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COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation

1. sete SW Slater 1 SW L 0 GSW 1090 BATTO 0 0 Bake 1S Bat BRK A Brake 2 SW Starter Relay H 3 40 No 1 Cylinder A3i i No 3 Cylinder No 2 Cylinder LAIF B3 AIF Sensor HEATER Q004346E Operation Section 1 39 3 CX 7 Glow Voltage Monitor Exhaust Pressure Sensor Middle Engine Compartment Temperature Compensation ensor co B 29 e j N B B eo zd Exhaust Temperature Sensor Upper gt Sila m E m Exhaust Temperature Sensor Middle Exhaust Temperature Sensor Lower e A12 Es BE m AST E Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Accelerator Sensor 7 Rail Pressure Sensor E Air Conditioner Relay Glow Plug Main Fan BATO 7 7 35 Unit ADD Fan BATTO 77 3 Unit ALTF A86 Alternator Elec Shutter Valve DC Motor EGR EGR Valve DC Motor DSC Meter Other Unit Water Heater DIAG Connector TAPS Turbo Actuator Position Sensor VREFS Q004515E Operation Section 1 40 Sensor 2 intake Mainfold EGR Bypass Valve Intake Air EVRV Temperature E VGT Solenoid EVRV B20 Sensor Lom 5 Press SW
2. 245 EGR Cooler Bypass Control Circuit Low 2459 DPF Regeneration Freguency P2105 Throttle Actuator Control System Forced Engine Shutdown lt o o lt o lt o lt 2 Y Y Y Y 2 lt o o 2 s 2 TOR Em REC 58 CaA pon 8 KEA es es es es No No No No n z Operation Section 1 35 9 CONTROL SYSTEM COMPONENTS 9 1 Engine ECU External Wiring Diagrams 1 MAZDA3 Glow Voltage Monitor A60 Exhaust Pressure PEG2 Sensor Middle VREF7 Engine Compartment CLON A91 Temperature Compensation THPEG Sensor n Exhaust Temperature Sensor Upper THEG1 Exhaust Temperature Sensor Middle Air Conditioner Relay N 43 A19 NE A21 VREF3 Main Fan L i PWM Unit ABC PWMOUT B35 A20 VREFS Crankshaft Position Sensor Camshaft Position Sensor Accelerator Sensor Alternator ALTT VREF1 ISVP Elec Shutter 1 Valve DC Motor MAP Sensor VREF6 EGRP EGR Valve DC Motor Rail Pressure Sensor E CAN H DSC Meter Other Unit Coolant Temperature Sensor CAN L Fuel Temperature Sensor TAPS me ition Sensor Air Temperature Sensor 2 Intake Mainfold VREF8 Q004347E Operation Section 1 36 EGR Bypass Valve Intake Air Temperature Sensor PRESS TEST Main Relay Clutch SW CL SW
3. Sassy 1 8 4 2 eed BAR eb alee ed bad bu 1 8 4 3 Pressure Limiter orte Deus ie aaa wien 1 9 5 INJECTOR 5j Quilihe HR e RR 1 10 5 2 Quick Response QR 1 1 11 6 OPERATION OF CONTROL SYSTEM COMPONENTS 6 1 Engine Electronic Control Unit 1 13 6 2 Sensor Operation tox LT mas CREER seedy eee ad NU Rea 1 14 7 CONTROL SYSTEM OUTING a su Bape Mio RS Gee ve S hpk a vestes 1 19 7 2 Fuel Injection Timing rs 1 22 7 3 Idle Speed Controls Gt oro E et tesi te oat e te ee eed 1 23 7 4 Microinjection Quantity Learning 1 1 24 7 5 Run Dry Prevention RDP 030 9 4 1 25 7 6 Diesel Particulate Filter DPF System 1 26 7 7 Selective Catalytic Reduction SCR System 1 29 8 DIAGNOSTIC TROUBLE CODES DTC
4. A below microinjection quantity learning takes place In addition it is also possible to perform microinjection quantity learning control manually as a diagnostic tool Presumed Conditions Barometric pressure intake air temperature coolant temperature and fuel temperature are all within the prescribed ranges Manual Learning Operations as a Diagnostic Tool Establishment of Vehicle Running Distance Learning Operations Injection Quantity Deterioration Over Time Judgment No Load Idle Stability Conditions Q001250E Operational outline Microinjection quantity learning control applies ISC target speed correction quantity and FCCB cylinder to cylinder correction quantity controls ISC and FCCB feed back the injection quantity based on engine rotational speed Corrections are then applied to each cylinder from ISC and FCCB correction information to calculate the corrected injection quantity Further microinjection quantity learning control divides injection into five separate injections Under these conditions the learning value is calculated as the corrected injection quantities for ISC and FCCB divided by five injections Calculated Microinjection Quantity 1st Cylinder 2nd a IA M 3rd Cylinder A 4th Cylinder Ww ISC Correction Portion LJ FCCB Correction Portion When Performing Microinjection Quantity Learning 1st Cylinder 2nd Cylinder 3rd Cylinder 4
5. DSC Control Initiates traction control and ABS control in accordance with the driving conditions Data from the differential pressure sensor exhaust temperature sensor and MAF DPF Control meter are accumulated in the DPF and used to estimate the Particulate Matter PM volume and to perform proper PM combustion Controls fan rotational speed in accordance with engine conditions For the MAZDA3 Fan Control and CX 7 the fan is operated via duty control for the MAZDAG the fan is operated via relay control 7 2 Fuel Injection Timing Control Operation Section 1 22 The figure below shows representative injection patterns Injection patterns change according to engine load conditions Top Dead Center When the DPF is Pilot Injection TDC Operating PL QPL1 QPL2 QPL3 Top Dead Center When Driving Pilot Injection TDC Intermediate Load QPL1 QPL2 QPL3 Top Dead Center Pilot Injection TDC QPL1 QPL2 QPL3 Top Dead Center Pilot Injection TDC 5 Idling When Cold Main Injection Post Injection woe EN POSTI POST2 Main Injection Post Injection di Main Injection Main Injection Q004335E Operation Section 1 23 7 3 Idle Speed Control Engine speed control during Diesel Particulate Filter DPF manual regeneration idle speed control calculates the PM quantity based on the input signal from the exhaust gas pressure sensor and controls
