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Diagnosis & Repair Procedure

WARNING: This page is about a different car, the 2002 Mazda Protege5 and 2002 Mazda Protege. However, it is still accessible from the selected car via links, so may be relevant.
  1. Turn ignition off. Connect scan tool to DLC-2. Turn ignition on, engine off. Monitor for FREEZE FRAME DATA and ensure data has been recorded. Check service bulletins for repair information related to this DTC. If repair information is not available, go to next step. If repair information is available, perform diagnosis and repair as necessary. After repair, go to step  9.
  2. Start engine. Turn on A/C to operate cooling fan. Using scan tool, check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTC P0480 is present, go to next step. If DTC P0480 is not present, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
  3. Turn ignition switch off. Remove cooling fan relay. Cooling fan relay is located in main fuse block at left side of engine compartment. Check for loose or damaged terminals, poor contact or corrosion. If problem is found, repair or replace as necessary. After repair, go to step  9. If no problem is found, go to next step.
  4. Turn ignition switch on, engine off. Measure voltage between ground and cooling fan relay terminal "C". See Fig 1. If battery voltage is present, go to next step. If battery voltage is not present, repair or replace wire harness. After repair, go to step  9.
  5. Using fused jumper wires, apply battery voltage to cooling fan relay terminal "A" and ground terminal "B". See Fig 1. Check for continuity between cooling fan relay terminals "C" and "D". Continuity should be present. If continuity is not as specified, replace cooling fan relay. If continuity is as specified, go to next step.
  6. Disconnect PCM 104-pin harness connector. Check connector for loose or damaged terminals, poor contact or corrosion. If problem is found, repair as necessary. After repair, go to step  9. If no problem is found, go to next step.
  7. Check for continuity between ground and cooling fan relay fuse block terminal "B" (Red/Black wire). If continuity is present, repair short to ground in Red/Black wire between cooling fan relay and PCM 104-pin harness connector terminal No. 47. See WIRING DIAGRAMS article. Go to step  9. If continuity is not present, turn ignition switch on. Measure voltage between ground and cooling fan relay terminal "B" (Red/Black wire). If battery voltage is present, repair Red/Black wire for short to power. After repair, go to next step. If about zero volts is present, go to next step.
  8. Turn ignition switch off. Check for continuity in Red/Black wire between cooling fan relay fuse block terminal "B" and PCM 104-pin harness connector terminal No. 47. See Figure. If continuity is present, go to next step. If continuity is not present, repair open in Red/Black wire. After repair, go to next step.
  9. Reconnect all connectors. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Start engine. Turn A/C on. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTC P0480 is present, replace PCM and go to next step. If DTC P0480 is not present, go to next step.
  10. Cycle ignition switch from off to on. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If no other DTCs are present, testing is complete. If any other DTC is present, go to applicable test and repair.
Fig 1: Identifying Cooling Fan Relay Terminals
G00042188Courtesy of MAZDA MOTORS CORP.
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