1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682 683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740 741 742 743 744 745 746 747 748 749 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769 770 771 772 773 774 775 776 777 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876 877 878 879 880 881 882 883 884 885 886 887 888 889 890 891 892 893 894 895 896 897 898 899 900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919 920 921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940 941 942 943 944 945 946 947 948 949 950 951 952 953 954 955 956 957 958 959 960 961 962 963 964 965 966 967 968 969 970 971 972 973 974 975 976 977 978 979 980 981 982 983 984 985 986 987 988 989 990
2007
Mazda
CX-7
Workshop
Manual
FOREWORD
This manual contains on-vehicle service
and/or diagnosis procedures for the Mazda
CX-7.
For proper repair and maintenance,
a thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
CONTENTS
ENGINE
SUSPENSION
DRIVELINE/AXLE
BRAKES
TRANSMISSION/TRANSAXLE
STEERING
HEATER, VENTILATION &
AIR CONDITIONING (HVAC)
RESTRAINTS
BODY & ACCESSORIES
© 2006 Mazda Motor Corporation
PRINTED IN U.S.A., FEBRUARY 2006
Form No. 1871–1U–06B
Part No. 9999–95–034B–07
Title
Section
00
01
02
03
04
05
06
07
08
09
AI

   Related Manuals for Mazda CX-7 2007

   Summary of Contents for Mazda CX-7 2007

  • Page 1: General Information

    Manual SUSPENSION DRIVELINE/AXLE FOREWORD This manual contains on-vehicle service BRAKES and/or diagnosis procedures for the Mazda CX-7. TRANSMISSION/TRANSAXLE For proper repair and maintenance, a thorough familiarization with this manual is STEERING important, and it should always be kept in a HEATER, VENTILATION &...

  • Page 2

    VEHICLE IDENTIFICATION NUMBERS (VIN) JM3 ER29L✻7# 100001— JM3 ER293✻7# 100001— RELATED MATERIALS Material Name MNAO Part No. Mazda Material No. Mazda CX-7 2007 Service Highlights 9999–95–045F–07 3416–1U–06B Engine Workshop Manual L3 WITH TC 9999–95–0L3T–06 1833–1U–05H Automatic Transaxle and Transfer Workshop Manual 9999–95–0AW6–07 1874–1U–06B...

  • Page 3

    GENERAL INFORMATION SECTION 00-00 Toc of SCT GENERAL INFORMATION ..00-00 Toc of SCT 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION SST ......00-00–19 NUMBER (VIN) CODE .

  • Page 4

    (1814 2267 kg) — Resraint system 2= with Curtain and Side air bags Carline, Series ER= Mazda CX-7 JM3= Mazda/Multi-purpose vehicle category/U.S.A. World manufacturer identification acxuuw00002316 End Of Sie VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300 JM3 ER29L*7# 100001— JM3 ER293*7# 100001—...

  • Page 5

    GENERAL INFORMATION HOW TO USE THIS MANUAL id000000800100 Range of Topics • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation 00-00 — Disassembly/Assembly — Replacement — Inspection —...

  • Page 6

    GENERAL INFORMATION Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2.

  • Page 7

    GENERAL INFORMATION Symbols • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. use. These symbols show application points or use of these materials during service. Symbol Meaning Kind 00-00 New appropriate Apply oil engine oil or gear New appropriate Apply brake fluid...

  • Page 8

    GENERAL INFORMATION Troubleshooting Procedure Basic flow of troubleshooting CUSTOMER ARRIVES WARNING LIGHT* NO WARNING LIGHT* ON/FLASHING WITH SYMPTOM CHECK FOR CHECK DTC IGNITION ON TEST, IDLING PRIORITIZED DTC TEST WITHOUT DTC DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM (ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING) DTC TABLE 1.

  • Page 9

    GENERAL INFORMATION Procedures for Use Using the basic inspection (section 05) • Perform the basic inspection procedure before symptom troubleshooting. • Perform each step in the order shown. • The reference column lists the location of the detailed procedure for each basic inspection. •...

  • Page 10

    GENERAL INFORMATION Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC. DETECTION CONDITION describes the condition under which the DTC is TROUBLE CONDITION detected. DTC P0103 DTC PO103 MAF circuit high input PCM monitors input voltage from TP sensor after ignition key is turned on.

  • Page 11

    GENERAL INFORMATION Using the diagnostic index • Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting. • The exact malfunction symptoms can be selected by following the index. TROUBLESHOOTING ITEM DESCRIPTION Page 00-00 (See 01-03-6 MELT NO.1 MAIN OR Melting of main or other fuses OTHER FUSE) MIL comes on...

  • Page 12

    GENERAL INFORMATION Using the quick diagnosis chart • The chart lists the relation between the symptom and the cause of the malfunction. • The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies a range of common causes when multiple malfunction symptoms occur.

  • Page 13

    GENERAL INFORMATION Using the symptom troubleshooting • Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for each trouble symptom. DESCRIPTION 00-00 describes what kind of TROUBLE TROUBLE SYMPTOM SYMPTOM Engine flares up or slips when upshifting or down shifting When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase slowly.

  • Page 14

    GENERAL INFORMATION UNITS id000000100400 Electrical current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm (kilogram force per square Positive pressure...

  • Page 15

    Special Service Tools • Use special service tools or the equivalent when they are required. 49 SE01 310 acxuuw00002395 Malfunction Diagnosis System • Use the Mazda modular diagnostic system (M-MDS) for malfunction diagnosis. 00-00–13 Revised 7/2006 (Ref. No. R065/06)

  • Page 16

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) GENERAL INFORMATION Disconnection of the Negative Battery Cable • When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power supply of the SAS control module to deplete its stored power after the cable is disconnected.

  • Page 17

    GENERAL INFORMATION Disassembly • If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance, and 00-00 identified so that reassembly can be performed easily and efficiently.

  • Page 18

    GENERAL INFORMATION Reassembly • Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. • If removed, these parts should be replaced with new ones: — Oil seals — Gaskets — O-rings —...

  • Page 19

    GENERAL INFORMATION Hose Clamps • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. 00-00 acxuuw00000018 Torque Formulas • When using a torque wrench-SST or equivalent combination, the specified torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench.

  • Page 20

    GENERAL INFORMATION Note • When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC CM determines that there is a malfunction in the DSC and illuminates the following lights: — ABS warning light —...

  • Page 21

    • Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are marked with global SST numbers. • Note that a global SST number is written together with a corresponding Mazda SST number as shown below. Example (section **-60)

  • Page 22

    GENERAL INFORMATION INSTALLATION OF RADIO SYSTEM id000000800300 • If a radio system is installed improperly or if a high-powered type system is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions: —...

  • Page 23

    GENERAL INFORMATION Connectors Disconnecting connectors • When disconnecting a connector, grasp the NO GOOD connectors, not the wires. GOOD 00-00 acxuuw00000454 • Connectors can be disconnected by pressing or pulling the lock lever as shown. acxuuw00000455 Locking connector • When locking connectors, listen for a click indicating they are securely locked.

  • Page 24

    GENERAL INFORMATION Inspection Caution • To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal. • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from GOOD NO GOOD the wiring harness side.

  • Page 25

    GENERAL INFORMATION Replacement • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. • Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab 00-00 pressed down, pull the terminal out from the TYPE A...

  • Page 26

    GENERAL INFORMATION Fuse Replacement • When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse malfunctions again, the circuit probably has a short and the wiring should be inspected. • Be sure the negative battery terminal is disconnected before replacing a main fuse. •...

  • Page 27

    GENERAL INFORMATION Other When it is necessary to show the terminal side of the vehicle wiring harness-side connectors, such as the DLC-2 following connectors, the viewing orientation is from the terminal side. • Main fuse block and the main fuse block relays 00-00 •...

  • Page 28

    GENERAL INFORMATION Ohmmeter Caution • Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the ohmmeter. • The ohmmeter is used to measure the resistance NO GOOD between two points in a circuit and to inspect for continuity and short circuits.

  • Page 29

    GENERAL INFORMATION JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS id000000800500 Jacking Positions Warning • Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious 00-00 injury. Use only the correct front and rear jacking points and block the wheels. •...

  • Page 30

    GENERAL INFORMATION Vehicle Lift Positions Front and rear Warning • Lifting a vehicle that is not stabilized is dangerous. The vehicle can slip off the lift and cause serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by adjusting the height of the support at the end of the arm of the lift.

  • Page 31

    GENERAL INFORMATION TOWING id000000800600 • Proper lifting and towing are necessary to prevent damage to the vehicle. Particularly when towing a AWD vehicle, where all the wheels are connected to the drive train, proper transporting of the vehicle is absolutely essential to avoid damaging the drive system. Government and local laws must be followed.

  • Page 32

    GENERAL INFORMATION Towing a AWD Vehicle Warning • Towing a AWD vehicle with either the front or rear wheels on the ground is dangerous as the drive train could be damaged, or the vehicle could trail away from the tow truck and cause an accident.

  • Page 33

    GENERAL INFORMATION 4. Hook the tying rope to the tiedown eyelet. 00-00 acxuuw00000519 acxuuw00000520 Caution • If the tiedown eyelet is not securely tightened, it may loosen or disengage from the bumper when tying down the vehicle. Make sure that the tiedown eyelet is securely tightened to the bumper. End Of Sie TIEDOWN HOOK id000000800700...

  • Page 34

    GENERAL INFORMATION IDENTIFICATION NUMBER LOCATIONS id000000800800 Vehicle Identification Number (VIN) acxuuw00002317 Engine Identification Number End Of Sie FRONT acxuuw00000346 00-00–32...

  • Page 35

    • In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.

  • Page 36

    GENERAL INFORMATION ABBREVIATIONS id000000801000 Antilock Brake System Left Rear Accessories Limited Slip Differential Automatic Locking Retractor Motor Automatic Transaxle Fluid Maximum Automatic Transaxle Minimum All-Wheel Drive Oil Control Valve Body Control Module Positive Crankcase Ventilation BTDC Before Top Dead Center Portable Diagnostic Software Calibration ID Parameter Identification...

  • Page 37

    GENERAL INFORMATION PRE-DELIVERY INSPECTION id000000801100 Pre-Delivery Inspection Table Exterior INSPECT and ADJUST, if necessary, the following items to specification: ❏ Glass, exterior bright metal and paint for damage 00-00 ❏ Wheel lug nuts ❏ All weatherstrips for damage or detachment ❏...

  • Page 38

    GENERAL INFORMATION Under hood— engine running at operating temperature INSPECT the following items: ❏ Automatic transaxle fluid level ❏ Operation of idle-up system for electrical load, air conditioner or power steering (if equipped) ❏ Ignition timing ❏ Idle speed ❏ Operation of throttle position sensor ❏...

  • Page 39

    *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

  • Page 40

    GENERAL INFORMATION Schedule 2: CANADA, Puerto Rico and (Unique Driving Conditions) for U.S.A. • Repeated short-distance driving • Driving in dusty conditions • Driving with extended use of brakes • Driving in areas where salt or other corrosive materials are used •...

  • Page 41

    *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

  • Page 43: Charging System, Ignition System, Starting System, Cooling System, Cruise Control System, Fuel System, Exhaust System

    ENGINE SECTION 01-02 Toc of SCT ON-BOARD DIAGNOSTIC EMISSION SYSTEM [L3 WITH TC] ... . . 01-02 [L3 WITH TC] ... . . 01-16 SYMPTOM TROUBLESHOOTING CHARGING SYSTEM [L3 WITH TC] .

  • Page 44

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0038[L3 WITH TC]... . . 01-02–34 DTC P0481[L3 WITH TC] ... . 01-02–154 DTC P0069[L3 WITH TC]... . . 01-02–36 DTC P050A[L3 WITH TC] .

  • Page 45

    ON-BOARD DIAGNOSTIC [L3 WITH TC] ON-BOARD DIAGNOSTIC WIRING DIAGRAM[L3 WITH TC] id010239800100 FUEL INJECTOR NO.1 FUEL INJECTOR NO.4 01-02 FUEL INJECTOR NO.3 FUEL INJECTOR NO.2 FUEL INJECTOR RELAY IAT SENSOR SENSOR HO2S HEATER (FRONT) HO2S HEATER (REAR) SENSOR FAN CONTROL MODULE NO.1 COOLING FAN RELAY NO.1 FUEL PRESSURE SENSOR...

  • Page 46

    ON-BOARD DIAGNOSTIC [L3 WITH TC] EGR VALVE EVAP SYSTEM LEAK DETECTION PUMP TP SENSOR PURGE SOLENOID VALVE BRAKE SWITCH NO.1 WASTEGATE CONTROL SOLENOID VALVE BRAKE SWITCH NO.2 VARIABLE SWIRL SOLENOID VALVE VARIABLE SWIRL SHUTTER VALVE SWITCH REFRIGERANT PRESSURE SWITCH (HIGH, LOW) THROTTLE REFRIGERANT PRESSURE SWITCH (MIDDLE) ACTUATOR...

  • Page 47

    ON-BOARD DIAGNOSTIC [L3 WITH TC] MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART[L3 WITH TC] id010239800200 ×: Applicable 01-02 Component Input Battery Ignition switch A/C switch, refrigerant pressure switch (high, low pressure) TP sensor ECT sensor IAT sensor MAF sensor HO2S (front) HO2S (rear) Fuel gauge sender unit...

  • Page 48

    ON-BOARD DIAGNOSTIC [L3 WITH TC] FOREWORD[L3 WITH TC] id010239800300 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and diagnostic trouble code (DTC), then diagnose the malfunction according to the following flowchart. — If a DTC exists, diagnose the applicable DTC inspection. (See 01-02-13 DTC TABLE[L3 WITH TC].) —...

  • Page 49

    ON-BOARD DIAGNOSTIC [L3 WITH TC] OBD-II DIAGNOSTIC MONITORING TEST RESULTS[L3 WITH TC] id010239800700 • These result from the intermittent monitor system technical data, which are used to determine whether the system is normal or not. They also display the system’s thresholds and diagnostic results. The intermittent monitor system monitors the oxygen sensor, EVAP purge system, catalyst and the EGR system.

  • Page 50

    ON-BOARD DIAGNOSTIC [L3 WITH TC] On-Board System Readiness Tests Access Procedure 1. Connect the M-MDS to the DLC-2. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS. • When using the IDS (notebook PC) 1.

  • Page 51

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Simulation Function Procedure 1. Connect the M-MDS to the DLC-2. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS. • When using the IDS (notebook PC) 1. Select the “Toolbox” tab. 2.

  • Page 52

    ON-BOARD DIAGNOSTIC [L3 WITH TC] AFTER REPAIR PROCEDURE[L3 WITH TC] id010239801100 1. Connect the M-MDS to the DLC-2. 2. Cycle the ignition switch from the off to the ON position. 3. Any retrieved DTCs. 4. Clear all diagnostic data using the M-MDS. End Of Sie DLC-2 acxuuw00001892...

  • Page 53

    ON-BOARD DIAGNOSTIC [L3 WITH TC] EGR System Repair Verification Drive Mode 1. Perform “PCM Adaptive Memory Production Drive Mode” first. 2. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off. 3. Drive the vehicle as shown in the graph. 4.

  • Page 54

    ON-BOARD DIAGNOSTIC [L3 WITH TC] EVAP System Repair Verification Drive Mode Note • If “EVAP System Repair Verification Drive Mode” cannot be performed (it is impossible to drive the vehicle under this drive mode condition), perform the EVAP system test procedure as an alternative. 1.

  • Page 55

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] Engine speed Vehicle speed Step Time Vehicle condition (rpm) (km/h {mph}) Idle the engine after the cooling fan T1: More than 10 s N3: Idle 0 {0} has stopped...

  • Page 56

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02-37 × P0089 Fuel pressure regulator performance Other C, O, R DTC P0089[L3 WITH TC].) (See01-02-38 Fuel pressure regulator control circuit ×...

  • Page 57

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type Engine cooling (See01-02-74 × P0126 Coolant thermostat stuck open system DTC P0126, P0128[L3 Engine cooling × P0128 Coolant thermostat stuck open WITH TC].) system (See01-02-76 01-02 ×...

  • Page 58

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- 112 DTC × P0245 Turbocharger wastegate solenoid low Other C, O, R P0245[L3 WITH TC].) (See01-02- 114 DTC × P0246 Turbocharger wastegate solenoid high Other C, O, R P0246[L3...

  • Page 59

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- Change over valve (COV) (EVAP 142 DTC × P0446 system leak detection pump) stuck C, R P0446[L3 close WITH TC].) (See01-02- 01-02 EVAP control system leak detected EVAP system 144 DTC ×...

  • Page 60

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- 168 DTC × P0571 Brake switch circuit malfunction Other P0571[L3 WITH TC].) (See01-02- Internal control module memory 170 DTC × P0601 C, O, R check sum error P0601[L3 WITH TC].)

  • Page 61

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- 191 DTC × P2096 Target A/F feedback system too lean Fuel system P2096[L3 WITH TC].) (See01-02- 01-02 194 DTC × P2097 Target A/F feedback system too rich Fuel system P2097[L3 WITH TC].)

  • Page 62

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- 220 DTC × P2178 Fuel system too rich at off idle Fuel system C, R P2178[L3 WITH TC].) (See01-02- 223 DTC × P2187 Fuel system too lean at idle Fuel system C, R P2187[L3...

  • Page 63

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] Self-test Memory DTC No. Condition Monitor item Page function type (See01-02- 251 DTC × P2502 Generator terminal B circuit open – C, R P2502[L3 WITH TC].) (See01-02- 01-02 Generator output voltage signal no 252 DTC ×...

  • Page 64

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0011[L3 WITH TC] id010239801600 DTC P0011 CMP Timing over-advanced • Actual valve timing is over-advanced by 17 ° (when the following conditions are met) from the target valve timing when the OCV is controlled at the maximum valve timing retard condition.

  • Page 65

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0011 Yes Replace the PCM, then go to the next step. (See 01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all the disconnected TC].) connectors. Go to the next step. •...

  • Page 66

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step. • Stop the engine. Reinstall the timing chain, then go to Step 8. • Remove the timing chain cover. • Is the camshaft timing mark at the correct point? (See 01-10-10 TIMING CHAIN REMOVAL/ INSTALLATION[L3 WITH TC].)

  • Page 67

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0016[L3 WITH TC] id010239801800 DTC P0016 CKP-CMP correlation • The PCM monitors the input pulses from the CKP sensor and CMP sensor. If the input pulse pick-up timing do not match each other, the PCM determines that the camshaft position does not coincide with the crankshaft position.

  • Page 68

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT CKP SENSOR FOR FOREIGN Yes Remove foreign material from the CKP sensor, then go to Step 13. MATERIAL • Remove the CKP sensor. Go to the next step. • Inspect the CKP sensor for foreign material. •...

  • Page 69

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0030 Front HO2S heater control circuit problem • Front HO2S heater malfunction • Connector or terminal malfunction • Open circuit in wiring harness between front HO2S heater terminal 2D and PCM terminal 2C POSSIBLE •...

  • Page 70

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P0031[L3 WITH TC] id010239802000 DTC P0031 Front HO2S heater circuit low input • The PCM monitors the front HO2S heater output voltage. If the PCM turns the front HO2S heater off or on but the front HO2S heater circuit voltage remains low the PCM determines that the front HO2S heater circuit has a malfunction.

  • Page 71

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next step. • Verify related Service Bulletins and/or on-line repair information availability.

  • Page 72

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0032[L3 WITH TC] id010239802100 DTC P0032 Front HO2S heater circuit high input • The PCM monitors the front HO2S heater output voltage. If the PCM turns the front HO2S heater on or off but the front HO2S heater circuit voltage remains high the PCM determines that the front HO2S heater circuit has a malfunction.

  • Page 73

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 74

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0037[L3 WITH TC] id010239802200 DTC P0037 Rear HO2S heater circuit low input • The PCM monitors the rear HO2S heater output voltage. If the PCM turns the rear HO2S heater on or off but the rear HO2S heater circuit voltage remains low the PCM determines that the rear HO2S heater circuit has a malfunction.

  • Page 75

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT REAR HO2S CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 9. POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the rear HO2S connector. •...

  • Page 76

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0038[L3 WITH TC] id010239802300 DTC P0038 Rear HO2S heater circuit high input • The PCM monitors the rear HO2S heater output voltage. If the PCM turns the rear HO2S heater off but the rear HO2S heater circuit voltage remains high the PCM determines that the rear HO2S heater circuit has a malfunction.

  • Page 77

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 78

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0069[L3 WITH TC] id010239802400 DTC P0069 Manifold absolute pressure/atmospheric pressure correlation • PCM monitors differences between intake manifold vacuum and atmospheric pressure. If the difference is below –12 kPa {–90 mmHg, –3.5 inHg} or above 12 kPa {90 mmHg, 3.5 inHg} when the following conditions are met, the PCM determines that there is a MAP sensor performance problem.

  • Page 79

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P0089[L3 WITH TC] id010239802500 DTC P0089 Fuel pressure regulator performance • If the fuel pressure average value measured by the PCM exceeds the specification when the camshaft is rotating at a specified rate, the PCM determines that there is a fuel pressure regulator performance problem.

  • Page 80

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0091[L3 WITH TC] id010239802600 DTC P0091 Fuel pressure regulator control circuit low • When the PCM turns the spill valve control solenoid valve off but the spill valve control solenoid valve control circuit voltage is low, the PCM determines that the spill valve control solenoid valve control circuit has malfunction.

  • Page 81

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT HIGH PRESSURE FUEL PUMP Yes Repair or replace the terminal, then go to Step 8. CONNECTOR FOR POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the high pressure fuel pump connector.

  • Page 82

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0092[L3 WITH TC] id010239802700 DTC P0092 Fuel pressure regulator control circuit high • When the PCM turns the spill valve control solenoid valve on but the spill valve control solenoid valve circuit voltage is high, the PCM determines that the spill valve control solenoid valve control circuit has malfunction.

  • Page 83

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available...

  • Page 84

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0096[L3 WITH TC] id010239802800 DTC P0096 Boost air temperature sensor circuit range/performance problem • If the intake air temperature is higher than the engine coolant temperature by 23 °C {41.4 °F} for 1.2 s with the ignition switch turn to the ON position*, the PCM determines that there is a boost air temperature sensor circuit range/performance problem.

  • Page 85

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 86

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0097[L3 WITH TC] id010239802900 DTC P0097 Boost air temperature sensor circuit low • If the PCM detects that the boost air temperature sensor voltage is 0.1 V or less, the PCM determines that the boost air temperature sensor circuit voltage is low. Diagnostic support note DETECTION •...

  • Page 87

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 88

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0098[L3 WITH TC] id010239803000 DTC P0098 Boost air temperature sensor circuit high • If the PCM detects that the boost air temperature sensor voltage is 4.96 V or more, the PCM determines that the boost air temperature sensor circuit voltage is high. Diagnostic support note DETECTION •...

  • Page 89

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT MAP/BOOST AIR TEMPERATURE Yes Repair or replace the terminal, then go to Step 8. SENSOR CONNECTOR FOR POOR Go to the next step. CONNECTION • Turn the ignition switch off. • Disconnect the MAP/boost air temperature sensor connector.

  • Page 90

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0101[L3 WITH TC] id010239803100 DTC P0101 MAF circuit range/performance problem • PCM monitors the mass intake air flow amount when the engine is running. — If the mass intake air amount is above 71.8 l/s for 6 s and engine speed is below 2,000 rpm with the engine running, the PCM determines that detected mass intake air flow amount is too high.

  • Page 91

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Repair terminal, then go to the next step. CONNECTION Go to the next step. • Disconnect the PCM connector. • Check for poor connection (damaged, pulled- out pins, corrosion, etc.).

  • Page 92

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0102[L3 WITH TC] id010239803200 DTC P0102 MAF circuit low input • PCM monitors input voltage from the MAF sensor when engine is running. If the input voltage is below 0.21 V, the PCM determines that the MAF circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 93

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 94

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0103[L3 WITH TC] id010239803300 DTC P0103 MAF circuit high input • The PCM monitors input voltage from the MAF sensor when the engine is running. If the input voltage is above 4.9 V, the PCM determines that the MAF circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 95

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 96

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0107[L3 WITH TC] id010239803400 DTC P0107 MAP sensor circuit low input • PCM monitors input voltage from the MAP sensor when the intake air temperature is above –10 °C {14 °F}. If the input voltage is below 0.10 V, the PCM determines that the MAP sensor circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 97

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Recorded FREEZE FRAME DATA on the repair order, then • Has the FREEZE FRAME DATA been go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available...

  • Page 98

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0108[L3 WITH TC] id010239803500 DTC P0108 MAP sensor circuit high input • PCM monitors input voltage from the MAP sensor when the intake air temperature is above –10 °C {14 °F}. If the input voltage is above 4.9 V, the PCM determines that MAP sensor circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 99

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 100

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0111[L3 WITH TC] id010239803600 DTC P0111 IAT circuit performance problem • If the intake air temperature is higher than the engine coolant temperature by 18 °C {32.4 °F} for 1.2 s with the ignition switch turn in the ON position*, the PCM determines that there is an IAT sensor circuit range/ performance problem.

  • Page 101

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0112[L3 WITH TC] id010239803700 DTC P0112 IAT circuit low input • The PCM monitors the IAT sensor signal. If the PCM detects on IAT sensor voltage below 0.06 V, the PCM determines that the IAT sensor circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 102

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 103

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0113[L3 WITH TC] id010239803800 DTC P0113 IAT circuit high input • The PCM monitors the IAT sensor signal. If the PCM detected IAT sensor voltage above 4.9 V, the PCM determines that the IAT sensor circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 104

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT IAT SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 9. POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the MAF/IAT sensor connector. •...

  • Page 105

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0116[L3 WITH TC] id010239803900 DTC P0116 ECT circuit range/performance problem • The PCM monitors the maximum value and minimum value of engine coolant temperature when the engine is started and5 min have been passed after leaving the vehicle 6 h or more. If the difference between the maximum and the minimum values of the engine coolant temperature is below 6 °C {10.8 °F}, the PCM determines that there is an ECT circuit range/performance problem.

  • Page 106

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT ECT SENSOR Yes Replace the ECT sensor, then go to Step 6. • Inspect the ECT sensor. (See01-40-24 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION[L3 WITH TC].) (See01-40-25 ENGINE COOLANT TEMPERATURE (ECT) SENSOR Go to the next step.

  • Page 107

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0117 ECT sensor circuit low input ECT SENSOR 01-02 ECT SENSOR WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2G 2C...

  • Page 108

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT ECT SIGNAL CIRCUIT FOR SHORT Yes Repair or replace the wiring harness for a short to ground, then go to Step 7. TO GROUND • Turn the ignition switch off. Go to the next step. •...

  • Page 109

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0118 ECT sensor circuit high input ECT SENSOR 01-02 ECT SENSOR WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2G 2C...

  • Page 110

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT ECT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a short to power supply, then go to Step 9. SHORT TO POWER • Turn the ignition switch to the ON position Go to the next step.

  • Page 111

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0122 TP sensor No.1 circuit low input TP SENSOR NO.1 (THROTTLE BODY) 01-02 THROTTLE BODY HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O...

  • Page 112

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT POWER SUPPLY CIRCUIT VOLTAGE Yes Go to the next step. AT THROTTLE BODY CONNECTOR Repair or replace for an open circuit between throttle body connector terminal B (harness-side) and PCM connector Note terminal 2AO (harness-side).

  • Page 113

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0123 TP sensor No.1 circuit high input TP SENSOR NO.1 (THROTTLE BODY) 01-02 THROTTLE BODY HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O...

  • Page 114

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT TP1 SIGNAL CIRCUIT FOR OPEN Yes Go to the next step. CIRCUIT Repair or replace for short to a power supply. Then, go to • Turn ignition switch to the ON position (Engine Step 10.

  • Page 115

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 116

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0126, P0128[L3 WITH TC] id010239815400 DTC P0126 Coolant thermostat stuck open DTC P0128 DTC P0126 • If the ECT signal never exceeds 71 °C {160 °F} after engine start for specified period, PCM determines that the coolant thermostat is stuck open.

  • Page 117

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY MONITORING CONDITION FOR Yes Take corrective action (e.g. cool down engine), then repeat this step. REPAIR VERIFICATION • Make sure to reconnect all disconnected Go to the next step for DTC P0126 or go to step 7 for DTC connectors.

  • Page 118

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0128 Yes Go to the next step. COMPLETED Replace PCM, then go to the next step. • Start engine and turn off E/L and A/C. • Access DIAGNOSTIC MONITORING TEST RESULTS using the M-MDS and monitor TEST #10: E1: 80 (Heat radiation ratio) or #10: E1: 81 (ECT).

  • Page 119

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0131 Front HO2S circuit low input FRONT HO2S 01-02 FRONT HO2S WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2G 2C...

  • Page 120

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FRONT HO2S CIRCUIT FOR SHORT Yes Repair or replace the wiring harness for a possible short to ground, then go to Step 10. TO GROUND • Turn the ignition switch off. Go to the next step.

  • Page 121

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0132[L3 WITH TC] id010239804700 DTC P0132 Front HO2S circuit high input • The PCM monitors the input voltage from the front HO2S when the engine is running. If the input voltage is less than 1.0 V for 2 s, the PCM determines that the front HO2S circuit voltage is high. Diagnostic support note •...

  • Page 122

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING OR STORED DTC Yes Go to the appropriate DTC troubleshooting procedures. • Turn the ignition switch off, then to the ON (See01-02-13 DTC TABLE[L3 WITH TC].) position (Engine off). Go to the next step.

  • Page 123

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0133[L3 WITH TC] id010239804800 DTC P0133 Front HO2S circuit slow response • An oxygen sensor malfunction can be detected by measuring the average frequency of the oxygen sensor signal, time required to pass from rich to lean, and the time required to pass from lean to rich. •...

  • Page 124

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to Step 8. • Warm up the engine. Go to the next step. • Access the O2S11 PID using the M-MDS. • Inspect the PID under the following accelerator pedal conditions in NEUTRAL.

  • Page 125

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0133 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. •...

  • Page 126

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0134 Front HO2S no activity detected FRONT HO2S MAIN RELAY FRONT HO2S HEATER FRONT HO2S WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O...

  • Page 127

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step. DATA Go to troubleshooting procedures for the DTC on the • Is DTC P0134 on the FREEZE FRAME DATA? FREEZE FRAME DATA. (See01-02-13 DTC TABLE[L3 WITH TC].) VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to Step 8.

  • Page 128

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0137[L3 WITH TC] id010239805000 DTC P0137 Rear HO2S circuit low input • The PCM monitors the input voltage from the rear HO2S. If the input voltage from the rear HO2S sensor is below 0.1 V for 41.6 s, the PCM determines that the circuit input is low. MONITORING CONDITIONS —...

  • Page 129

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 130

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0138[L3 WITH TC] id010239805100 DTC P0138 Rear HO2S circuit high input • The PCM monitors the input voltage from the rear HO2S. If the input voltage from the rear HO2S sensor is above 1.2 V for 0.8 s, the PCM determines that the circuit input is high. Diagnostic support note •...

  • Page 131

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 132

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0139[L3 WITH TC] id010239805200 DTC P0139 Rear HO2S circuit problem • The PCM monitors the rich (0.4 V) to lean (0.3 V) response time of the rear HO2S. The PCM measures the response time when the following conditions are met. The PCM determines that the rear HO2S response deteriorated when the measured response time is more than the threshold value (130 ms) five consecutive times.

  • Page 133

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING AND STORED Yes Go to DTC P0443 troubleshooting procedures, then go to Step 13. • Turn the ignition switch off, then to the ON Go to the next step. position (Engine off).

  • Page 134

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT SEALING OF ENGINE COOLANT Yes Go to the next step. PASSAGE Repair or replace the malfunctioning part according to • Perform the “ENGINE COOLANT LEAKAGE inspection results. INSPECTION.” Then go to the next step. (See01-12-6 ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC].) •...

  • Page 135

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0140 Rear HO2S no activity detected REAR HO2S 01-02 REAR HO2S WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1G 1C...

  • Page 136

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to Step 8. • Warm up the engine. Go to the next step. • Access the O2S12 or the P0140 PID using the M-MDS. • Verify the PID while racing the engine at least 10 times in NEUTRAL.