6. OBATT Key SW Starter Relay O a 92 STA REL Bin Slater SW Q X Starter 1 SW 0 47 IG SW 0 4 Starter Relay BATT IGSW BATT Brake 1 SW SAT TBR No 1 Cylinder No 3 Cylinder No 2 Cylinder LAIF B3 AIF Sensor HEATER Q004348E Operation Section 1 37 2 MAZDAG Glow Voltage Monitor Exhaust Pressure M Sensor Middle Air Conditioner Relay VREF7 Engine Compartment CLON A91 Temperature Compensation THPEG ensor 15 Exhaust Temperature Sensor Upper THEG1 Exhaust Temperature Sensor Middle THEG2 Glow Plug Exhaust Temperature Sensor Lower A36 THEG3 12 C REL 90 x Crankshaft Position ADD Fan Relay Sensor 2 FANAD ihe O Camshaf Posi amshaft Position RAM p Sensor Main Fan Relay No 1 FANTR 193 Uren Alternator ISVP Elec Shutter Valve DC Motor MAP Sensor KAI VREFG ear vate EGR B45 DC Motor Rail Pressure Sensor CANH DSC Meter Other Unit Water Heater Coolant Temperature Sensor CAN L DIAG Connector Fuel Temperature Sensor TAPS Turbo Actuator Position Sensor Air Temperature Sensor 2 VREFS Intake Mainfold Q004345E Operation Section 1 38 EGR Bypass Valve Intake Air Temperature Sensor PRESS TEST Main Relay CL SW WL SW S Aner ey Starter Relay O rm ISTA REL iik
7. 8 1 About the Codes Shown inthe Table 1 1 30 8 2 DTC lt et Oe OO eet GPR PRON RRR LAE eS EE fo ie ORT RAR Ret E PRO Ene OED 1 30 9 CONTROL SYSTEM COMPONENTS 9 1 Engine ECU External Wiring 1 35 9 2 ECU Connector Terminal 1 41 10 AIR BLEEDING FROM THE FUEL INTAKE LINE 1027 Attention ze Dao sia ede eS en eeu ee Ia DIN et Eb etiamfi TROP 1 42 10 2 Procedure vr t S A E e Pi E DE AN pte IC 1 42 Operation Section 1 PRODUCT APPLICATION INFORMATION 1 1 Outline The has undergone a full model change In addition the engine used in the MAZDA6 has been changed As a result the MZR CD 2 2 engine is now used in both the MAZDA3 and MAZDAG Further the Common Rail System CRS has been modified due to the aforementioned engine change For CRS basics refer to the COMMON RAIL SYSTEM SERVICE MANUAL OPERATION Doc ID 00400534EA Modifications made due to the model change are listed below Maximum injection pressure increased to 200 MPa Run Dry Prevention RDP control added Microinjection quantity learning control added Diesel Particulate Filter DPF system added As a result of a model change to the MAZDA CX 7 beginning from October 2009 the CX 7
8. EGR Cooler Bypass Valve Bypasses the EGR cooler Q004351E Operation Section 1 21 3 Control system Controls injector fuel injection timing and injection quantity by adding corrections Fuel Injection Control based on the signals from the sensors to the basic injection duration The basic injection duration is calculated in accordance with the engine conditions Controls the rail pressure in accordance with the engine conditions by sending Rail Pressure Control signals to the SCV of the supply pump Controls the boost pressure in accordance with the operating conditions by VGT Control calculating the signals that are output to the E VRV Intake Restriction Controls the opening of the intake restriction mechanism in accordance with the Control driving conditions Controls the opening of the EGR valve in accordance with operating conditions by EGR Control A calculating the output signals Glow Plug Relay Controls the duration of the current applied to the glow plug relay in accordance with Control the water temperature when the engine is started Air Conditioner 1 dra Cuts off the air conditioner during acceleration to improve drivability Cutoff Control Illuminates a warning light to alert the driver if a failure occurs the computer Initiates feedback control so that the actual vehicle speed matches the speed set in Auto Cruise Control j accordance with the cruise control switch
9. No No es es es es es es es es es es es Yes Yes Yes Yes Yes Yes Yes No Yes Yes No No Yes Yes Yes Yes Yes Yes es Operation Section 1 92 5 7 Applicable Vehicle Applicable Vehicle TG iagnosis em MAZDA3 MAZDAG Fuel Injector Group A Supply Voltage Circuit High KREM Fuel Injector Group B Supply Voltage Circuit High KOSE SE SE US Fuel Injector Group A Supply Voltage Circuit Low Yes Ye Yes Yes 2150 Fuel Injector Group Supply Voltage Circuit Low eec Canara Ye m Ye P0202 InecorGreuiOpen Cyinder ve Ye Yes m Za o Fuel Injector Group B Supply Voltage Circuit P2149 Posse camera Position Sensor A Circuit Range P0341 Performance PO337 Crankshaft Position Sensor A Circuit Low tote th NE Position Sensor A Circuit Range P0336 Yes Yes Yes Yes EOS serm a a 0 28 a E P0016 eles Man Res Position Camshaft Position ca Operation Section 1 33 T it Applicable Vehicle Applicable Vehicle SIS iagnosis em MAZDA3 MAZDAG P0606 ECM PCM Processor Internal Control Module Read Only Memory xi P0605 P0500 ee Se P0579 Control Multi Function Input A Circuit Range Performance P0581 Cruise Control Multi Function Input A Circuit High tote Fat Pomp Poco FPig ve Ye Yr Yor P2621 Trott Poston Ou
