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COOLING SYSTEM CONCERNS-OVERHEATING [SKYACTIV-X]

COOLING SYSTEM CONCERNS-OVERHEATING [SKYACTIV-X]

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Troubleshooting item

Cooling system concerns-overheating
Description
•  The engine coolant temperature is abnormally high.
Possible cause
•  Engine heat generation amount is excessive
―  Engine speed is high and remains high for continuous long periods
•  PCM DTC is stored
•  Improper operation of A/C system
•  Insufficient air blow volume
―  Cooling fan inoperative
―  Active air shutter is fully-closed and does not operate
―  Fan rotation speed decreases (such as charging system malfunction) due to battery voltage decrease
―  ECT sensor No.1 malfunction (value lower than actual engine coolant temperature detected)
―  ECT sensor No.2 malfunction (value lower than actual engine coolant temperature detected)
―  ECT sensor No.3 malfunction (value lower than actual engine coolant temperature detected)
•  Fan control module malfunction
•  Cooling fan system malfunction
―  Cooling fan motor malfunction
•  Active air shutter malfunction
•  Cooling system cap malfunction
•  Improper indication of high engine coolant temperature warning indication
―  ECT sensor No.1 signal malfunction
―  ECT sensor No.2 signal malfunction
―  ECT sensor No.3 signal malfunction
―  Center display malfunction
―  Body control module (BCM) malfunction
•  Multi-information display malfunction
•  Blown fuse
•  Engine coolant system malfunction
―  Improper engine coolant level
•  Water pump malfunction
•  Electric water pump malfunction
―  Engine coolant performance deterioration
―  Coolant leakage (engine internal, external)
―  Improper water/anti-freeze mixture
―  Thermostat malfunction (not fully open)
―  Electric thermostat malfunction (not fully open)
―  Coolant switching valve (CSV) malfunction (not fully open)
―  Radiator malfunction (clogging)
―  Inappropriate engine coolant concentration (engine coolant in radiator freezes and engine coolant does not flow)
―  Foreign matter penetration in engine coolant
•  Leakage around heater unit in passenger compartment
•  Drive belt damage
System wiring diagram
•  Not applicable
Connector diagram
•  Not applicable