  • Page 137

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0192[L3 WITH TC] id010239805400 DTC P0192 Fuel pressure sensor circuit low input • If the input voltage from the fuel pressure sensor is less than 0.19 V for 1.3 s, the PCM determines that the fuel pressure sensor circuit is low.

  • Page 138

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE SENSOR Yes Repair or replace the terminal, then go to Step 7. CONNECTOR FOR POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the fuel pressure sensor connector. •...

  • Page 139

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0193 Fuel pressure sensor circuit high input FUEL PRESSURE SENSOR 01-02 FUEL PRESSURE SENSOR HARNESS SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O...

  • Page 140

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 8. CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the PCM connector. •...

  • Page 141

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0201 Injector circuit/open cylinder No.1 FUEL INJECTOR NO.1 01-02 FUEL INJECTOR NO.1 WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2G 2C...

  • Page 142

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL INJECTOR NO.1 CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to power supply, then go to Step 10. SHORT TO POWER SUPPLY • Turn the ignition switch to the ON position Go to the next step.

  • Page 143

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0202[L3 WITH TC] id010239805700 DTC P0202 Injector circuit/open cylinder No.2 • If the fuel injection verification signal is not input at 255 times continuously even though the PCM drives the fuel injector No.2, the PCM determines that there is an open circuit in the fuel injector No.2 control circuit. MONITORING CONDITION —...

  • Page 144

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL INJECTOR NO.2 CONNECTOR Yes Repair or replace the terminal, then go to Step 10. FOR POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the fuel injector No.2 connector. •...

  • Page 145

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0203[L3 WITH TC] id010239805800 DTC P0203 Injector circuit/open cylinder No.3 • If the fuel injection verification signal is not input at 255 times continuously even though the PCM drives fuel injector No.3, the PCM determines that there is an open circuit in the fuel injector No.3 control circuit. MONITORING CONDITION —...

  • Page 146

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL INJECTOR NO.3 CONNECTOR Yes Repair or replace the terminal, then go to Step 10. FOR POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the fuel injector No.3 connector. •...

  • Page 147

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0204[L3 WITH TC] id010239805900 DTC P0204 Injector circuit/open cylinder No.4 • If the fuel injection verification signal is not input at 255 times continuously even though the PCM drives fuel injector No.4, the PCM determines that there is an open circuit in the fuel injector No.4 control circuit. MONITORING CONDITION —...

  • Page 148

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL INJECTOR NO.4 CONNECTOR Yes Repair or replace the terminal, then go to Step 10. FOR POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the fuel injector No.4 connector. •...

  • Page 149

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0222[L3 WITH TC] id010239806000 DTC P0222 TP sensor No.2 circuit low input • If PCM detects that the TP sensor No.2 voltage is below 0.2 V after the ignition switch to the ON position, the PCM determines that TP circuit has a malfunction.

  • Page 150

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT TP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 8. POOR CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the TP sensor connector. •...

  • Page 151

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0223[L3 WITH TC] id010239806100 DTC P0223 TP sensor No.2 circuit high input • If the PCM detects that the TP sensor No.2 voltage is above 4.85 V after the ignition switch to the ON position, the PCM determines that the TP circuit has a malfunction.

  • Page 152

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT TP SENSOR Yes Go to the next step. • Perform the TP sensor inspection. Replace the throttle body, then go to Step 8. (See01-40-32 THROTTLE POSITION (TP) SENSOR INSPECTION[L3 WITH TC]) •...

  • Page 153

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0234[L3 WITH TC] id010239806200 DTC P0234 Turbocharger over boost condition • If the manifold absolute pressure or charging efficiency are more than the specification for the specified period of time, the PCM determines that the turbocharger is in an over boost condition. MONITORING CONDITIONS —...

  • Page 154

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0245[L3 WITH TC] id010239806300 DTC P0245 Turbocharger wastegate solenoid low • When the PCM turns the wastegate control solenoid valve off but the wastegate control solenoid valve circuit voltage is low, the PCM determines that the wastegate control solenoid valve control circuit voltage is low.

  • Page 155

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 156

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0246[L3 WITH TC] id010239806400 DTC P0246 Turbocharger wastegate solenoid high • When the PCM turns the wastegate control solenoid valve on but the wastegate control solenoid valve circuit voltage is high, the PCM determines that the wastegate control solenoid valve control circuit voltage is high.

  • Page 157

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT WASTEGATE CONTROL SOLENOID Yes Replace the wastegate control solenoid valve, then go to Step 7. VALVE • Inspect the wastegate control solenoid valve. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/ INSTALLATION[L3 WITH TC].) (See01-13-14 WASTEGATE CONTROL SOLENOID VALVE INSPECTION[L3 WITH Go to the next step.

  • Page 158

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0300 Random misfire detected • CKP sensor malfunction • CMP sensor malfunction • Ignition coil malfunction • Ignition system malfunction • MAF sensor contamination • Excess air suction in intake air system (between MAF sensor and intake manifold) •...

  • Page 159

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CKP SENSOR INSTALLATION Yes Retighten the CKP sensor, then go to Step. CONDITION Go to the next step. • Inspect the CKP sensor for looseness. • Is the CKP sensor loose? INSPECT IGNITION COIL HARNESSES Yes Go to the next step.

  • Page 160

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT OPERATION OF PURGE CONTROL Yes Go to the next step. SOLENOID VALVE Replace the purge control solenoid valve, then go to Step • Turn the ignition switch off. • Connect the vacuum pump to the purge control solenoid valve and apply vacuum to the solenoid.

  • Page 161

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE (LOW-SIDE) Yes Go to the next step. • Connect the fuel pressure gauge between the Inspect for the following. • Fuel line restriction fuel pump and the high pressure fuel pump. •...

  • Page 162

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 163

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL INJECTOR WIRING HARNESS Yes Go to the next step. • Remove the intake air system parts. Inspect the fuel injector wiring harnesses. • Disconnect the fuel injector connector on Repair or replace if necessary, then go to Step 14. suspected cylinder.

  • Page 164

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0327[L3 WITH TC] id010239806700 DTC P0327 Knock sensor circuit low input • PCM monitors the input signal from the knock sensor when the engine is running. If the input voltage at the PCM terminals between 2V and 2U is below 0.12 V, the PCM determines that the knock sensor circuit has a malfunction.

  • Page 165

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT KNOCK SENSOR Yes Go to the next step. • Perform the knock sensor inspection. Replace the knock sensor, then go to the next step. (See01-40-47 KNOCK SENSOR (KS) INSPECTION[L3 WITH TC]) •...

  • Page 166

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0328[L3 WITH TC] id010239806800 DTC P0328 Knock sensor circuit high input • PCM monitors the input signal from the knock sensor when the engine is running. If the input voltage at the PCM terminals between 2V and 2U is below 4.9 V, the PCM determines that the knock sensor circuit has a malfunction.

  • Page 167

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 168

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0335[L3 WITH TC] id010239806900 DTC P0335 CKP sensor circuit malfunction • If the PCM does not receive the input voltage from the CKP sensor for 4.2 s while the MAF is 2.0 g/s {0.26 lb/min.} or above, the PCM determines that the CKP sensor circuit has a malfunction.

  • Page 169

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 170

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT CKP SENSOR Yes Go to the next step. • Turn the ignition switch off. Inspect the CKP sensor pulse wheel for damage. Replace • Perform the CKP sensor inspection. the CKP sensor pulse wheel and go to the next step. (See01-40-43 CRANKSHAFT POSITION (CKP) SENSOR INSPECTION[L3 WITH TC]) •...

  • Page 171

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0340 Camshaft position (CMP) sensor circuit malfunction MAIN RELAY CMP SENSOR 01-02 CMP SENSOR WIRING HARNESS SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O...

  • Page 172

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT CMP CIRCUIT FOR SHORT TO Yes Repair or replace the suspected wiring harness, then go to Step 15. POWER • Turn ignition switch OFF. Go to the next step. • Disconnect the CMP sensor connector. •...

  • Page 173

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT STOPPER PIN MECHANISM Yes Go to the next step. • Remove the timing chain. Replace the variable valve timing actuator, then go to Step • Inspect the stopper pin. (See01-10-27 VARIABLE VALVE TIMING ACTUATOR INSPECTION[L3 WITH TC].) •...

  • Page 174

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 175

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P0403[L3 WITH TC] id010239807100 DTC P0403 EGR valve (stepper motor) circuit malfunction • PCM monitors the input voltage from the EGR valve. If the voltage remain low or high, the PCM determines that the EGR valve circuit has a malfunction.

  • Page 176

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 177

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT CONTROL CIRCUIT FOR OPEN Yes Go to the next step. CIRCUIT Repair or replace harness for open circuit then go to the • Remove the PCM with PCM connector next step. connected.

  • Page 178

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next step. • Verify related Service Bulletins and/or on-line repair information availability.

  • Page 179

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0441[L3 WITH TC] id010239041100 DTC P0441 Evaporative emission control system incorrect purge flow • PCM measures the purge line pressure under the following conditions. If the vacuum between the charcoal canister and the intake manifold does not reach the specification, PCM determines that the EVAP system is clogged.

  • Page 180

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION LOCATE LEAK POINT Yes Repair leakage or replace the part, then go to Step 10. • Inspect the following for leakage using the Go to the next step. ultrasonic leak detector. — Charcoal canister —...

  • Page 181

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0442[L3 WITH TC] id010239807500 DTC P0442 Evaporative emission control system leak detected (small leak) • PCM measures the pump load current (EVAP line pressure) when the specified period has passed after the EVAP system is sealed when the monitoring conditions are met. If the load does not reach the reference current value within the specified period, the PCM determines that the EVAP system has a small leak.

  • Page 182

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PURGE SOLENOID VALVE Yes Go to the next step. • Inspect purge solenoid valve is stuck closed. Replace the purge solenoid valve, then go to Step 10. (See01-16-9 PURGE SOLENOID VALVE INSPECTION[L3 WITH TC].) •...

  • Page 183

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0443 EVAP control system purge control valve circuit malfunction MAIN RELAY PURGE SOLENOID VALVE 01-02 PURGE SOLENOID VALVE WIRING HARNESS SIDE CONNECTOR WIRING HARNESS SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 184

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PURGE SOLENOID VALVE POWER Yes Go to the next step. SUPPLY CIRCUIT FOR OPEN CIRCUIT Repair or replace the wiring harness for an open circuit, • Turn ignition switch to the ON position (Engine then go to Step 10.

  • Page 185

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0446 Change over valve (COV) (EVAP system leak detection pump) stuck close MAIN RELAY EVAP SYSTEM LEAK DETECTION PUMP 01-02 EVAP SYSTEM LEAK DETECTION PUMP PCM WIRING WIRING HARNESS-SIDE CONNECTOR HARNESS-SIDE CONNECTOR 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B...

  • Page 186

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0446 Yes Replace the PCM, then go to the next step. COMPLETED Go to the next step. • Make sure to reconnect all disconnected connectors. • Turn the ignition switch to the ON position (Engine off).

  • Page 187

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 188

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY POOR CONNECTION OF VACUUM Yes Connect the vacuum hose correctly, then go to Step 17. HOSE Go to the next step. • Verify the vacuum hose installation condition between the fuel tank and the charcoal canister.

  • Page 189

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0456[L3 WITH TC] id010239807900 DTC P0456 Evaporative emission control system leak detected (very small leak) • PCM measures the pump load current (EVAP line pressure) when a specified period has passed after the EVAP system is sealed when monitoring conditions are met. If the load does not reach the reference load value or the rate of the load increase is lower than the specification within a specified period, the PCM determines that the EVAP system has a very small leak.

  • Page 190

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION LOCATE LEAK POINT Yes Repair the leakage or replace the part, then go to Step 10. • Check for leakage for the following using the Go to the next step. Evaporative Emission Tester —...

  • Page 191

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0461[L3 WITH TC] id010239808000 DTC P0461 Fuel gauge sender unit circuit range/performance • PCM monitors the fuel level voltage difference before and after the PCM-calculated fuel consumption has reached 25 L {26.4 US qt., 22 Imp qt.}. If the difference is 5% less than the PCM-calculated fuel consumption, the PCM determines that the fuel gauge sender unit range/performance is in error.

  • Page 192

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0462[L3 WITH TC] id010239808100 DTC P0462 Fuel gauge sender unit circuit low input • The PCM monitors the signals of the fuel level and fuel gauge sender unit output voltage from the instrument cluster. If the PCM detects that the fuel level or fuel gauge sender unit output voltage is too low, the PCM determines that the fuel gauge sender unit circuit has a malfunction.

  • Page 193

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0463[L3 WITH TC] id010239808200 DTC P0463 Fuel gauge sender unit circuit high input • The PCM monitors the signals of the fuel level and fuel gauge sender unit output voltage from the instrument cluster. If the PCM detects that the fuel level or fuel gauge sender unit output voltage is too high, the PCM determines that the fuel gauge sender unit circuit has a malfunction.

  • Page 194

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0480[L3 WITH TC] id010239807400 DTC P0480 Fan control circuit problem • The PCM monitors the input voltage from the fan control module No.1. If the voltage remains low or high, the PCM determines that the fan control circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 195

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available...

  • Page 196

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0481[L3 WITH TC] id010239815200 DTC P0481 Fan control circuit problem • The PCM monitors the input voltage from the fan control module No.2. If the voltage remains low or high, the PCM determines that the fan control circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 197

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FAN CONTROL MODULE No.2 Yes Repair or replace the wiring harness for an open circuit, then go to Step 9. SIGNAL CIRCUIT FOR SHORT TO POWER SUPPLY Go to the next step.

  • Page 198

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P050A Cold start idle air control system performance • The air into the fuel line by exchange or re-installation • Electronic throttle control system malfunction POSSIBLE • Throttle valve stuck or blockage CAUSE •...

  • Page 199

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.(See01-02-13 • Perform the AFTER REPAIR PROCEDURE. DTC TABLE[L3 WITH TC].) (See01-02-10 AFTER REPAIR Go to the next step.

  • Page 200

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VISUALLY INSPECT CMP SENSOR AND PULSE Yes Replace the suspected part, then go to Step 10. WHEEL Go to the next step. • Visually inspect for CMP sensor and pulse wheel.

  • Page 201

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0500 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. •...

  • Page 202

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT A/C MAGNETIC CLUTCH OPERATION Yes Go to “A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.” of ENGINE SYMPTOM TROUBLESHOOTING then go to Step 9. Note • The following test should be performed for (See01-03-5 ENGINE SYMPTOM TROUBLESHOOTING[L3 WITH TC].) vehicles with A/C.

  • Page 203

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 204

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0506 Yes Replace the PCM, then go to the next step. COMPLETED Go to the next step. • Make sure to reconnect all disconnected connectors. • Start the engine. •...

  • Page 205

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT ELECTRONIC THROTTLE CONTROL Yes Go to the next step. SYSTEM MALFUNCTION Replace the necessary parts, then go to the next step. • Inspect the following parts: — APP sensor (See01-40-33 ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION[L3 WITH TC].) 01-02...

  • Page 206

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0550[L3 WITH TC] id010239808800 DTC P0550 PSP switch circuit malfunction • The PCM monitors the PSP switch signal, If the input voltage is low voltage (switch stays on) for 1 min. when the VSS is above 60.0 km/h {37.4 mph} and the ECT is above 60 °C {140 °F}, the PCM determines that the PSP switch circuit has a malfunction.

  • Page 207

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PSP CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 8. CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the PSP connector. •...

  • Page 208

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0564[L3 WITH TC] id010239808900 DTC P0564 Cruise control switch circuit malfunction • The PCM monitors the cruise control switch signal. If the PCM detects that any one of following switches (Main, CANCEL, SET/COAST, RESUME/ACCEL) remains on for 2 min, the PCM determines that the cruise control switch circuit has a malfunction.

  • Page 209

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next step. • Check for related Service Bulletins and/or on- line repair information availability.

  • Page 210

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0571[L3 WITH TC] id010239809000 DTC P0571 Brake switch circuit problem • The PCM monitors the change in the input voltage for brake switch No.1 and No.2. If the PCM detects that both brake switches No.1 and No.2 remain on or off for 15 s, it determines that the brake switch circuit has a malfunction.

  • Page 211

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING CODE OR Yes Go to the applicable DTC inspection. (See01-02-13 DTC TABLE[L3 WITH TC].) STORED DTC • Turn the ignition switch off then to the ON Go to the next step. position (Engine off).

  • Page 212

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0601[L3 WITH TC] id010239809100 DTC P0601 Internal control module memory check sum error • PCM internal memory check sum error. Diagnostic support note • This is a continuous monitor (CCM). DETECTION • MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle. CONDITION •...

  • Page 213

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 214

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P0606[L3 WITH TC] id010239809400 DTC P0606 ECM/PCM processor • PCM internal CPU malfunction. Diagnostic support note • This is a continuous monitor (CCM). DETECTION • MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle. CONDITION •...

  • Page 215

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF P0607 Yes Replace PCM, go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. • Clear the DTC from the PCM memory using the M-MDS.

  • Page 216

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0638[L3 WITH TC] id010239809800 DTC P0638 Throttle actuator control range/performance • The PCM compares the actual TP with the target TP when the engine is running. If the difference is more than the specification, the PCM determines that there is a throttle actuator control circuit range/ performance problem.

  • Page 217

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P0703 Brake switch No.1 circuit malfunction • Brake switch malfunction • Poor connection of the brake switch connector or the PCM connector • Short to the power supply between brake switch terminal D and PCM connector terminal 1AB POSSIBLE •...

  • Page 218

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION CLASSIFY BRAKE SWITCH OR CIRCUIT Yes Go to the next step. • Connect the M-MDS to the DLC-2. Go to Step 7. • Access the BOO PID. • Connect a jumper wire between brake switch terminal B and D (harness-side).

  • Page 219

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].) (See01-02-10 AFTER REPAIR Troubleshooting completed. PROCEDURE[L3 WITH TC].) • Are any DTCs present? End Of Sie 01-02 WM: DTC P12XX...

  • Page 220

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2004[L3 WITH TC] id010239810200 DTC P2004 Variable swirl control system shutter valve stuck open • PCM monitors the mass variable swirl shutter valve position using the variable swirl shutter valve switch. If the PCM turns variable swirl solenoid valve on but variable swirl shutter valve position still remains open (variable swirl shutter valve switch is on), the PCM determines that the variable swirl shutter valve is stuck open.

  • Page 221

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 222

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT VARIABLE SWIRL SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 13. OR VARIABLE SWIRL SHUTTER VALVE Go to the next step. SWICTH CONNECTOR FOR POOR CONNECTION • Turn the ignition switch to off. •...

  • Page 223

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P2006[L3 WITH TC] id010239810300 DTC P2006 Variable swirl control system shutter valve stuck closed • PCM monitors the mass variable swirl shutter valve position using the variable swirl shutter valve switch. If PCM turns the variable swirl solenoid valve off but the variable swirl position still remains closed (variable swirl shutter valve switch is off), the PCM determines that the variable swirl shutter valve is stuck closed.

  • Page 224

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 225

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT VARIABLE SWIRL SOLENOID VALVE Yes Repair or replace the wiring harness for a short to ground, then go to the next step. OR VARIABLE SWIRL SHUTTER VALVE SWITCH SIGNAL CIRCUIT FOR SHORT TO Go to the next step.

  • Page 226

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2009[L3 WITH TC] id010239810400 DTC P2009 Variable swirl solenoid valve control circuit low • PCM monitors the variable swirl solenoid valve control signal. If the PCM turns variable swirl solenoid valve off but the voltage still remains low, the PCM determines that the variable swirl solenoid valve control circuit has a malfunction.

  • Page 227

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT VARIABLE SWIRL SOLENOID VALVE Yes Go to the next step. • Perform the variable swirl solenoid valve Replace the variable swirl solenoid valve, then go to Step 9. inspection. (See01-13-13 VARIABLE SWIRL SOLENOID VALVE INSPECTION[L3 WITH TC].) •...

  • Page 228

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2010[L3 WITH TC] id010239810500 DTC P2010 Variable swirl solenoid valve control circuit high • PCM monitors the variable swirl solenoid valve control signal. If the PCM turns variable swirl solenoid valve on but the voltage still remains high, the PCM determines that the variable swirl solenoid valve control circuit has a malfunction.

  • Page 229

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 230

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2088[L3 WITH TC] id010239810600 DTC P2088 OCV actuator circuit low • PCM monitors the OCV voltage. If the PCM detects that the OCV control voltage (calculated from OCV) is below the threshold voltage (calculated from battery positive voltage), the PCM determines that the OCV circuit has a malfunction.

  • Page 231

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 232

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P2089[L3 WITH TC] id010239810700 DTC P2089 OCV actuator circuit high • PCM monitors the OCV voltage. If the PCM detects that the OCV control voltage (calculated from OCV) is above the threshold voltage (calculated from battery positive voltage), the PCM determines that the OCV circuit has a malfunction.

  • Page 233

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Repair terminal, then go to Step 7. CONNECTION Go to the next step. • Turn the ignition switch to off. • Disconnect the PCM connector. • Inspect for poor connection at PCM terminal 2AF.

  • Page 234

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 235

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to the next step. FRONT HO2S Visually inspect for the exhaust gas leakage between the • Connect the M-MDS to the DLC-2. exhaust manifold and front HO2S. •...

  • Page 236

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE (LOW-SIDE) Yes Go to the next step. • Connect the fuel pressure gauge between fuel Inspect for following: • Fuel line restriction pump and high pressure fuel pump. • Measure the low side fuel pressure. •...

  • Page 237

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 238

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to the next step. FRONT HO2S Visually inspect for exhaust gas leakage between the • Connect the M-MDS to the DLC-2. exhaust manifold and front HO2S. •...

  • Page 239

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2100[L3 WITH TC] id010239811000 DTC P2100 Throttle actuator circuit open • PCM monitors the electronic throttle valve motor current. If the PCM detects that the electronic throttle valve motor current is below the threshold current, the PCM determines that the electronic throttle valve motor circuit has a malfunction.

  • Page 240

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION CLASSIFY INTERMITTENT CONCERN OR Yes Go to the next step. CONTINUOUS CONCERN Go to INTERMITTENT CONCERNS • Clear the DTC using the M-MDS. TROUBLESHOOTING procedure. • Start the engine and let it idle. (See01-03-76 INTERMITTENT CONCERN •...

  • Page 241

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].) (See01-02-10 AFTER REPAIR Troubleshooting completed. PROCEDURE[L3 WITH TC].) • Are any DTCs present? End Of Sie 01-02 DTC P2101[L3 WITH TC]...

  • Page 242

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT MAIN RELAY CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 22. POOR CONNECTION Go to the next step. • Turn the ignition switch to off. • Disconnect the main relay. •...

  • Page 243

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT POWER SUPPLY FOR CONTROL Yes Go to the next step. CIRCUIT OF DRIVE-BY-WIRE-RELAY Repair or replace the wiring harness for an open circuit • Turn ignition switch to the ON position (Engine between drive-by-wire-relay terminal E and main relay off).

  • Page 244

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2102[L3 WITH TC] id010239811200 DTC P2102 Throttle actuator circuit low input • PCM monitors the throttle actuator circuit current. If the PCM detects that the throttle actuator circuit current is excessively low, the PCM determines that the throttle actuator circuit was a malfunction. Diagnostic support note DETECTION •...

  • Page 245

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING CODE AND Yes Go to appropriate the DTC troubleshooting procedure, then go to Step 10. STORED DTCS • Turn ignition switch to OFF, then ON (Engine Go to the next step. off).

  • Page 246

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2103[L3 WITH TC] id010239811300 DTC P2103 Throttle actuator circuit high input • PCM monitors the throttle actuator circuit current. If the PCM detects that the throttle actuator circuit current is excessively high, the PCM determines that the electronic throttle actuator circuit has a malfunction. Diagnostic support note DETECTION •...

  • Page 247

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT CONTROL CIRCUIT OF THROTTLE Yes Repair or replace the wiring harness for a short to power supply, then go to Step 5. ACTUATOR FOR SHORT TO POWER SUPPLY • Turn the ignition switch to off. Go to the next step.

  • Page 248

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].) (See01-02-10 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[L3 WITH TC].) • Are any DTCs present? End Of Sie DTC P2108[L3 WITH TC] id010239811500...

  • Page 249

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY INTERMITTENT MALFUNCTION AT TP Yes Repair or replace malfunctioning part, according to inspection result, the go to Step 7. SENSOR NO.2 CIRCUIT • Perform the INTERMITTENT Go to the next step. TROUBLESHOOTING procedure to TP sensor No.2 related harnesses and connectors.

  • Page 250

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2119 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. •...

  • Page 251

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 252

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2123[L3 WITH TC] id010239811800 DTC P2123 Accelerator pedal position (APP) sensor No.1 circuit high input • The PCM monitors the APP sensor No.1 signal. If the PCM detects that the APP sensor No.1 voltage is above 4.5 V, the PCM determines that the APP sensor No.1 circuit has a malfunction.

  • Page 253

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace the suspected terminal, then go to Step POOR CONNECTION • Disconnect the APP sensor connector. Go to the next step. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 254

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2127[L3 WITH TC] id010239811900 DTC P2127 Accelerator pedal position (APP) sensor No.2 circuit low input • The PCM monitors the APP sensor No.2 signal. If the PCM detects that the APP sensor No.2 voltage is below 0.2 V, the PCM determines that the APP sensor No.2 circuit has a malfunction.

  • Page 255

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 256

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2128[L3 WITH TC] id010239812000 DTC P2128 Accelerator pedal position (APP) sensor No.2 circuit high input • The PCM monitors the APP sensor No.2 signal. If the PCM detects that the APP sensor No.2 voltage is above 4.5 V, the PCM determines that the APP sensor No.2 circuit has a malfunction.

  • Page 257

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace the suspected terminal, then go to Step POOR CONNECTION • Disconnect the APP sensor connector. Go to the next step. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 258

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2135[L3 WITH TC] id010239812100 DTC P2135 TP sensor No.1/No.2 voltage correlation problem • The PCM compares the input voltage from TP sensor No.1 with the input voltage from TP sensor No.2 when the engine is running. If the difference is more than the specification, the PCM determines that there is a TP sensor No.1/No.2 voltage correlation problem.

  • Page 259

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2138[L3 WITH TC] id010239812200 DTC P2138 APP sensor No.1/No.2 voltage correlation problem • The PCM compares the input voltage from APP sensor No.1 with the input voltage from APP sensor No.2 when the engine is running. If the difference is more than the specification, the PCM determines that there is an APP sensor No.1/No.2 angle correlation problem.

  • Page 260

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2177[L3 WITH TC] id010239812300 DTC P2177 Fuel system too lean at off idle • PCM monitors the short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control at off-idle. If the LONGFT and the sum total of these fuel trims exceed the preprogrammed criteria, the PCM determines that the fuel system is too lean at off-idle.

  • Page 261

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the sensor and related wiring harnesses repair or replace it. UNDER TROUBLE CONDITION • Inspect the same PIDs as Step 5 while Then go to Step 20. simulating FREEZE FRAME DATA condition.

  • Page 262

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT IGNITION SYSTEM Yes Go to the next step. • Perform the spark test. Repair or replace the malfunctioning part according to (See01-03-78 ENGINE CONTROL SYSTEM spark test result, then go to Step 20. OPERATION INSPECTION[L3 WITH TC].) •...

  • Page 263

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2178 Fuel system too rich at off idle • Misfire • Front HO2S deterioration • Front HO2S heater malfunction • MAF sensor malfunction • Pressure regulator malfunction • Fuel pressure sensor malfunction • Relief valve (built-in fuel delivery pipe) malfunction 01-02 •...

  • Page 264

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to the next step. MAF SENSOR Replace the MAF/IAT sensor, then go to Step 19. • Connect the M-MDS to the DLC-2 • Start the engine. •...

  • Page 265

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE (LOW-SIDE) Yes Go to the next step. • Connect the fuel pressure gauge between fuel Inspect for following: • Fuel line restriction pump and high pressure fuel pump. • Measure the low side fuel pressure. •...

  • Page 266

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 267

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PURGE SOLENOID VALVE STUCK Yes Replace the purge solenoid valve. Then go to Step 20. OPEN • Turn the ignition switch to off. Go to the next step. • Disconnect the both hoses from purge solenoid valve.

  • Page 268

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2187 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. •...

  • Page 269

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING CODE OR Yes If misfire the DTC is present, go to Step 8. If other DTCs is present, go to the applicable DTC STORED DTCS • Turn the ignition switch to off, then to the ON inspection.

  • Page 270

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT VARIABLE VALVE TIMING CONTROL Yes Go to the next step. SYSTEM OPERATION Repair or replace the malfunctioning part according to • Inspect the variable valve timing control system inspection results, then go to Step 18. operation.

  • Page 271

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2195[L3 WITH TC] id010239812700 DTC P2195 Front HO2S signal stuck lean • The PCM monitors the front HO2S output current when the following conditions are met. If the average output current is more than 1.2 A for25 s, the PCM determines that the front HO2S has a malfunction. MONITORING CONDITION —...

  • Page 272

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step. UNDER FREEZE FRAME DATA CONDITION Inspect the malfunctioning part according to the inspection • Connect the M-MDS to the DLC-2. results. •...

  • Page 273

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE (LOW-SIDE) Yes Go to the next step. • Connect the fuel pressure gauge between fuel Inspect for following: • Fuel line restriction pump and high pressure fuel pump. • Fuel filter clogging (See01-14-19 HIGH PRESSURE FUEL PUMP INSPECTION[L3 WITH TC].) If okay replace the fuel pump.

  • Page 274

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 275

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FUEL PRESSURE (HIGH-SIDE) Yes Go to Step 14. • Access and monitor FRP PID. Go to the next step. • Is the FRP PID value within the specified? (See01-40-6 PCM INSPECTION[L3 WITH TC].) IDENTIFY CAUSE BY FUEL PRESSURE Yes Go to the next step.

  • Page 276

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 277

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2229 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. No concern is detected. Go to the next step. •...

  • Page 278

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA AND Yes Go to the next step. DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then •...

  • Page 279

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2245[L3 WITH TC] id010239813200 DTC P2245 Front HO2S sensor reference voltage circuit low input • The PCM monitors is front HO2S sensor reference voltage circuit voltage. If the voltage below the threshold value while the engine is running, the PCM determines that the front HO2S sensor reference voltage circuit is low.

  • Page 280

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FRONT HO2S CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 8. POOR CONNECTION Go to the next step. • Turn the ignition switch to off. • Disconnect the front HO2S connector. •...

  • Page 281

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2246[L3 WITH TC] id010239813300 DTC P2246 Front HO2S sensor reference voltage circuit high input • The PCM monitors the front HO2S sensor reference voltage circuit voltage. If the voltage is above the threshold value while the engine is running, the PCM determines that the front HO2S sensor reference voltage circuit is high.

  • Page 282

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT FRONT HO2S CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 9. POOR CONNECTION Go to the next step. • Turn the ignition switch to off. • Disconnect the front HO2S connector. •...

  • Page 283

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2251[L3 WITH TC] id010239813400 DTC P2251 Front HO2S negative current control circuit open • The PCM monitors the front HO2S negative current control circuit voltage. If the voltage does not change with the PCM control value while the engine is running, the PCM determines that the front HO2S negative current control circuit is open.

  • Page 284

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC troubleshooting procedure. (See01-02-13 DTC TABLE[L3 WITH TC].) STORED DTC • Turn the ignition switch to off, then ON position Go to the next step. (Engine off).

  • Page 285

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2401[L3 WITH TC] id010239813500 DTC P2401 EVAP system leak detection pump motor circuit low • The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating. If the pump load current is lower than specified, the PCM determines that the EVAP system leak detection pump motor circuit has a malfunction.

  • Page 286

    ON-BOARD DIAGNOSTIC [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record FREEZE FRAME DATA on the repair order, then go • Has the FREEZE FRAME DATA been to the next step.

  • Page 287

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2401 Yes Replace the PCM, then go to the next step. COMPLETED Go to the next step. • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the M-MDS.