10. Pressure Circuit Range Performance Yes Throttle Pedal Position Sensor Switch A Circuit P0123 Yes Yes Yes Yes High Throttle Pedal Position Sensor Switch A Circuit P0122 Yes Yes Yes Yes Low Throttle Pedal Position Sensor Switch A Circuit P0121 Yes Yes Yes Yes Range Performance Throttle Pedal Position Sensor Switch B Circuit 3 Yes Yes Yes Yes gh Throttle Pedal Position Sensor Switch B Circuit P022 Yes Yes Yes Low we P0103 Mass or Volume Air Flow A Circuit High Input Yes Yes Yes P0102 Mass or Volume Air Flow A Circuit Low Input Yes Ye Performance P040 Exhaust Gas Recirculation EGR Sensor A Circuit High im I U O N N N Yes Yes KOE EE M s poer X s gt Gas Temperature Sensor raton No Diesel Particulate Filter DPF Differential Pressure Y Sensor Circuit High P2454 DPF Differential Pressure Sensor Circuit Low P1392 Glow Plug Voltage High Yes 1391 Glow Plug Voltage Low Yes Y Y Y Y Y Y U N KR C1 P0132 02 Sensor Circuit High Voltage Bank 1 P0131 02 Sensor Circuit Low Voltage Bank 1 Ye P0152 O2 Sensor Circuit High Voltage Bank 2 Yes P0151 O2 Sensor Circuit Low Voltage Bank 2 Yes P0134 O2 Sensor Circuit No Activity Detected P0030 HO2S Heater Control Circuit P0133 O2 Sensor Circuit Slow Response Y Y Y Yes Yes es Yes Yes es es es No No es es
11. MID Press SW Test SW 0 Neutral SW Main Relay i Clutch SW 46 Key SW Slater Relay 0 mm EDIPOWER 3 EO2 POWER B4 Starter SW Q BATT Power platen SW 4 0 Ground BATT C E Brake 1 SW D1 56 Brake 2 SW U mal tice Starter Relay 2 H No 3 Cylinder Fim No 4 Cinder 4 ui No 2 Cylinder SGND B A F Sensor HEATER 832 Q004616E Operation Section 1 41 9 2 ECU Connector Terminal Layout Changes have been made to the ECU Terminal layouts are as per the figures below sR BAMA BEI a pr VA A ASO A A40 4 48 of ZZ eel E bel Aes else 5 A6 A10 5 20 24 MAZDA3 FRAG SAI SEE eel AT2 25 A30 A40 A A48 mfo ZZ eel Al AS ella of abel fe hotel 7 AB ATO A15 A20 MAZDAG TARTE EET Is A 49 A A A30 A40 A4 A48 AAAH E PAWA Een de edet A A5 A10 A15 A20 A24 CX 7 iV nde pota Ve eiee ac Q004344E 2 40 45 4121012122 B7 BIO BIS BIg Q004343E B B6 B46 B50 B B58 a a unu PAEA 10 B15 B19 B7 Q004517E Operation Section 1 42 10 AIR BLEEDING FROM THE FUEL INTAKE LINE 10 1 Attention Do
12. engine speed The PM quantity is made to correspond with the target engine speed during DPF manual regeneration Engine speed during DPF manual regeneration when normal engine speed 1 750 rpm If there is abnormal combustion of soot during DPF manual regeneration the exhaust gas temperature increases which may damage the DPF Under the aforementioned conditions post injection is stopped and the engine speed is increased to 2 500 rpm Damage is thus prevented by rapidly sending low temperature exhaust gas to the oxidation catalytic converter to cool the DPF Operation Section 1 24 7 4 Microinjection Quantity Learning Control Outline Microinjection quantity learning control is used in every vehicle engine injector to preserve the accuracy of the pilot injection quantity Microinjection quantity learning control is first performed when shipped from the factory L O and later is automatically performed every time the vehicle runs a set distance for details see item A As a result the accuracy of each injector can be preserved not only initially but also as deterioration in injection occurs over time Microinjection quantity learning control stores correction values in the ECU During normal driving operations these correction values are used to make modifications to the injection commands resulting in accurate microinjection Learning operations For every two no load idle instability conditions established see item
13. fuel from the rail when the rail internal pressure becomes abnormally high Injector Side Supply Pump Side Rail Pressure Sensor Pressure Limiter Q004250E 4 2 Rail Pressure Sensor The rail pressure sensor detects the fuel pressure in the rail and sends a corresponding signal to the engine ECU The sensor is made from a semiconductor that uses the Piezo resistive effect to detect changes in electrical resistance based on the pressure applied to the elemental silicon In comparison to the old model the current sensor is compatible with high pressure Popt MPa Q004251E Operation Section 1 9 4 3 Pressure Limiter The pressure limiter releases fuel when the internal rail pressure becomes abnormally high The pressure limiter opens when internal pressure reaches 241 MPa 2458 kg cm2 and closes when rail pressure reaches a given set pressure Fuel released from the pressure limiter is returned to the fuel tank Cut Away View Steel Ball Housing Q004252E Operation Section 1 10 5 INJECTOR 5 1 Outline The type injectors equipped in the MAZDA3 MAZDA6 7 can inject fuel at extremely high pressure 200 MPa As a result the atomization of the fuel mist from the nozzle has been improved leading to increased combustion efficiency and reduced exhaust gas quantity to Fuel Tank lt J L l Connector C High Pressure Fuel from Rail Two Way Valve TWV V
