
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [Z6]....................................785
Operation Inspection..........................................................................................................................785
Circuit Open/Short Inspection...........................................................................................................786
Open circuit .....................................................................................................................................786
Short circuit......................................................................................................................................786
ACCELERATOR PEDAL REMOVAL/INSTALLATION [Z6].............................................................786
ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6].........................................................787
INTAKE-AIR SYSTEM[LF] ............................................................................................................................788
INTAKE-AIR SYSTEM LOCATION INDEX [LF]................................................................................788
INTAKE-AIR SYSTEM DIAGRAM [LF]...............................................................................................789
INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM [LF]...............................................................789
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INTAKE-AIR SYSTEM MANIFOLD VACUUM INSPECTION [LF].................................................790
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF].................................................................791
Fresh-air Duct Removal Note...........................................................................................................793
Intake Manifold Removal Note.........................................................................................................793
Air Cleaner Case Installation Note...................................................................................................793
Strap Installation Note .......................................................................................................................794
Air Hose Installation Note..................................................................................................................794
AIR CLEANER ELEMENT INSPECTION [LF]...................................................................................794
IDLE AIR CONTROL (IAC) VALVE INSPECTION [LF]....................................................................794
Operation Test....................................................................................................................................795
Resistance Inspection........................................................................................................................795
Circuit Open/Short Inspection...........................................................................................................795
Open circuit .....................................................................................................................................795
Short circuit......................................................................................................................................795
VARIABLE INTAKE-AIR SOLENOID VALVE INSPECTION [LF]...................................................795
Circuit Open/Short Inspection...........................................................................................................796
Open circuit .....................................................................................................................................796
Short circuit......................................................................................................................................796
VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [LF].............................797
VARIABLE TUMBLE SOLENOID VALVE INSPECTION [LF].........................................................797
Circuit Open/Short Inspection...........................................................................................................798
Open circuit .....................................................................................................................................798
Short circuit......................................................................................................................................798
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF]....................................798
ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF].............................................................799
ACCELERATOR CABLE INSPECTION/ADJUSTMENT [LF].........................................................800
FUEL SYSTEM.............................................................................................................................................801
FUEL SYSTEM LOCATION INDEX....................................................................................................801
Engine Compartment Side................................................................................................................801
Fuel Tank Side....................................................................................................................................803
FUEL SYSTEM FLOW DIAGRAM.......................................................................................................803
BEFORE SERVICE PRECAUTION ....................................................................................................804
Fuel Line Safety Procedure ..............................................................................................................805
AFTER SERVICE PRECAUTION........................................................................................................805
Fuel Leakage Inspection...................................................................................................................805
FUEL LINE PRESSURE INSPECTION..............................................................................................806
FUEL TANK REMOVAL/INSTALLATION...........................................................................................808
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Fuel-filler Pipe Removal Note...........................................................................................................811
Joint Hose Installation Note..............................................................................................................811
Breather Hose Installation Note.......................................................................................................811
FUEL TANK INSPECTION...................................................................................................................812
NONRETURN VALVE INSPECTION..................................................................................................813
FUEL PUMP UNIT REMOVAL/INSTALLATION ...............................................................................814
Fuel Pump Cap Removal Note.........................................................................................................815
Fuel Pump Cap Installation Note.....................................................................................................815
Fuel Leakage Inspection After Pump Unit Installation..................................................................816
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY..............................................................................816
FUEL PUMP UNIT INSPECTION........................................................................................................816
Fuel Pump Operation Inspection......................................................................................................816
Continuity Inspection..........................................................................................................................817
Circuit Open/Short Inspection...........................................................................................................817
Fuel Static Pressure Inspection........................................................................................................818
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION......................................................818
Quick Release Connector Type.......................................................................................................818
Type A Removal.................................................................................................................................819
Type B Removal.................................................................................................................................820
Using the SST.................................................................................................................................820
Without using the SST...................................................................................................................821
Type C Removal.................................................................................................................................822
Type D Removal.................................................................................................................................822
Type A Installation..............................................................................................................................823
Type B Installation..............................................................................................................................823
Using the SST.................................................................................................................................824
Without using the SST...................................................................................................................824
Type C Installation..............................................................................................................................824
Type D Installation..............................................................................................................................825
FUEL INJECTOR REMOVAL/INSTALLATION [LF] .........................................................................826
Fuel Injector Removal Note [LF] ......................................................................................................827
Fuel Injector Installation Note [LF]...................................................................................................828
FUEL INJECTOR REMOVAL/INSTALLATION [Z6] .........................................................................828
Injector Clip Removal Note [Z6].......................................................................................................829
Fuel Injector Installation Note [Z6]...................................................................................................831
Injector Clip Installation Note [Z6]....................................................................................................831
FUEL INJECTOR INSPECTION..........................................................................................................832
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Fuel Injector Operation Inspection...................................................................................................832
Fuel Cut Control Inspection ..............................................................................................................833
Resistance Inspection........................................................................................................................834
Circuit Open/Short Inspection [LF]...................................................................................................834
Circuit Open/Short Inspection [Z6]...................................................................................................835