  • Page 288

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2402[L3 WITH TC] id010239813600 DTC P2402 EVAP system leak detection pump motor circuit high • The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating. If the pump load current is higher than specified, the PCM determines that the EVAP system leak detection pump motor circuit has a malfunction.

  • Page 289

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY RELATED PENDING CODE OR Yes Go to the next step. STORED DTCS Replace the EVAP system leak detection pump, then go to • Turn the ignition switch to the OFF then ON step 6.

  • Page 290

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2404[L3 WITH TC] id010239813700 DTC P2404 EVAP system leak detection pump sensor circuit malfunction • The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating. After obtaining the reference current value, If the pump load current is greater than or equal to the reference current value plus 2 mA within the specified time, the PCM determines that the air filter has a malfunction.

  • Page 291

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2405[L3 WITH TC] id010239813800 DTC P2405 EVAP system leak detection pump sensor circuit low input • The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating. If the current is lower than the specification while the PCM obtains the reference current value, the PCM determines that the EVAP system leak detection pump orifice has a malfunction.

  • Page 292

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2407[L3 WITH TC] id010239813900 DTC P2407 EVAP system leak detection pump sensor circuit intermittent • The PCM monitors pump the load current (EVAP line pressure), while the EVAP leak monitor is operating. When either of the following is detected6 times or more successively, the PCM determines that the EVAP system leak detection pump heater has a malfunction: —...

  • Page 293

    ON-BOARD DIAGNOSTIC [L3 WITH TC] End Of Sie DTC P2502[L3 WITH TC] WM: DTC P25XX id010239814000 DTC P2502 Charging system voltage problem • PCM determines that the generator output voltage is above 17 V or the battery voltage is below 11 V while the engine is running.

  • Page 294

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT BATTERY Yes Go to the next step. • Turn the ignition switch off. Replace the battery, then go to Step 8. • Inspect the battery. • Is the battery normal? INSPECT GENERATOR Yes Go to the next step.

  • Page 295

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2503 Charging system voltage low GENERATOR MAIN RELAY 01-02 BATTERY GENERATOR WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1G 1C...

  • Page 296

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT GENERATOR CONTROL CIRCUIT Yes Repair or replace the wiring harness for a short to ground, then go to Step 10. FOR SHORT TO GROUND • Inspect for continuity between generator Go to the next step. terminal D (wiring harness-side) and body ground.

  • Page 297

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2504 Charging system voltage high GENERATOR MAIN RELAY 01-02 BATTERY GENERATOR WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1G 1C...

  • Page 298

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the pins, then go to Step 8. CONNECTION Go to the next step. • Turn the ignition switch off. • Disconnect the PCM connector. •...

  • Page 299

    ON-BOARD DIAGNOSTIC [L3 WITH TC] DTC P2507 PCM +BB (back-up battery) voltage low FUSE 01-02 BATTERY WIRING HARNESS SIDE CONNECTOR 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1G 1C...

  • Page 300

    ON-BOARD DIAGNOSTIC [L3 WITH TC] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2507 Yes Replace the PCM, then go to the next step. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH COMPLETED • Make sure to reconnect all disconnected TC].) connectors. Go to the next step. •...

  • Page 301

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] 01-03 SYMPTOM TROUBLESHOOTING [L3 WITH TC] SYMPTOM TROUBLESHOOTING WIRING NO.21 ENGINE NOISE DIAGRAM[L3 WITH TC] ... . 01-03–2 [L3 WITH TC] ..... 01-03–66 FOREWORD[L3 WITH TC] .

  • Page 302

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] WM: SYMPTOM TROUBLESHOOTING (ENGINE CONTROL SYSTEM) SYMPTOM TROUBLESHOOTING WIRING DIAGRAM[L3 WITH TC] id010339800100 FUEL INJECTOR NO.1 FUEL INJECTOR NO.4 FUEL INJECTOR NO.3 FUEL INJECTOR NO.2 FUEL INJECTOR RELAY IAT SENSOR SENSOR HO2S HEATER (FRONT) HO2S HEATER (REAR) SENSOR FAN CONTROL MODULE NO.1 COOLING FAN...

  • Page 303

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] EGR VALVE 01-03 EVAP SYSTEM LEAK DETECTION PUMP TP SENSOR PURGE SOLENOID VALVE BRAKE SWITCH NO.1 WASTEGATE CONTROL SOLENOID VALVE BRAKE SWITCH NO.2 VARIABLE SWIRL SOLENOID VALVE VARIABLE SWIRL SHUTTER VALVE SWITCH REFRIGERANT PRESSURE SWITCH (HIGH, LOW) THROTTLE REFRIGERANT PRESSURE SWITCH (MIDDLE) ACTUATOR...

  • Page 304

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] FOREWORD[L3 WITH TC] id010339800300 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and diagnostic trouble code (DTC), then diagnose the malfunction according to the following flowchart: — If a DTC exists, diagnose the applicable DTC inspection. (See 01-02-13 DTC TABLE[L3 WITH TC].) —...

  • Page 305

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] ENGINE SYMPTOM TROUBLESHOOTING[L3 WITH TC] id010339800500 • Verify malfunction symptoms using the following diagnostic index, then go to the appropriate troubleshooting chart. Diagnostic Index TROUBLESHOOTING ITEM DESCRIPTION Melting of main or other fuses — MIL illuminates MIL is illuminated.

  • Page 306

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] CONTROL SYSTEM DEVICE AND CONTROL RELATIONSHIP CHART[L3 WITH TC] id010339800200 X: Applied Item Input device IAT sensor MAF sensor TP sensor No.1, No.2 APP sensor No.1, No.2 MAP sensor ECT sensor CMP sensor CKP sensor HO2S (front, rear) BARO sensor Neutral switch...

  • Page 307

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] 01-03 Item Variable swirl shutter valve actuator Injector driver module Fuel pump relay Ignition coil EGR valve Purge solenoid valve HO2S heater (front, rear) A/C relay Fan control module Starter relay Generator (Terminal D: field coil) ABS HU/CM (With ABS) (CAN signal) Instrument cluster...

  • Page 308

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] QUICK DIAGNOSTIC CHART[L3 WITH TC] id010339800600 X: Applied Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank After start/at idle Engine stalls Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on...

  • Page 309

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor 01-03 Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank After start/at idle Engine stalls Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 310

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank After start/at idle Engine stalls Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 311

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor 01-03 Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 312

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank After start/at idle Engine stalls Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 313

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor 01-03 Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank After start/at idle Engine stalls Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 314

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] X: Applied Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast/idle runs on Low idle/stalls during deceleration...

  • Page 315

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.1 MELTING OF MAIN OR OTHER FUSES[L3 WITH TC] id010339800700 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. 01-03 Deterioration Shorted wiring harness Fuse Replace fuse Repair shorted wiring harness and replace fuse Damaged fuse Related wiring harness MAIN...

  • Page 316

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Damaged fuse Related wiring harness ETC fuse • PCM • Drive-by-wire relay ECM fuse • PCM • Drive-by-wire relay • Cooling fan relay No.1 • Cooling fan relay No.2 ENG BAR 1 ENG BAR 1 fuse •...

  • Page 317

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.3 WILL NOT CRANK[L3 WITH TC] id010339800900 WILL NOT CRANK DESCRIPTION Starter does not work. • Open starter circuit between the ignition switch and the starter • Low or dead battery •...

  • Page 318

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect the following wiring harness and Repair or replace malfunctioning part. connectors. With advanced keyless entry system With advanced keyless entry system Go to the next step.

  • Page 319

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the self-test function using the M-MDS. DTC is displayed: Turn the ignition switch to the ON position. Go to the appropriate DTC test. Retrieve any DTCs. (See01-02-13 DTC TABLE[L3 WITH TC].) Is a DTC displayed? No DTC is displayed: Inspect the following:...

  • Page 320

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK[L3 WITH TC] id010339801000 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • Starter cranks the engine at normal speed but the engine requires excessive cranking time before DESCRIPTION starting. • Battery is operating normally •...

  • Page 321

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for the following: Go to the next step. • Fuel quality (proper octane, contamination, Service if necessary. winter/summer blend) Repeat Step 1. • Fuel leakage • Intake-air system leakage or restriction •...

  • Page 322

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the spark test. Go to the next step. (See01-03-78 ENGINE CONTROL SYSTEM Inspect or replace the malfunctioning parts, according OPERATION INSPECTION[L3 WITH TC].) to the inspection results. Is a strong blue spark visible at each cylinder? Access and monitor the FUEL_PRES PID.

  • Page 323

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.5 ENGINE STALLS-AFTER START/AT IDLE[L3 WITH TC] id010339801100 ENGINE STALLS - AFTER START/AT IDLE • Engine stops unexpectedly. DESCRIPTION • A/C system improper operation • Air leakage from intake-air system •...

  • Page 324

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Both conditions are appear: Do any of the following conditions appear? Go to Step 5. • Engine does not start completely.

  • Page 325

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Turn the ignition switch to the ON position. Go to the next step. (Engine off.) Repair or replace the wiring harness. Measure the voltage between keyless CM harness-side connector terminal 2A, 2C, 2D and body ground.

  • Page 326

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the Variable Valve Timing Control Inspect the valve timing. System Operation Inspection. Inspect or replace the malfunctioning parts, according (See01-03-78 ENGINE CONTROL SYSTEM to the inspection results.

  • Page 327

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Measure the compression pressure for each Replace the injector driver module. cylinder. If the problem remains, overhaul the engine. (See01-10-9 COMPRESSION INSPECTION[L3 Inspect for the following: WITH TC].) • Damaged valve seat Are the compression pressures within the •...

  • Page 328

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.6 CRANKS NORMALLY BUT WILL NOT START[L3 WITH TC] id010339801200 CRANKS NORMALLY BUT NOT START • Starter cranks engine at normal speed but engine will not run. • Refer to symptom troubleshooting “No.5 Engine stalls” if this symptom appears after the engine stalls. DESCRIPTION •...

  • Page 329

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Both conditions are appear: Do any of the following conditions appear? Go to Step 5. • Engine does not completely start.

  • Page 330

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Turn the ignition switch to the ON position. Go to the next step. (Engine off.) Repair or replace the wiring harness. Measure the voltage between keyless CM harness-side connector terminal 2A, 2C, 2D and body ground.

  • Page 331

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect CMP sensor for the following; Repair or replace the malfunctioning part according • Installation condition inspection results. (See01-40-45 CAMSHAFT POSITION Go to the next step. (CMP) SENSOR REMOVAL/ INSTALLATION[L3 WITH TC].) •...

  • Page 332

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Measure the compression pressure for each Replace the injector driver module. cylinder. If the problem remains, overhaul the engine. (See01-10-9 COMPRESSION INSPECTION[L3 Inspect for the following: WITH TC].) • Damaged valve seat Are the compression pressures within the •...

  • Page 333

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the self-test function using the M-MDS. DTC is displayed: Turn the ignition switch to the ON position. Go to the appropriate DTC test. Retrieve any DTCs. (See01-02-13 DTC TABLE[L3 WITH TC].) Is a DTC displayed? No DTC is displayed: Go to the next step.

  • Page 334

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the repair or diagnosis.

  • Page 335

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for the following: Go to the next step. • Fuel quality (proper octane, contamination, Service if necessary. winter/summer blend) Repeat Step 1. • Intake-air system restriction or leakage •...

  • Page 336

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Go to the next step. Access and monitor following PIDs using the Inspect and repair or replace suspected parts and the data monitor function. related harnesses. •...

  • Page 337

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.9 FAST IDLE/RUNS ON[L3 WITH TC] id010339801500 FAST IDLE/RUNS ON • Engine speed continues at fast idle after warm-up. DESCRIPTION • Engine runs after the ignition switch is turned off. • ECT sensor or related circuit malfunction •...

  • Page 338

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC. Go to the next step. Access the ECT PID. ECT PID is higher than 112 °C {234 °F}: Start and warm-up engine to normal operating Go to symptom troubleshooting "NO.17 COOLING temperature.

  • Page 339

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.10 LOW IDLE/STALLS DURING DECELERATION[L3 WITH TC] id010339801600 LOW IDLE/STALLS DURING DECELERATION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. DESCRIPTION • Poor fuel quality • Vacuum leakage • Improper operation of electronic throttle control system •...

  • Page 340

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect CMP and CKP sensor for the following; Repair or replace the malfunctioning part according • Installation condition inspection results. (See01-40-45 CAMSHAFT POSITION Go to the next step. (CMP) SENSOR REMOVAL/ INSTALLATION[L3 WITH TC].) (See01-40-42 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/...

  • Page 341

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect the fuel pressure sensor. Go to Step 15. (See01-40-35 FUEL PRESSURE SENSOR Replace the delivery pipe. INSPECTION[L3 WITH TC].) Is the fuel pressure sensor normal? Replace the high pressure fuel pump Troubleshooting is completed.

  • Page 342

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] ENGINE STALLS/QUITS (ACCELERATION/CRUISE) ENGINE RUNS ROUGH (ACCELERATION/CRUISE) BUCK/JERK (ACCELERATION/CRUISE/DECELERATION) HESITATION/STUMBLE (ACCELERATION) SURGES (ACCELERATION/CRUISE) • A/C system improper operation • Air leakage from intake-air system • Intake-air system restriction • Purge solenoid valve malfunction • Improper operation of electronic throttle control system •...

  • Page 343

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for the following: Go to the next step. • Fuel quality (proper octane, contamination, Service if necessary. winter/summer blend) Repeat Step 1. • Air leakage from intake-air system •...

  • Page 344

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the TP sweep inspection. Visually inspect the throttle body (damaged/ (See01-03-78 ENGINE CONTROL SYSTEM scratching.) If normal, go to the next step. OPERATION INSPECTION[L3 WITH TC].) Inspect or replace the malfunctioning parts, according Does the electronic throttle control system work to the inspection results.

  • Page 345

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Perform the spark test. Go to the next step. (See01-03-78 ENGINE CONTROL SYSTEM Inspect or replace the malfunctioning parts, according OPERATION INSPECTION[L3 WITH TC].) to the inspection results. Is a strong blue spark visible at each cylinder? Access and monitor the FUEL_PRES PID.

  • Page 346

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.12 LACK/LOSS OF POWER (ACCELERATION/CRUISE)[L3 WITH TC] id010339801800 LACK/LOSS OF POWER (ACCELERATION/CRUISE) DESCRIPTION Performance is poor under load (e.g., powers down when climbing hills). • Improper A/C system operation • Improper operation of A/C cut-off control •...

  • Page 347

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Verify the following: Go to the next step. • Fuel quality (proper octane, contamination, Service if necessary. winter/summer blend) Repeat Step 1. • Air cleaner restriction or dirty • Intake-air system restriction or leakage •...

  • Page 348

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to DLC-2. Go to the next step. Access and monitor following PIDs using the Inspect and repair or replace suspected parts and data monitor function. related harnesses. • ECT If the malfunction remains, perform the intermittent •...

  • Page 349

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Is any engine oil found inside turbocharger Wipe oil out vehicle and install all removed parts in compressor housing? Step 16. Then, Go to the next step. Turbocharger is normal. Install all parts removed in Step 17. Then, Go to the next step.

  • Page 350

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.13 KNOCKING/PINGING[L3 WITH TC] id010339801900 KNOCKING/PINGING Sound is produced when air/fuel mixture is ignited by something other than a spark plug (e.g., hot spot in DESCRIPTION the combustion chamber). • Poor fuel quality • Engine overheating due to cooling system malfunction •...

  • Page 351

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Go to the next step. Access the ECT PID. The cause of this concern could be from the cooling Verify that the ECT PID is less than 116°C system overheating.

  • Page 352

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Go to the next step. Access and monitor the following PIDs using the Inspect and repair or replace suspected parts and the data monitor function. related harnesses.

  • Page 353

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.14 POOR FUEL ECONOMY[L3 WITH TC] id010339802000 POOR FUEL ECONOMY DESCRIPTION Fuel economy is unsatisfactory. • Contaminated air cleaner element • Engine cooling system malfunction • Improper ATF level • Weak spark 01-03 • Spark plug malfunction •...

  • Page 354

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for the following: Go to the next step. • Air cleaner element for contamination Service if necessary. • Intake-air system restriction Repeat Step 1. • Fuel quality (proper octane, contamination, winter/summer blend) •...

  • Page 355

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. Go to the next step. Access and monitor following PIDs using the Inspect and repair or replace suspected parts and the data monitor function. related harnesses. •...

  • Page 356

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.15 EMISSION COMPLIANCE[L3 WITH TC] id010339802100 EMISSION COMPLIANCE DESCRIPTION Fails emissions test. • Poor fuel quality • Vacuum lines leakage or blockage • Cooling system malfunction • Engine overheating • Spark plug malfunction • Air leakage from intake-air system •...

  • Page 357

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION RESULTS ACTION Is the engine overheating? Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS - OVERHEATING.” Go to the next step. Is the engine runs cold? Go to symptom troubleshooting “NO.18 COOLING SYSTEM CONCERNS - RUNS COLD.”...

  • Page 358

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect CMP and CKP sensor for the following; Repair or replace the malfunctioning part according to • Installation condition the inspection results. (See01-40-45 CAMSHAFT POSITION Go to the next step. (CMP) SENSOR REMOVAL/ INSTALLATION[L3 WITH TC].) (See01-40-42 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/...

  • Page 359

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the repair or diagnosis.

  • Page 360

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.17 COOLING SYSTEM CONCERNS-OVERHEATING[L3 WITH TC] id010339802300 COOLING SYSTEM CONCERNS -OVERHEATING DESCRIPTION Engine runs at higher than normal temperature/overheats. • Improper coolant level • Blown fuse • Coolant leakage (engine internal, turbocharger, external) • Excessive A/C system pressure •...

  • Page 361

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Cool down the engine. Thermostat is normal. Remove the thermostat and inspect operation. Inspect the cylinder block for leakage or blockage. (See01-12-11 THERMOSTAT REMOVAL/ Access the ECT PID using the M-MDS. INSTALLATION[L3 WITH TC].) Inspect for both ECT PID and temperature gauge (See01-12-11 THERMOSTAT INSPECTION[L3...

  • Page 362

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the repair or diagnosis.

  • Page 363

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Remove the parts necessary to inspect Install all parts removed in this step. turbocharger without removing the turbocharger. Perform the following, according to inspection Visually inspect for the turbocharger compressor results. Excessive amount of oil is found: housing.

  • Page 364

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to DLC-2. Go to the next step. Access and monitor following PIDs using the Inspect and repair or replace suspected parts and data monitor function. related harnesses. • ECT If the malfunction remains, perform the intermittent •...

  • Page 365

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.20 FUEL ODOR (IN ENGINE COMPARTMENT)[L3 WITH TC] id010339802600 FUEL ODOR (IN ENGINE COMPARTMENT) DESCRIPTION Gasoline fuel smell or visible leakage • Excessive fuel pressure • Purge solenoid valve malfunction • Fuel system vent system blockage •...

  • Page 366

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.21 ENGINE NOISE[L3 WITH TC] id010339802700 ENGINE NOISE DESCRIPTION Engine noise under hood Squeal, click or chirp noise: • Improper engine oil level • Loose installation of solenoid valves • Improper drive belt tension Rumble or grinding sound noise: •...

  • Page 367

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Is hiss sound present? Inspect and repair the following; • Vacuum leakage • Spark plug looseness • Intake-air system leakage Go to the next step. Is rap or roar sound present? Inspect the exhaust system or loose parts.

  • Page 368

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the repair or diagnosis.

  • Page 369

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY[L3 WITH TC] id010339803000 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY. DESCRIPTION A/C compressor magnetic clutch does not disengage. • A/C compressor magnetic clutch engagement is stuck. •...

  • Page 370

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS[L3 WITH TC] id010339803100 A/C IS NOT CUT OFF UNDER WOT CONDITIONS. DESCRIPTION A/C compressor magnetic clutch does not disengage under WOT. • Accelerator position sensor malfunction POSSIBLE CAUSE •...

  • Page 371

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Connect the M-MDS to the DLC-2. DTC is displayed: Turn the ignition switch to the ON position Go to the appropriate DTC test. (Engine off). No DTC is displayed: Retrieve any DTCs. Go to the next step.

  • Page 372

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Diagnostic procedure STEP INSPECTION ACTION Connect the M-MDS to the DLC-2. DTC is displayed: Turn the ignition switch to the ON position Go to the appropriate DTC test. (Engine off). No DTC is displayed: Retrieve any DTCs. Go to the next step.

  • Page 373

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION ACTION Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the repair or diagnosis.

  • Page 374

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect the spark plugs for the following: Go to the next step. • Cracked insulator Replace the spark plug. • Heat range • Air gap • Worn electrode Is the spark plug normal? Inspect the compression pressure at the Go to the next step.

  • Page 375

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] STEP INSPECTION RESULTS ACTION Inspect the following PIDs: Go to the next step. • ECT Repair or replace the malfunctioning parts. • O2S11 (When engine can be started) • MAF (See01-40-6 PCM INSPECTION[L3 WITH TC].) Are the PIDs normal? Perform the purge control inspection.

  • Page 376

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] INTERMITTENT CONCERN TROUBLESHOOTING[L3 WITH TC] id010339800400 Vibration Method • If a malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating, perform the steps below. Note • There are several reasons why the vehicle or engine vibration could cause an electrical malfunction. Check the following: —...

  • Page 377

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Inspection Method for Sensors 1. Connect the M-MDS to the DLC-2. 2. Turn the ignition switch to the ON position (Engine off). Note • If the engine starts and runs, perform the following steps during idle. 3.

  • Page 378

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] ENGINE CONTROL SYSTEM OPERATION INSPECTION[L3 WITH TC] id010339803700 Input Signal System Investigation Procedure 1. Find an unusual signal. (See01-03-78 Finding unusual signals.) 2. Locate the source. (See01-03-78 Locating the source of unusual signals.) 3. Repair or replace the defective part. 4.

  • Page 379

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Investigate the standard power supply system for variable resistance type 1 • Confirm that the #3 terminal is at 5 V. — If the measured voltage on the #3 terminal is5 V, inspect the following points on the sensor connector. —...

  • Page 380

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Investigate the electrical supply system for variable resistance type 2 • Confirm that the sensor #3 terminal is B+. — If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. —...

  • Page 381

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] INPUT 01-03 acxuuw00002367 1. Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch to the ON position and the engine is idling. • If it is at 0 V or 5 V, intermittent concern exists. (See01-03-76 INTERMITTENT CONCERN TROUBLESHOOTING[L3 WITH TC].) •...

  • Page 382

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it is idling. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the intake manifold side.

  • Page 383

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Throttle position (TP) sweep inspection 1. Connect the M-MDS to the DLC-2. 2. Reform the KOER self-test function. (See01-02-10 KOEO/KOER SELF TEST[L3 WITH TC].) 3. Verify that none of the following DTCs are displayed: • P0122, P0123, P0222, P0223, P2100, P2101, P2102, P2103, P2107, P2108, P2119, P2122, P2123, P2127, P2128, P2135, P2138 —...

  • Page 384

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Fuel Injector Operation Inspection If simulation function of M-MDS is used: STEP INSPECTION ACTION Start the engine and warm it up until normal Fuel injector work properly operating temperature. Engine speed does not drop an any cylinder: Connect the M-MDS to DLC-2.

  • Page 385

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Fuel Cut Control System Inspection Note • This inspection has to be performed after the Fuel Injector Operation Inspection. If simulation function of M-MDS is used: 1. Warm up the engine and idle it. 2. Connect the M-MDS to the DLC-2. 01-03 3.

  • Page 386

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] 5. Measure the voltage at wiring harness side fuel pump connector terminal B. • If the voltage is as specified, inspect the following: — Fuel pump continuity — Fuel pump ground — Wiring harness between the fuel pump relay and PCM terminal, 1H •...

  • Page 387

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] Spark Test 1. Disconnect the fuel pump relay. 2. Verify that each ignition coil and connector is connected properly. 3. Inspect the ignition system in the following procedure. Warning •...

  • Page 388

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SYMPTOM TROUBLESHOOTING [L3 WITH TC] 8. Put the vehicle in drive. 9. Depress the accelerator pedal and verify that the SEGRP value increases. • If the SEGRP value does not increase, inspect the VSS, TP and ECT PIDs. (See01-40-6 PCM INSPECTION[L3 WITH TC].)

  • Page 389

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] 10. Set the vehicle on the dynamometer or chassis roller. Warning • When the dynamometer or chassis roller is operating, there is a possibility that the operator may come into contact with or be caught up in the rotating parts, leading to serious injuries or death. When performing work while the dynamometer or chassis roller is operating, be careful not to contact or be caught up in any of the rotating parts.

  • Page 390

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Wastegate Control System Operation Inspection If simulation function of M-MDS is used: 1. Start the engine and run it is idling. 2. Disconnect the hose between the wastegate control solenoid valve and the intake pipe. 3.

  • Page 391

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] When idling can be continued If simulation function of M-MDS is used: 1. Warm up the engine to normal operating temperature. 2. Connect the M-MDS to the DLC-2. 3. Start the engine and run it is idling. 4.

  • Page 392

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] iii. The PCM continues to monitor the air pump load current value (LDP_MON CHANGE- PID) until the end of the test. CLOSED OVER-VALVE OPEN AIR-PUMP (LDP-REF) PASS LOAD FAIL CURRENT (LDP-MON) (LDP-IDL) acxuuw00000321 • You can confirm whether any EVAP gas leak has occurred or not by reading the test INTAKE MANIFOID...

  • Page 393

    SYMPTOM TROUBLESHOOTING [L3 WITH TC] Evaporative system test procedure 1. Select the EVAP system test from the Toolbox on the M-MDS display and follow the instructions. 2. Verify that all of the following PIDs are within the specifications at the pre-test confirmation screen. Note •...

  • Page 394

    8. If the gauge and the flow meter do not settle to a measurable level after 2— 3 min, then refer to the Mazda Workshop Manual to verify that the cut or vent valve is properly closed.

  • Page 395

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 01-10 MECHANICAL [L3 WITH TC] MECHANICAL LOCATION INDEX CYLINDER HEAD GASKET [L3 WITH TC] ....01-10–2 REPLACEMENT[L3 WITH TC] .

  • Page 396

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] MECHANICAL LOCATION INDEX[L3 WITH TC] id011039800100 acxuuw00000134 Cylinder head gasket Drive belt (See01-10-20 CYLINDER HEAD GASKET (See01-10-3 DRIVE BELT INSPECTION[L3 WITH REPLACEMENT[L3 WITH TC].) TC].) (See01-10-3 DRIVE BELT REMOVAL/ Front oil seal INSTALLATION[L3 WITH TC].)

  • Page 397

    MECHANICAL [L3 WITH TC] End Of Sie DRIVE BELT INSPECTION[L3 WITH TC] WM: DRIVE BELT id011039801500 Note • Drive belt deflection/tension inspection is not necessary because of the use of the drive belt auto tensioner. 1. Verify that the drive belt auto tensioner indicator mark does not exceed the limit. •...

  • Page 398

    MECHANICAL [L3 WITH TC] DRIVE BELT AUTO TENSIONER INSPECTION[L3 WITH TC] id011039801700 1. Remove the drive belt. (See01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].) 2. Verify that the drive belt auto tensioner moves smoothly in the operational direction. • Replace the drive belt auto tensioner if necessary.

  • Page 399

    MECHANICAL [L3 WITH TC] Valve Clearance Adjustment 1. Disconnect the negative battery cable. 2. Remove the splash shield (RH). 3. Remove the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 4. Remove the high pressure fuel pump. (See01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/ INSTALLATION[L3 WITH TC].) 5.

  • Page 400

    MECHANICAL [L3 WITH TC] (1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet. (2) Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the tension on the timing chain. (3) Using a suitable bolt (M6 X 1.0 length 25mm—...

  • Page 401

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 23. Carefully apply adhesive agent (Loctite 518 or 962) to the area indicated in the figure so that it does not leak into the sliding part. Thickness SEALANT SEALANT 1.0 mm {0.039 in}...

  • Page 402

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 28. Install the SST on the camshaft as shown in the 303-1061 figure. (49 UN30 310610) 29. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25—...

  • Page 403

    MECHANICAL [L3 WITH TC] 40. Install the ventilation hose. 41. Connect the wiring harness. 42. Install the ignition coils. (See01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].) 43. Install the high pressure fuel pump. (See01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/ INSTALLATION[L3 WITH TC].) 44.

  • Page 404

    MECHANICAL [L3 WITH TC] TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC] id011039801000 1. Disconnect the negative battery cable. 2. Remove the under cover. 3. Remove the splash shield. 4. Remove the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 5. Remove the high pressure fuel pump. (See01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/ INSTALLATION[L3 WITH TC].) 6.

  • Page 405

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 7.8—10.8 N·m {80—110 kgf·cm, 70—95 in·lbf} 74.5—104.9 {7.6—10.6, 55.0—77.3 } 8.0—9.5 N·m {82—96 kgf·cm, 71—84 in·lbf} 01-10 74.5—104.9 {7.6—10.6, 55.0—77.3 } SEALANT SEALANT 8.0—11.5 N·m 40—55 {82—117 kgf·cm, {4.1—5.6, 71—101 in·lbf} 30—40}...

  • Page 406

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] Cylinder Head Cover Removal Note 1. Loosen the cylinder head cover bolts in the order shown in the figure. acxuuw00000219 Crankshaft Pulley Lock Bolt Removal Note 1. Rotate the crankshaft in the direction of the engine rotation and remove the cylinder block lower blind plug when the No.

  • Page 407

    MECHANICAL [L3 WITH TC] 5. Install the SST using the following procedure. Caution • Refer to the SST instruction manual for MAIN FRAME the basic handing procedure. REAR SHAFT 01-10 SIDE BAR FRONT SHAFT FRONT FOOT No.1 (ADAPTER FOR FRONT SHAFT) FRONT FOOT No.2 (ADAPTER FOR FRONT SHAFT) acxuuw00000223...

  • Page 408

    MECHANICAL [L3 WITH TC] 6. Support the engine using the SST. 49 C017 5A0 acxuuw00000226 Front Oil Seal Removal Note 1. Remove the front oil seal using a flathead screwdriver or similar tool. acxuuw00000227 Chain Tensioner Removal Note 1. Press the timing chain tensioner ratchet to the left using a thin flathead screwdriver (precision RATCHET screwdriver) to unlock the plunger.

  • Page 409

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 3. Release the ratchet with the plunger still pressed down. RATCHET 01-10 acxuuw00000230 4. Press-in the plunger until the ratchet position is as indicated in the figure, and then insert the wire to RATCHET lock the plunger.

  • Page 410

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] Oil Pump Driven Sprocket Installation Note 1. Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the oil pump against rotation as shown in figure.

  • Page 411

    MECHANICAL [L3 WITH TC] Engine Front Cover Installation Note 1. Apply silicone sealant to the engine front cover. Caution • Install the engine front cover within 10 min of applying the silicone sealant. • Silicone sealant is not needed in area C shown in the figure.

  • Page 412

    MECHANICAL [L3 WITH TC] 2. Temporarily tighten the bolts and nuts in the order shown in the figure. FRONT acxuuw00000241 3. Tighten the bolts and nuts in the order shown in the figure. Tightening torque 74.5— 104.9 N·m {7.6— 10.6 kgf·m, 55.0— 77.3 ft·lbf} FRONT acxuuw00000242...

  • Page 413

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 5. Remove the bolt (M6 X 1.0 length 25— 35 mm {0.99— 1.3 in}) installed to the crankshaft pulley. 6. Remove the SST from the camshaft. 7. Remove the SST installed in the cylinder block lower blind plug hole.

  • Page 414

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] CYLINDER HEAD GASKET REPLACEMENT[L3 WITH TC] id011039800700 Warning • Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always keep sparks and flames away from fuel.

  • Page 415

    MECHANICAL [L3 WITH TC] 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf} 8.0—11.5 N·m {82—117 +14—17 {1.5—1.7, 11—12} kgf·cm, 71—101 in·lbf} SEALANT 01-10 3.0—11 N·m {31—112 kgf·cm, 27—97 in·lbf} +13—17 N·m {133—173 kgf·cm, 116—150 in·lbf} +43—47 {4.4—4.7, 32—34} ° ° —92 ° °...

