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Repair Procedure

NOTE:
This concern may have several causes so it is important to thoroughly complete each step.

NOTE:
Make sure the vehicle is in the following conditions when performing all tests described below:

^ Transmission in Park

^ Engine at idle at approximately 750 RPM

^ Engine temperature should be at least 88°C (190°F)

^ All accessories and the engine cooling fan should be off

NOTE:
Parts will be collected for warranty inspection and any unnecessary replacements will be debited.

1. Inspection of Evaporative (EVAP) Vapor Management Valve

a. Determine if the Evaporative Vapor Management (EVAPVM) duty cycle is operating properly. Monitor these parameters using PIDs - EVAPVM # (in percent) and FTP (in volts).

- If EVAPVM is functioning correctly, the duty cycle should increase to 84-100% with the FTP decreasing to approximately 2.2 volts and then reset back to 0% duty cycle while FTP hold at approximately 2.6 volts. If the duty cycle does not increase within 5 minutes, turn on the headlights and the AC with the blower on high. The duty cycle should start increasing within 5-10 minutes. Do not replace the EVAPVM valve if the duty cycle functions correctly.





- If the duty cycle stops increasing and remains at 95-100% while Fuel Tank Pressure (FTP) holds at approximately 2.6 volts, replace the EVAPVM valve with part number AJ03-18-741A.

b. Verify corrective action, then proceed to Step 2.

2. Inspection of EVAP System Vent Line.





a. Disconnect the vent line in the evaporative emissions system from the check valve side. This connection is located just forward of the evaporative emissions canister assembly, underneath the vehicle in the area of the driver side rear seat.

b. Using shop air, blow the vent line from the check valve side forward (towards the brake booster). In the past, spiders have been known to construct webs in vent lines, so handle with caution. Possible obstructions in the vent line can prevent the evaporative emissions system from purging properly, and in some cases, can cause the condition to occur.

c. Verify corrective action, then proceed to Step 3.





3. Inspection of Idle Air Control (IAC) Valve

a. Inspect the Idle Air Control (IAC) valve.

- If the valve is not stamped with part number 1L8E-9F715AA, replace with AJ71-20-660.

b. Verify that IAC duty cycle is between 32-40% with no purge flow (EVAPVM duty cycle is 0%) and fuel trims (SHRTFT1, SHRTFT2, LONGFT1, LONGFT2) are less than 15%.

- If IAC duty cycle is out of specification, replace the throttle body with part number AJ03-13-640B.

- If IAC duty cycle is within specification proceed to Step 3c now.

c. If the fuel trims are above 15%, disconnect the Mass Air Flow Sensor (MAF) and recheck the fuel trims.

- If the fuel trims drop to below 15%, replace the MAF sensor with part number 1F22-13-210A.

- If fuel trims stay above 15%, check for vacuum leaks and check the fuel system (Refer to Workshop Manual section 01-01 and 01-14 Troubleshooting and Fuel System).

d. Verify corrective action, then proceed to Step 4.

4. PCM Reflashing

a. Reprogram PCM with WDS version 21.5 or later. Only use WDS version 21.5 or later during this reprogramming.

b. Some 2001 model year PCMs cannot be reprogrammed and must be replaced. This is determined by the MPC # located in the upper left corner of the barcode on the PCM.

- If the PCM is an MPC 160, then replace with part AJY8-18-881D.

- If the PCM is an MPC 161, then just reprogram with WDS version 21.5 or later.

c. Verify the latest calibration was successfully reprogrammed.

^ WDS should show latest calibration level as 1U7A-12A650-AYD if PCM tear tag is # SJC0, SJC1, or SJC2.

^ For PCM tear tag # HQP1, HQP2, HQP3, or RKG0, the latest calibration level is 2U7A-12A650-CRB.

^ For tear tag # BAR0 or BAR1, the latest calibration level is 3L8A-12A650-BC.

NOTE:
For additional details on PCM reflashing, refer to the PCM REFLASH PROCEDURE SUPPLEMENT. Then proceed to Step 5.





5. Inspection of Electronic Engine Control (EEC) Relay

a. Inspection of Electronic Engine Control (EEC) Relay.

- If the Electronic Engine Control (EEC) relay has black stamped lettering, proceed to Step 6 now.

- If the EEC relay has white lettering printed on the top surface, replace with a new Hella service relay, BTDA-67-740, that is all black and has stamped lettering on the top surface.

NOTE:
Both the new Hella service relay and the old relay have the same part number (BTDA-67-740). Make sure the relay you are installing has stamped lettering.

b. Confirm EEC relay female terminal tightness on the Battery Junction Box side using tester part number 49-L088-OA2-020 from the Mazda terminal repair kit.

- If loose, adjust terminals as needed.

- If okay, proceed to Step 6.





6. Inspection of Differential Pressure Feedback EGR (DPFE) Sensor Part Number

- If DPFE sensor is stamped with part number 2F1E-9J460-AA or AB, proceed to Step 7 now.

- If the DPFE sensor is stamped with part number YF1E-9J460-AD, check for a white dot on the sensor housing (note: white dot can be anywhere on housing). If there is a white dot, proceed to Step 7 now. If there is not a white dot, replace the DPFE with part 1F22-20-302A. Proceed to Step 7.





7. Inspection of Mass Air Flow (MAF) Sensor Gasket

a. Ensure the Mass Air Flow (MAF) sensor gasket is properly installed and not blocking the air stream by disconnecting the airbox and looking inside the airbox towards the MAF sensor. If gasket is damaged, replace with part AJ03-13-211. Proceed to Step 8.

8. Verify PCM Harness Integrity





a. Verify the PCM harness integrity by removing the module from the COWL and moving the PCM harness around while the engine is running. If any abnormalities are observed, repair/replace the harness. Proceed to Step 9.

9. Inspection of Key Ring Weight

a. Inform the customer that significant weight (approximately 9 oz or more) hanging from the key ring while the keys are in the ignition may move the ignition cylinder out of the Run position and stop the engine. When this occurs, all gauges immediately shut off (fuel reads "E", tachometer goes to zero, speedometer goes to zero immediately).

b It is recommended that the customer attaches fewer keys to the key ring that retains the vehicle ignition key.

c. Proceed to Step 10.

10. Road Test

a. Road test the vehicle long enough to experience 3 closed throttle decelerations from approximately 40 mph down to 10 mph. Use scan tool to examine engine RPM during test.

b. Ensure that there are no engine RPM dips below 680 RPM. Then proceed to Step 11.

11. Obtain an Authorized Modification PCM Label through MStore (part number 9999-95-AMDC-97) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Label. Clean the area, install the decal, and cover it with a clear plastic decal shield.
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