MAZDA 6 DITD P0204 problem

[dimitar]

Hi guys i hope some of you will have the experience to help. Im having some trouble with mazda 6 2.0 diesel common rail . KTS540 reports P0204 cylinder 4 open circuit . I have swapped the injectors 3 with 4 same problem the i swapped the calibrating resistors still same checked the wiring everything looks untouched measured all the resistances of the wiring 0 ohms. Looking at the wiring diagrams there is an injector Driver beneath the air filter box bolted on the chasiss which receives digital signal from the ecu to fire the injectors. I would like to know did anyone had any experince with these modules because all the things point out the problem on the engine ecu and this injector driver module. Waiting for replys

[dimitar]

Come on guys , none of you work with mazdas?

[MOBILTRONIC]

Hello.If you replaced 3 and 4 connectors, such error appeared again?It should be a fault to the third nozzle.Does the engine can start?If you can not,then attempt to disconnect one by one nozzle and each time try to start the engine.Nozzle that is disconnected,and engine in this case starts,she is your real problem.Resistance at the nozzle is small (approx.1-2 Ohm)but the large power consumption,translating into ampere,20A.Maybe a short circuit on a nozzle(maybe first),so you because you have a problem.Trying a little experiment at the nozzle, check the wiring connections,so we hear later.Best regards.

[exxl]

mobiltronic is right,

did you try to disconnect the 4 nozzle at all and then start the engine? or you just replaced the nozzles and left the connectors connected ?

try like mobiltronic has said disconnect connectors from nozzles one by one and try to start engine, when and if the engine start then you know which nozzle is faulty.

[Ashraf6119]

Hi Dimitar

I am sure you have checked the wiring properly as you getting a fault code for Open Circuit mean there is a brake in the wiring or the Injector it self is faulty..........But, again as you have already tried to swap from #3 to #4 and you still have the same fault.

Have you tried the check if you getting any pulsing signals at the Cylinder #4 at idle....can you check it with Noid Light.

Ash

[dimitar]

Well guys im very thankfull for your replies i thougth that no one will reply anyway here is the situation. The car starts and runs ok for days and suddenly dies then you have to wait for 5 minutes and it wil restart again without problem. The diagnostic says P0204 cylinder 4 open circuit, ive tried to simulate the fault by disconecting the plugs from the injectors at idle and the check engine comes on and the engine wouldnt rev past 1500rpms, BUT if you disconect an injector when the engine is reviing past 2500rpms the engine dies.
Things i have done:
1. swapped injector 3 with injector 4 to see if the same fault reapears or will be another fault. Same fault P0204 happened and this is excluding the injectors

2. There are calibrating resistors at the injecors to compensate for the heat of the engine to calibrate the injectors, swapped cylinder 3 with cylinder 4 same thing P0204.



3 Disconected injector 1 to check the liability of the KTS540 everything ok


4.Checked all the wiring the conectors and ended up at the RF5C module bolted on the chassis beneath the air filter. This is a first time i see Common Rail Diesel injectors driven by a separate module and not the ECU. Im not into mazdas too much i hope some of you had similar expirience . Regards



P.S. Opened the injector driver module and guess full of jelly hybrid shit whch receives 5v digital signal from the main ECU (EEC5 acording to user manuals or EDC16xx acording to KTS540 never the less EDC16 never used external injector Driver module so it has to be EEC5 ford crap ) to fire the injectors .

[cleevesy]

i would say that the injector driver module was where your fault lies , looking at what you have said , check wiring and connections to ecu and injectors again just to be sure and get one ordered and if its not that its something else

[dimitar]

Finally stripped the whole car , wiring problems it turned out that the wires from the injector module started rubbing on the intercooler and finaly lost contact. New wires in soldered everything works like charm. Greetings all

[Ashraf6119]

Hi Dimitar,

I am glad at last you got it sorted I like a person who never give up the headache jobs...........

Ash

[dimitar]

mazda still works like charm

[HeXeN]

Is possible to change used RF5C injector module? any adaptations needed?