  • Page 416

    MECHANICAL [L3 WITH TC] Camshaft Removal Note Note • The camshaft caps are to be kept ordered for correct reassembly in their original positions. 1. Loosen the camshaft cap bolts in two or three passes in the order shown, and remove them. No.1 No.2 No.3...

  • Page 417

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] Camshaft Installation Note 1. Install the camshaft with No.3 cylinder cam aligned at TDC of compression stroke. 2. Carefully apply adhesive agent (Loctite 518 or 962) to the area indicated in the figure so that it does not leak into the sliding part.

  • Page 418

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] N·m { kgf·m, ft·lbf} ˚ ˚ 96—104 {9.8—10.6 , 70.9—76.7} +87 —93 acxuuw00002584 Crankshaft pulley Crankshaft pulley lock bolt (See01-10-24 Crankshaft Pulley Lock Bolt Removal Front oil seal Note.) (See01-10-25 Front Oil Seal Removal Note.) (See01-10-25 Crankshaft Pulley Lock Bolt Installation (See01-10-25 Front Oil Seal Installation Note.)

  • Page 419

    MECHANICAL [L3 WITH TC] Front Oil Seal Removal Note 1. Remove the oil seal lip using a razor. 2. Remove the oil seal using a flathead screwdriver with the tip protected by a rag to prevent crankshaft oil seal damage. FRONT OIL SEAL 01-10 acxuuw00000199...

  • Page 420

    MECHANICAL [L3 WITH TC] 3. To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 x 1.0), fix the crankshaft pulley to the engine front cover. BOLT acxuuw00000203 4. Install the SSTs to the crankshaft pulley and lock the crankshaft against rotation, and tighten the crankshaft pulley lock bolt using the following two 205-07202...

  • Page 421

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] Rear Oil Seal Installation Note 1. Apply silicone sealant to the areas shown in the figure. Caution • Install the rear oil seal within 10 min of applying the silicone sealant.

  • Page 422

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] VARIABLE VALVE TIMING ACTUATOR INSPECTION[L3 WITH TC] id011039801200 Caution • Due to the precision interior construction of the variable valve timing actuator, it cannot be disassembled. 1. Disconnect the negative battery cable.

  • Page 423

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] 01-10-28 MECHANICAL [L3 WITH TC] 3. Install a new washer. 4. Install the variable valve timing actuator. (1) Fix the camshaft in a vise. (2) Align the marks on the camshaft and the variable valve timing actuator.

  • Page 424

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) MECHANICAL [L3 WITH TC] THIS PAGE INTENTIONALLY LEFT BLANK 01-10-28–2...

  • Page 425

    MECHANICAL [L3 WITH TC] OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION[L3 WITH TC] id011039801300 1. Disconnect the negative battery cable. 2. Remove the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove the ignition coils. (See01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].) 4.

  • Page 426

    MECHANICAL [L3 WITH TC] 6. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and moves to the maximum valve timing advance position. • If not as specified, replace the OCV. acxuuw00000139 Note • When applying battery positive voltage between the OCV terminals, the connection VALVE TIMING VALVE TIMING...

  • Page 427

    MECHANICAL [L3 WITH TC] ENGINE REMOVAL/INSTALLATION[L3 WITH TC] id011039800400 Warning • Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always keep sparks and flames away from fuel.' • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite and cause serious injury or death and damage.

  • Page 428

    MECHANICAL [L3 WITH TC] 74.5—104.9 {7.6—10.6, 55.0—77.3} 66.6—93.1 {6.8—9.4, 50—68} 66.6—93.1 {6.8—9.4, 50—68} 74.5—104.9 {7.6—10.6, 55.0—77.3} 93.1—116.6 {9.5—11.8, 68.7—85.9} 85.3—116.6 {8.7—11.8, 63.0—85.9} N·m {kgf·m, ft·lbf} acxuuw00000185 No.3 engine mount rubber No.1 engine mount (See01-10-33 No.3 Engine Mount Rubber, No.4 (See01-10-33 No.1 Engine Mount Removal Note.) Engine Mount Bracket Removal Note.) (See01-10-33 Engine Mount Installation Note.) (See01-10-33 Engine Mount Installation Note.)

  • Page 429

    MECHANICAL [L3 WITH TC] No.1 Engine Mount Removal Note 1. Remove the No.1 engine mount bracket from the underside of the vehicle. FRONT 01-10 No.1 ENGINE MOUNT BRACKET acxuuw00000186 2. Remove the No.1 engine mount rubber and the front crossmember as a single unit. (See02-13-10 FRONT CROSSMEMBER REMOVAL/ INSTALLATION.) No.1 ENGINE...

  • Page 430

    MECHANICAL [L3 WITH TC] 2. Tighten the No.1 engine mount bracket in the order shown in the figure. Tightening torque 93.1— 116.6 N·m {9.5— 11.8 kgf·m, 68.7— FRONT 85.9 ft·lbf} acxuuw00000190 3. Secure the engine and transaxle using an engine ENGINE, TRANSAXLE jack and attachment.

  • Page 431

    MECHANICAL [L3 WITH TC] 7. Tighten the No.4 engine mount bracket in the order shown in the figure. Tightening torque Installation Tightening Torque Position 66.6— 93.1 N·m {6.8— 9.4 kgf·m, 50— 13 68 ft·lbf} 01-10 74.5— 104.9 N·m {7.6— 10.6 kgf·m, 55.0—...

  • Page 432

    MECHANICAL [L3 WITH TC] Ignition Timing Inspection Note • The ignition timing cannot be adjusted. • The M-MDS is required to verify the ignition timing. 1. Verify the ignition timing (M-MDS: SPARKADV) using the PID/data monitor function of the M-MDS. Ignition timing Approx.

  • Page 433

    LUBRICATION [L3 WITH TC] 01-11 LUBRICATION [L3 WITH TC] LUBRICATION SYSTEM OIL COOLER REMOVAL/INSTALLATION LOCATION INDEX[L3 WITH TC] ..01-11–1 [L3 WITH TC] ..... 01-11–6 OIL PRESSURE INSPECTION OIL PAN REMOVAL/INSTALLATION [L3 WITH TC] .

  • Page 434

    LUBRICATION [L3 WITH TC] OIL PRESSURE INSPECTION[L3 WITH TC] id011139800300 Warning • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. • A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury.

  • Page 435

    LUBRICATION [L3 WITH TC] ENGINE OIL LEVEL INSPECTION[L3 WITH TC] id011139800500 1. Position the vehicle on level ground. 2. Warm up the engine. 3. Stop the engine and allow approx. 5 min before continuing. 4. Rotate the service hole cap (installed to charge air cooler duct) used to remove/install the dipstick CHARGE AIR in the direction shown in the figure and remove it.

  • Page 436

    LUBRICATION [L3 WITH TC] ENGINE OIL REPLACEMENT[L3 WITH TC] id011139800400 Warning • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. • A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury.

  • Page 437

    LUBRICATION [L3 WITH TC] OIL FILTER REPLACEMENT[L3 WITH TC] WM: OIL FILTER id011139800700 Warning • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. • A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury.

  • Page 438

    LUBRICATION [L3 WITH TC] OIL COOLER REMOVAL/INSTALLATION[L3 WITH TC] id011139800800 Warning • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. • A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury.

  • Page 439

    LUBRICATION [L3 WITH TC] 10. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].) 11. Loosen the water pump pulley bolts before removing the drive belt. 12. Remove the drive belt. (See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].) 13.

  • Page 440

    LUBRICATION [L3 WITH TC] Oil Pan Installation Note Caution • Apply the silicon sealant in a single, unbroken line around the whole perimeter. • Using bolts with the old seal adhering could cause cracks in the housing. 1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing and oil pan.

  • Page 441

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) LUBRICATION [L3 WITH TC] 6. Tighten the oil pan-transaxle installation bolts. Tightening torque 37— 52 N·m {3.8— 5.3 kgf·m, 28— 38 ft·lbf} End Of Sie WM: OIL PUMP 01-11 OIL PAN-TRANSAXLE INSTALLATION BOLTS acxuuw00001997...

  • Page 442

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) LUBRICATION [L3 WITH TC] 8.0—11.5 {82—117, 71—101} 8.0—11.5 {82—117, 71—101} : 20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf} N·m {kgf·cm, in·lbf} : 8—12 N·m {82—122 kgf·cm, 71—105 in·lbf}, 17—23 N·m {1.8—2.3 kgf·m, 12.6—16.9 ft·lbf} acxuuw00002574...

  • Page 443

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) COOLING SYSTEM [L3 WITH TC] 01-12 COOLING SYSTEM [L3 WITH TC] COOLING SYSTEM LOCATION INDEX Radiator Removal Note ... . . 01-12–10 [L3 WITH TC] ....01-12–2...

  • Page 444

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) COOLING SYSTEM [L3 WITH TC] COOLING SYSTEM LOCATION INDEX[L3 WITH TC] id011239800100 acxuuw00002010 Cooling system cap Water pump (See 01-12-7 COOLING SYSTEM CAP (See 01-12-12 WATER PUMP REMOVAL/ INSPECTION[L3 WITH TC].) INSTALLATION[L3 WITH TC].) Coolant reserve tank Cooling fan motor No.1...

  • Page 445

    COOLING SYSTEM [L3 WITH TC] ENGINE COOLANT LEVEL INSPECTION[L3 WITH TC] id011239800300 Warning • Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury.

  • Page 446

    COOLING SYSTEM [L3 WITH TC] ENGINE COOLANT PROTECTION INSPECTION[L3 WITH TC] id011239800400 1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer. Caution • Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur.

  • Page 447

    COOLING SYSTEM [L3 WITH TC] ENGINE COOLANT REPLACEMENT[L3 WITH TC] id011239800600 Warning • Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury.

  • Page 448

    COOLING SYSTEM [L3 WITH TC] 7. Refill the engine coolant from the radiator filler neck until it is close to the top of the radiator filler neck. 8. Refill the engine coolant into the coolant reserve tank up to the FULL mark on the tank. 9.

  • Page 449

    COOLING SYSTEM [L3 WITH TC] COOLING SYSTEM CAP INSPECTION[L3 WITH TC] id011239801500 Warning • Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury.

  • Page 450

    COOLING SYSTEM [L3 WITH TC] Coolant Reserve Tank Removal Note 1. Remove the coolant reserve tank from the radiator cowling tabs shown in the figure by lifting them with a flathead screwdriver. End Of Sie acxuuw00002067 RADIATOR REMOVAL/INSTALLATION[L3 WITH TC] id011239801400 Warning •...

  • Page 451

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] Simulation Function Procedure 1. Connect the M-MDS to the DLC-2. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS. • When using the IDS (notebook PC) 1.

  • Page 452

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) ON-BOARD DIAGNOSTIC [L3 WITH TC] AFTER REPAIR PROCEDURE[L3 WITH TC] id010239801100 1. Connect the M-MDS to the DLC-2. 2. Cycle the ignition switch from the off to the ON position. 3. Any retrieved DTCs.

  • Page 453

    COOLING SYSTEM [L3 WITH TC] THERMOSTAT REMOVAL/INSTALLATION[L3 WITH TC] id011239801200 Warning • Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury.

  • Page 454

    COOLING SYSTEM [L3 WITH TC] End Of Sie WATER PUMP REMOVAL/INSTALLATION[L3 WITH TC] id011239800700 Warning • Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury.

  • Page 455

    COOLING SYSTEM [L3 WITH TC] 1. Disconnect the negative battery cable. 2. Remove the under cover. 3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].) 4. Remove the charge air cooler duct, air cleaner and fresh air duct component. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 5.

  • Page 456

    COOLING SYSTEM [L3 WITH TC] ATF Oil Cooler Pipe Removal Note 1. Remove the ATF oil cooler pipe with the hoses still connected. Position the ATF oil cooler pipe so that it is out of the way. Cooling Fan Component Removal Note 1.

  • Page 457

    COOLING SYSTEM [L3 WITH TC] Fan control module No.1 Inspection Result Condition Engine coolant temp. 95 °C {203 °F} or less IG SW ON 0 V (Fan stops.) 95 °C {203 °F} or less IG SW ON (Idling) 0 V (Fan stops.) 95 °C {203 °F} or less IG SW ON (Idling) 4.1 V...

  • Page 459

    INTAKE-AIR SYSTEM [L3 WITH TC] 01-13 INTAKE-AIR SYSTEM [L3 WITH TC] INTAKE AIR SYSTEM LOCATION INDEX CHARGE AIR COOLER INSPECTION [L3 WITH TC] ....01-13–2 [L3 WITH TC] .

  • Page 460

    INTAKE-AIR SYSTEM [L3 WITH TC] INTAKE AIR SYSTEM LOCATION INDEX[L3 WITH TC] id011339800100 acxuuw00000152 Air cleaner Air bypass valve (See01-13-5 INTAKE AIR SYSTEM REMOVAL/ (See01-13-11 AIR BYPASS VALVE INSTALLATION[L3 WITH TC].) INSPECTION[L3 WITH TC].) (See01-13-11 AIR CLEANER ELEMENT Turbocharger INSPECTION[L3 WITH TC].) (See01-13-5 INTAKE AIR SYSTEM REMOVAL/ Throttle body INSTALLATION[L3 WITH TC].)

  • Page 461

    INTAKE-AIR SYSTEM [L3 WITH TC] End Of Sie INTAKE AIR SYSTEM FLOW DIAGRAM[L3 WITH TC] id011339800200 RESONANCE CHAMBER 01-13 CHARGE AIR FRESH-AIR TURBOCHARGER COOLER CLEANER DUCT AIR BYPASS VALVE THROTTLE BODY INTAKE MANIFOLD COMBUSTION THROTTLE CHAMBERS VALVE VARIABLE SWIRL SHUTTER VALVE : INTAKE AIR FLOW acxuuw00000282 End Of Sie...

  • Page 462

    INTAKE-AIR SYSTEM [L3 WITH TC] VACUUM HOSE ROUTING DIAGRAM[L3 WITH TC] id011339800300 CHECK VALVE PURGE SOLENOID VALVE VARIABLE SWIRL SOLENOID VALVE PCV VALVE VARIABLE SWIRL SHATTER VALVE ACTUATOR acxuuw00000153 End Of Sie INTAKE AIR SYSTEM MANIFOLD VACUUM INSPECTION[L3 WITH TC] id011339804200 1.

  • Page 463

    INTAKE-AIR SYSTEM [L3 WITH TC] INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC] id011339800400 Warning • A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system. •...

  • Page 464

    INTAKE-AIR SYSTEM [L3 WITH TC] 7. Complete the “AFTER REPAIR PROCEDURE”. (See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].) 7.8—10.8 {80—110, 70—95} 23.5—35.3 N·m {2.40—3.59 kgf·m, 17.4—26.0 ft·lbf} 18.6—25.5 N·m {1.90—2.60 kgf·m, 4.9 {50—43} 13.8—18.8 ft·lbf} 7.8—10.8 {80—110, 7.9—10.7 70—95} {81—109, 70—94} 7.8—10.8 {80—110, 70—95}...

  • Page 465

    INTAKE-AIR SYSTEM [L3 WITH TC] MAF/IAT sensor Throttle body (See01-13-7 Throttle Body Removal Note.) Fresh air duct (See01-13-10 Throttle Body Installation Note.) Air cleaner cover Vacuum chamber Air cleaner element Variable swirl solenoid valve Air cleaner case Intake manifold Resonance chamber (See01-13-7 Intake Manifold Removal Note.) (See01-13-7 Air Hose Removal Note.) 01-13...

  • Page 466

    INTAKE-AIR SYSTEM [L3 WITH TC] Turbocharger Removal Note 1. Remove the middle pipe (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Disconnect the rear HO2S connector. 3. Remove the front pipe. (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) Caution • When removing the cowl grille, a part or tool may hit the edge of the windshield and could damage it.

  • Page 467

    INTAKE-AIR SYSTEM [L3 WITH TC] Turbocharger Installation Note 1. Install the turbocharger. 38—51 N·m Tightening torque {3.9—5.2 kgf·m, 29—37 ft·lbf} 38— 51 N·m {3.9— 5.2 kgf·m, 29— 37 ft·lbf} 2. Install the WU-TWC. (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH 01-13 TC].) 3.

  • Page 468

    INTAKE-AIR SYSTEM [L3 WITH TC] Wastegate Control Solenoid Valve Installation Note 1. Install the wastegate control solenoid valve. Tightening torque 7.8— 10.8 N·m {80— 110 kgf·cm, 70— 95 in·lbf} 1—3 mm {0.04—0.11 in} (36˚) (95˚) DETAIL A WASTEGATE CONTROL SOLENOID VALVE (190˚) 1—4 mm...

  • Page 469

    INTAKE-AIR SYSTEM [L3 WITH TC] End Of Sie AIR CLEANER ELEMENT INSPECTION[L3 WITH TC] WM: AIR CLEANER id011339800800 1. Remove the air cleaner element. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Verify that the air cleaner element surface is free of dirt. •...

  • Page 470

    INTAKE-AIR SYSTEM [L3 WITH TC] 4. Verify that the airflow is as indicated in the table. • If there is any malfunction, replace the air bypass valve. Vacuum Valve operation Airflow between (kPa {mmHg, inHg}) condition port A— B –66 {–496, –20} Open or more –49 {–367, –14}...

  • Page 471

    INTAKE-AIR SYSTEM [L3 WITH TC] VARIABLE SWIRL SHUTTER VALVE ACTUATOR INSPECTION[L3 WITH TC] id011339801200 1. Remove the air hose. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Disconnect the vacuum hose from the variable swirl control solenoid valve. 3. Connect a vacuum pump to the variable swirl shutter valve actuator. 4.

  • Page 472

    INTAKE-AIR SYSTEM [L3 WITH TC] WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B...

  • Page 473

    INTAKE-AIR SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harness for an open or short circuit (continuity check). WASTEGATE CONTROL SOLENOID VALVE WIRING HARNESS SIDE CONNECTOR 01-13 acxuuw00000032 FUSE BOX...

  • Page 474

    INTAKE-AIR SYSTEM [L3 WITH TC] WASTEGATE ACTUATOR INSPECTION[L3 WITH TC] id011339800700 1. Remove the air hose and air duct. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]) 2. Disconnect the hose from the wastegate actuator. 3. Plug the wastegate actuator as shown in the figure.

  • Page 475

    INTAKE-AIR SYSTEM [L3 WITH TC] TURBOCHARGER INSPECTION[L3 WITH TC] id011339801000 Compressor Wheel Inspection 1. Remove the turbocharger. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Visually inspect the compressor wheel from view A for the cracks, damage, or bending on all the compressor wheel blades.

  • Page 477

    FUEL SYSTEM [L3 WITH TC] 01-14 FUEL SYSTEM [L3 WITH TC] FUEL SYSTEM LOCATION INDEX FUEL PUMP RESISTOR [L3 WITH TC] ....01-14–2 REMOVAL/INSTALLATION Engine Room Side .

  • Page 478

    FUEL SYSTEM [L3 WITH TC] FUEL SYSTEM LOCATION INDEX[L3 WITH TC] id011439800100 Engine Room Side acxuuw00000154 Fuel injector High pressure fuel pump (See01-14-23 FUEL INJECTOR REMOVAL/ (See01-14-16 HIGH PRESSURE FUEL PUMP INSTALLATION[L3 WITH TC].) REMOVAL/INSTALLATION[L3 WITH TC].) (See01-14-27 FUEL INJECTOR INSPECTION[L3 (See01-14-19 HIGH PRESSURE FUEL PUMP WITH TC].) INSPECTION[L3 WITH TC].)

  • Page 479

    FUEL SYSTEM [L3 WITH TC] Fuel Tank Side 01-14 acxuuw00000155 Nonreturn valve Fuel tank (See01-14-7 FUEL TANK REMOVAL/ Fuel filler pipe INSTALLATION[L3 WITH TC].) Fuel pump unit (See01-14-11 FUEL PUMP UNIT REMOVAL/ INSTALLATION[L3 WITH TC].) (See01-14-13 FUEL PUMP UNIT DISASSEMBLY/ ASSEMBLY[L3 WITH TC].) (See01-14-13 FUEL PUMP UNIT INSPECTION[L3 WITH TC].)

  • Page 480

    FUEL SYSTEM [L3 WITH TC] BEFORE REPAIR PROCEDURE[L3 WITH TC] id011439800300 Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.

  • Page 481

    FUEL SYSTEM [L3 WITH TC] 1. Start the fuel pump using the following procedure. Using M-MDS 1. Connect the M-MDS to the DLC-2. 2. Using the simulation function “FP”, start the fuel pump. Without using M-MDS 1. Disconnect the negative battery cable. 2.

  • Page 482

    FUEL SYSTEM [L3 WITH TC] 6. Turn the lever parallel to the hose of the SST as shown. 49 B019 901B 49 N013 101A 49 N013 102A acxuuw00000248 7. Connect the vacuum hose to the intake manifold that connecting to the brake booster. 8.

  • Page 483

    FUEL SYSTEM [L3 WITH TC] FUEL TANK REMOVAL/INSTALLATION[L3 WITH TC] id011439801600 Warning • Repairing a fuel tank that has not been properly steam-cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. •...

  • Page 484

    FUEL SYSTEM [L3 WITH TC] 15. Remove in the order indicated in the table. 9.0—13.0 N·m {92—132 kgf·cm, 80—115 in·lbf} RIVET 43.1—60.8 {4.40—6.20, 31.8—44.8} RIVET 43.1—60.8 {4.40—6.20, 31.8—44.8} 43.1—60.8 {4.40—6.20, 31.8—44.8} N·m {kgf·m,ft·lbf} acxuuw00000195 Strap Evaporative hose (See 01-14-19 QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[L3 WITH Fuel tank TC])

  • Page 485

    FUEL SYSTEM [L3 WITH TC] 16. Install in the reverse order of removal. 17. Complete the “AFTER REPAIR PROCEDURE”. (See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].) Rivet Removal Note Caution • Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

  • Page 486

    FUEL SYSTEM [L3 WITH TC] Breather Hose Installation Note 1. Install the breather hose and clamp as shown in the figure. CLAMP End Of Sie BREATHER HOSE TIGHTENING AREA WM: FUEL SHUT-OFF VALVE 45° 45° VIEW B acxuuw00000266 FUEL SHUT-OFF/ROLLOVER VALVE INSPECTION[L3 WITH TC] id011439801800 Caution •...

  • Page 487

    FUEL SYSTEM [L3 WITH TC] FUEL PUMP UNIT REMOVAL/INSTALLATION[L3 WITH TC] id011439800900 Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”.

  • Page 488

    FUEL SYSTEM [L3 WITH TC] 6. Start the fuel pump using the following procedure. Using M-MDS 1. Connect the M-MDS to the DLC-2. 2. Using the simulation function “FP”, start the fuel pump. Without using M-MDS 1. Remove the fuel pump relay. Caution •...

  • Page 489

    FUEL SYSTEM [L3 WITH TC] FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY[L3 WITH TC] id011439801000 Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

  • Page 490

    FUEL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Inspect the following wiring harnesses as for open FUEL PUMP UNIT FUSE BOX or short circuit (continuity check). WIRING HARNESS SIDE CONNECTOR (FUEL PUMP RELAY) acxuuw00000035 Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. —...

  • Page 491

    FUEL SYSTEM [L3 WITH TC] 8. Start the fuel pump using the following procedure. Using M-MDS 1. Connect the negative battery cable. 2. Connect the M-MDS to the DLC-2. 3. Using the simulation function “FP”, start the fuel pump. Without using M-MDS 1.

  • Page 492

    FUEL SYSTEM [L3 WITH TC] FUEL PUMP RESISTOR INSPECTION[L3 WITH TC] id011439801300 Resistance Inspection 1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].) 2. Remove the fuel pump resister. (See 01-14-15 FUEL PUMP RESISTOR REMOVAL/INSTALLATION[L3 WITH TC].) 3.

  • Page 493

    FUEL SYSTEM [L3 WITH TC] Warning • If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When removing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench.

  • Page 494

    FUEL SYSTEM [L3 WITH TC] Caution • If the high pressure fuel pump installation bolts are tightened with the high pressure fuel pump tilted, the high pressure fuel pump may not operate correctly. Tighten the high pressure fuel pump installation bolts in a few passes with equal torque. 14.

  • Page 495

    FUEL SYSTEM [L3 WITH TC] HIGH PRESSURE FUEL PUMP INSPECTION[L3 WITH TC] id011439801500 Note • Perform the following inspection only when directed. • The following vacuum values are indicated by relative pressure from the fuel pressure sensor. 1. Verify that the fuel pressure sensor is normal. (See01-40-35 FUEL PRESSURE SENSOR INSPECTION[L3 WITH TC].) 01-14 2.

  • Page 496

    FUEL SYSTEM [L3 WITH TC] Type A Removal 1. Follow “BEFORE REPAIR PROCEDURE” before performing any work operations to prevent fuel from spilling from the fuel system. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].) Caution • The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper.

  • Page 497

    FUEL SYSTEM [L3 WITH TC] Type B Removal Caution • Be careful not to damage the pipe when unlocking the retainer. Note • When removing the quick connector, either SST 49 E042 001 or 49 N013 103A. 01-14 When using SST 49 N013 103A 1.

  • Page 498

    FUEL SYSTEM [L3 WITH TC] Type C Removal 1. Follow “BEFORE REPAIR PROCEDURE” and remove dirt from the connecting surfaces before performing any work operations. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].) 2. Move the retainer upward using a small flathead FLATHEAD screwdriver or a similar tool.

  • Page 499

    FUEL SYSTEM [L3 WITH TC] Type B Installation Note • If the quick release connector O-ring is damaged or has slipped, replace the fuel hose. • A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses.

  • Page 500

    FUEL SYSTEM [L3 WITH TC] 1. Complete the “BEFORE REPAIR PROCEDURE”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].) 2. Disconnect the negative battery cable. 3. Remove the intake manifold. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 4. Remove in the order indicated in the table. 8—11.5 N·m 21.5—25.5 17—23...

  • Page 501

    FUEL SYSTEM [L3 WITH TC] Fuel Injector Removal Note Note • Depending on the driving conditions, carbon may accumulate on the inserted part of the fuel injector, causing the fuel injector to stick. Remove the fuel injector using the following procedure. 1.

  • Page 502

    FUEL SYSTEM [L3 WITH TC] Fuel Delivery Pipe Installation Note 1. Tighten the bolts in the order shown in the figure. Tightening torque 17— 23 N·m {1.8— 2.3 kgf·m, 13— 16 ft·lbf} FUEL DELIVERY PIPE acxuuw00000271 High Pressure Line Pipe Installation Note 1.

  • Page 503

    FUEL SYSTEM [L3 WITH TC] 3. Tighten No.2 bolts shown in the figure. DO NOT ALLOW JOINT SPILL VALVE CONTROL NUT TO ROTATE SOLENOID VALVE 01-14 JOINT NUT HIGH PRESSURE LINE PIPE INSTALLATION NUT HIGH PRESSURE LINE PIPE WATER OUTLET CASE INSTALLATION BOLT acxuuw00000273 (1) Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.

  • Page 504

    FUEL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harnesses for an open or short circuit (continuity check). FUEL INJECTOR WIRING HARNESS SIDE CONNECTOR acxuuw00000039 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M...

  • Page 505

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EXHAUST SYSTEM [L3 WITH TC] 01-15 EXHAUST SYSTEM [L3 WITH TC] EXHAUST SYSTEM INSPECTION Exhaust Manifold Insulator (Upper) [L3 WITH TC] ....01-15–1 Removal Note .

  • Page 506

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EXHAUST SYSTEM [L3 WITH TC] EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC] id011539800200 Warning • A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

  • Page 507

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EXHAUST SYSTEM [L3 WITH TC] Main silencer Exhaust manifold insulator (Upper) Seal ring (middle pipe side) (See 01-15-3 Exhaust Manifold Insulator (Upper) (See 01-15-3 Seal Ring Removal Note.) Removal Note.) (See 01-15-4 Seal Ring Installation Note.)

  • Page 508

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EXHAUST SYSTEM [L3 WITH TC] Exhaust Manifold Installation Note 1. Tighten the exhaust manifold installation nuts in the order shown. Tightening torque 43— 64 N·m {4.4— 6.5 kgf·m, 32— 47 ft·lbf} acxuuw00000175 WU-TWC Installation Note 1.

  • Page 509

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EXHAUST SYSTEM [L3 WITH TC] 2. Install the SST to the seal ring so that the SST is even with the flange. 49 G040 002 01-15 FLANGE 49 G040 001 acxuuw00002571 3. Press in the seal ring by tapping the SST using a...

  • Page 511

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] 01-16 EMISSION SYSTEM [L3 WITH TC] EVAPORATIVE EMISSION (EVAP) Airflow Inspection ....01-16–8 CONTROL SYSTEM LOCATION INDEX Resistance Inspection .

  • Page 512

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM LOCATION INDEX[L3 WITH TC] id011639800100 Engine Compartment Side acxuuw00000176 Purge solenoid valve PCV valve (See 01-16-9 PURGE SOLENOID VALVE (See 01-16-14 POSITIVE CRANKCASE REMOVAL/INSTALLATION[L3 WITH TC].)

  • Page 513

    EMISSION SYSTEM [L3 WITH TC] Fuel Tank Side 01-16 TO PURGE SOLENOID VALVE acxuuw00000178 Fuel shut-off valve EVAP system leak detection pump (See 01-16-7 EVAPORATIVE EMISSION (EVAP) Rollover valve SYSTEM LEAK DETECTION PUMP REMOVAL/ Charcoal canister INSTALLATION[L3 WITH TC].) (See 01-16-6 CHARCOAL CANISTER REMOVAL/ (See 01-16-7 EVAPORATIVE EMISSION (EVAP) INSTALLATION[L3 WITH TC].) SYSTEM LEAK DETECTION PUMP...

  • Page 514

    EMISSION SYSTEM [L3 WITH TC] EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM DIAGRAM[L3 WITH TC] id011639800200 EVAP SYSTEM LEAK PURGE SOLENOID VALVE DETECTION PUMP CHECK VALVE CHARCOAL CANISTER AIR FILTER EGR VALVE ROLLOVER VALVE FUEL SHUT-OFF VALVE PCV VALVE acxuuw00000062 End Of Sie FUEL-FILLER CAP INSPECTION[L3 WITH TC] WM: FUEL FILLER CAP id011639801300...

  • Page 515

    EMISSION SYSTEM [L3 WITH TC] 3. Connect the fuel cap receiver assembly (part of SST) to the manifold assembly and fuel-filler cap from the vehicle. • If the fuel-filler cap is not a genuine part, replace it. 4. Turn the control valve to the FILL position. 5.

  • Page 516

    EMISSION SYSTEM [L3 WITH TC] CHARCOAL CANISTER REMOVAL/INSTALLATION[L3 WITH TC] id011639801500 1. Remove the under cover (LR). 2. Remove in the order indicated in the table. Evaporative hose 9.0—13.0 Quick release connector {92—132, 80—115} (See 01-14-19 QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[L3 WITH TC]) Charcoal canister 9.0—13.0 {92—132, 80—115}...

  • Page 517

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION[L3 WITH id011639800700 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Connector Evaporative hose 01-16 9.0—13.0...

  • Page 518

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] EVAP system leak detection pump and bracket removal note Note • Because the AWD EVAP system leak detection pump is installed surrounded by the rear differential, there is insufficient space for removing the pump from the vehicle. Therefore, it is necessary to remove the EVAP system leak detection pump and bracket separately from the vehicle.

  • Page 519

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] 01-16-8 EMISSION SYSTEM [L3 WITH TC] Resistance Inspection Note • Perform the following procedure only when directed. 1. Disconnect the negative battery cable. 2. Inspect resistance of the EVAP system leak detection pump.

  • Page 520

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) EMISSION SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harnesses for an open or short circuit (continuity check). EVAP SYSTEM...

  • Page 521

    EMISSION SYSTEM [L3 WITH TC] PURGE SOLENOID VALVE REMOVAL/INSTALLATION[L3 WITH TC] id011639803500 1. Disconnect the negative battery cable. 2. Remove the charge air cooler duct. 3. Remove in the order indicated in the table. Connector Vacuum hose 01-16 Purge solenoid valve 4.