14. to value c enabling restart and low speed driving DTC P115B is detected Fuel E Level Signal 1 Fuel E Light Lit ON Fuel Gauge Signal 1 4 i CAN Signal DTC P0313 DTC P115A RDP Control Status Running Restriction nome Sta Restart Low Speed Driving l Possible Command Injection Quantity Summation Injection Control During Vegetation Injection Quantity Normal Q Normal Q x Coefficient Prescribed Time Prescribed Time Q004341E Operation Section 1 26 7 6 Diesel Particulate Filter DPF System Outline The DPF collects and removes Particulate Matter PM from the exhaust gas The DPF is located behind the catalyst relative to the direction of exhaust gas flow The catalytic converter and DPF are integrated into one housing The DPF is a silicon carbide honey comb type filter The filter ends are blocked in sequence and small holes on the wall inside the filter accumulate PM The accumulated PM is then burned and eliminated The DPF has a platinum coated surface Operation Section 1 27 1 Other sensors Exhaust gas temperature sensor Exhaust gas temperature sensor no 1 Detects the exhaust gas temperature before flowing into the oxidation catalyst to check if the temperature is within the catalytic activity range Exhaust gas temperature sensor 2 Detects the exhaust gas temperature before flowing into the DPF to check if the temperature is at
15. A F value eee Pressure Detects pressure both before and after the DPF ensor Exhaust Temperature Detects the exhaust temperature before the DPF Sensor 1 p Exhaust Temperature Detects the exhaust temperature inside the DPF Sensor 2 p i Exhaust Temperature Detects the exhaust temperature after the DPF Sensor 3 P Detects the ambient temperature in the vicinity of the engine Temperature Sensor compartment differential pressure sensor g 5 a a c 1111110 0000 w Q004348E Operation Section 1 20 Fuel Injection Intake Restriction EGR Valve Lift Sensor Detects the EGR valve position lm Throttle Position Sensor Detects the diesel throttle position a Turbo Lift Sensor Detects the turbo nozzle position E 2 Actuator system m KDI Main Relay Supplies power to the system Precisely injects fuel Suction Control Valve Controls the volume of fuel that is supplied to the SCV supply pump EGR Valve DC Motor Controls the vacuum that is applied to the EGR valve VGT E VRV Controls the vacuum that is applied to the turbo o 9 KO E 3 L Electronic Control Throttle Controls the vacuum that is applied to the intake DC Motor suction valve Intake Restriction Controls the duration of time that current is Fan Relay applied to the electric fan Relay Supplies power to the A C Starter Relay Supplies power to the starter
16. Absolute Pressure MAP 079800 744 RF7J18211 Sensor Crankshaft Position Sensor NE 949979 191 R2AA18221A Camshaft Position Sensor TDC Mass Air Flow MAF Meter 197400 201 710113215 Coolant Temperature Sensor 179700 0224 B59318840A C Y 265600 244 R2AJ187G0A MAZDA3 265600 245 R2AK187G0A Exhaust Temperature Sensor 265600 199 RF8G187G0 MAZDA6 265600 200 RF8H187G0 211200 437 R2AJ188G1A 2 A F Sensor 211200 438 R2AA188G1 MAZDA6 104990 172 R2AJ182B5 MAZDA3 Differential Pressure Sensor 104990 153 RF8G182B5 MAZDA6 Accelerator Pedal Module 198800 348 CC3041600 Diesel Throttle 197920 007 R2AA136B0 Operation Section CX 7 Part Name DENSO Part Manufacturer Part Remarks mm Raw Ru mme Manifold Absolute Pressure MAP 079800 744 RF7J18211 Sensor pM Crankshaft Position Sensor NE 949979 191 R2AA18221 Camshaft Position Sensor TDC i l Mass Air Flow MAF Meter 197400 224 L3K913215 Po Coolant Temperature Sensor 179700 022 B59318840A Exhaust Temperature Sensor 1 265600 261 R2AX187G0B DL Exhaust Temperature Sensor 2 265600 262 R2BA187G0B PO Exhaust Temperature Sensor 3 265600 263 R2BB187G0B Differential Pressure Sensor 104990 155 R2AX182B5 EL 198800 736 L20641600A Right hand driver vehicles Accelerator Pedal Module 198800 739 EG2141600A Left
17. MZR CD2 2 Engine COMMON RAIL SYSTEM CRS SERVICE MANUAL Operation Issued February 2009 Revised October 2009 Applicable Vehicle 2222 MAD 00400689 Revision History 2009 10 Added applicable vehicles and products Added system information for the CX 7 Y Sensor Operation Y Selective Catalytic Reduction SCR System Y DIAGNOSTIC TROUBLE CODES DTC Y Engine ECU External Wiring Diagrams Y ECU Connector Terminal Layout 2009 DENSO CORPORATION All rights reserved This material may not be reproduced or copied in whole or in part without the written permission of DENSO Corporation Table of Contents Operation Section 1 PRODUCT APPLICATION INFORMATION 1 1 OUTING a Ce in Be ee ERU DER LR ad XE 1 1 122 Applicable Vehicles 252 unis 1 1 1 3 System Component Part Numbers 1 2 2 SYSTEM OUTLINE 2 1 Contiguration and Operatif yr ee ee es ee edn 1 4 2 2 Component Mounting 4 1 4 3 SUPPLY PUMP 3 1 OUTING 5 ole uero Ae tete ee te ee wel tetris 1 5 3 2 Suction Control Valve 1 6 4 RAIL 41 OUTING pete OTt ete ute Bek nee Su NE eae