Leakage Inspection............................................................................................................................836
Injection Volume Inspection [LF]......................................................................................................838
Injection volume Inspection [Z6].......................................................................................................840
Atomization Inspection.......................................................................................................................841
EXHAUST SYSTEM[Z6] ...............................................................................................................................842
EXHAUST SYSTEM INSPECTION [Z6].............................................................................................842
EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6] ....................................................................842
Exhaust Manifold/Exhaust Manifold Insulator Removal Note......................................................844
Exhaust Manifold Installation Note..................................................................................................845
EGR Pipe Installation Note...............................................................................................................845
EXHAUST SYSTEM[LF]................................................................................................................................846
EXHAUST SYSTEM INSPECTION [LF].............................................................................................846
EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] ....................................................................846
Main Silencer Removal Note............................................................................................................848
Exhaust Manifold Removal Note......................................................................................................848
Exhaust Manifold Installation Note ..................................................................................................848
EMISSION SYSTEM.....................................................................................................................................850
EMISSION SYSTEM LOCATION INDEX...........................................................................................850
Engine Compartment Side................................................................................................................850
Fuel Tank Side....................................................................................................................................852
EMISSION SYSTEM DIAGRAM..........................................................................................................852
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION........................................853
PURGE SOLENOID VALVE REMOVAL/INSTALLATION [LF].......................................................854
Evaporative Hose Installation Note..................................................................................................855
PURGE SOLENOID VALVE REMOVAL/INSTALLATION [Z6].......................................................855
PURGE SOLENOID VALVE INSPECTION.......................................................................................856
Evaporative Purge Control Inspection.............................................................................................856
Without using WDS or equivalent................................................................................................856
Using WDS or equivalent..............................................................................................................857
Airflow Inspection ...............................................................................................................................858
Circuit Open/Short Inspection [LF]...................................................................................................859
Circuit Open/Short Inspection [Z6]...................................................................................................860
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EGR VALVE REMOVAL/INSTALLATION [LF]..................................................................................861
Water Hose Removal Note [LF].......................................................................................................862
EGR Valve Removal Note [LF].........................................................................................................862
EGR VALVE REMOVAL/INSTALLATION [Z6]..................................................................................862
EGR VALVE INSPECTION...................................................................................................................863
EGR Control Inspection.....................................................................................................................863
Without using WDS or equivalent................................................................................................863
Using WDS or equivalent..............................................................................................................863
On-vehicle Inspection........................................................................................................................864
Resistance Inspection........................................................................................................................864
Circuit Open/Short Inspection [LF]...................................................................................................865
Circuit Open/Short Inspection [Z6]...................................................................................................866
CHARCOAL CANISTER REMOVAL/INSTALLATION.....................................................................867
CHARCOAL CANISTER INSPECTION..............................................................................................867
ROLLOVER VALVE REMOVAL/INSTALLATION.............................................................................868
ROLLOVER VALVE INSPECTION......................................................................................................868
CHARGING SYSTEM ...................................................................................................................................869
CHARGING SYSTEM LOCATION INDEX [Z6].................................................................................869
CHARGING SYSTEM LOCATION INDEX [LF].................................................................................869
BATTERY REMOVAL/INSTALLATION [Z6]......................................................................................870
Battery Box Installation Note ............................................................................................................871
Battery Cover Installation Note.........................................................................................................871
BATTERY REMOVAL/INSTALLATION [LF]......................................................................................872
PCM Cover Installation Note ............................................................................................................873
Battery Box Installation Note ............................................................................................................874
Battery Duct Installation Note...........................................................................................................874
Battery Cover Installation Note.........................................................................................................875
BATTERY INSPECTION.......................................................................................................................876
Electrolyte gravity...............................................................................................................................876
Battery voltage....................................................................................................................................876
Back-up current...................................................................................................................................877
BATTERY RECHARGING....................................................................................................................877
GENERATOR REMOVAL/INSTALLATION [Z6] ...............................................................................878
Generator Removal Note ..................................................................................................................879
GENERATOR REMOVAL/INSTALLATION [LF] ...............................................................................879
Generator Installation Note...............................................................................................................880
GENERATOR INSPECTION................................................................................................................880
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Generator warning light.....................................................................................................................880
Generator.............................................................................................................................................881
Voltage.............................................................................................................................................881
Current .............................................................................................................................................882
IGNITION SYSTEM......................................................................................................................................883
IGNITION SYSTEM LOCATION INDEX [Z6].....................................................................................883
IGNITION SYSTEM LOCATION INDEX [LF].....................................................................................883
IGNITION COIL REMOVAL/INSTALLATION [Z6].............................................................................884
IGNITION COIL REMOVAL/INSTALLATION [LF].............................................................................885
IGNITION COIL INSPECTION [Z6].....................................................................................................886
IGNITION COIL WITH BUILT-IN POWER SWITCH INSPECTION...........................................886
IGNITION COIL INSPECTION [LF].....................................................................................................887
Primary Coil Winding .........................................................................................................................887
Secondary Coil Winding....................................................................................................................887
Insulation Resistance of Case..........................................................................................................888
SPARK PLUG REMOVAL/INSTALLATION [Z6]...............................................................................888
SPARK PLUG REMOVAL/INSTALLATION [LF]...............................................................................889
SPARK PLUG INSPECTION................................................................................................................889
Specification........................................................................................................................................889
Plug Gap Inspection...........................................................................................................................890
Cleaning...............................................................................................................................................890