  • Page 522

    EMISSION SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See 01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harnesses for an PURGE SOLENOID VALVE open or short circuit (continuity check). WIRING HARNESS SIDE CONNECTOR acxuuw00000047 FUSE BOX (MAIN RELAY)

  • Page 523

    EMISSION SYSTEM [L3 WITH TC] CHECK VALVE INSPECTION[L3 WITH TC] id011639801400 1. Remove the charge air cooler duct. 2. Disconnect the vacuum hose connected between the check valve and the purge solenoid valve from the purge solenoid valve. 3. Disconnect the vacuum hose connected between the check valve and the intake manifold from the intake manifold.

  • Page 524

    EMISSION SYSTEM [L3 WITH TC] EGR VALVE INSPECTION[L3 WITH TC] id011639801100 Resistance Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Inspect resistance of the EGR valve coils. • If not as specified, replace the EGR valve. (See 01-16-11 EGR VALVE REMOVAL/ INSTALLATION[L3 WITH TC]) •...

  • Page 525

    EMISSION SYSTEM [L3 WITH TC] Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See 01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harnesses for open or EGR VALVE short circuit (continuity check). WIRING HARNESS SIDE CONNECTOR 01-16 acxuuw00000051 FUSE BOX (MAIN RELAY) FRONT...

  • Page 526

    EMISSION SYSTEM [L3 WITH TC] POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION[L3 WITH TC] id011639800400 1. Remove the intake manifold. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]) 2. Remove the PCV valve. 3. Blow through the valve and verify that air flows as specified.

  • Page 527

    CHARGING SYSTEM [L3 WITH TC] 01-17 CHARGING SYSTEM [L3 WITH TC] CHARGING SYSTEM LOCATION INDEX GENERATOR REMOVAL/INSTALLATION [L3 WITH TC] ....01-17–1 [L3 WITH TC] .

  • Page 528

    CHARGING SYSTEM [L3 WITH TC] BATTERY REMOVAL/INSTALLATION[L3 WITH TC] id011739800500 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 5.0—6.9 {51.0—70.3, Negative battery cable 44.3—61.0} Positive battery cable cap Positive battery cable 2.9—4.9 Battery clamp {29.6—49.9,...

  • Page 529

    CHARGING SYSTEM [L3 WITH TC] Battery Voltage 1. Inspect the battery as follows: Step Inspection Action Measure the battery 12.4 V or Go to Step positive voltage. more Less Go to the than next step. 01-17 12.4 V Quick charge for 30 12.4 V or Go to the min and recheck...

  • Page 530

    CHARGING SYSTEM [L3 WITH TC] BATTERY RECHARGING[L3 WITH TC] id011739800700 Warning • Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch fire, and cause serious injury. • Remove the battery filler caps when recharging to prevent battery deformation or damage. Caution •...

  • Page 531

    CHARGING SYSTEM [L3 WITH TC] 9.8—14.7 N·m {100—149 kgf·cm, 87—130 in·lbf} 01-17 7.8—10.8 N·m {79.6—110.1 kgf·cm, 69.1—95.5 in·lbf} 38—51 {3.9—5.2, 29—37} 7.8—10.8 N·m {79.6—110.1 kgf·cm, 69.1—95.5 in·lbf} 38—51 {3.9—5.2, 29—37} N·m {kgf·m, ft·lbf} acxuuw00002016 Generator duct Generator connector Wiring harness bracket Generator (See 01-17-5 Generator Removal Note.) Terminal B cable...

  • Page 532

    CHARGING SYSTEM [L3 WITH TC] GENERATOR INSPECTION[L3 WITH TC] id011739800300 Caution • Do not apply direct battery positive voltage to generator terminal D, otherwise it could cause damage to the internal parts (power transistor) of the generator. Generator Warning Light 1.

  • Page 533

    CHARGING SYSTEM [L3 WITH TC] 9. Turn the following electrical loads on and verify that the current reading increases more than the minimum value indicated below. — If it is not as specified, go to the PCM and generator shearing inspection. (See 01-17-7 PCM and generator shearing inspection.) •...

  • Page 534

    CHARGING SYSTEM [L3 WITH TC] Step Inspection Action Monitor the ALTF PID using the M-MDS, or calculate the PCM input error. duty value of the PCM terminal 2AI using an oscilloscope. PCM, generator, or Is the duty value 0 % ? both are not normal.

  • Page 535

    CHARGING SYSTEM [L3 WITH TC] Stator coil 1. Verify that the continuity is as indicated in the table. 01-17 acxuuw00002023 • If there is any malfunction, replace the stator. : Continuity Terminal acxuuw00002024 2. Verify that there is no continuity between the stator coil leads and core using a tester.

  • Page 536

    CHARGING SYSTEM [L3 WITH TC] Brush spring 1. Measure the force of the brush spring using a spring pressure gauge. 2. Read the spring pressure gauge at the brush tip projection of 2 mm {0.079 in}. • Replace the brush spring if necessary. Generator brush spring force 2 mm Standard: 4.1—...

  • Page 537

    CHARGING SYSTEM [L3 WITH TC] GENERATOR DISASSEMBLY/ASSEMBLY[L3 WITH TC] id011739800400 Caution • Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive heat. 1. Disassemble in the order indicated in the table. 01-17 2. Assemble in the reverse order of disassembly. 3.5—5.3 {35—55, 31—47} 6.9—10.8...

  • Page 539

    IGNITION SYSTEM [L3 WITH TC] 01-18 IGNITION SYSTEM [L3 WITH TC] IGNITION SYSTEM LOCATION INDEX SPARK PLUG [L3 WITH TC] ....01-18–1 REMOVAL/INSTALLATION IGNITION COIL [L3 WITH TC] .

  • Page 540

    IGNITION SYSTEM [L3 WITH TC] IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC] id011839800200 1. Disconnect the negative battery cable. 2. Remove the charge air cooler. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove in the order indicated in the table. 4.

  • Page 541

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) IGNITION SYSTEM [L3 WITH TC] SPARK PLUG REMOVAL/INSTALLATION[L3 WITH TC] id011839800400 Caution • If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install only the specified spark plug when replacing.

  • Page 542

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) IGNITION SYSTEM [L3 WITH TC] Visual Inspection 1. Inspect the following items: • If any of the following malfunctions are DAMAGE BREAKAGE indicated, replace the spark plug. BURNS — Insulator breakage — Worn electrode —...

  • Page 543

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] 01-19 STARTING SYSTEM [L3 WITH TC] STARTING SYSTEM LOCATION INDEX On-vehicle Inspection ....01-19–4 [L3 WITH TC] ....01-19–1 No-load Test .

  • Page 544

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] STARTER REMOVAL/INSTALLATION[L3 WITH TC] id011939800200 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. • When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks.

  • Page 545

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] Heater Pipe Removal Note 1. Remove the heater pipe with the water hoses still connected. Position the heater pipe so that it is out of the way. Starter Removal Note 1.

  • Page 546

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] STARTER INSPECTION[L3 WITH TC] id011939800300 On-vehicle Inspection 1. Verify that the battery is fully charged. 2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.

  • Page 547

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] Return test 01-19-4 STARTING SYSTEM [L3 WITH TC] 1. Disconnect the motor wire from terminal M. 2. Connect battery positive voltage to terminal M TERMINAL M and ground the starter body.

  • Page 548

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) STARTING SYSTEM [L3 WITH TC] THIS PAGE INTENTIONALLY LEFT BLANK 01-19-4–2...

  • Page 549

    STARTING SYSTEM [L3 WITH TC] 2. Verify that there is no continuity between the commutator and the shaft using a tester. • If there is continuity, replace the armature. 01-19 acxuuw00002045 3. Place the armature on V-blocks, and measure the runout using a dial indicator.

  • Page 550

    STARTING SYSTEM [L3 WITH TC] Magnetic switch 1. Inspect for continuity between terminals S and M TERMINAL S using a tester. TERMINAL M • If there is no continuity, replace the magnetic switch. acxuuw00002049 2. Inspect for continuity between terminal S and the TERMINAL S body using a tester.

  • Page 551

    STARTING SYSTEM [L3 WITH TC] 2. Measure the brush length. • If any brush is worn almost to or beyond the minimum specification, replace all of the brushes. MINIMUM BRUSH LENGTH Starter brush length Standard: 12.3 mm {0.48 in} Minimum: 7.0 mm {0.28 in} 01-19 CONTACT FACE WITH COMMUTATOR acxuuw00002053...

  • Page 553

    CRUISE CONTROL SYSTEM [L3 WITH TC] 01-20 CRUISE CONTROL SYSTEM [L3 WITH TC] CRUISE CONTROL SWITCH INSPECTION[L3 WITH TC] ..01-20–1 End of Toc WM: CRUISE CONTROL SWITCH CRUISE CONTROL SWITCH INSPECTION[L3 WITH TC] 01-20 id012039800100 1.

  • Page 555

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] 01-40 CONTROL SYSTEM [L3 WITH TC] CONTROL SYSTEM COMPONENT Voltage Inspection ....01-40–32 Circuit Open/Short Inspection .

  • Page 556

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] WM: ENGINE CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION INDEX[L3 WITH TC] id014039800200 WU-TWC acxuuw00000130 PCM (Built-in BARO sensor) TP sensor (See01-40-6 PCM REMOVAL/INSTALLATION[L3 (See01-40-32 THROTTLE POSITION (TP) WITH TC].) SENSOR INSPECTION[L3 WITH TC].)

  • Page 557

    CONTROL SYSTEM [L3 WITH TC] HO2S (See01-40-37 HEATED OXYGEN SENSOR (HO2S) (See01-40-47 KNOCK SENSOR (KS) REMOVAL/ REMOVAL/INSTALLATION[L3 WITH TC].) INSTALLATION[L3 WITH TC].) (See01-40-37 HEATED OXYGEN SENSOR (HO2S) (See01-40-47 KNOCK SENSOR (KS) INSPECTION[L3 WITH TC].) INSPECTION[L3 WITH TC].) MAP/boost air temperature sensor CKP sensor (See01-40-29 MANIFOLD ABSOLUTE PRESSURE (See01-40-42 CRANKSHAFT POSITION (CKP)

  • Page 558

    CONTROL SYSTEM [L3 WITH TC] CONTROL SYSTEM WIRING DIAGRAM[L3 WITH TC] id014039800400 FUEL INJECTOR NO.1 FUEL INJECTOR NO.4 FUEL INJECTOR NO.3 FUEL INJECTOR NO.2 FUEL INJECTOR RELAY IAT SENSOR SENSOR HO2S HEATER (FRONT) HO2S HEATER (REAR) SENSOR FAN CONTROL MODULE NO.1 COOLING FAN RELAY NO.1 FUEL PRESSURE SENSOR...

  • Page 559

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] EGR VALVE 01-40 EVAP SYSTEM LEAK DETECTION PUMP TP SENSOR PURGE SOLENOID VALVE BRAKE SWITCH NO.1 WASTEGATE CONTROL SOLENOID VALVE BRAKE SWITCH NO.2 VARIABLE SWIRL SOLENOID VALVE VARIABLE SWIRL SHUTTER VALVE SWITCH...

  • Page 560

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] PCM REMOVAL/INSTALLATION[L3 WITH TC] id014039802400 Note • For PCM replacement, set up the M-MDS and perform the PCM configuration. (See 01-40-21 PCM CONFIGURATION[L3 WITH TC].) 1. Disconnect the negative battery cable.

  • Page 561

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] 1. Verify that the PCM connector lever is tilted 01-40-6 WM: PCM CONTROL SYSTEM [L3 WITH TC] LEVER towards the wiring harness side as shown in the WIRING figure.

  • Page 562

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) CONTROL SYSTEM [L3 WITH TC] THIS PAGE INTENTIONALLY LEFT BLANK 01-40-6–2...

  • Page 563

    CONTROL SYSTEM [L3 WITH TC] PCM terminal voltage table (Reference) WIRING HARNESS SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 564

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item • Fan control module Fan not operate Below 1.0 Fan control module Fan control No.2 Approx. • Related wiring (No.2) module No.2 Fan operates harness — —...

  • Page 565

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item — — — — — — — — — — ON/OFF switch Approx. 0 pressed in CANCEL switch Approx. 01-40 pressed in SET/COAST • Cruise control switch Ignition switch Approx.

  • Page 566

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item • Throttle actuator Approx. Ignition switch off Throttle actuator • Related wiring Throttle body control (–) harness Ignition switch to the ON position • Inspect using the wave profile. •...

  • Page 567

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item Ignition switch to the ON position (Use digital type voltmeter, • KS because measurement voltage Approx. • Related wiring Knocking (+) will be detected less than true harness voltage when using analog type voltmeter)

  • Page 568

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item • TP sensor APP is released 0.4—0.6 Ignition switch • Related wiring TP sensor (No. 1) TP sensor (No. 1) to the ON APP is 4.7—4.9 position harness depressed...

  • Page 569

    CONTROL SYSTEM [L3 WITH TC] Voltage Terminal Signal Connected to Test condition Inspection item • Fuel Injector relay Ignition switch off Below 1.0 Fuel injector power • Related wiring Fuel Injector relay supply 2 Ignition switch to the ON position harness •...

  • Page 570

    CONTROL SYSTEM [L3 WITH TC] CKP sensor signal PCM terminals • 2W (+)— body ground (–) Oscilloscope setting • 2 V/DIV (Y), 5 ms/DIV (X), DC range Vehicle condition • Idle after warm up (no load, P/S off, A/C off) acxuuw00000128 Wastegate control solenoid valve signal PCM terminals...

  • Page 571

    CONTROL SYSTEM [L3 WITH TC] Generator field coil control signal PCM terminals • 2AI (+)— body ground (–) Oscilloscope setting • 0.5 V/DIV (Y), 2 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm, no load) 01-40 ampjjw00001528...

  • Page 572

    CONTROL SYSTEM [L3 WITH TC] Fuel injection control (+) PCM terminals • Fuel injection No.1, No.4: 2BG (+)— body ground (–) • Fuel injection No.2, No.3: 2BH (+)— body ground (–) Oscilloscope setting • 20 V/DIV (Y), 400 µs/DIV (X), DC range Vehicle condition •...

  • Page 573

    CONTROL SYSTEM [L3 WITH TC] PID/DATA monitor table (reference) Monitor item Unit/ Condition/Specification Inspection item (Definition) Condition (Reference) terminal AAT (Ambient air Ignition switch to the ON position: °C °F • MAF/IAT sensor temperature) Indicate the ambient air temperature Refrigerant pressure is more than AC_REQ (Refrigerant the specification or less than the •...

  • Page 574

    CONTROL SYSTEM [L3 WITH TC] Monitor item Unit/ Condition/Specification Inspection item (Definition) Condition (Reference) terminal Brake pedal depressed: On • Brake switch No.1/No.2 (Brake pressure On/Off Brake pedal released: Off applied switch) CATT11_DSD • Perform applicable DTC Indicate the estimated catalytic °C °F (Estimated catalytic...

  • Page 575

    CONTROL SYSTEM [L3 WITH TC] Monitor item Unit/ Condition/Specification Inspection item (Definition) Condition (Reference) terminal • The following PIDs: OL/CL/ — IAT, MAF, TP, MAP, ECT, RPM, Ignition switch to the ON position: FUELSYS OL-Drive/ OL_Drive O2S11, O2S12, INGEAR, PSP, —...

  • Page 576

    CONTROL SYSTEM [L3 WITH TC] Monitor item Unit/ Condition/Specification Inspection item (Definition) Condition (Reference) terminal • Perform applicable DTC LONGFT1 (long term Idle (after warm up):–14— 14% — fuel trim) troubleshooting. Ignition switch to the ON position: Approx. 0 g/s Idle (after warm up): 2.72—...

  • Page 577

    CONTROL SYSTEM [L3 WITH TC] Monitor item Unit/ Condition/Specification Inspection item (Definition) Condition (Reference) terminal Ignition switch to the ON position • TP sensor TP REL (Relative TP) APP is released: Approx. 5% APP is depressed: Approx. 46 % Ignition switch to the ON position APP is released: Approx.

  • Page 578

    CONTROL SYSTEM [L3 WITH TC] WM: POWER STEERING PRESSURE SWITCH POWER STEERING PRESSURE (PSP) SWITCH INSPECTION[L3 WITH TC] id014039803100 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.) Continuity Inspection 1.

  • Page 579

    CONTROL SYSTEM [L3 WITH TC] End Of Sie VARIABLE SWIRL SHUTTER VALVE SWITCH INSPECTION[L3 WITH TC] WM: SHUTTER VALVE SWITCH id014039803000 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See00-00-3 HOW TO USE THIS MANUAL.) Voltage Inspection 01-40 1.

  • Page 580

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection VARIABLE SWIRL SHUTTER VALVE SWITCH WIRING HARNESS SIDE CONNECTOR acxuuw00000115 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 581

    CONTROL SYSTEM [L3 WITH TC] 7. Remove the ECT sensor. 8. Install in the reverse order of removal. Tightening torque ECT SENSOR 10— 14 N·m {102— 142 kgf·cm, 89— 123 in·lbf} 9. Refill the engine coolant. (See01-12-2 COOLING 01-40 SYSTEM SERVICE WARNINGS[L3 WITH TC].) End Of Sie acxuuw00000091 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION[L3 WITH TC]...

  • Page 582

    CONTROL SYSTEM [L3 WITH TC] Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. — ECT sensor terminal A and PCM terminal 2AH — ECT sensor terminal B and PCM terminal 2AY Short circuit •...

  • Page 583

    CONTROL SYSTEM [L3 WITH TC] WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1F 1B...

  • Page 584

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection MAF/IAT SENSOR WIRING HARNESS SIDE CONNECTOR acxuuw00000097 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 585

    CONTROL SYSTEM [L3 WITH TC] MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/BOOST AIR TEMPERATURE SENSOR REMOVAL/ INSTALLATION[L3 WITH TC] id014039801000 1. Disconnect the negative battery cable. 2. Remove the charge air cooler duct. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove the oil level gauge pipe. (See01-11-6 OIL PAN REMOVAL/INSTALLATION[L3 WITH TC].) 4.

  • Page 586

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection MAP/BOOST AIR TEMPERATURE SENSOR WIRING HARNESS SIDE CONNECTOR acxuuw00000080 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 587

    CONTROL SYSTEM [L3 WITH TC] BOOST AIR TEMPERATURE SENSOR INSPECTION[L3 WITH TC] id014039802100 Resistance Inspection Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.) 01-40 1.

  • Page 588

    CONTROL SYSTEM [L3 WITH TC] End Of Sie THROTTLE POSITION (TP) SENSOR INSPECTION[L3 WITH TC] WM: THROTTLE POSITION SENSOR id014039802700 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.) Voltage Inspection 1.

  • Page 589

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection TP SENSOR WIRING HARNESS SIDE CONNECTOR 01-40 acxuuw00000110 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 590

    CONTROL SYSTEM [L3 WITH TC] 3. Verify that the PCM terminal 1Y and 1AC voltages are as shown in the following table. WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 591

    CONTROL SYSTEM [L3 WITH TC] 1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Inspect the following wiring harnesses for an open or short circuit. (Continuity check) Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. —...

  • Page 592

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection FUEL PRESSURE SENSOR WIRING HARNESS SIDE CONNECTOR acxuuw00000085 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 593

    CONTROL SYSTEM [L3 WITH TC] HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[L3 WITH TC] id014039804000 Warning • A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system. 1.

  • Page 594

    CONTROL SYSTEM [L3 WITH TC] 4. Verify that the front HO2S current (PID: O2S11) is 0.25 mA or more while decelerating as shown in the figure. 0 KPH 3,000 RPM 2,000 RPM 1,000 RPM 0 RPM 0.25 mA 0.25 mA OR MORE O2S11 0 mA acxuuw00000099...

  • Page 595

    CONTROL SYSTEM [L3 WITH TC] FUSE BOX (MAIN RELAY) FRONT 01-40 acxuuw00000538 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 596

    CONTROL SYSTEM [L3 WITH TC] 4. Verify that the rear HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the rear HO2S voltage (PID: O2S12) is 0.3 V or less while decelerating as shown in the figure. 0 KPH 3,000 RPM 2,000 RPM...

  • Page 597

    CONTROL SYSTEM [L3 WITH TC] Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. — Rear HO2S terminal A and PCM terminal 2Q — Rear HO2S terminal B and PCM terminal 1BC Short circuit •...

  • Page 598

    CONTROL SYSTEM [L3 WITH TC] End Of Sie CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION[L3 WITH TC] WM: CRANKSHAFT POSITION PLATE id014039800600 Removal 1. Disconnect the negative battery cable. 2. Remove the charge air cooler duct. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3.

  • Page 599

    CONTROL SYSTEM [L3 WITH TC] CRANKSHAFT POSITION (CKP) SENSOR INSPECTION[L3 WITH TC] id014039800500 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.) Air Gap Inspection 01-40 1.

  • Page 600

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection CKP SENSOR WIRING HARNESS SIDE CONNECTOR acxuuw00000071 FUSE BOX (MAIN RELAY) FRONT acxuuw00000538 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 601

    CONTROL SYSTEM [L3 WITH TC] CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION[L3 WITH TC] id014039801500 Caution • When replacing the CMP sensor, make sure there is no foreign material on it such as metal shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting from fluctuation in magnetic flux and cause a deterioration in engine control.

  • Page 602

    CONTROL SYSTEM [L3 WITH TC] 2. Measure the output voltage using an oscilloscope. CMP SENSOR • If not within the specification, replace the WIRING HARNESS SIDE CONNECTOR CMP sensor. • If the monitor item condition/specification (reference) is not within the specification, even though the voltage is within the specification, carry out the “Circuit Open/ Short Inspection”.

  • Page 603

    CONTROL SYSTEM [L3 WITH TC] Open circuit • If there is no continuity, the circuit is open. Repair or replace the wiring harness. — CMP sensor terminal A and main relay terminal E — CMP sensor terminal B and PCM terminal 2P —...

  • Page 604

    CONTROL SYSTEM [L3 WITH TC] Circuit Open/Short Inspection WIRING HARNESS SIDE CONNECTOR acxuuw00000111 WIRING HARNESS-SIDE CONNECTOR 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1E 1A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2F 2B...

  • Page 605

    TECHNICAL DATA [L3 WITH TC] 01-50 TECHNICAL DATA [L3 WITH TC] ENGINE TECHNICAL DATA [L3 WITH TC] ....01-50–1 End of Toc WM: ENGINE ENGINE TECHNICAL DATA[L3 WITH TC] 01-50...

  • Page 606

    TECHNICAL DATA [L3 WITH TC] Item Specification Terminal B: 13—15 V Terminal P: Approx. 3—8 V Generator standard voltage [Idle, 20 °C {68 °F}] Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster) on and verify that the voltage reading increases. 70 % of the nominal output current (nominal output current: 110 A) Generator generated current minimum value [Ambient temp.

  • Page 607

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SERVICE TOOLS [L3 WITH TC] 01-60 SERVICE TOOLS [L3 WITH TC] ENGINE SST[L3 WITH TC]... 01-60–1 End of Toc ENGINE SST[L3 WITH TC] WM: ENGINE...

  • Page 608

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SERVICE TOOLS [L3 WITH TC] 1:49 L018 001 1:49 N013 102A 1:49 B019 901B 2:– 2:– 2:– O2 sensor Adapter Hose Gauge wrench (Components (Components part of 49 N013 part of 49 N013 1A0D)

  • Page 609

    SUSPENSION SECTION Toc of SCT ON-BOARD DIAGNOSTIC ..02-02 WHEEL AND TIRES..02-12 02-02 SYMPTOM FRONT SUSPENSION ..02-13 TROUBLESHOOTING ..02-03 REAR SUSPENSION .

  • Page 610

    ON-BOARD DIAGNOSTIC TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM id020200800100 With Advanced Keyless System WHEEL UNIT NO.1 NO.2 NO.3 NO.4 KEYLESS RF SIGNAL RECEIVE INSTRUMENT CLUSTER ANTENNA KEYLESS CM CAN_H CAN_L DRIVER DLC-2 acxuuw00002405 With Keyless Entry System WHEEL UNIT NO.1 NO.2 NO.3...

  • Page 611

    ON-BOARD DIAGNOSTIC TIRE PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD DIAGNOSIS id020200800200 On-Board Diagnostic (OBD) Test Description • The OBD test inspects the integrity and function of the TPMS and outputs the results when requested by the specific tests. • On-board diagnostic test also: —...

  • Page 612

    ON-BOARD DIAGNOSTIC PID/Data Monitor and Record Procedure 1. Connect the M-MDS to the DLC-2 connector. 2. After the vehicle is identified, select the following items from the initialization screen of the M-MDS. • When using the IDS (notebook PC) 1. Select the “Toolbox” tab. 2.

  • Page 613

    ON-BOARD DIAGNOSTIC DTC Table Description Page M-MDS B1342 Instrument cluster internal malfunction (See 09-02E-5 DTC B1342[INSTRUMENT CLUSTER].) B2143 ID registration failure (See 02-02-8 DTC B2143.) B2477 Instrument cluster configuration not performed (See 09-02E-5 DTC B2477[INSTRUMENT CLUSTER].) B2868 Wheel unit No.1 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870, 02-02 B2871.)

  • Page 614

    ON-BOARD DIAGNOSTIC PID Name Unit/ Condition/Specification Action (Definition) Condition FFD2_WU1_T FFD2_WU2_T FFD2_WU3_T Indicates the internal tire air °C/°F Adjust tire pressure. FFD2_WU4_T temperature. (Freeze frame PID data 2) (Internal tire air temperature value (freeze frame PID data 2)) FFD1_MLG Indicates the mileage. (Freeze frame (Wheel unit mileage value (freeze m/mi (ft) Adjust tire pressure.

  • Page 615

    ON-BOARD DIAGNOSTIC MALFUNCTIONING WHEEL UNIT IDENTIFICATION id020200800300 Note • The tire pressure monitoring system (TPMS) does not identify the location of the malfunctioning wheel unit on the vehicle (RF, LF, LR, RR). The TPMS identifies each wheel unit as No.1, No.2, No.3 and No.4. In order to identify the location of the wheel unit, perform the following procedure.

  • Page 616

    ON-BOARD DIAGNOSTIC DTC B2143 id020200800400 • ID registration failure DTC B2143 DETECTION • Two or more codes are overlapping. CONDITION POSSIBLE • ID registration procedure has not been performed properly. CAUSE Diagnostic procedure STEP INSPECTION ACTION VERIFY THE PROGRAMMED ID Register the wheel unit ID, then go to the next step.

  • Page 617

    ON-BOARD DIAGNOSTIC DTC U0127 id020200800600 • Communication failure between instrument cluster and keyless receiver DTC U0127 DETECTION • The instrument cluster cannot receive signal from the keyless CM or keyless receiver. CONDITION With advanced keyless system • Open or short circuit in the wiring harness between the keyless CM terminal 3Q and the instrument cluster terminal 2N.

  • Page 618

    ON-BOARD DIAGNOSTIC With Keyless Entry System Diagnostic procedure STEP INSPECTION ACTION INSPECT WHEEL UNIT SIGNAL FOR OPEN Go to the next step. CIRCUIT Repair or replace the wiring harness for an open circuit • Turn the ignition switch off. between keyless receiver terminal D and instrument cluster •...

  • Page 619

    ON-BOARD DIAGNOSTIC DTC U2616, U2617, U2618, U2619 id020200800700 U2616 Wheel unit No.1 (No response) U2617 Wheel unit No.2 (No response) U2618 Wheel unit No.3 (No response) U2619 Wheel unit No.4 (No response) DETECTION • The keyless receiver has continuously not received a signal from the wheel unit for a certain period. CONDITION •...

  • Page 621

    SYMPTOM TROUBLESHOOTING 02-03 SYMPTOM TROUBLESHOOTING TIRE PRESSURE No.1 TPMS WARNING LIGHT MONITORING SYSTEM (TPMS) ILLUMINATES CONTINUOUSLY ..02-03–4 WIRING DIAGRAM ....02-03–2 No.2 TPMS WARNING LIGHT With Advanced Keyless System.

  • Page 622

    SYMPTOM TROUBLESHOOTING TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM id020300800100 With Advanced Keyless System WHEEL UNIT NO.1 NO.2 NO.3 NO.4 KEYLESS RF SIGNAL RECEIVE INSTRUMENT CLUSTER ANTENNA KEYLESS CM CAN_H CAN_L DRIVER DLC-2 acxuuw00002407 With Keyless Entry System WHEEL UNIT NO.1 NO.2 NO.3...

  • Page 623

    SYMPTOM TROUBLESHOOTING PRECAUTION id020300800300 Intermittent Concern Troubleshooting Vibration method • If malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating, perform the steps below. Note • There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for are: —...

  • Page 624

    SYMPTOM TROUBLESHOOTING Connector terminal check method 1. Check the connection condition of each female terminal. 2. Insert male terminal; fit the female terminal side to female terminal and check to see whether the malfunction is in the female terminal or not. End Of Sie acxuuw00000959 SYMPTOM TROUBLESHOOTING...

  • Page 625

    SYMPTOM TROUBLESHOOTING No.2 TPMS WARNING LIGHT (LOW PRESSURE WARNING) ILLUMINATES AFTER ENGINE START AND TURNS OFF AFTER DRIVING FOR PERIOD OF TIME id020300800600 Caution • The tire pressure cannot be measured accurately after driving for a long period due to increased internal temperature and pressure.

  • Page 626

    SYMPTOM TROUBLESHOOTING No.3 WHEEL UNIT ID REGISTRATION CANNOT BE PERFORMED (TPMS WARNING LIGHT FLASHES) id020300800900 Caution • Activate the wheel unit ID registration mode using the M-MDS, and perform the following steps if the TPMS warning light does not turn off after driving at 25 km/h {15.5 mph} or more for 10 min or more.

  • Page 627

    SYMPTOM TROUBLESHOOTING Display Of M-MDS (Example) Registered ID: 0xAAAAAAAA, 0xBBBBBBBB, 0xCCCCCCCC, and 0xDDDDDDDD (AAAAAAAA, BBBBBBBB, CCCCCCCC, and DDDDDDDD mean arbitrary numbers.) Unregistered ID: 0x00000000 Tire pressure: aaa kPa, bbb kPa, ccc kPa, ddd kPa (aaa, bbb, ccc, and ddd mean measurement value.) * The battery is removed, the stored tire pressure is reset to 0 kPa.

  • Page 628

    SYMPTOM TROUBLESHOOTING When a registered wheel unit malfunctions WU_1 WU_2 WU_3 WU_4 ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000 Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa Tire Pressure (Candidate) eee kPa fff kPa 0 kPa...

  • Page 629

    SYMPTOM TROUBLESHOOTING When a replaced wheel unit and a registered wheel unit malfunction WU_1 WU_2 WU_3 WU_4 ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000 Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa Tire Pressure (Candidate) eee kPa...

  • Page 631

    GENERAL PROCEDURES 02-10 GENERAL PROCEDURES PRECAUTION (SUSPENSION)..02-10–1 Brake Lines Wheels and Tires Disconnection/Connection ..02-10–1 Removal/Installation....02-10–1 Power Steering Components Suspension Links Removal/Installation .

  • Page 633: Wheel Alignment

    WHEEL ALIGNMENT 02-11 WHEEL ALIGNMENT WHEEL ALIGNMENT Steering Angle Adjustment ..02-11–2 PRE-INSPECTION ....02-11–1 Camber and Caster Adjustment ..02-11–3 FRONT WHEEL ALIGNMENT .

  • Page 634

    WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT id021100800200 Front wheel alignment (Unloaded) Fuel gauge indication Item Empty Full Inner 36°06′ Maximum steering angle [Tolerance ±3°] Outer 30°54′ [Tolerance ±2 {±0.08}] (mm {in}) 0 {0.00} Total toe-in (degree) 0°00′±0°09′ [Tolerance ±1°] 3°02′ 3°05′ 3°08′...

  • Page 635

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) WHEEL ALIGNMENT Camber and Caster Adjustment 1. Remove the windshield wiper arm. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/ INSTALLATION.) 2. Remove the cowl grille. (See 09-16-11 COWL GRILLE REMOVAL/INSTALLATION.) 3. Jack up the front of the vehicle and support it on safety stands.