18. alve Spring Nozzle Spring Nozzle Needle External View Q004322E Operation Section 1 11 5 2 Quick Response QR Codes Conventionally injectors were corrected during replacement using a correction resistor However QR codes have been adopted to improve injection quantity precision QR Codes O 9 9mm ID Codes 30 base 16 characters Base 16 characters noting fuel injection quantity correction information for market service use Q004323E QR codes have resulted in a substantial increase in the number of fuel injection quantity correction points greatly improving precision The characteristics of the engine cylinders have been further unified primarily contributing to improvements in combustion efficiency and reductions in exhaust gas emissions Injection Quantity Q 200 MPa 135 MPa 110 MPa Correction 8 Points 90 MPa 25 MPa Actuating Pulse Width TQ Q004324E Operation Section 1 12 1 Repair procedure changes reference When replacing injectors with QR codes or the engine ECU it is necessary to record the ID codes in the ECU If the ID codes for the installed injectors are not registered correctly engine malfunctions such as rough idling and noise will result The ID codes are registered in the ECU at a MAZDA dealer using approved MAZDA tools No correction resistance cannot be detected electrically Replaced Injector Engine ECU Injector ID code must be reg
19. by both the main and sub systems As a result even if one of the sensors malfunctions the correct accelerator position can be detected Accelerator Position Accelerator q 4 Sensor Position Sensor Vea2 GND2 VC2 MAZDA3 MAZDA6 Accelerator Position Sensor Out put Voltage Characteristic Accelerator Position Sensor Main Sensor Hall Element 9 9 Accelerator Pedal Large Depression Amount Small Q004514E Operation Section 1 18 5 Mass Air Flow MAF meter The MAF meter is attached to the air cleaner The MAF meter is built into the intake air temperature sensor The MAF meter converts the mass intake air flow quantity into a voltage When the temperature of the metal in the sensor decreases sensor resistance lowers Using this characteristic the hot wire captures heat from the flow of intake air and converts the intake airflow quantity to a voltage The cold wire converts intake air density to a voltage using the ambient temperature of the cold wire This conversion is accomplished by using the characteristic of air whereby the intake air density decreases due to the increase in intake air temperature The voltages obtained by the hot wire intake airflow amount and the cold wire are compared The electric potential is then stabilized by supplying the voltage difference to the transistor The voltage supplied to the hot wire is then output as the mass intake air flo
20. fuel required for the target rail pressure is drawn in the drive load on the supply pump decreases thus resulting in improved fuel economy Needle Valve Q004363E 1 SCV opening small duty on time long Refer to the Relationship between actuation signal and current figure When the SCV opening is small the fuel suction area is kept small thereby decreasing the transferable fuel volume Feed Pump Needle Valve Small Opening Q001114E Operation Section 2 SCV opening large duty on time short Refer to the Relationship between actuation signal and current figure When the SCV opening is large the fuel suction area is kept large thereby increasing the transferable fuel volume f Needle Valve Large Opening Q001115E 3 Relationship between actuation signal and current Small Suction Volume Large Suction Volume On Actuation Voltage Off 1 t LI Current 001116 Operation Section 1 8 4 RAIL 4 1 Outline rail stores high pressure fuel delivered from the supply pump for distribution to the individual injector for each cylinder A rail pressure sensor and pressure limiter are attached to the rail The rail pressure sensor detects the fuel pressure within the rail and sends a corresponding signal to the engine ECU The engine ECU then controls fuel pressure based on the aforementioned signal information The pressure limiter releases
21. hand driver vehicles Diesel Throttle 197920 007 R2AA136B0 et ee Operation Section 1 4 2 SYSTEM OUTLINE 2 1 Configuration and Operation The primary CRS components are shown in the figure below Pressure Limiter Supply Pump U 1 T Injector Rail E d Suction z Control Rail Pressure Sensor Fuel Filter Temperature Sensor to Engine ECU Fuel Tank Fuel Flow Q004248bE 2 2 Component Mounting Locations The mounting locations for primary CRS system components are shown in the figure below SCV Supply Injectors Q004249E Operation Section 3 SUPPLY PUMP 3 1 Outline The supply pump equipped with the Mazda3 and Mazda6 uses a compact SV2 Suction Control Valve SCV the same as prior to the model change External View Cut Away Model Reference Suction Valve Feed Pump Fuel Temperature Sensor Bing Suction Control Valve SCV Delivery Valve Q004342E Operation Section 3 2 Suction Control Valve SCV The SCV is a linear type solenoid valve The length of time that the ECU applies current to the SCV is controlled duty cycle control in order to regulate the volume of fuel suctioned into the pumping area Since only the volume of