Diagnostic Procedure

Step

Inspection

Results

Action
1
INSPECT VEHICLE CONDITION FOR EFFECT ON MALFUNCTION
•  Verify how the customer drives the vehicle by asking the customer the following:
―  Engine speed is high and remains high for continuous long periods like when climbing a long, steep grade.
•  Is the engine generating excessive heat when driven?
Yes
Explain to the customer that the vehicle is normal and give them advice how to use vehicle and provide a specific example of the conditions in which the engine overheats.
No
Go to the next step.
2
VERIFY PCM DTC
•  Perform the DTC inspection for the PCM.
•  Are any DTCs displayed?
Yes
Repair the malfunctioning location according to the applicable DTC troubleshooting.
(See DTC TABLE [PCM (SKYACTIV-X)].)
No
Go to the next step.
3
VERIFY DTCs
•  Perform the DTC inspection for the following modules.
―  Mazda M Hybrid battery
―  DC-DC converter (Mazda M Hybrid)
―  Integrated starter generator (ISG)
•  Are any DTCs displayed?
Yes
Repair the malfunctioning location according to the applicable DTC troubleshooting.
(See DTC TABLE [Mazda M Hybrid BATTERY].)
(See DTC TABLE [DC-DC CONVERTER (Mazda M Hybrid)].)
(See DTC TABLE [INTEGRATED STARTER GENERATOR (ISG)].)
No
Go to the next step.
4
DETERMINE IF MALFUNCTION CAUSE IS A/C SYSTEM OR OTHER
•  Start the engine and run it at idle speed.
•  Turn the A/C switch off.
•  Does the A/C compressor disengaged?
Yes
Go to the next step.
No
Perform the symptom troubleshooting “A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY”.
(See A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [SKYACTIV-X].)
5
INSPECT ECT SENSOR No.1 SIGNAL
•  Access the ECT PID using the M-MDS.
•  Compare the ECT PID and high engine coolant temperature warning indication operation.
•  Is the ECT PID value same as warning indication readings
Yes
Go to Step 7.
No
Go to the next step.
6
INSPECT ECT SENSOR No.1 FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Inspect the body control module (BCM).
(See BODY CONTROL MODULE (BCM) INSPECTION [(E)].)
•  If there is any malfunction:
―  Replace the body control module (BCM) and perform the repair completion verification.
•  If there is no malfunction:
―  Replace the center display and perform the repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
7
INSPECT ECT SENSOR No.2 SIGNAL
•  Access the ECT2 PID using the M-MDS.
•  Compare the ECT2 PID and high engine coolant temperature warning indication operation.
•  Is the ECT2 PID value same as warning indication readings
Yes
Go to Step 9.
No
Go to the next step.
8
INSPECT ECT SENSOR No.2 FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Inspect the body control module (BCM).
(See BODY CONTROL MODULE (BCM) INSPECTION [(E)].)
•  If there is any malfunction:
―  Replace the body control module (BCM) and perform the repair completion verification.
•  If there is no malfunction:
―  Replace the center display and perform the repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
9
INSPECT ECT SENSOR No.3 FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Inspect the body control module (BCM).
(See BODY CONTROL MODULE (BCM) INSPECTION [(E)].)
•  If there is any malfunction:
―  Replace the body control module (BCM) and perform the repair completion verification.
•  If there is no malfunction:
―  Replace the center display and perform the repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
10
INSPECT COOLANT SWITCHING VALVE (CSV) FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See COOLANT SWITCHING VALVE (CSV) REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
11
INSPECT FAN CONTROL MODULE FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
12
INSPECT ACTIVE AIR SHUTTER FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION.)
13
INSPECT COOLING SYSTEM CAP FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
14
INSPECT RELATED PART CONDITION
•  Inspect the following:
―  Engine coolant performance
―  Coolant leakage (engine internal, external)
―  Water and anti-freeze mixture
―  Thermostat (not fully open)
―  Electric thermostat malfunction (not fully open)
―  Fuses
―  Inappropriate engine coolant concentration (engine coolant in radiator freezes and engine coolant does not flow)
―  Foreign matter penetration in engine coolant
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
No
Go to the next step.
15
VERIFY IF MALFUNCTION CAUSED BY LACK OF ENGINE COOLANT
•  Inspect the engine coolant level.
•  Is there any malfunction?
Yes
Add engine coolant and verify that there is no engine coolant leakage.
(See ENGINE COOLANT REPLACEMENT [SKYACTIV-X 2.0].)
(See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-X 2.0].)
•  If there is any malfunction:
―  Repair or replace the malfunctioning location and perform the repair completion verification.
No
Go to the next step.
16
INSPECT DRIVE BELT
•  Inspect the drive belt.
•  Is the indicator mark on the drive belt auto tensioner within the normal range?
Yes
Go to the next step.
No
Replace the drive belt and perform the repair completion verification.
(See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
17
INSPECT RADIATOR FOR CLOGGING
•  Inspect for clogging in the radiator.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
No
Replace the engine coolant and perform the repair completion verification.
(See ENGINE COOLANT REPLACEMENT [SKYACTIV-X 2.0].)
Repair completion verification 1
VERIFY THAT VEHICLE IS REPAIRED
•  Install/connect the part removed/disconnected during the troubleshooting procedure.
•  Has the malfunction symptom been eliminated?
Yes
Complete the symptom troubleshooting. (Explain contents of repair to customer)
No
Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.
(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)
•  If the CAN communication is normal, perform the diagnosis from Step 1.
―  If the malfunction recurs, go to the next step.
Repair completion verification 2
VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING
•  Verify repair information and verify that there is a new calibration in the PCM.
•  Is there a new calibration in the PCM?
Yes
Perform the PCM reprogramming and verify if the malfunction symptom was corrected.
•  If the malfunction recurs, replace the PCM.
No
Replace the PCM.
(See PCM REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)