  • Page 636

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) WHEEL ALIGNMENT WM: REAR SUSPENSION REAR WHEEL ALIGNMENT id021100800300 Rear wheel alignment (Unloaded) Fuel gauge indication Item Empty Full [Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08} Total toe-in (degree) 0°10′±0°20′ Camber angle (Reference value) −0°51′...

  • Page 637

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) WHEEL AND TIRES 02-12 WHEEL AND TIRES WHEEL AND TIRE SPECIFICATION . . . 02-12–1 WHEEL UNIT ID REGISTRATION ..02-12–4 WHEEL BALANCE ADJUSTMENT ..02-12–2 Using M-MDS .

  • Page 638

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) WHEEL AND TIRES WHEEL BALANCE ADJUSTMENT id021200800200 Caution • Adjust the outer wheel balance first, then the inner wheel balance. • Be careful not to scratch the wheels. Adhesive-type Balance Weight (Outer) 1. Remove the old balance weight from the wheel.

  • Page 639

    WHEEL AND TIRES Knock-type Balance Weight (Inner) 1. Measure the amount of unbalance with a wheel balancer. 2. Attach a weight corresponding to the measured weight value on the position (inner) indicated by KNOCK-TYPE the wheel balancer. WHEEL CENTER OF BALANCE WEIGHT BALANCE WEIGHT Caution...

  • Page 640

    WHEEL AND TIRES WHEEL UNIT ID REGISTRATION id021200800400 Note • After the wheel unit replacement, registration of the wheel unit identification codes must be performed. • ID registration can be done using the M-MDS, or not using the M-MDS. Using M-MDS 1.

  • Page 641

    WHEEL AND TIRES 7.5—8.5 02-12 {77—86, 67—75} N·m {kgf·cm, in·lbf} acxuuw00001040 Valve cap Wheel unit (See 02-12-5 Wheel Unit Removal Note.) Valve core (See 02-12-6 Wheel Unit Installation Note.) (See 02-12-5 Valve Core Removal Note.) Seal washer Valve nut and washer Seal Valve Core Removal Note 1.

  • Page 642

    WHEEL AND TIRES Wheel Unit Installation Note 1. Insert the wheel unit valve into the valve hole so that the polyurethane foam side faces the rim. WHEEL UNIT Note • Maintain the wheel unit in contact with the rim, then start manually to screw the valve nut for a few turns.

  • Page 643: Front Suspension

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) FRONT SUSPENSION 02-13 FRONT SUSPENSION FRONT SUSPENSION FRONT STABILIZER LOCATION INDEX....02-13–2 REMOVAL/INSTALLATION ..02-13–8 FRONT SHOCK ABSORBER Front Stabilizer Installation Note .

  • Page 644

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) FRONT SUSPENSION FRONT SUSPENSION LOCATION INDEX id021300800100 acxuuw00001673 Front shock absorber and coil spring Front stabilizer (See 02-13-3 FRONT SHOCK ABSORBER AND (See 02-13-8 FRONT STABILIZER REMOVAL/ SPRING REMOVAL/INSTALLATION) INSTALLATION) (See 02-13-4 FRONT SHOCK ABSORBER AND...

  • Page 645

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) FRONT SUSPENSION FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION id021300800200 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 646

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) FRONT SUSPENSION Cap Installation Note Caution • If the pad in the strut mount area is removed, clean the attachment surface and install the cap. If the cap is not installed, the front shock absorber may corrode due to water penetration and cause a malfunction.

  • Page 647

    FRONT SUSPENSION Piston Rod Nut Disassembly Note Warning • Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under tremendous pressure and cause serious injury or death. Secure the shock absorber in the SSTs before removing the piston rod nut.

  • Page 648

    FRONT SUSPENSION Mounting Rubber Assembly Note 1. Slide the mounting rubber identification mark away from the notch of the spring seat and install. FRONT End Of Sie WM: FRONT SHOCK ABSORBER IDENTIFICATION MARK 45˚ ± 5˚ 45˚ ± 5˚ FRONT SHOCK ABSORBER BOTTOM BRACKET acxuuw00001062 FRONT SHOCK ABSORBER INSPECTION id021300800800...

  • Page 649

    FRONT SUSPENSION FRONT LOWER ARM REMOVAL/INSTALLATION id021300800600 1. Remove the under cover. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 47.0—59.0 {4.80—6.01, 7.8—10.8 N·m 34.7—43.5} {80—110 kgf·cm, 69.1—95.5 in·lbf} 02-13 85.7—100.0 {8.74—10.19, 63.21—73.75} 85.7—100.0...

  • Page 650

    FRONT SUSPENSION FRONT STABILIZER REMOVAL/INSTALLATION id021300800400 1. Remove the side cover and under cover. 2. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.) 3. Remove the transverse member. (See 02-13-14 TRANSVERSE MEMBER REMOVAL/INSTALLATION.) 4. Remove the front crossmember component. (See 02-13-10 FRONT CROSSMEMBER REMOVAL/ INSTALLATION.) 5.

  • Page 651

    FRONT SUSPENSION Stabilizer Bushing Installation Note 1. Align the outer side of the positioning plate with the stabilizer bushing. FRONT IDENTIFICATION MARK STABILIZER BUSHING 02-13 POSITIONING PLATE acxuuw00001100 Stabilizer Bracket Installation Note 1. Install the stabilizer bracket so that the arrow is pointed to the front.

  • Page 652

    FRONT SUSPENSION FRONT CROSSMEMBER REMOVAL/INSTALLATION id021300801000 1. Remove the side cover and under cover. 2. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.) 3. Remove the transverse member. (See 02-13-14 TRANSVERSE MEMBER REMOVAL/INSTALLATION.) 4. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 5.

  • Page 653

    FRONT SUSPENSION Tie-rod End Ball Joint Removal Note 1. Remove the tie-rod end ball joint locknut. 2. Disconnect the tie-rod end ball joint using the SST. 49 T028 3A0 02-13 ampjjw00003208 Steering Gear And Linkage, Front Stabilizer, Front Lower Arm And Front Crossmember Component Removal Note 1.

  • Page 654

    FRONT SUSPENSION 5. Disconnect the return hose indicated in the figure. 6. Disconnect the pressure hose (power steering pump side) indicated in the figure. acxuuw00001691 Front Crossmember Mounting Rubber (front) Installation Note 1. Install the front crossmember mounting rubber (front) so that the smaller outer diameter is facing upward.

  • Page 655

    FRONT SUSPENSION Steering Gear And Linkage, Front Stabilizer, Front Lower Arm And Front Crossmember Component Installation Note 1. Raise the steering gear and linkage, front stabilizer, front lower arm and front crossmember component to the appropriately level, and install the return hose and pressure hose. Tightening torque Return hose: 7.8—...

  • Page 656

    FRONT SUSPENSION TRANSVERSE MEMBER REMOVAL/INSTALLATION id021300801100 1. Remove the transverse member. TRANSVERSE MEMBER 93.1—131.3 {9.50—13.38, 68.67—96.84} 93.1—131.3 {9.50—13.38, 119.6—154.8 68.67—96.84} {12.20—15.78, 119.6—154.8 88.3—114.1} {12.20—15.78, N·m {kgf·m, ft·lbf} 88.3—114.1} acxuuw00001674 2. Install the transverse member so that the arrow is pointing to the front of the vehicle. FRONT acxuuw00001675 3.

  • Page 657: Rear Suspension

    REAR SUSPENSION 02-14 REAR SUSPENSION REAR SUSPENSION TRAILING LINK LOCATION INDEX[2WD] ... 02-14–2 REMOVAL/INSTALLATION[AWD] ..02-14–15 REAR SUSPENSION Rear ABS Wheel-speed Sensor LOCATION INDEX[AWD] ... 02-14–3 Removal Note .

  • Page 658

    REAR SUSPENSION REAR SUSPENSION LOCATION INDEX[2WD] id0214008004a1 VIEW FROM A acxuuw00001677 Rear shock absorber Rear lateral link (See 02-14-4 REAR SHOCK ABSORBER (See 02-14-8 REAR LATERAL LINK REMOVAL/ REMOVAL/INSTALLATION.) INSTALLATION.) (See 02-14-5 REAR SHOCK ABSORBER Trailing link INSPECTION.) (See 02-14-12 TRAILING LINK REMOVAL/ (See 02-14-5 REAR SHOCK ABSORBER INSTALLATION[2WD].) DISPOSAL.)

  • Page 659

    REAR SUSPENSION REAR SUSPENSION LOCATION INDEX[AWD] id0214008004a3 02-14 VIEW FROM A acxuuw00001678 Rear shock absorber Rear lateral link (See 02-14-4 REAR SHOCK ABSORBER (See 02-14-8 REAR LATERAL LINK REMOVAL/ REMOVAL/INSTALLATION.) INSTALLATION.) (See 02-14-5 REAR SHOCK ABSORBER Rear trailing arm INSPECTION.) (See 02-14-15 TRAILING LINK REMOVAL/ (See 02-14-5 REAR SHOCK ABSORBER INSTALLATION[AWD].)

  • Page 660

    REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL/INSTALLATION id021400801300 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 24.5—34.6 {2.50—3.49, 18.1—25.2} 46.1—62.7 {4.71—6.39, 34.1—46.2} 75.5—102 {7.70—10.4, 55.7—75.2} N·m {kgf·m, ft·lbf} acxuuw00001680 Retainer (See 02-14-5 Nut Removal Note) Bushing Rear shock absorber component Rear shock absorber...

  • Page 661

    REAR SUSPENSION Nut Removal Note 1. Support the rear axle with the jack. 02-14 JACK acxuuw00001975 2. Remove the service hole cover on the trunk side trim. 3. Remove the nuts. SERVICE HOLE End Of Sie COVER acxuuw00001719 REAR SHOCK ABSORBER INSPECTION id021400801400 1.

  • Page 662

    REAR SUSPENSION REAR COIL SPRING REMOVAL/INSTALLATION id021400800700 1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5.

  • Page 663

    REAR SUSPENSION 4. Support the lower arm with a jack. 5. Loosen the inner bolt of the lower arm. 6. Remove the outer bolt of the lower arm. 7. Jack down slowly and remove the coil spring. Warning • Removing the coil spring is dangerous. The coil spring could fly off, the cause serious injury or death.

  • Page 664

    REAR SUSPENSION REAR LOWER ARM REMOVAL/INSTALLATION id021400800900 1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5.

  • Page 665

    REAR SUSPENSION 2. Remove the rear lateral link. 75.5—102 {7.70—10.4, 55.7—75.2} 02-14 REAR LATERAL LINK N·m {kgf·m, ft·lbf} acxuuw00001684 3. Install the rear lateral link shown in the figure. 4. Inspect the rear wheel alignment. (See 02-11-4 SECTION A-A REAR WHEEL ALIGNMENT.) End Of Sie WM: REAR UPPER ARM FRONT...

  • Page 666

    REAR SUSPENSION REAR UPPER ARM REMOVAL/INSTALLATION id021400800800 1. Raise the trailing link to the unloaded condition with the jack. Note • Jacking up the rear suspension to the no- occupant position will lighten the force on the bushing and make it easier to perform the procedure.

  • Page 667

    REAR SUSPENSION REAR STABILIZER REMOVAL/INSTALLATION id021400800500 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 02-14 43.1—60.8 {4.40—6.19, 31.8—44.8} 43.1—60.8 {4.40—6.19, 43.1—60.8 31.8—44.8} {4.40—6.19, 31.8—44.8} RUBBER GREASE N·m {kgf·m, ft·lbf} acxuuw00001686 Stabilizer control link Bushing (See 02-14-12 Stabilizer Control Link Installation (See 02-14-12 Bushing Installation Note.)

  • Page 668

    REAR SUSPENSION Bushing Installation Note 1. Align the outer side of the marking with the stabilizer bushing. FRONT MARKING BUSHING acxuuw00001796 Stabilizer Control Link Installation Note 1. Install the control link with white marking to the left side of the vehicle. End Of Sie WM: STABILIZER CONTROL LINK (FRONT/REAR) WHITE MARKING...

  • Page 669

    REAR SUSPENSION 78.4—101.9 {8.00—10.3, 57.9—75.1} 75.5—102 {7.70—10.4, 55.7—75.2} 75.5—102 {7.70—10.4, 55.7—75.2} 02-14 9.8—14.7 N·m {100—149 kgf·cm, 87—130 in·lbf} 97.7—132.3 {9.97—13.49, 72.06—97.57} 75.5—102 {7.70—10.4, 55.7—75.2} 98—120 {10.0—12.2, 72.3—88.5} N·m {kgf·m, ft·lbf} acxuuw00001785 ABS wheel-speed sensor Bolt (rear lateral link outer side) (See 02-14-14 ABS Wheel-speed Sensor Removal (See 02-14-14 Bolts (Rear Lateral Link Outer Side Note)

  • Page 670

    REAR SUSPENSION ABS Wheel-speed Sensor Removal Note 1. Remove the rear ABS wheel-speed sensor and rear ABS wheel-speed sensor harness connected to the rear trailing link. acxuuw00001786 Caliper Component Removal Note 1. Suspend the caliper aside with cable. Bolt (Rear Shock Absorber Lower Side) Removal Note 1.

  • Page 671

    REAR SUSPENSION TRAILING LINK REMOVAL/INSTALLATION[AWD] id0214008001a3 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 672

    REAR SUSPENSION Disc plate Bolt (rear upper arm outer side) (See 04-11-22 REAR BRAKE (DISC) REMOVAL/ (See 02-14-16 Bolts (Rear Lateral Link Outer Side INSTALLATION.) And Rear Upper Arm Outer Side) Removal Note.) (See 02-14-17 Bolts (Rear Lateral Link Outer Side Bolt (rear shock absorber lower side) And Rear Upper Arm Outer Side) Installation Note.) (See 02-14-16 Bolt (Rear Shock Absorber Lower...

  • Page 673

    REAR SUSPENSION Rear Trailing Link Component Removal Note 1. Support the trailing link with a jack. Caution • Removing the trailing link is dangerous. The trailing link could fall and cause serious injury or death. Verify that the jack securely supports the trailing link. 2.

  • Page 674

    REAR SUSPENSION REAR CROSSMEMBER REMOVAL/INSTALLATION[2WD] id0214008010a1 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 675

    REAR SUSPENSION Bolt (Rear Upper Arm Outer Side And Rear Lateral Link Outer Side) Removal Note 1. Raise the rear trailing link to the unloaded condition with a jack. Note • Jacking up the rear suspension to the no- occupant position will lighten the force on the bushing and make it easier to perform the procedure.

  • Page 676

    REAR SUSPENSION REAR CROSSMEMBER REMOVAL/INSTALLATION[AWD] id0214008010a3 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 677

    REAR SUSPENSION Parking brake cable Rear trailing link and wheel hub component (See 02-14-15 TRAILING LINK REMOVAL/ Brake caliper component INSTALLATION[AWD].) (See 02-14-21 Brake Caliper Component Removal Note) Differential oil temperature sensor connector Disc plate AWD solenoid connector (See 04-11-22 REAR BRAKE (DISC) REMOVAL/ Rear crossmember and rear differential component INSTALLATION.) (See 02-14-22 Rear Crossmember And Rear...

  • Page 678

    REAR SUSPENSION Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Removal Note 1. Raise the rear trailing link to the unloaded condition with a jack. Note • Jacking up the rear suspension to the no- occupant position will lighten the force on the bushing and make it easier to perform the procedure.

  • Page 679: Technical Data

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) TECHNICAL DATA 02-50 TECHNICAL DATA SUSPENSION TECHNICAL DATA ..02-50–1 End of Toc SUSPENSION TECHNICAL DATA WM: SUSPENSION id025000800100 Front wheel alignment (Unloaded) Fuel gauge indication Item 02-50 Empty Full Inner 36°06′...

  • Page 680

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) TECHNICAL DATA Wheel and tire Item Specification Standard tire and wheel 18 × 7 1/2J Size Offset (mm {in}) 50 {1.97} Wheel Pitch circle diameter (mm {in}) 114.3 {4.50} Material Aluminum alloy Size P235/60R18 102H 235/60R18 103H (Mexico spec.)

  • Page 681

    SERVICE TOOLS 02-60 SERVICE TOOLS SUSPENSION SST ....02-60–1 End of Toc SUSPENSION SST WM: SUSPENSION id026000800100 49 T034 1A0 49 T028 3A0 49 FT01 389 Coil spring Ball Joint Puller Preload adapter...

  • Page 683

    DRIVELINE/AXLE SECTION Toc of SCT ON-BOARD DIAGNOSTIC ..03-02 DIFFERENTIAL ... . 03-14 SYMPTOM PROPELLER SHAFT ..03-15 TROUBLESHOOTING ..03-03 TRANSFER .

  • Page 684

    ON-BOARD DIAGNOSTIC ELECTRONIC AWD CONTROL SYSTEM ON-BOARD DIAGNOSIS id030200800200 Reading DTCs Procedure 1. Connect the M-MDS to the DLC-2 connector. 2. After the vehicle is identified, select the following items from the initialization screen of the M-MDS. • When using the IDS (notebook PC) 1.

  • Page 685

    ON-BOARD DIAGNOSTIC DTC P1887 id030200800300 P1887 AWD solenoid circuit • Current detection circuit in AWD CM detects current above specification for more than specified period. • AWD CM detects that AWD solenoid control signal differs from current detected at current detection DETECTION circuit for more than specified period.

  • Page 686

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT AWD SOLENOID CONDITION Go to next step. • Turn ignition key to OFF. Replace AWD solenoid, then go to Step 7. • Disconnect AWD solenoid connector. • Inspect AWD solenoid. (See 03-19-11 AWD SOLENOID INSPECTION) •...

  • Page 687

    ON-BOARD DIAGNOSTIC DTC P1888 id030200800400 P1888 Differential oil temperature sensor circuit DETECTION • Differential oil temperature sensor voltage monitor circuit detects abnormal input voltage. CONDITION • Open circuit, or short to battery or GND between AWD CM terminal A and differential oil temperature sensor terminal A •...

  • Page 688

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT DIFFERENTIAL OIL Go to next step. TEMPERATURE SENSOR CONDITION Replace differential oil temperature sensor, then go to Step • Turn ignition key to OFF. • Disconnect differential oil temperature sensor connector. • Is it okay? INSPECT AWD CM TO DIFFERENTIAL OIL Go to next step.

  • Page 689

    SYMPTOM TROUBLESHOOTING 03-03 SYMPTOM TROUBLESHOOTING ELECTRONIC AWD CONTROL NO.1 FREQUENT FRONT WHEEL SYSTEM WIRING DIAGRAM ..03-03–1 SLIP ......03-03–3 FOREWORD .

  • Page 690

    SYMPTOM TROUBLESHOOTING FOREWORD id030300800200 Malfunction vehicle delivered Confirm all customer problems using a questionnaire. Questionnaire Verify malfunction symptoms Confirm malfunction on actual vehicle. DTC inspection Inspect for DTCs using M-MDS. Symptom troubleshooting Perform applicable troubleshooting inspection according to diagnostic index. Verify that malfunctions have been repaired Troubleshooting completed acxuuw00001066...

  • Page 691

    SYMPTOM TROUBLESHOOTING NO.1 FREQUENT FRONT WHEEL SLIP id030300800400 Frequent front wheel slip [TROUBLESHOOTING HINTS] • Tire traction performance is extremely poor for given road friction. (AWD system is normal.) • Improper wheel alignment (AWD system is normal.) • Rear differential oil temperature is extremely high (Fail-safe condition) •...

  • Page 692

    SYMPTOM TROUBLESHOOTING NO.2 TIGHT CORNER BRAKING id030300800500 Tight corner braking [TROUBLESHOOTING HINTS] • Because the coupling component locks up easily (similar to direct AWD), rotational difference between the front and rear wheels cannot be absorbed and brake-like phenomenon occurs. • Due to the coupling component construction, slight tight corner braking effect occurs during tight cornering on a paved road.

  • Page 693

    SYMPTOM TROUBLESHOOTING NO.3 ABNORMAL NOISE AND/OR VIBRATION FROM COUPLING COMPONENT id030300800600 Abnormal noise and/or vibration from coupling component [TROUBLESHOOTING HINTS] • Abnormal noise and/or vibration from coupling component during driving • Propeller shaft is malfunctioning or attached improperly. • Engine mount or differential mount malfunction •...

  • Page 695

    GENERAL PROCEDURES 03-10 GENERAL PROCEDURES GENERAL PROCEDURES Suspension Links (FRONT AND REAR AXLES) ..03-10–1 Removal/Installation ....03-10–1 Wheel and Tire Installation ..03-10–1 Connector Disconnection .

  • Page 697: Front Axle

    FRONT AXLE 03-11 FRONT AXLE FRONT AXLE LOCATION INDEX..03-11–1 Brake Caliper Removal Note ..03-11–4 FRONT WHEEL HUB BOLT Wheel Hub Removal Note... 03-11–5 REPLACEMENT.

  • Page 698

    FRONT AXLE FRONT WHEEL HUB BOLT REPLACEMENT id031100800200 1. Remove the brake calliper component from the steering knuckle and suspend it out of the way using a cable. 2. Remove the disc plate. 3. Tap the dust cover (the part shown in the figure) with a chisel lightly and bend the processing point back to the steering knuckle side.

  • Page 699

    FRONT AXLE WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION id031100800400 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed sensor connector (axle side) and fix the wiring harness to an appropriate place where it will not be pulled by mistake while servicing the vehicle.

  • Page 700

    FRONT AXLE Retaining ring Steering knuckle Wheel bearing Wheel hub bolt (See 03-11-5 Wheel Bearing Removal Note.) (See 03-11-6 Wheel Hub Bolt Removal Note.) (See 03-11-7 Wheel Bearing Installation Note.) (See 03-11-6 Wheel Hub Bolt Installation Note.) Dust cover (See 03-11-5 Dust Cover Removal Note.) (See 03-11-6 Dust Cover Installation Note.) Locknut Removal Note 1.

  • Page 701

    FRONT AXLE Wheel Hub Removal Note 1. Remove the wheel hub using the SSTs. Substitution SST 49 G033 102 49 G033 105 • 49 G033 105 Outer diameter: 37— 43 mm {1.5— 1.6 in} 49 F026 103 03-11 acxuuw00001117 2. If the bearing inner race remains on the front wheel hub component, grind a section of the bearing inner race until approx.

  • Page 702

    FRONT AXLE 2. Remove the dust cover using a chisel. acxuuw00001121 Wheel Hub Bolt Removal Note Note • The hub bolts do not need to be removed unless they are being replaced. 1. Remove the hub bolt using a press. acxuuw00001122 Wheel Hub Bolt Installation Note 1.

  • Page 703

    FRONT AXLE 3. Install the new dust cover using the SSTs. Substitution SST STEEL PLATE • 49 G033 107A 49 G033 107A Inner diameter: 98— 108 mm {3.9— 4.2 in} Tube with board thickness 3 mm {0.2 in} or more •...

  • Page 705: Rear Axle

    REAR AXLE 03-12 REAR AXLE REAR AXLE LOCATION INDEX ..03-12–1 WHEEL HUB COMPONENT REAR WHEEL HUB BOLT REMOVAL/INSTALLATION[2WD]..03-12–3 REPLACEMENT ....03-12–2 Brake Caliper Component WHEEL HUB COMPONENT Removal Note .

  • Page 706

    REAR AXLE REAR WHEEL HUB BOLT REPLACEMENT id031200800200 1. Remove the brake calliper component and suspend it out of the way using a cable. 2. Remove the disc plate. 3. Remove the parking brake shoe. 4. Remove the wheel hub bolt using the SST as shown in the figure.

  • Page 707

    REAR AXLE WHEEL HUB COMPONENT REMOVAL/INSTALLATION[2WD] id0312008004a1 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix the wiring harness to an appropriate place where it will not be pulled by mistake while servicing the vehicle.

  • Page 708

    REAR AXLE Brake Caliper Component Removal Note 1. Remove the brake caliper component from the trailing link and suspend it out of the way using a cable. Wheel Hub Bolt Removal Note Note • The wheel hub bolts do not need to be removed unless they are being replaced. 1.

  • Page 709

    REAR AXLE WHEEL HUB COMPONENT REMOVAL/INSTALLATION[AWD] id0312008004a3 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix the wiring harness to an appropriate place where it will not be pulled by mistake while servicing the vehicle.

  • Page 711: Drive Shaft

    DRIVE SHAFT 03-13 DRIVE SHAFT DRIVE SHAFT LOCATION INDEX ..03-13–2 FRONT DRIVE SHAFT JOINT SHAFT PRE-INSPECTION DISASSEMBLY/ASSEMBLY ..03-13–15 [2WD]......03-13–2 Boot Band (Wheel Side) JOINT SHAFT Disassembly Note .

  • Page 712

    DRIVE SHAFT DRIVE SHAFT LOCATION INDEX id031300800100 acxuuw00001153 Joint shaft Front drive shaft (See 03-13-2 JOINT SHAFT PRE- (See 03-13-11 FRONT DRIVE SHAFT PRE- INSPECTION[2WD]) INSPECTION) (See 03-13-3 JOINT SHAFT REMOVAL/ (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/ INSTALLATION[2WD]) INSTALLATION) (See 03-13-4 JOINT SHAFT REMOVAL/ (See 03-13-15 FRONT DRIVE SHAFT INSTALLATION[AWD]) DISASSEMBLY/ASSEMBLY)

  • Page 713

    DRIVE SHAFT 2. Turn the joint shaft by hand and verify that the bearing rotates smoothly and freely. • Replace it as necessary. End Of Sie acxuuw00001164 JOINT SHAFT REMOVAL/INSTALLATION[2WD] id0313008009a3 03-13 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake.

  • Page 714

    DRIVE SHAFT Joint Shaft Removal Note 1. Separate the right side drive shaft from the joint shaft by tapping on a brass bar inserted between them. 2. Remove the bolts. 3. Pull the joint shaft straight out. Caution • The sharp edges of the joint shaft can slice or puncture the oil seal.

  • Page 715

    DRIVE SHAFT 19—27 {1.93—2.75, 14.1—19.9} 47.0—59.0 {4.80—6.01, 34.7—43.5} 03-13 43.1—58.8 {4.40—5.99, 31.8—43.3} 42.3—60.1 {4.32—6.12, 31.2—44.3} N·m {kgf·m, ft·lbf} acxuuw00001187 Tie-rod end ball joint Joint shaft (See 02-13-10 FRONT CROSSMEMBER (See 03-13-5 Joint Shaft Removal Note) REMOVAL/INSTALLATION) Clip Stabilizer control link (lower side) (See 03-13-5 Clip Installation Note) Lower arm ball joint Joint Shaft Removal Note...

  • Page 716

    DRIVE SHAFT 2. After installation, measure the outer diameter. If it exceeds the specification, repeat Step 1 using a new clip. CLIP Outer diameter specification 34.0 mm {1.34 in} max. OPENING End Of Sie OUTER DIAMETER acxuuw00001189 JOINT SHAFT DISASSEMBLY[2WD] id0313008010a3 1.

  • Page 717

    DRIVE SHAFT Dust Seal (Differential Side) Disassembly Note 1. Remove the dust seal using a flathead screwdriver. Bearing Disassembly Note 1. Remove the bearing using a press and the SSTs. Substitution SST • 49 B014 001 49 B014 001 Outer diameter: 47— 55 mm {1.9— 2.1 in} •...

  • Page 718

    DRIVE SHAFT Bearing Disassembly Note 1. Remove the bearing from the joint shaft using a press. End Of Sie BEARING acxuuw00001354 JOINT SHAFT ASSEMBLY[2WD] id0313008011a3 1. Assemble in the order indicated in the table. 7.8—10.8 N·m {80—110 kgf·cm, 69.1—95.5 in·lbf} acxuuw00001348 Bearing housing Dust seal (axle side)

  • Page 719

    DRIVE SHAFT Dust Seal (Differential Side) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the dust seal (differential side) using a press and the SSTs. 49 G030 797 Substitution SST • 49 B025 004 Outer diameter: 58— 59.8 mm {2.2— 2.3 in} 49 B025 004 or less Inner diameter: 53 mm {2.1 in} or more...

  • Page 720

    DRIVE SHAFT JOINT SHAFT ASSEMBLY[AWD] id0313008011a5 1. Assemble in the order indicated in the table. acxuuw00001355 Bearing housing Joint shaft (See 03-13-10 Joint Shaft Assembly Note) Bearing (See 03-13-10 Bearing Assembly Note) Clip Snap ring Dust seal (See 03-13-11 Dust Seal Assembly Note) Bearing Assembly Note 1.

  • Page 721

    DRIVE SHAFT Dust Seal Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new dust seal using a press and the SSTs. Substitution SST • 49 G028 203 Outer diameter: 64 mm {2.5 in} or more Inner diameter: 57.6—...

  • Page 722

    DRIVE SHAFT FRONT DRIVE SHAFT REMOVAL/INSTALLATION id031300800300 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.

  • Page 723

    DRIVE SHAFT Locknut Removal Note 1. Lock the hub by applying the brakes. 2. Knock the crimped portion of the locknut outward using a small chisel and a hammer. 3. Remove the locknut. 03-13 acxuuw00001114 Front Drive Shaft Removal Note 1.

  • Page 724

    DRIVE SHAFT 2. After installation, measure the outer diameter. If it exceeds the specification, repeat Steps 1— 2 using a new clip. CLIP Clip outer diameter specification LH: 33.5 mm {1.32 in} OPENING RH (joint shaft): 34.0 mm {1.34 in} OUTER DIAMETER acxuuw00001225...

  • Page 725

    DRIVE SHAFT FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY id031300800400 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 03-13 RIGHT SIDE acxuuw00001241 Boot band (wheel side) Snap ring (See 03-13-16 Boot Band (Wheel Side) (See 03-13-17 Snap Ring, Tripod Joint Disassembly Disassembly Note.) Note.)

  • Page 726

    DRIVE SHAFT Boot Band (Wheel Side) Disassembly Note Note • The boot band does not need to be removed unless it is being replaced. 1. Remove the boot clamp with end clamp pliers as shown and discard the clamp. acxuuw00001242 Boot Band (Transaxle Side) Disassembly Note 1.

  • Page 727

    DRIVE SHAFT Snap Ring, Tripod Joint Disassembly Note 1. Mark the shaft and tripod joint for proper assembly. 2. Remove the snap ring using snap-ring pliers. 3. Remove the tripod joint from the shaft. Caution • Do not tap the tripod joint with a hammer. MARK 03-13 acxuuw00001246...

  • Page 728

    DRIVE SHAFT Tripod Joint, Snap Ring Assembly Note 1. Align the marks and install the tripod joint using a bar and a hammer. MARK 2. Install the new snap ring using snap-ring pliers. Caution • Be sure the snap ring engages correctly in the groove of the shaft.

  • Page 729

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) DRIVE SHAFT Boot Band (Wheel Side) Assembly Note 1. Adjust clearance A by turning the adjusting bolt of the SST. Clearance A ADJUSTING BOLT 2.9 mm {0.11 in} 49 T025 001 03-13 acxuuw00001251 2. Crimp the wheel side small boot band using the SST.

  • Page 730

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) DRIVE SHAFT REAR DRIVE SHAFT REMOVAL/INSTALLATION id031300800600 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the...

  • Page 731

    DRIVE SHAFT Clip Installation Note 1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does not exceed the specification on installation. 2. After installation, measure the outer diameter. If it exceeds the specification, repeat Steps 1—...

  • Page 732

    DRIVE SHAFT Boot Band (Wheel Side) Disassembly Note Note • The boot band does not need to be removed unless it is being replaced. 1. Remove the boot clamp with end clamp pliers as shown and discard the clamp. acxuuw00001242 Boot Band (Differential Side) Disassembly Note 1.

  • Page 733

    DRIVE SHAFT Balls, Inner Ring, Cage Disassembly Note 1. Mark the inner ring and cage for proper reassembly. Caution • Mark with paint; do not use a punch. 2. Turn the cage approx. 22.5° and pull the cage 22.5° and balls from the inner ring. 03-13 acxuuw00001298 Boot Assembly Note...