22. ing circuit and then inputted to the ECU as a sensor output signal If the NE sensor is removed installed or replaced magnetized objects such as metal shavings adhering to the sensor may cause fluctuations in the magnetic flux of the MRE As a result engine control may be adversely affected due to abnormal sensor output Sensor External View Sensor Mounting Position OUT GND Circuit Diagram Crankshaft Position Sensor Crankshaft Position Sensor Pulse Chart Pulse Wheel G CA Crank Angle Crankshaft Position Sensor 4 V or More 30 Below 1 V Ground 6 esi 360 CA Q004326E Operation Section 1 15 2 Camshaft position sensor TDC sensor TDC sensor consists of IC with an integrated Magneto Resistance Element MRE and signal processing circuit and a magnet Sensor output signal reliability has been improved by using the MRE resulting in the detection signal amplitude being wider compared to the Hall element Signal detection utilizes special characteristics of the MRE to change the electrical resistance corresponding to the magnetic field and magnetic flux changes The change in magnetic flux detected by the MRE MRE output is turned into short waves or rectangular waves at the signal processing circuit and then inputted to the ECU as a sensor output signal Five pulses are detected for every one rotation of the camshaft via the projections
23. istered with the engine ECU Q001133E Injector Replacement No correction resistance cannot be detected electrically 1 gt lt Vehicle Injectors i LI Replaced Engine ECU Injector ID code must be registered with the engine ECU Q001134E Engine ECU Replacement Operation Section 1 13 6 OPERATION OF CONTROL SYSTEM COMPONENTS 6 1 Engine Electronic Control Unit ECU The engine ECU is the command center that controls the fuel injection system as well as overall engine operation lt Outline Diagram gt Sensor Engine ECU Actuator 5 Calculation 9 Actuation Q004325E Operation Section 1 14 6 2 Sensor Operation 1 Crankshaft position sensor NE sensor The pulse wheel attached to the crankshaft pulley has 56 projections and spaces with 6 of crank angle between each projection NE sensor consists of an IC with an integrated Magneto Resistance Element MRE and signal processing circuit as well as a magnet Sensor output signal reliability has been improved by using the MRE resulting in the detection signal amplitude being wider compared to the Hall element Signal detection utilizes special characteristics of the MRE to change the electrical resistance corresponding to the magnetic field and magnetic flux changes The change in magnetic flux detected by the MRE MRE output is turned into short waves or rectangular waves at the signal process
24. n outputs the signals to the engine ECU The differential pressure sensor is a semiconductor type in which a difference in electrical potential occurs when pressure is applied Output voltage from the differential pressure sensor increases as the difference in exhaust gas pressures increases Exhaust Gas Pressure Sensor Exhaust Gas Engine ECU Output Voltage Characteristic Pressure Sensor High Output Voltage lt Difference in Exhaust gt Small Gas Pressures Large qoo4340E Operation Section 1 29 7 7 Selective Catalytic Reduction SCR System Outline The SCR system is only specified for the MAZDA 7 The SCR system is an exhaust gas cleaning system that injects an aqueous solution of urea known as AdBlue into the exhaust pipe just before the catalyst to create a chemical reaction with the exhaust gas As a result approximately 40 of the NOx contained in the exhaust gas is converted into non hazardous nitrogen Until now the SCR system was large and was therefore only equipped in heavy duty vehicles However beginning with the AdBlue storage tank mounted under the CX 7 trunk the entire SCR system has been made compact and lightweight MAZDA is the first automobile manufacturer in Japan to equip the SCR system in a passenger vehicle SCR system components are made by manufacturers other than DENSO However the DENSO engine ECU calculates the NOx exhaust quantity and conducts CAN communication SCR S
25. not operate the starter motor for 10 seconds or longer at a time After 10 seconds switch the ignition to ON and allow the starter motor to cool for 30 seconds before attempting to start the engine again 10 2 Procedure 1 Disconnect the fuel return hose 2 Connect the Special Service Tool SST 3 Operate the SST several times a Operate the hand pump unit of the SST until firm when squeezed b Squeeze and hold the hand pump unit for 10 seconds lt K c Release the hand pump Fuel Return Hose Q004364E d Repeat steps b and c once again 4 Disconnect the SST 5 Connect the fuel return hose Attention Continuously cranking the engine for over 30 seconds may damage the battery and starter 6 Crank the engine for less than 30 seconds then stop for 5 to 10 seconds until the engine starts If the engine does not start return to step 1 Service Department DENSO CORPORATION 06K500S 1 1 Showa cho Kariya shi Aichi ken 448 8661 Japan Printed in Japan