Visual inspection.................................................................................................................................890
Resistance Inspection........................................................................................................................890
STARTING SYSTEM.....................................................................................................................................892
STARTING SYSTEM LOCATION INDEX [Z6]..................................................................................892
STARTING SYSTEM LOCATION INDEX [LF]..................................................................................892
STARTER REMOVAL/INSTALLATION [Z6]......................................................................................893
STARTER REMOVAL/INSTALLATION [LF]......................................................................................894
STARTER INSPECTION.......................................................................................................................895
On-vehicle Inspection........................................................................................................................895
No-load test.........................................................................................................................................895
CONTROL SYSTEM[Z6]...............................................................................................................................897
CONTROL SYSTEM LOCATION INDEX [Z6]...................................................................................897
CONTROL SYSTEM DIAGRAM [Z6]..................................................................................................899
CONTROL SYSTEM WIRING DIAGRAM [Z6]..................................................................................899
PCM REMOVAL/INSTALLATION [Z6]................................................................................................901
PCM INSPECTION [Z6] ........................................................................................................................902
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Not Using the WDS or Equivalent....................................................................................................902
PCM terminal voltage table (Reference).....................................................................................902
Inspection Using An Oscilloscope (Reference).............................................................................913
Input/turbine speed sensor (-) signal...........................................................................................913
Input/turbine speed sensor (+) signal..........................................................................................913
Vehicle speed output signal..........................................................................................................914
Pressure control solenoid (+) signal............................................................................................914
Pressure control solenoid (-) signal.............................................................................................915
Vehicle speed signal (ATX)...........................................................................................................915
Shift solenoid A signal....................................................................................................................916
Shift solenoid C signal...................................................................................................................916
Shift solenoid B signal....................................................................................................................917
Fuel injection control signal...........................................................................................................917
ESA control signal..........................................................................................................................918
CKP signal.......................................................................................................................................918
IAC (+) signal ..................................................................................................................................919
IAC (-) signal ...................................................................................................................................919
Oxygen concentration signal ........................................................................................................920
Variable valve timing control (+) signal.......................................................................................920
HO2S heater signal........................................................................................................................921
Generator control signal................................................................................................................921
Generator output voltage signal...................................................................................................922
Purge control signal........................................................................................................................922
CMP signal......................................................................................................................................923
Using the WDS or Equivalent...........................................................................................................923
PCM CONFIGURATION [Z6]...............................................................................................................933
NEUTRAL SWITCH INSPECTION [Z6]..............................................................................................934
Continuity Inspection..........................................................................................................................934
Circuit Open/Short Inspection...........................................................................................................934
Open circuit .....................................................................................................................................935
Short circuit......................................................................................................................................935
CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [Z6]..................................................935
Continuity Inspection..........................................................................................................................935
Circuit Open/Short Inspection...........................................................................................................936
Open circuit .....................................................................................................................................936
Short circuit......................................................................................................................................936
POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [Z6].........................................936
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Continuity Inspection..........................................................................................................................937
Circuit Open/Short Inspection...........................................................................................................937
Open circuit .....................................................................................................................................938
Short circuit......................................................................................................................................938
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6]........938
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [Z6].................................939
Continuity Inspection..........................................................................................................................939
Circuit Open/Short Inspection...........................................................................................................940
Open circuit .....................................................................................................................................940
Short circuit......................................................................................................................................940
INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [Z6]................................................941
Resistance Inspection........................................................................................................................941
Circuit Open/Short Inspection...........................................................................................................942
Open circuit .....................................................................................................................................942
Short circuit......................................................................................................................................942
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6]............................943
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [Z6]....................................................943
Visual inspection.................................................................................................................................944
Air Gap Inspection..............................................................................................................................944
Voltage inspection..............................................................................................................................944
Circuit Open/Short Inspection...........................................................................................................945
Open circuit .....................................................................................................................................945
Short circuit......................................................................................................................................946
CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [Z6]................................946
CAMSHAFT POSITION (CMP) SENSOR INSPECTION [Z6].........................................................946
Visual inspection.................................................................................................................................947
Voltage inspection..............................................................................................................................947
Circuit Open/Short Inspection...........................................................................................................948
Open circuit .....................................................................................................................................948
Short circuit......................................................................................................................................948
THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION [Z6].....................................948
THROTTLE POSITION (TP) SENSOR INSPECTION [Z6].............................................................949
Resistance Inspection........................................................................................................................949
Circuit Open/Short Inspection...........................................................................................................950
Open circuit .....................................................................................................................................951
Short circuit......................................................................................................................................951
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