  • Page 734

    DRIVE SHAFT Outer Ring, Clip Assembly Note 1. Fill the outer ring and boot (differential side) with the specified grease. Caution • Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

  • Page 735

    DRIVE SHAFT Boot Band (Wheel Side) Assembly Note 1. Adjust clearance A by turning the adjusting bolt of the SST. Clearance A ADJUSTING BOLT 2.9 mm {0.11 in} 49 T025 001 03-13 acxuuw00001251 2. Crimp the wheel side small boot band using the SST.

  • Page 737

    DIFFERENTIAL 03-14 DIFFERENTIAL REAR DIFFERENTIAL Bearing Inner Race (Rear Bearing) LOCATION INDEX....03-14–1 Disassembly Note ....03-14–8 DIFFERENTIAL OIL INSPECTION .

  • Page 738

    DIFFERENTIAL DIFFERENTIAL OIL INSPECTION id031400800100 1. Place the vehicle on level ground. 2. Remove the filler plug and washer. 3. Verify that the oil is at the brim of the filler plug FILLER PLUG hole. 4. If it is low, add the specified oil. 5.

  • Page 739

    DIFFERENTIAL 5. Remove the oil seal from the differential casing using a screwdriver. 6. Apply differential oil to the new oil seal lip. acxuuw00001378 03-14 7. Install the new oil seal to the differential carrier using the SSTs. Substitution SST •...

  • Page 740

    DIFFERENTIAL 6. Pull the companion flange off using the SST. 7. Remove the oil seal from the differential carrier 49 0839 425C using a screwdriver or similar tool. 8. Apply differential oil to the new oil seal lip. acxuuw00001375 9. Install the new oil seal to the differential carrier using the SST.

  • Page 741

    DIFFERENTIAL REAR DIFFERENTIAL REMOVAL/INSTALLATION id031400800400 1. Drain the rear differential oil into a container. 2. Remove the main silencer and middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove the propeller shaft. (See 03-15-3 PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the rear drive shaft. (See 03-13-20 REAR DRIVE SHAFT REMOVAL/INSTALLATION.) 5.

  • Page 742

    DIFFERENTIAL REAR DIFFERENTIAL DISASSEMBLY id031400800500 Warning • The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a tilted condition, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted condition.

  • Page 743

    DIFFERENTIAL Side bearing inner race Oil seal (See 03-14-9 Side Bearing Inner Race Disassembly Gear case Note) Rear Cover Disassembly Note 1. Install the SSTs to the engine stand. 49 L027 0A2 03-14 49 0107 680A acxuuw00001406 2. Install the rear differential to the SSTs. 3.

  • Page 744

    DIFFERENTIAL Locknut Disassembly Note 1. Remove the locknut using the SSTs. 49 L027 006 49 L027 007 acxuuw00001410 Drive Pinion Disassembly Note 1. Remove the drive pinion by lightly tapping with a copper hammer. acxuuw00001411 Bearing Inner Race (Rear Bearing) Disassembly Note 1.

  • Page 745

    DIFFERENTIAL Ring Gear Disassembly Note 1. Secure the gear case in a vice and remove the bolts. 2. Lightly tap around the ring gear using a plastic hammer to remove the ring gear from the gear case. 03-14 acxuuw00001414 Side Bearing Inner Race Disassembly Note Note •...

  • Page 746

    DIFFERENTIAL REAR DIFFERENTIAL ASSEMBLY id031400800600 Warning • The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a tilted condition, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted condition.

  • Page 747

    DIFFERENTIAL Bearing inner race (front bearing) Spacer (See 03-14-13 Spacer, Bearing Inner Race Side bearing outer race Assembly Note) Rear differential component Collapsible spacer Adjusting shim (R) Drive pinion Bearing cap Locknut (See 03-14-17 Bearing Cap Assembly Note) (See 03-14-15 Locknut Assembly Note) Rear cover Washer (See 03-14-18 Rear Cover Assembly Note)

  • Page 748

    DIFFERENTIAL Ring Gear Assembly Note Caution • The differential gear and ring gear could be damaged if the ring gear is installed with old thread- locking compound remaining on the bolt threads. Before installing the ring gear, completely remove the old thread-locking compound from the bolt threads. 1.

  • Page 749

    DIFFERENTIAL Spacer, Bearing Inner Race Assembly Note Pinion height adjustment Note • Use the same spacer. • Install the spacer with the chamfer on the SST side. 1. Assemble the spacer, the bearing inner race (rear bearing), and the SST O-ring to the SST (49 8531 49 0305 555 565) as shown in the figure.

  • Page 750

    DIFFERENTIAL 9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

  • Page 751

    DIFFERENTIAL Locknut Assembly Note Drive pinion preload adjustment 1. Apply differential oil to a new locknut. 2. Assemble a new collapsible spacer, bearing inner race (front bearing), spacer and locknut to the drive pinion, and temporarily tighten the locknut. 3. Turn the serrated part of the drive pinion by hand to seat the bearing. 4.

  • Page 752

    DIFFERENTIAL 7. If the combined thickness of the previously installed adjusting shims is not between C1 and C2, or if the adjusting shims have to be replaced, select two appropriate adjusting shims from the table below. Adjusting shim thickness Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})

  • Page 753

    DIFFERENTIAL Bearing Cap Assembly Note 1. Align the bearing cap alignment marks to assemble the bearing cap. Tightening torque 38— 51 N·m {3.9— 5.2 kgf·m, 28.1— 37.0 ft·lbf} 2. Inspect the drive pinion and ring gear teeth contact points. MARK 03-14 acxuuw00001432 (1) Coat both surfaces of the ring gear uniformly...

  • Page 754

    DIFFERENTIAL Rear Cover Assembly Note Caution • Clean away the old sealant before applying the new sealant. • Install the rear differential within 10 minutes after applying sealant. • Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.

  • Page 755: Propeller Shaft

    PROPELLER SHAFT 03-15 PROPELLER SHAFT PROPELLER SHAFT PROPELLER SHAFT LOCATION INDEX....03-15–1 REMOVAL/INSTALLATION ..03-15–3 PROPELLER SHAFT Bolt and Nut Removal Note.

  • Page 756

    PROPELLER SHAFT PROPELLER SHAFT ON-VEHICLE INSPECTION id031500800200 Joint Area Excessive Play Inspection 1. Shake the universal joint by hand and verify that there is no excessive play. 2. If there is any excessive play, replace the propeller shaft. (See 03-15-3 PROPELLER SHAFT REMOVAL/INSTALLATION.) ampjjw00003160 Propeller Shaft Runout Inspection...

  • Page 757

    PROPELLER SHAFT PROPELLER SHAFT REMOVAL/INSTALLATION id031500800300 1. Remove the negative battery cable. 2. Remove the middle pipe, and front pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove in the order indicated in the figure. 4. Install in the reverse order of removal. 49.0—58.0 {5.0—5.9, 37—42} 03-15 49.0—58.0 {5.0—5.9, 37—42}...

  • Page 758

    PROPELLER SHAFT Bolt and Nut Removal Note Caution • Do not mark with a punch to prevent imbalance. 1. Before removing the nut, place alignment marks FRONT REAR on the companion flange (front) and constant velocity joint, and on the companion flange (rear) and yoke.

  • Page 759

    PROPELLER SHAFT PROPELLER SHAFT INSPECTION id031500800500 1. Measure the propeller shaft center runout using the dial gauge. • If it exceeds the maximum specification, replace the propeller shaft as a single component. Maximum propeller shaft runout 0.8 mm {0.031 in} 03-15 acxuuw00000573 2.

  • Page 761

    TRANSFER 03-16 TRANSFER TRANSFER LOCATION INDEX ..03-16–1 TRANSFER OIL COOLER TRANSFER OIL INSPECTION ..03-16–2 REMOVAL/INSTALLATION ..03-16–3 TRANSFER OIL REPLACEMENT .

  • Page 762

    TRANSFER TRANSFER OIL INSPECTION id031600800200 1. Park the vehicle on level ground. 2. Remove the oil level plug and with the washer. 3. Verify that the oil is near the brim of the plug port. • If the oil level is low, add the specified amount and type of oil through the oil level plug hole.

  • Page 763

    TRANSFER TRANSFER OIL COOLER REMOVAL/INSTALLATION id031600800500 1. Disconnect the propeller shaft from the transfer side. (See 03-15-3 PROPELLER SHAFT REMOVAL/ INSTALLATION.) 2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].) 3. Drain the transfer oil into a suitable container. (See 03-16-2 TRANSFER OIL REPLACEMENT.) 4.

  • Page 764

    TRANSFER 38—51 {3.9—5.2, 29—37} 7.8—10.8 N·m 42—62 {80—110 kgf·cm, {4.3—6.3, 70—95 in·lbf} 31—45} 64—89 {6.6—9.0, 48—65} 19—27 {2.0—2.7, 15—19} 47.0—59.0 93.1—116.6 {4.80—6.01, {9.50—11.88, 34.7—43.5} 68.7—85.9} 42.3—60.1 {4.32—6.12, 85.3—116.6 31.2—44.3} {8.70—11.88, 62.9—85.9} 43.1—58.8 {4.40—5.99, 18.6—26.5 31.8—43.3} {1.9—2.7, 14—19} 93.1—131.3 42.3—60.1 {9.5—13.3, 68.7—96.8} {4.32—6.12, 31.2—44.3} 119.6—154.8...

  • Page 765

    TRANSFER Drive shaft WU-TWC (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/ (See 01-15-2 EXHAUST SYSTEM REMOVAL/ INSTALLATION.) INSTALLATION[L3 WITH TC].) Transfer bracket Heat shield HO2S (front) Joint shaft (See 01-15-2 EXHAUST SYSTEM REMOVAL/ (See 03-13-4 JOINT SHAFT REMOVAL/ INSTALLATION[L3 WITH TC].) INSTALLATION[AWD].) WU-TWC bracket Transfer...

  • Page 767

    ALL WHEEL DRIVE (AWD) 03-19 ALL WHEEL DRIVE (AWD) ELECTRONIC AWD CONTROL Companion Flange SYSTEM LOCATION INDEX..03-19–1 Disassembly Note ....03-19–6 AWD CONTROL MODULE Output Shaft Disassembly Note .

  • Page 768

    ALL WHEEL DRIVE (AWD) AWD CONTROL MODULE INSPECTION id031900800200 Note • AWD CM terminal voltage can vary depending on measuring conditions and vehicle aging, resulting in misdiagnosis. Therefore, it is necessary to perform an overall inspection of the input/output systems and AWD CM to determine which part is malfunctioning.

  • Page 769

    ALL WHEEL DRIVE (AWD) Input/ Connected Measuring Voltage (V)/ Inspection location Terminal Signal Test condition output item Continuity in case of failure • AWD solenoid Ignition key ON AWD solenoid • Inspect related Output AWD solenoid Voltage Ignition key OFF 1.0 or below harness End Of Sie...

  • Page 770

    ALL WHEEL DRIVE (AWD) COUPLING COMPONENT REMOVAL/INSTALLATION id031900800400 1. Drain the rear differential oil into a container. 2. Remove the main silencer and middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].) 3. Remove the propeller shaft. (See 03-15-3 PROPELLER SHAFT REMOVAL/INSTALLATION.) 4.

  • Page 771

    ALL WHEEL DRIVE (AWD) Coupling Component Installation Note Note • Clean away the old sealant before applying the new sealant. • Install the coupling unit within 10 min after applying sealant. • Allow the sealant to set at least 30 min after installation before filling the differential with the specified oil. 1.

  • Page 772

    ALL WHEEL DRIVE (AWD) Output shaft Shim (See 03-19-7 Output Shaft Disassembly Note) Snap ring Coupling component Bearing Oil seal (See 03-19-7 Bearing Disassembly Note) Coupling case Locknut Disassembly Note 1. Assemble the SSTs to the engine stand. 49 L027 0A2 49 0107 680A acxuuw00001444 2.

  • Page 773

    ALL WHEEL DRIVE (AWD) Output Shaft Disassembly Note 1. Remove the coupling unit from the SST. 2. Install the coupling unit to the press as shown, and remove the output shaft together with the coupling unit. 3. Install the companion flange to the output shaft. 03-19 acxuuw00001448 4.

  • Page 774

    ALL WHEEL DRIVE (AWD) COUPLING COMPONENT ASSEMBLY id031900800600 Warning • The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a tilted condition, the self-lock mechanism could become inoperative. If the coupling unit unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted condition.

  • Page 775

    ALL WHEEL DRIVE (AWD) Output Shaft Assembly Note 1. Install the output shaft to the coupling unit and partially tighten the bolts. 2. Install the companion flange to the output shaft. 3. Secure the companion flange using the SST, and tighten the bolts.

  • Page 776

    ALL WHEEL DRIVE (AWD) Companion Flange Assembly Note 1. Install the coupling case to the SSTs as shown. 2. Install the companion flange. 49 L027 0A2 acxuuw00002358 Locknut Assembly Note 1. Secure the companion flange using the SST, and tighten a new locknut. 49 S120 710 Tightening torque 167—...

  • Page 777

    ALL WHEEL DRIVE (AWD) End Of Sie DIFFERENTIAL OIL TEMPERATURE SENSOR REMOVAL/INSTALLATION id031900800800 Warning • Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is hot. 1. Disconnect the negative battery cable. 2. Disconnect the differential oil temperature sensor connector. 3.

  • Page 779

    TECHNICAL DATA 03-50 TECHNICAL DATA DRIVELINE/AXLE TECHNICAL DATA . . 03-50–1 End of Toc DRIVELINE/AXLE TECHNICAL DATA WM: DRIVELINE/AXLE id035000800100 Item Specification Front wheel bearing maximum play 0.05 mm {0.002 in} Rear wheel bearing maximum play 0.05 mm {0.002 in} LH: 658.2—668.2 mm {25.92—26.30 in} Front drive shaft length RH: 621.2—631.2 mm {24.46—24.85 in}...

  • Page 781

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SERVICE TOOLS 03-60 SERVICE TOOLS DRIVELINE/AXLE SST ....03-60–1 End of Toc DRIVELINE/AXLE SST WM: DRIVELINE/AXLE id036000800200 49 T028 3A0 49 G033 102...

  • Page 782

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) SERVICE TOOLS 49 L027 006 49 L027 007 49 F401 331 Serrate socket Hex socket Bearing installer body 49 M005 797 49 F027 007 49 8531 565 φ Oil seal installer Attachment Drive pinion...

  • Page 783: Parking Brake

    BRAKES SECTION Toc of SCT ON-BOARD DIAGNOSTIC ..04-02 PARKING BRAKE SYMPTOM SYSTEM....04-12 TROUBLESHOOTING ..04-03 DYNAMIC STABILITY GENERAL PROCEDURES .

  • Page 784

    ON-BOARD DIAGNOSTIC SYSTEM WIRING DIAGRAM id040200804800 ABS 2 20A IG 1 ABS 1 40A COMBINED SENSOR DSC 7.5A IG SW BATTERY STEERING ANGLE SENSOR BRAKE SYSTEM ABS WARNING LIGHT WARNING LIGHT CAN_L CAN_H TSC OFF LIGHT DSC HU/CM DSC INDICATOR LIGHT DRIVER CAN_H...

  • Page 785

    ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSIS id040200800200 On-Board Diagnostic (OBD) Test Description • The OBD test inspects the integrity and function of the DSC and outputs the results when requested by the specific tests. • On-board diagnostic test also: — Provides a quick inspection of the DSC usually performed at the start of each diagnostic procedure. —...

  • Page 786

    ON-BOARD DIAGNOSTIC PID/Data Monitor and Record Procedure 1. Connect the M-MDS to the DLC-2 connector. 2. After the vehicle is identified, select the following items from the initialization screen of the M-MDS. • When using the IDS (notebook PC) 1. Select the “Toolbox” tab. 2.

  • Page 787

    ON-BOARD DIAGNOSTIC DTC Table System malfunction location Page M-MDS B1317 Power supply system (See 04-02-9 DTC B1317, B1318.) B1318 Power supply system (See 04-02-9 DTC B1317, B1318.) B1342 DSC HU/CM system (See 04-02-11 DTC B1342, C1730.) B1484 Brake switch system (See 04-02-11 DTC B1484, C1954.) C1095 Pump motor, motor relay system...

  • Page 788

    ON-BOARD DIAGNOSTIC System malfunction location Page M-MDS (See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951, C1281 Combined sensor system C1952, C1959, C2768.) (See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951, C1282 Combined sensor system C1952, C1959, C2768.) C1288 Brake fluid pressure sensor system (See 04-02-27 DTC C1288, C1290, C1953.) C1290 Brake fluid pressure sensor system...

  • Page 789

    ON-BOARD DIAGNOSTIC PID name Operation condition DSC HU/CM Unit/Condition Action (definition) (reference) terminal • Brake pedal depressed: BOO_ABS Inspect the brake switch. (Brake pedal switch On/Off (See 04-11-9 BRAKE SWITCH • Brake pedal released: Off input) INSPECTION.) CCNTABS Perform the DTC inspection. (Number of continuous —...

  • Page 790

    ON-BOARD DIAGNOSTIC PID name Operation condition DSC HU/CM Unit/Condition Action (definition) (reference) terminal • Solenoid valve activated: V_RF_OTL Inspect the DSC HU/CM. (Right front outlet On/Off (See 04-15-4 DSC SYSTEM — • Solenoid valve not solenoid valve output INSPECTION.) state) activated: Off •...

  • Page 791

    ON-BOARD DIAGNOSTIC Active Command Modes Table Operating Command name Output part Operation condition LATACCEL Combined sensor (lateral acceleration) initialization FALSE/TRUE PMP_MOTOR Pump motor On/Off SAS_CAL Steering angle sensor initialization FALSE/TRUE STAB_IND DSC indicator light TRAC OFF TCS OFF light V_LF_INL LF inlet solenoid valve V_LF_OTL LF outlet solenoid valve...

  • Page 792

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT BATTERY VOLTAGE Make sure that battery terminal connection is normal. • Is the battery terminal voltage normal? Go to the next step. Charge or replace the battery, then go to Step 6. (See 01-17-4 BATTERY RECHARGING[L3 WITH TC].) (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)

  • Page 793

    ON-BOARD DIAGNOSTIC DTC B1342, C1730 id040200800400 B1342, C1730 DSC HU/CM system • B1342 — The DSC HU/CM on-board diagnostic function detects control module malfunction. DETECTION • C1730 CONDITION — Excess current is detected in the power supply circuit of the ABS wheel-speed sensor. POSSIBLE •...

  • Page 794

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT DSC HU/CM TO BRAKE SWITCH Go to the next step. FOR OPEN CIRCUIT Repair or replace the wiring harness for open circuit • Turn the ignition switch off. between DSC HU/CM and brake switch, then go to the next •...

  • Page 795

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT ABS FUSE CONDITION Go to the next step. • Is the ABS 1 40A fuse normal? Replace the fuse, then go to Step 5. INSPECT MOTOR RELAY POWER SUPPLY Go to the next step. FOR OPEN CIRCUIT Repair or replace the wiring harness for open circuit •...

  • Page 796

    ON-BOARD DIAGNOSTIC DTC C1141, C1142, C1143, C1144 id040200801000 C1141 LF ABS sensor rotor system C1142 RF ABS sensor rotor system C1143 LR ABS sensor rotor system C1144 RR ABS sensor rotor system DETECTION • Periodic abnormality is detected in the signal wave pattern from the ABS wheel-speed sensors. CONDITION •...

  • Page 797

    ON-BOARD DIAGNOSTIC DTC C1145, C1155, C1165, C1175 id040200801100 C1145 RF ABS wheel-speed sensor (open circuit) system C1155 LF ABS wheel-speed sensor (open circuit) system C1165 RR ABS wheel-speed sensor (open circuit) system C1175 LR ABS wheel-speed sensor (open circuit) system •...

  • Page 798

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT PID TO VERIFY THAT WHEEL Go to Step 3. SPEED-SIGNALS ARE TRANSMITTED FROM Go to the next step. ABS WHEEL- SPEED SENSOR USING M- • Turn the ignition switch off. • Connect the M-MDS to the DLC-2. •...

  • Page 799

    ON-BOARD DIAGNOSTIC DTC C1148, C1158, C1168, C1178 id040200801200 C1148 RF ABS wheel-speed sensor/ABS sensor rotor system C1158 LF ABS wheel-speed sensor/ABS sensor rotor system C1168 RR ABS wheel-speed sensor/ABS sensor rotor system C1178 LR ABS wheel-speed sensor/ABS sensor rotor system •...

  • Page 800

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT PID FOR ABNORMAL OUTPUT Go to Step 4. FROM ABS WHEEL-SPEED SENSOR USING If there is a difference in speeds of the four wheels, go to the M-MDS next step. • Turn the ignition switch off. •...

  • Page 801

    ON-BOARD DIAGNOSTIC DTC C1186, C1266 id040200801300 C1186, C1266 Valve relay system • C1186 — DSC HU/CM internal valve relay remains OFF when valve relay ON is commanded. DETECTION • C1266 CONDITION — DSC HU/CM internal valve relay remains ON (stuck) when valve relay OFF is commanded. •...

  • Page 802

    ON-BOARD DIAGNOSTIC DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254, C1400, C1410, C1957, C1958 id040200801400 C 1194 LF outlet solenoid valve system C 1198 LF inlet solenoid valve system C 1210 RF outlet solenoid valve system C 1214 RF inlet solenoid valve system C 1242 LR outlet solenoid valve system C 1246...

  • Page 803

    ON-BOARD DIAGNOSTIC ABS WHEEL-SPEED SENSOR ABS WHEEL-SPEED SENSOR DSC HU/CM ABS WHEEL-SPEED SENSOR ABS WHEEL-SPEED SENSOR 04-02 DSC HU/CM WIRING HARNESS-SIDE CONNECTOR ABS WHEEL-SPEED SENSOR WIRING HARNESS-SIDE CONNECTOR FRONT REAR Diagnostic procedure STEP INSPECTION ACTION INSPECT PID FOR ABS WHEEL-SPEED Go to Step 4.

  • Page 804

    ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IF MALFUNCTION OCCURRED Go to the next step. DUE TO IMPROPER SENSOR CLEARANCE. Replace the ABS wheel-speed sensor, then go to Step 4. • Inspect the clearance between the ABS (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR wheel-speed sensor and the ABS sensor REMOVAL/INSTALLATION.) rotor.

  • Page 805

    ON-BOARD DIAGNOSTIC ABS WHEEL-SPEED SENSOR ABS WHEEL-SPEED SENSOR DSC HU/CM ABS WHEEL-SPEED SENSOR ABS WHEEL-SPEED SENSOR 04-02 DSC HU/CM WIRING HARNESS-SIDE CONNECTOR ABS WHEEL-SPEED SENSOR WIRING HARNESS-SIDE CONNECTOR FRONT REAR Diagnostic procedure STEP INSPECTION ACTION INSPECT PID TO VERIFY THAT WHEEL Go to Step 3.

  • Page 806

    ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FOR OPEN CIRCUIT IN WIRING Replace the ABS wheel-speed sensor, then go to the next step. HARNESS BETWEEN DSC HU/CM AND ABS (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR WHEEL-SPEED SENSOR • Turn the ignition switch off. REMOVAL/INSTALLATION.) (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR •...

  • Page 807

    ON-BOARD DIAGNOSTIC • Open circuit in the wiring harness between ignition switch and combined sensor terminal E or short circuit to ground • Open circuit in the wiring harness between DSC HU/CM terminal Y and combined sensor terminal F or short circuit to ground •...

  • Page 808

    ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT COMBINED SENSOR POWER Go to the next step. SUPPLY FOR OPEN CIRCUIT Repair or replace the wiring harness for open circuit • Turn the ignition switch to the ON position between combined sensor terminal E and ignition switch, (engine off).

  • Page 809

    ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TEST SIGNAL FOR SHORT TO Repair or replace the wiring harness for short to ground between DSC HU/CM terminal AB and combined sensor GROUND • Turn the ignition switch off. terminal C, then go to Step 12. •...

  • Page 810

    ON-BOARD DIAGNOSTIC DTC C1295, C1307, C1937, C1938 id040200805000 C1295, C1307, C1937, C1938 Steering angle sensor system • C1295 — The steering angle sensor detects an internal abnormality. • C1307 — The steering angle sensor detects an abnormality in the signal. •...

  • Page 811

    ON-BOARD DIAGNOSTIC DTC C1306 id040200802000 Note • The steering angle initialization value of the BCM is stored using the battery power supply. Therefore, the battery power supply of the BCM is cut and the stored steering angle initialization value is cleared when any of the following items are performed.

  • Page 812

    ON-BOARD DIAGNOSTIC DTC C1414 id040200805200 C1414 Incorrect DSC HU/CM installed • Detection of situation where vehicle-type or drive system input signal and DSC HU/CM information DETECTION CONDITION remains incongruent through CAN information POSSIBLE • Mismatched installation of DSC HU/CM CAUSE Diagnostic procedure STEP INSPECTION...

  • Page 813

    SYMPTOM TROUBLESHOOTING 04-03 SYMPTOM TROUBLESHOOTING SYSTEM WIRING DIAGRAM ..04-03–2 NO.3 THERE IS A MALFUNCTION FOREWORD ..... . 04-03–3 IN THE SYSTEM EVEN THOUGH PRECAUTION .

  • Page 814

    SYMPTOM TROUBLESHOOTING SYSTEM WIRING DIAGRAM id040300800100 ABS 2 20A IG 1 ABS 1 40A COMBINED SENSOR DSC 7.5A IG SW BATTERY STEERING ANGLE SENSOR BRAKE SYSTEM ABS WARNING LIGHT WARNING LIGHT CAN_L CAN_H TSC OFF LIGHT DSC HU/CM DSC INDICATOR LIGHT DRIVER CAN_H...

  • Page 815

    SYMPTOM TROUBLESHOOTING FOREWORD id040300800200 • Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection. To check the DTC, follow the DTC Inspection steps. (See 04-02-3 ON-BOARD DIAGNOSIS.) End Of Sie PRECAUTION id040300800300 1. The ABS warning light and/or BRAKE system warning light and/or DSC indicator light and/or TCS OFF light illuminate even when the system is normal.

  • Page 816

    SYMPTOM TROUBLESHOOTING • To protect the control module, make sure the ignition is off before connecting or disconnecting the control module connector. (2) Malfunctions in hydraulic system • Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction. However, it is necessary to determine if the malfunction is in a DSC component or the conventional brake system.

  • Page 817

    SYMPTOM TROUBLESHOOTING 4. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID. • If the PID value is unstable, inspect for poor connection. acxuuw00000961 Inspection method for sensors 1. Connect the M-MDS to DLC-2. 04-03 2.

  • Page 818

    SYMPTOM TROUBLESHOOTING SYMPTOM TROUBLESHOOTING id040300800400 • Verify the symptoms, and perform troubleshooting according to the appropriate number. Symptom Any of the following lights do not illuminate when the ignition switch is turned to the ON position. • ABS warning light •...

  • Page 819

    SYMPTOM TROUBLESHOOTING x: Applicable Possible factor 04-03 Troubleshooting item Any of the following lights do not illuminate when the ignition switch is turned to the on position: (ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS OFF light). Any of the following lights remain on: (ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS OFF light).

  • Page 820

    SYMPTOM TROUBLESHOOTING NO.1 ANY OF THE FOLLOWING LIGHTS DO NOT ILLUMINATE WHEN IGNITION SWITCH TURNED TO ON POSITION: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR TCS OFF LIGHT) id040300803600 Any of the following lights do not illuminate when the ignition switch is turned to the ON position: (ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS OFF light).

  • Page 821

    SYMPTOM TROUBLESHOOTING NO.2 ANY OF THE FOLLOWING LIGHTS REMAIN ON: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR TCS OFF LIGHT) id040300803700 Any of the following lights remain on: (ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS OFF light) [TROUBLESHOOTING HINTS] •...

  • Page 822

    SYMPTOM TROUBLESHOOTING NO.3 THERE IS A MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND TCS OFF LIGHT DO NOT ILLUMINATE id040300803800 There is a malfunction in the system even though the ABS warning light, BRAKE system warning light, DSC indicator light and TCS OFF light do not illuminate.

  • Page 823

    SYMPTOM TROUBLESHOOTING NO.5 DSC OPERATES FREQUENTLY/DSC DOES NOT WORK CORRECTLY : DSC INDICATOR LIGHT GOES ON AND OFF WHILE DSC IS OPERATING id040300803500 DSC (*2) operates frequently. /DSC does not work correctly. (*2): DSC indicator light goes on and off while DSC is operating. [TROUBLESHOOTING HINTS] •...

  • Page 825

    GENERAL PROCEDURES 04-10 GENERAL PROCEDURES GENERAL PROCEDURES (BRAKE) . . . 04-10–1 DSC Related Parts ....04-10–1 Wheel and Tire Installation ..04-10–1 DSC Related Part Sensor Brake Lines Disconnection.

  • Page 826

    GENERAL PROCEDURES Steering Angle Sensor Initialization Procedure Warning • Unless the initialization procedure of the steering angle sensor is completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the power supply to the BCM has been cut off due to disconnection of the BCM connector or negative battery cable, or any other cause.

  • Page 827

    CONVENTIONAL BRAKE SYSTEM 04-11 CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT LOCATION INDEX....04-11–2 REMOVAL/INSTALLATION ..04-11–13 AIR BLEEDING .

  • Page 828

    CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM LOCATION INDEX id041100800100 acxuuw00001738 Brake fluid reserve tank Power brake unit (See 04-11-3 AIR BLEEDING.) (See 04-11-11 POWER BRAKE UNIT INSPECTION.) Vacuum line (See 04-11-13 POWER BRAKE UNIT REMOVAL/ (See 04-11-3 VACUUM LINE INSPECTION.) INSTALLATION.) (See 04-11-4 VACUUM HOSE REMOVAL/ INSTALLATION.)

  • Page 829

    CONVENTIONAL BRAKE SYSTEM AIR BLEEDING id041100800200 Caution • Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately. Note • Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding. •...

  • Page 830

    CONVENTIONAL BRAKE SYSTEM VACUUM HOSE REMOVAL/INSTALLATION id041100801600 1. Remove the clamps and vacuum hose (power brake unit side). 2. Insert a thin flathead screwdriver at the point indicated by the arrow in the figure, push the ring down and disconnect the vacuum hose from the POWER BRAKE UNIT intake manifold.

  • Page 831

    CONVENTIONAL BRAKE SYSTEM Pedal Play Inspection 1. Pump the pedal several times to release the vacuum in the power brake unit. 2. Gently depress the pedal by hand and measure the pedal play. • If not within the specification, inspect the wear of the clevis pin. Replace it if there is any malfunction. Brake pedal play 2—...

  • Page 832

    CONVENTIONAL BRAKE SYSTEM BRAKE PEDAL REMOVAL/INSTALLATION id041100801200 Caution • The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place.

  • Page 833

    CONVENTIONAL BRAKE SYSTEM Bolt, nut Pedal pad Brake pedal (See 04-11-7 Brake Pedal Removal Note.) Brake Pedal Removal Note 1. Remove the console panel. (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.) 2. Remove the console. (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.) 3. Remove the front scuff plate inner. (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.) 4.

  • Page 834

    CONVENTIONAL BRAKE SYSTEM 12. Lift up the upper side of the dashboard and move it 20 mm {0.78 in} towards the vehicle rear. Caution • If the dashboard is moved towards the vehicle rear excessively, the wiring DASHBOARD harness could be damaged. Mark the BRACKET position and verify the distance when moving the dashboard.

  • Page 835

    CONVENTIONAL BRAKE SYSTEM BRAKE SWITCH INSPECTION id041100801900 Caution • Inspect the brake switch with it installed to the brake pedal, otherwise the brake switch may not operate normally. If the brake switch is removed from the brake pedal, replace the brake switch with a new one.

  • Page 836

    CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER REMOVAL/INSTALLATION id041100801300 1. Remove the battery. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.) 4.2—6.2 {43—63, 38—54} 7.8—12.7...

  • Page 837

    CONVENTIONAL BRAKE SYSTEM BRAKE FLUID LEVEL SENSOR INSPECTION id041100801400 1. Disconnect the brake fluid level sensor connector from the master cylinder. 2. Inspect for continuity according to fluid level between the brake fluid level sensor terminals. • If not as indicated in the table, replace the No.1 reserve tank.