26. now also uses the MZR CD 2 2 engine The MZD CD 2 2 engine in the CX 7 is equipped with the Selective Catalytic Reduction SCR system The SCR system dramatically reduces the quantity of NOx exhaust and achieves superior environmental protection functionality suited to the stringent European emission standards stipulated in the EURO 5 regulations In comparison to the CRS used in the MAZDA3 and MAZDAG the CRS for the CX 7 includes the following additional system An explanation of this system has been added to this manual e Refer to Selective Catalytic Reduction SCR System on P 1 29 Unless otherwise noted the explanations for each control and part applies to all three vehicles mentioned in this manual 1 2 Applicable Vehicles Model Name Engine Displacement Line Off Period MAZDA3 January 2009 2009 ens MZR CD 2 2 Europe MEUM 2008 o 0 7 October 2009 2009 Operation Section 1 3 System Component Part Numbers MAZDA3 MAZDA6 Part Name DENSO Part Manufacturer Part Remarks Number Number Supply Pump 294000 062 R2AA13800 Eu 275800 837 2 18881 low output engine MAZDA3 high output 275800 838 R2AK18881 275800 839 R2AW18881 MAZDAS for Australia 275800 914 R2AA18881 MAZDAG low output engine Engine ECU MAZDA6 intermediate 275800 915 R2AB18881 output engine MAZDA6 high output 275800 916 R2AC18881 engine 275800 917 2 18881 MAZDAG for Australia Manifold
27. on the drive gear plate component with drive gear installed on the rear of the camshaft If the TDC sensor is removed installed or replaced magnetized objects such as metal shavings adhering to the sensor may cause fluctuations in the magnetic flux of the MRE As a result engine control may be adversely affected due to abnormal sensor output Sensor External View Sensor Mounting Position OUT GND Vort Camshaft Position Sensor Camshaft Position Sensor Pulse Chart Cam Angle 7 15 CA Camshaft v quu SEQ Output n Below 1 V Position 1 Ground Sensor AV va 90 CA 90 CA 90 CA Sensor 4 V or More 360 CA Drive Gear Plate z Q004332E Operation Section 1 16 3 Manifold Absolute Pressure MAP sensor The MAP sensor is a semiconductor type pressure sensor which utilizes the electrical resistance of the silicon element The electrical resistance changes with the fluctuations in the pressure applied to the silicon element VIN TRI OUT GND kPa abs Q001140E Operation Section 1 17 4 Accelerator pedal module accelerator pedal module is a single unit consisting of the accelerator position sensor and accelerator pedal Hall element sensor is used for the detecting element Durability is improved through the use non contact type sensor There are both main sub accelerator position sensors and the accelerator position is detected
28. pa ves ves ves ve P1589 Diesel Throttle Valve Stuck Se P2101 Actuator Control Motor Circuit Range Performance i c EGR Fw nn sms a HE SE EMIT Boost Control Circuit Open P0078 ambien Air Temperature Sensor Range P0071 Performance P2456 Diesel Particulate Filter DPF Differential Pressure Sensor Circuit Intermittent Erratic P2002 Particulate Trap Efficiency Below Threshold Trap Efficiency Below Threshold Peer e Differential Pressure Sensor Circuit Range P2453 Performance PPP ER ER HM EE NZ ory vos m Te Operation Section 1 34 Gus S Applicable Vehicle MIA lagnosis MAZDA3 MAZDAG Lost Communication With Anti Lock Brake System ABS Control Module 00121 Yes o B Lost Communication With Dynamic Stability Control DSC Lit only for the MAZDA6 U0121 2 d 0 Lost Communication With Instrument Panel Cluster IPC Control Module es No es es U0155 o o oj o0 S o ata 0 2 Z ojo o o Turbocharger Boost Control Position Sensor A P256 CUN Yes Circuit High s s 2 o o o Y lt 2 lt o o Turbocharger Boost Control Position Sensor A P2564 Yes Circuit Low P245D EGR Cooler Bypass Control Circuit High
29. th Cylinder i ISC FCCB Correction Correction _ Learning CN 7 Value Q001251E Operation Section 1 25 7 5 Run Dry Prevention RDP Control Outline When the diesel fuel is completely expended engine restartability may worsen To prevent the aforementioned situation a pseudo gas shortage condition is created alerting the driver that fuel is in short supply The driver is thus prompted to refuel the vehicle therefore avoiding an actual empty fuel tank Operation The engine is operated according to processes 1 through 5 in the figure below 1 A fuel gauge E level signal is inputted to the engine ECU via CAN communication 2 The engine ECU command injection quantity begins to be summed 3 When the summed value for the engine ECU internal command injection quantity is greater than A the injection quantity guard is set to value a and output control is initiated DTC P115A is detected 4 When the summed value for the engine ECU internal command injection quantity is greater than B the injection quantity guard is set to value b and hesitation operation is initiated For details on injection quantity control during hesitation refer to the figure below DTC P0313 is detected 5 When the summed value for the engine ECU internal command injection quantity is greater than C the engine is stopped In addition the injection quantity guard is set
30. the target temperature for DPF manual regeneration Exhaust gas temperature sensors are attached at two locations on the oxidation catalytic converter The exhaust gas temperature sensors utilize thermistor elements in which the resistance value varies according to the exhaust gas temperature Exhaust Gas Temperature Sensor Cover Sheath Pin Ace 8 Thermistor Element Oxidation Catalytic Converter Z Exhaust Gas Temperature Sensor No 2 Exhaust Gas Temperature Sensor No 1 Q004337E When the exhaust gas temperature increases the resistance value decreases Conversely when the exhaust gas temperature decreases the resistance value increases Exhaust Gas Engine ECU Temperature Sensor Exhaust Gas Temperature Sensor Characteristic Resistance Small 4 Exhaust Low Temperature High Q004338E Operation Section 1 28 Differential pressure sensor differential pressure sensor detects the difference in pressure between the exhaust gas pressure before and after the DPF This pressure difference is used to predict the amount of PM accumulation in the DPF Differential Pressure Sensor Oxidation Catalytic Exhaust gas Exhaust gas pressure before pressure after Converter nu passing DPF passing DPF Differential Pressure Sensor Q004339E differential pressure sensor converts the exhaust gas pressure values before and after the to voltage signals the
31. ure Yes ves Ye m P0117 Engine Engine Coolant Temperature 1 Circuit Low Temperature 1 Circuit Low ee epee Engine Coolant Temperature 1 Circuit Range P0116 Yes Performance P0098 Intake Air Temperature Sensor 2 Circuit High P0097 Intake Air Intake Air Temperature Sensor 2 CircuitLow Intake Air Temperature Sensor 2 CircuitLow 2 Circuit Low Intake Air Temperature Sensor 2 Circuit WEN P0096 Performance P0113 Intake Air Temperature Sensor 1 Circuit High P0112 Intake Air Intake Air Temperature Sensor 1 CircuitLow Intake Air Temperature Sensor 1 CircuitLow 1 Circuit Low P0111 Intake Air Temperature Sensor 1 Circuit Range Performance P0183 Fuel Temperature Sensor A Circuit High P0182 Fuel Temperature Sensor A Circuit Low Fuel Temperature Sensor A Circuit Range Unlit only Performance for the MAZDA6 P0193 Fuel Pressure Sensor A Circuit High P0192 Fuel Rail Pressure Sensor A Circuit Low P0191 Fuel Rail Pressure Sensor A Circuit Range Performance P0108 Manifold Absolute Pressure MAP Barometric Pressure Circuit High Input P0107 Pressure Circuit Low Input MAP Barometric Pressure Circuit Range Performance P2229 Barometric Pressure Circuit High P0106 Operation Section Gs D T Applicable Vehicle TE lagnosis MAZDA3 MAZDAG P2228 Barometric Pressure Circuit Low P2227
32. w quantity MAF Meter E2 THA Ex B Hot Cold Wire Control wire Circuit T Fixed 7 Resistance Cold Wire pees MAF Meter Voltage Characteristic Intake Air MAF Meter Low IntakeAir High Quantity Q004334E Operation Section 1 19 7 CONTROL SYSTEM 7 1 Outline 1 Sensor system Sensor Name Mass Air Flow MAF Sensor Uses a hot wire to detect the intake airflow rate Located in the air flow meter this sensor detects the intake Air Temperature Sensor air temperature Intake Air Temperature Detects the intake WAF sensor after the turbocharger Sensor Coolant Temperature Sen Detects the water temperature sor Rail Pressure Sensor Detects the fuel pressure in the rail Fuel Temperature Sensor Detects the fuel temperature in the supply pump MAP Sensor Detects the intake air pressure Air Pressure Sensor Detects the air pressure Accelerator Position Sen Attached to the accelerator pedal this sensor detects the sor position of the accelerator pedal Crankshaft Position Sen sor NE sensor Fuel Injection Intake Restriction Detects the engine speed based on the crankshaft position Camshaft Position Identifies the cylinder based on the rotation of the rotor Sensor TDC sensor attached to the camshaft Starter Signal Starter voltage signal during starting Vehicle Speed Sensor Detects the vehicle speed A F Sensor UHEGO Detects the exhaust gas
33. ystem System components are made by Engine ECU manufacturers other than DENSO PER RE RE REE RE SE ERE E SERRE RE SE SESE EERE RES ERE EE FY A Meter Display L DCM th a CAN Communication Urea Temperature Sensor Urea 115 from Engine a Differential p Pressure v a n n a a a a a E a a u C n u EI U Sensor N Exhaust Gas Temperature E SCR NOx Sensor DOC Sensor 1 Exhafst Gas Exhaust Gas I I R H RT T R T H R T T T T T R T T T T T R T T T T R R R TR T T P T T T T RT RE R Temperature DOC DPF Temperature A F Sensor Sensor 2 Sensor 3 Q004518E SCR The SCR is a urea selective type reduction catalyst Urea is used to chemically decompose and convert the NOx contained in the exhaust gas into non hazardous materials Urea is added to the exhaust gas via injection causing NOx decomposition The resulting non hazardous water H20 and nitrogen gas N2 are then discharged Operation Section 1 30 8 DIAGNOSTIC TROUBLE CODES DTC 8 1 About the Codes Shown in the Table The SAE DTC indicates codes that are output through the use of the WDS SAE Society of Automotive Engineers 8 2 DTC Table S Applicable Vehicle Applicable Vehicle iagnosis em MAZDA3 MAZDAG Poses Ye ve Yoo Low Xe Yor e Engine Coolant Temperat

COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation

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