  • Page 838

    CONVENTIONAL BRAKE SYSTEM Using SST Pre-inspection preparation 1. Install the SST (49 N043 001) to the master TO SST cylinder in the orientation shown in the figure. 49 N043 001 FLARE NUT ACROSS FLAT Note 12 mm {0.47 in} • When installing the SST (49 N043 001) to the master cylinder, use a commercially available flare nut wrench.

  • Page 839

    CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION id041100801800 1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].) 2. Remove the battery tray bracket as shown in the figure. 3. Remove the master cylinder component. (See 04- 11-10 MASTER CYLINDER REMOVAL/ INSTALLATION.) BATTERY TRAY BRACKET...

  • Page 840

    CONVENTIONAL BRAKE SYSTEM 7. Install in the reverse order of removal. 8. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.) 9. Inspect the brake pedal. (See 04-11-4 BRAKE PEDAL INSPECTION.) 18.6—25.5 N·m {1.90—2.60 kgf·m, 13.8—18.8 ft·lbf} acxuuw00001091...

  • Page 841

    CONVENTIONAL BRAKE SYSTEM The disc plate is deformed by heat. Repeated panic braking may raise the temperature in some portions of disc plate by approx. 1,000 °C {1,832 °F}. This results in deformed disc plate. Due to corrosion, the thickness and friction coefficient of disc plate change. If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.

  • Page 842

    CONVENTIONAL BRAKE SYSTEM Thickness variation inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner. 2. Measure the points indicated in the illustration using a caliper (micrometer). 3. Subtract the minimum value from the maximum. • If the result is not within specification, machine the disc plate using a lathe. Thickness variation limit 0.015 mm {0.0005 in} Warning...

  • Page 843

    CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION id041100800900 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.) 4.

  • Page 844

    CONVENTIONAL BRAKE SYSTEM DISC PAD (FRONT) REPLACEMENT id041100800700 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

  • Page 845

    CONVENTIONAL BRAKE SYSTEM Piston Disassembly Note Warning • When compressed air is blown into the caliper body, injury to a finger or other part from pinching could result from the piston springing up. When blowing in compressed air, do not place your fingers between the piston and caliper body when performing the work.

  • Page 846

    CONVENTIONAL BRAKE SYSTEM Inspection and repair procedure Confirm customer s complaint Perform lateral runout inspection. More than 0.05 mm {0.002 in} (Refer to Lateral Runout Inspection.) Less than Less than 0.05 mm 0.05 mm {0.002 in} {0.002 in} Occurs Remove disc plate and Verify whether brake reinstall in other phase.

  • Page 847

    CONVENTIONAL BRAKE SYSTEM Thickness variation inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner. 2. Measure the points indicated in the illustration using a caliper (micrometer). 3. Subtract the minimum value from the maximum. • If the result is not within specification, machine the disc plate using a lathe. Thickness variation limit 0.015 mm {0.0005 in} Warning...

  • Page 848

    CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DISC) REMOVAL/INSTALLATION id041100800500 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.) 4.

  • Page 849

    CONVENTIONAL BRAKE SYSTEM Disc Plate Removal Note 1. If any disc plate is difficult to remove, perform the following steps to remove it. (1) Insert a flathead screwdriver into the service hole and turn the adjuster in the direction of the arrow to compress the parking brake shoe.

  • Page 850

    CONVENTIONAL BRAKE SYSTEM Caliper Installation Note 1. Push the piston fully inward using the SST. 2. Install the caliper. End Of Sie WM: DISC PAD (REAR) 49 0221 600C acxuuw00001075 DISC PAD (REAR) REPLACEMENT id041100800300 1. Remove in the order indicated in the table. 2.

  • Page 851

    CONVENTIONAL BRAKE SYSTEM CALIPER (REAR) DISASSEMBLY/ASSEMBLY id041100800600 1. Disassemble in the order indicated in the table. Bleeder cap Bleeder screw Piston (See 04-11-25 Piston Disassembly Note) Dust seal Piston seal Caliper 6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf} 2. Assemble in the reverse order of removal. BRAKE FLUID 04-11...

  • Page 853: Parking Brake System

    PARKING BRAKE SYSTEM 04-12 PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM End Cable Installation Note..04-12–7 LOCATION INDEX ....04-12–1 PARKING BRAKE PARKING BRAKE INSPECTION .

  • Page 854

    PARKING BRAKE SYSTEM PARKING BRAKE INSPECTION id041200800300 1. Depress the parking brake pedal a few times. 2. Depress the brake pedal a few times. 3. Inspect the parking brake stroke by depressing the parking brake pedal with a force of 180 N {18.4 kgf, 40.5 lbf}.

  • Page 855

    PARKING BRAKE SYSTEM PARKING BRAKE REMOVAL/INSTALLATION[2WD] id0412008002a1 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 856

    PARKING BRAKE SYSTEM 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the parking brake stroke. (See 04-12-2 PARKING BRAKE ADJUSTMENT.) 18.6—25.5 18.6—25.5 {1.90—2.60, {1.90—2.60, 13.8—18.8} 13.8—18.8} 18.6—25.5 {1.90—2.60, 13.8—18.8} 98—120 {10—12, 73—88} 78.4—101.9...

  • Page 857

    PARKING BRAKE SYSTEM Operation lever Plate (See 04-12-6 Operation lever, Pin, Adjuster Bolt and Dust boot Nut, Tappet Installation Note.) End Cable Removal Note 1. Remove the end cable installation bolts. 2. Disconnect the end cable from the operation lever. 3.

  • Page 858

    PARKING BRAKE SYSTEM Parking Brake Shoe Removal Note 1. Pull the parking brake shoe downward and PARKING BRAKE SHOE disengage it from the shoe stopper. 2. Press the adjuster bolt and tappet by hand, and SHOE STOPPER slowly remove the parking brake shoe. Note •...

  • Page 859

    PARKING BRAKE SYSTEM Disc Plate, Screw Installation Note 1. Measure the inner diameter of the disc plate with a vernier caliper. • If it exceeds the maximum diameter, install the new disc plate. Maximum rear disc plate inner diameter 191.0 mm {7.52 in} 2.

  • Page 860

    PARKING BRAKE SYSTEM PARKING BRAKE REMOVAL/INSTALLATION[AWD] id0412008002a4 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

  • Page 861

    PARKING BRAKE SYSTEM 8. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT.) 18.6—25.5 18.6—25.5 {1.90—2.60, {1.90—2.60, 13.8—18.8} 13.8—18.8} 18.6—25.5 {1.90—2.60, 13.8—18.8} 04-12 98—120 {10—12, 73—88} 18.6—25.5 {1.90—2.60, 13.8—18.8} 78.4—101.9 {8.0—10.3, 57.9—75.1} 18.6—25.5 {1.90—2.60, 13.8—18.8} 3—6 N·m {40—60 kgf·cm, 3—6 N·m 7.8—10.8...

  • Page 862

    PARKING BRAKE SYSTEM End Cable Removal Note 1. Remove the end cable installation bolts. 2. Disconnect the end cable from the operation lever. 3. Bend the end cable tab (rear parking brake cable side) in the direction shown in the figure. 4.

  • Page 863

    PARKING BRAKE SYSTEM Parking Brake Shoe Removal Note 1. Pull the parking brake shoe downward and PARKING BRAKE SHOE disengage it from the shoe stopper. 2. Press the adjuster bolt and tappet by hand, and SHOE STOPPER slowly remove the parking brake shoe. Note •...

  • Page 864

    PARKING BRAKE SYSTEM Disc Plate, Screw Installation Note 1. Measure the inner diameter of the disc plate with a vernier caliper. • If it exceeds the maximum diameter, install the new disc plate. Maximum rear disc plate inner diameter 191.0 mm {7.52 in} 2.

  • Page 865

    PARKING BRAKE SYSTEM End Cable Installation Note 1. Move the rear parking brake cable end in the direction shown in the figure and install it to the end cable. 2. Verify that the end cable tab (rear parking brake cable side) is attached properly to the rear parking brake cable end.

  • Page 867

    DYNAMIC STABILITY CONTROL 04-15 DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL REAR ABS WHEEL-SPEED SENSOR LOCATION INDEX....04-15–2 REMOVAL/INSTALLATION[2WD]..04-15–13 DSC SYSTEM WIRING DIAGRAM ..04-15–3 REAR ABS WHEEL-SPEED SENSOR DSC SYSTEM INSPECTION.

  • Page 868

    DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL LOCATION INDEX id041500800500 acxuuw00001778 DSC HU/CM Combined sensor (See 04-15-3 DSC SYSTEM WIRING DIAGRAM.) (See 04-15-15 COMBINED SENSOR REMOVAL/ (See 04-15-4 DSC SYSTEM INSPECTION.) INSTALLATION.) (See 04-15-6 DSC HU/CM REMOVAL/ (See 04-15-16 COMBINED SENSOR INSTALLATION.) INSPECTION.) (See 04-15-9 DSC HU/CM INSPECTION.)

  • Page 869

    DYNAMIC STABILITY CONTROL DSC SYSTEM WIRING DIAGRAM id041500800600 ABS 2 20A IG 1 ABS 1 40A COMBINED SENSOR DSC 7.5A 04-15 IG SW BATTERY STEERING ANGLE SENSOR ABS WARNING BRAKE SYSTEM LIGHT WARNING LIGHT CAN_L CAN_H TSC OFF LIGHT DSC HU/CM DSC INDICATOR LIGHT DRIVER...

  • Page 870

    DYNAMIC STABILITY CONTROL DSC SYSTEM INSPECTION id041500800700 Preparation 1. Verify that battery is fully charged. 2. Turn the ignition switch to the ON position, and verify that the ABS warning light goes out after approx. 3 s. 3. Turn the ignition switch off. 4.

  • Page 871

    DYNAMIC STABILITY CONTROL Brake pressure retention Inspected wheels Command name V_TRC_L V_TRC_R V_STB_L V_STB_R LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET 04-15 RR_INLET RR_OUTLET PMP_MOTOR Brake pressure reduction Inspected wheels Command name V_TRC_L V_TRC_R V_STB_L V_STB_R LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET...

  • Page 872

    DYNAMIC STABILITY CONTROL DSC Control Inspection 1. Perform “Preparation”. 2. Connect the M-MDS to the DLC-2. 3. Set up an active command mode inspection according to the combination of commands below. Caution • To protect the DSC HU/CM, the solenoid valve and the pump motor used during active command mode stay on for only 10 s or less each time they are switched on.

  • Page 873

    DYNAMIC STABILITY CONTROL 2. Remove the battery tray bracket as shown in the figure. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. After installation, add brake fluid, bleed the air, BATTERY TRAY BRACKET and inspect for fluid leakage.

  • Page 874

    DYNAMIC STABILITY CONTROL DSC HU/CM Connector Removal Note 1. Pull the lock lever up in the direction of the arrow. 2. Pull the connector toward the vehicle rear and LOCK LEVER remove it. acxuuw00001149 Brake Pipe Removal Note 1. Place an alignment mark on the brake pipe and MARK DSC HU/CM.

  • Page 875

    DYNAMIC STABILITY CONTROL DSC HU/CM Connector Installation Note 1. After connecting the connector, verify that the lock lever is completely pushed in. End Of Sie LOCK LEVER acxuuw00001152 DSC HU/CM INSPECTION id041500801100 04-15 1. Disconnect the DSC HU/CM connector. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.) 2.

  • Page 876

    DYNAMIC STABILITY CONTROL Measured Measured terminal Terminal Signal name Connected to Standard Inspection item(s) item (measured condition) • Wiring harness (I— RR RR wheel- I— RR ABS wheel- speed sensor RR ABS wheel- Continuity ABS wheel-speed Continuity speed sensor (power speed sensor detected sensor connector...

  • Page 877

    DYNAMIC STABILITY CONTROL Measured Measured terminal Terminal Signal name Connected to Standard Inspection item(s) item (measured condition) — — — — — — — — — — — — — — — — — — — — — — — —...

  • Page 878

    DYNAMIC STABILITY CONTROL FRONT ABS WHEEL-SPEED SENSOR INSPECTION id041500800400 Installation Visual Inspection 1. Inspect the following items: • If there is any malfunction, replace the applicable part. (1) Excessive play of the ABS wheel-speed sensor (2) Deformation of the ABS wheel-speed sensor (3) Deformation or damage of the ABS sensor rotor Clearance Inspection 1.

  • Page 879

    DYNAMIC STABILITY CONTROL REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION[2WD] id0415008001a1 1. Remove the rear seat. (See 09-13-7 REAR SEAT REMOVAL/INSTALLATION.) 2. Rear scuff plate inner. (See 09-17-19 REAR SCUFF PLATE REMOVAL/INSTALLATION.) 3. Remove the sub trunk box. (See 09-17-25 SUB TRUNK BOX REMOVAL/INSTALLATION.) 4.

  • Page 880

    DYNAMIC STABILITY CONTROL REAR ABS WHEEL-SPEED SENSOR INSPECTION[2WD] id0415008002a1 Installation Visual Inspection 1. Inspect the following items: • If there is any malfunction, replace the applicable part. (1) Excessive play of the ABS wheel-speed sensor (2) Deformation of the ABS wheel-speed sensor Clearance Inspection 1.

  • Page 881

    DYNAMIC STABILITY CONTROL Sensor Output Value Inspection 1. Turn the ignition switch off. 2. Connect the M-MDS to the DLC-2. 3. Select the following PIDs using the M-MDS: • WSPD_LR (LR ABS wheel-speed sensor) • WSPD_RR (RR ABS wheel-speed sensor) 4.

  • Page 882

    DYNAMIC STABILITY CONTROL COMBINED SENSOR INSPECTION id041500801300 1. Turn the ignition switch off. 2. Connect the M-MDS to the DLC-2. 3. Select the following PIDs, then inspect the lateral acceleration speed and the yaw rate. — LAT_ACCL: (lateral acceleration speed) —...

  • Page 883

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) DYNAMIC STABILITY CONTROL COMBINED SENSOR INITIALIZATION PROCEDURE id041500801400 Warning • Unless the initialization procedure of the combined sensor is completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the combined sensor and DSC HU/CM have been removed or replaced.

  • Page 884

    2007 Mazda CX-7 Workshop Manual (1871–1U–06B) DYNAMIC STABILITY CONTROL TCS OFF SWITCH REMOVAL/INSTALLATION id041500803000 1. Remove in the order indicated in the table. Switch bezel component (See 04-15-18 Switch Bezel Component Removal Note.) TCS OFF switch connector TCS OFF switch 2.

  • Page 885

    TECHNICAL DATA 04-50 TECHNICAL DATA BRAKES TECHNICAL DATA ..04-50–1 End of Toc BRAKES TECHNICAL DATA WM: BRAKES id045000800100 Item Specification Brake fluid type SAE J1703, FMVSS 116 DOT-3 Brake pedal height (reference value) 204.3 mm {8.043 in} Brake pedal play 2—5 mm {0.08—0.19 in}...

  • Page 887

    SERVICE TOOLS 04-60 SERVICE TOOLS BRAKES SST ..... 04-60–1 End of Toc BRAKES SST WM: BRAKES id046000800100 49 0259 770B 49 0221 600C 49 U043 004A Flare nut...

  • Page 889

    TRANSMISSION/TRANSAXLE SECTION Toc of SCT ON-BOARD DIAGNOSTIC AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL] ..05-02 [AW6A-EL, AW6AX-EL] ..05-17 SYMPTOM AUTOMATIC TRANSAXLE TROUBLESHOOTING SHIFT MECHANISM ..05-18 [AW6A-EL, AW6AX-EL] ..05-03 TECHNICAL DATA .

  • Page 890

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] AUTOMATIC TRANSAXLE CONTROL SYSTEM WIRING DIAGRAM[AW6A-EL, AW6AX-EL] id050211800100 SHIFT SOLENOID A TR SWITCH (INTEGRATED IN TCM) SHIFT SOLENOID B VEHICLE SPEED SENSOR TCC CONTROL SOLENOID INPUT/TURBINE SPEED SENSOR LINE PRESSURE CONTROL SOLENOID TFT SENSOR SHIFT SOLENOID F UP SWITCH DOWN SWITCH M RANGE SWITCH...

  • Page 891

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] FOREWORD[AW6A-EL, AW6AX-EL] id050211800200 • When the customer reports vehicle malfunction, check the malfunction indicator lamp (MIL) indication, AT warning indication, and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. — If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX- EL].) —...

  • Page 892

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] AFTER REPAIR PROCEDURE[AW6A-EL, AW6AX-EL] id050211800400 Caution • After repairing a malfunction, perform this procedure to verify that the malfunction has been corrected. • When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention to the other vehicles.

  • Page 893

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] iii. Drive the vehicle in D range, at 40 km/h {25 mph} or more for 2 s or more. iv. Go to Step 6. • For P0736 i. Start the engine. ii. Warm up the engine to normal operating temperature. iii.

  • Page 894

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Monitor Memory DTC No. Condition warning Page item function light (See 05-02-14 Transaxle fluid temperature (TFT) sensor P0711 P0711[AW6A- malfunction (stuck) EL, AW6AX- EL]) (See 05-02-15 Transaxle fluid temperature (TFT) sensor circuit P0712 P0712[AW6A- malfunction (short to ground) EL, AW6AX- EL]) (See 05-02-17...

  • Page 895

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Monitor Memory DTC No. Condition warning Page item function light (See 05-02-33 Gear reverse incorrect (incorrect gear ratio P0736 – – P0736[AW6A- detected) EL, AW6AX- EL]) (See 05-02-35 Valve control solenoid circuit malfunction (valve P0780 – P0780[AW6A- stuck) EL, AW6AX-...

  • Page 896

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Monitor Memory DTC No. Condition warning Page item function light (See 05-02-53 Shift solenoid B circuit malfunction (short to P0976 – – P0976[AW6A- ground) EL, AW6AX- EL]) (See 05-02-55 Shift solenoid B circuit malfunction (short to P0977 –...

  • Page 897

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Monitor Memory DTC No. Condition warning Page item function light (See 05-02-74 Shift solenoid F circuit malfunction (short to P0998 P0998[AW6A- ground/open circuit) EL, AW6AX- EL]) (See 05-02-76 Shift solenoid F circuit malfunction (short to P0999 P0999[AW6A- power) EL, AW6AX-...

  • Page 898

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0601[AW6A-EL, AW6AX-EL] id050211800600 DTC P0601 Flash ROM malfunction • Flash ROM (in TCM) internal circuit malfunction is detected. Diagnostic support note: • This is a continuous monitor (CCM). • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle. DETECTION •...

  • Page 899

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next step. • Verify related Service Bulletins and/or on-line repair information availability.

  • Page 900

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0706[AW6A-EL, AW6AX-EL] id050211800900 DTC P0706 Transaxle range (TR) switch circuit range/performance • TCM detects stuck TR switch when ignition switch is at ON position. Diagnostic support note: • This is continuous monitor (CCM). • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle. DETECTION •...

  • Page 901

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next step. • Verify related Service Bulletins and/or on-line repair information availability.

  • Page 902

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0711[AW6A-EL, AW6AX-EL] id050211801200 DTC P0711 Transaxle fluid temperature (TFT) sensor malfunction (stuck) • Change in ATF temperature cannot be detected for 15 min or more when driving in D range. Diagnostic support note: • This is continuous monitor (CCM). •...

  • Page 903

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT RESISTANCE OF TFT SENSOR Yes Go to the next step. CIRCUIT Replace the TFT sensor, then go to the next step. • Inspect for resistance between couple (See 05-17-13 TRANSAXLE FLUID TEMPERATURE component terminals B8 and B7 (wiring (TFT) SENSOR REMOVAL/INSTALLATION[AW6A-EL, harness-side).

  • Page 904

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0712 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground) COUPLE COMPONENT CONNECTOR COUPLE COMPONENT SENSOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, •...

  • Page 905

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P0713[AW6A-EL, AW6AX-EL] id050211801400...

  • Page 906

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 907

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0717 Input/turbine speed sensor circuit malfunction (open circuit/short circuit) • Input/turbine speed sensor malfunction • Open circuit between input/turbine speed sensor terminal B and TCM terminal B12 • Open circuit between input/turbine speed sensor terminal A and TCM terminal B13 •...

  • Page 908

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT CONTINUITY OF INPUT/TURBINE Yes Go to go to Step 8. SPEED SENSOR CIRCUIT Go to the next step. • Inspect for continuity between the couple component terminals B12 and B13 (wiring harness-side). •...

  • Page 909

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0722 Vehicle speed sensor (VSS) circuit malfunction (open circuit/short circuit) • VSS malfunction • Open circuit between VSS terminal B and TCM terminal B19 • Open circuit between VSS terminal A and TCM terminal B20 •...

  • Page 910

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT CONTINUITY OF VSS CIRCUIT Yes Go to go to Step 8. • Inspect for continuity between the couple Go to the next step. component terminals B19 and B20 (wiring harness-side). • Is there continuity? INSPECT TERMINAL VSS FOR POOR Yes Go to the next step.

  • Page 911

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0729 Gear 6 incorrect (incorrect gear ratio detected) • ATF level low • Deteriorated ATF • Shift solenoid C stuck • Shift solenoid E stuck • Line pressure control solenoid stuck POSSIBLE • Line pressure low CAUSE •...

  • Page 912

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0729 Yes Replace the TCM, then go to the next step. (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL, COMPLETED • Make sure to reconnect all the disconnected AW6AX-EL].) connectors. Go to the next step. •...

  • Page 913

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 914

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0731[AW6A-EL, AW6AX-EL] id050211801900 DTC P0731 Gear 1 incorrect (incorrect gear ratio detected) • Incorrect gear ratio detected when following conditions are satisfied while driving: Monitoring condition: — ATF temperature 20 °C {68 °F} or more —...

  • Page 915

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT SHIFT SOLENOID Yes Go to the next step. • Inspect the shift solenoid. Replace the control valve body. (See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/ INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].) •...

  • Page 916

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 917

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0733[AW6A-EL, AW6AX-EL] id050211802100 DTC P0733 Gear 3 incorrect (incorrect gear ratio detected) • Incorrect gear ratio detected when following conditions are satisfied while driving: Monitoring condition: — ATF temperature 20 °C {68 °F} or more —...

  • Page 918

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT SHIFT SOLENOID Yes Go to the next step. • Inspect the shift solenoid. Replace the control valve body. (See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/ INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].) •...

  • Page 919

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 920

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0735[AW6A-EL, AW6AX-EL] id050211802300 DTC P0735 Gear 5 incorrect (incorrect gear ratio detected) • Incorrect gear ratio detected when following conditions are satisfied while driving: Monitoring condition: — ATF temperature 20 °C {68 °F} or more —...

  • Page 921

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT SHIFT SOLENOID Yes Go to the next step. • Inspect the shift solenoid. Replace the control valve body. (See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/ INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].) •...

  • Page 922

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 923

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0780[AW6A-EL, AW6AX-EL] id050211802500 DTC P0780 Valve control solenoid circuit malfunction (valve stuck) • Irregular shift control detected when following conditions are satisfied while driving: Monitoring condition: — ATF temperature 65 °C {149 °F} or more —...

  • Page 924

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0817[AW6A-EL, AW6AX-EL] id050211802600 DTC P0817 Starter relay No.2 circuit malfunction (open circuit/short circuit) • Any of the following conditions are met when ignition switch is at ON position: — 0 V detected at TCM terminal A5 when in D range or R position —...

  • Page 925

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT VOLTAGE OF STARTER RELAY NO.2 Yes Go to go to Step 5. CIRCUIT Go to the next step. • Turn the ignition switch to the ON position (engine off). • Shift the selector lever to P or N position. •...

  • Page 926

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P0819[AW6A-EL, AW6AX-EL] id050211802700...

  • Page 927

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 928

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT M RANGE SWITCH, UP SWITCH, AND Yes Go to the next step. DOWN SWITCH CIRCUIT FOR OPEN CIRCUIT Repair or replace the harness, then go to the next step. • Inspect for continuity between TCM connector terminals and selector lever component terminals (wiring harness-side).

  • Page 929

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 930

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0883[AW6A-EL, AW6AX-EL] id050211802900 DTC P0883 TCM B+ high • Voltage of 18 V or more detected at TCM terminals A1 and A11 when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 931

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0942 Valve control solenoid circuit malfunction at D range (valve stuck) • Shift solenoid A stuck • Shift solenoid B stuck • Shift solenoid C stuck POSSIBLE • C1 clutch slipping CAUSE • Control valve stuck •...

  • Page 932

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0961[AW6A-EL, AW6AX-EL] id050211803100 DTC P0961 Line pressure control solenoid range/performance (stuck) • Feedback current corresponding to solenoid current command value is irregular when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 933

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0961 Yes Replace the TCM, then go to the next step. (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL, COMPLETED • Make sure to reconnect all the disconnected AW6AX-EL].) connectors. Go to the next step. •...

  • Page 934

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0962 Line pressure control solenoid circuit malfunction (short to ground/open circuit) COUPLE COMPONENT LINE PRESSURE CONTROL SOLENOID COUPLE COMPONENT CONNECTOR LINE PRESSURE CONTROL SOLENOID WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.

  • Page 935

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL LINE PRESSURE Yes Go to the next step. CONTROL SOLENOID FOR POOR Replace the couple component, then go to Step 8. CONNECTION • Disconnect the line pressure control solenoid connector. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 936

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0963 Line pressure control solenoid circuit malfunction (short to power) COUPLE COMPONENT LINE PRESSURE CONTROL SOLENOID COUPLE COMPONENT CONNECTOR LINE PRESSURE CONTROL SOLENOID WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.

  • Page 937

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL LINE PRESSURE Yes Go to the next step. CONTROL SOLENOID FOR POOR Replace the couple component, then go to Step 7. CONNECTION • Disconnect the line pressure control solenoid connector. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 938

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0973 Shift solenoid A circuit malfunction (short to ground) COUPLE COMPONENT SHIFT SOLENOID A COUPLE COMPONENT CONNECTOR SHIFT SOLENOID A WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, •...

  • Page 939

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the next step. CIRCUIT FOR SHORT TO GROUND • Inspect for continuity between couple Replace the control valve body, then go to the next step. component terminal B5 and all terminals (See 05-17-38 CONTROL VALVE BODY REMOVAL/ except B5 (wiring harness-side).

  • Page 940

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0974 Shift solenoid A circuit malfunction (short to power/open circuit) COUPLE COMPONENT SHIFT SOLENOID A COUPLE COMPONENT CONNECTOR SHIFT SOLENOID A WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.

  • Page 941

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step. CIRCUIT FOR OPEN CIRCUIT Repair or replace the couple component, then go to Step 8. • Inspect for continuity between couple component terminal B5 (wiring harness-side) and shift solenoid A terminal A wiring harness- side).

  • Page 942

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0976 Shift solenoid B circuit malfunction (short to ground) COUPLE COMPONENT SHIFT SOLENOID B COUPLE COMPONENT CONNECTOR SHIFT SOLENOID B WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, •...

  • Page 943

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL SHIFT SOLENOID B FOR Yes Go to the next step. POOR CONNECTION Replace the couple component, then go to Step 7. • Disconnect the shift solenoid B connector. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 944

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0977 Shift solenoid B circuit malfunction (short to power/open circuit) COUPLE COMPONENT SHIFT SOLENOID B COUPLE COMPONENT CONNECTOR SHIFT SOLENOID B WIRING HARNESS-SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.

  • Page 945

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT TERMINAL SHIFT SOLENOID B FOR Yes Go to the next step. POOR CONNECTION Replace the couple component, then go to Step 8. • Disconnect the shift solenoid B connector. • Inspect for poor connection (such as damaged/ pulled-out pins, corrosion).

  • Page 946

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 947

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0979[AW6A-EL, AW6AX-EL] id050211803900 DTC P0979 Shift solenoid C circuit malfunction (short to ground/open circuit) • Open or short circuit in shift solenoid C signal system (The solenoid circuit current value input to the TCM is continuously less than 23 mA for 100 ms or more).

  • Page 948

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 949

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0980[AW6A-EL, AW6AX-EL] id050211804000 DTC P0980 Shift solenoid C circuit malfunction (short to power) • Short circuit in shift solenoid C signal system (The solenoid circuit current value input to the TCM is continuously more than 1,333 mA for 100 ms or more). Diagnostic support note: •...

  • Page 950

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 951

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0981[AW6A-EL, AW6AX-EL] id050211804100 DTC P0981 Shift solenoid D range/performance (stuck) • Feedback current corresponding to solenoid current command value is irregular when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 952

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P0982[AW6A-EL, AW6AX-EL] id050211804200...

  • Page 953

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 954

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0983[AW6A-EL, AW6AX-EL] id050211804300 DTC P0983 Shift solenoid D circuit malfunction (short to power) • Short circuit in shift solenoid D signal system (The solenoid circuit current value input to the TCM is continuously more than 1,333 mA for 100 ms or more). Diagnostic support note: •...

  • Page 955

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 956

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0984[AW6A-EL, AW6AX-EL] id050211804400 DTC P0984 Shift solenoid E range/performance (stuck) • Feedback current corresponding to solenoid current command value is irregular when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 957

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P0985[AW6A-EL, AW6AX-EL] id050211804500...

  • Page 958

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 959

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0986[AW6A-EL, AW6AX-EL] id050211804600 DTC P0986 Shift solenoid E circuit malfunction (short to power) • Short circuit in shift solenoid E signal system (The solenoid circuit current value input to the TCM is continuously more than 1,333 mA for 100 ms or more). Diagnostic support note: •...

  • Page 960

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 961

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0997[AW6A-EL, AW6AX-EL] id050211804700 DTC P0997 Shift solenoid F range/performance (stuck) • Feedback current corresponding to solenoid current command value is irregular when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 962

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P0998[AW6A-EL, AW6AX-EL] id050211804800...

  • Page 963

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 964

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P0999[AW6A-EL, AW6AX-EL] id050211804900 DTC P0999 Shift solenoid F circuit malfunction (short to power) • Short circuit in shift solenoid F signal system (The solenoid circuit current value input to the TCM is continuously more than 1,333 mA for 100 ms or more). Diagnostic support note: •...

  • Page 965

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 966

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P1700[AW6A-EL, AW6AX-EL] id050211805000 DTC P1700 Valve control solenoid circuit malfunction at R range (valve stuck) • When all of the following conditions are met while driving in R position and the counter drive gear (output} speed is 500 rpm or less: —...

  • Page 967

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P2757[AW6A-EL, AW6AX-EL] id050211805100 DTC P2757 Torque converter clutch (TCC) stuck off • When all conditions below are satisfied. — ATF temperature 20 °C {68 °F} or more — Driving in 4GR— 6GR at D range —...

  • Page 968

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2757 Yes Replace the TCM, then go to the next step. (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL, COMPLETED • Make sure to reconnect all the disconnected AW6AX-EL].) connectors. Go to the next step. •...

  • Page 969

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION INSPECT ATF CONDITION Yes Go to the next step. • Turn the ignition switch to the LOCK position. If the ATF color is milky or reddish brown, replace ATF, then • Inspect the ATF condition. go to Step 7.

  • Page 970

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P2762[AW6A-EL, AW6AX-EL] id050211805300 DTC P2762 TCC control solenoid range/performance (stuck) • Feedback current corresponding to solenoid current command value is irregular when engine is running. Diagnostic support note: • This is a continuous monitor (CCM). •...

  • Page 971

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. • Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].) (See 05-02-4 AFTER REPAIR DTC troubleshooting completed. PROCEDURE[AW6A-EL, AW6AX-EL].) • Are any DTCs present? End Of Sie DTC P2763[AW6A-EL, AW6AX-EL] id050211805400...

  • Page 972

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the repair order, • Has the FREEZE FRAME DATA been then go to the next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available...

  • Page 973

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] DTC P2764[AW6A-EL, AW6AX-EL] id050211805500 DTC P2764 TCC control solenoid circuit malfunction (short to ground/open circuit) • Open or short circuit in TCC control solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the signal output by CPU in TCM is detected). Diagnostic support note: •...

  • Page 974

    ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL] Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on