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Issues with Throttle Response

18K views 38 replies 5 participants last post by  HerronScott  
#1 ·
OK, I thought about the title a bit, but couldn't come up with anything that describes my issue better.

I have a 2004 6 S MTX that I purchased new that currently has about 85,000miles. Have always done my own maintenance, with the exception of a new clutch early on at 17k(made odd noises)in warranty and a new actuator for the ventilation mixing valve (for lack of a better name).

I'll get to the real problem in a minute, but first some valuable background info.

I must admit I drive a bit like a granny when it comes to shifting. The 6 never seemed to mind, even shifting early into 2nd at low RPM, it seemed to have descent torque and not complain. In the last year this has changed, shift too early and you are rewarded with a bit of whiplash as the engine seems to cut out and come back again. Wasn't too worried about it, would just rev at least to 2,500 prior to shift.

We decided to sell the 2004 to my daughters, and I would get another car to drive to work. I have to say, I wanted to get something smaller for them, but my wife insisted on something more substantial, in case they get into an accident.

As you can imagine, learning to drive stick in a 3.0L V6 that likes to give you whiplash when shifting at low RPM can be challenging. So, I had it on my to do list to look into this further.

Anyway, that accident thing that my wife was concerned about, happened:(. Casey rear ended a Cadillac SUV (smaller one) and wedged the bumper up under. (See Attached Pics)

Double :( I was only carrying liability insurance on the car.

Regardless, there are not many projects that I shy away from. In fact, I had a similar accident (with a tree) when I was her age, and rebuilt the car soon after.

Post accident, I knew that the engine ran, had to get it on trailer. So my estimate was that I could fix for about $1k.. As my estimates go, that is code for $2k.

So, I've poured ~2k into parts (hood, bumper cover, radiator, condenser, headlights, hood latch, front valve cover, pass engine mount, air bags, seat belt, K&N cold air intake etc..). The last pic shows what it looks like now.

You may have noticed engine mount in that list. The top bolt on the passenger side engine mount broke, and the pass side of the engine was shifted to the rear about 2". After replacing the mount, I was able to jack up the engine and move it back into place. The valve cover seems troubling as well. One of the studs that holds that nice engine cover on got pushed and opened a small hole in the cover..

After getting the body into a drivable condition, I started checking out the engine. Initially when I started it, it ran a bit rough, in that the idle would hunt. I ended up finding a slice in a hose coming off the back of the intake, caused by an impact with the firewall. After that, idle is smooth.

The reason for the K&N is that the airbox got cracked up pretty good, and I couldn't see throwing too much money into a used one. I expected a different feel with the K&N, which wasn't optimal in trying to troubleshoot. Aside from the guttural sound you get from it, the engine seemed to bog down if you punched it quick.

As it stands right now. If you start it up cold, and road test, it exhibits similar symptoms from pre-accident (doesn't want to accelerate at low RPM. Once it warms up, the condition gets significantly worse. You could get it up to highway speed, but good luck if you want to pass someone.


After a lot of research on this forum, looking at the symptoms, I had myself convinced that my pre-cats were clogged and backpressure was causing my issues. Additionally I thought that the K&N was exacerbating the existing condition with the increased airflow.

Sunday I pulled the O2 sensors in front of both pre-cats. Running the engine with these ports open, led to good throttle response in the garage. Obviously also a fairly loud engine!!

So, convinced backpressure was the cause, I purchased a pressure gauge that screws into the O2 port.

Just tested both front and rear ports. At idle it doesn't even register a 1/2psi of pressure. Revving to 2500 gives similar results. Snapping the throttle, yields a gauge needle that jumps instantaneously to 6psi or so (hard to tell it moves so fast), then immediately back to near zero.

Was all geared up for the exhaust manifold / pre-cat replacement. But now I'm stumped. The limited view I got looking in through the front O2 port didn't reveal anything about the cat that looked odd to me, typical honeycomb.

Could a bad EGR or something cause this? I have access to a scanner (Torque Pro Android App), if there is anything specific I should check for. I haven't seen anything odd, but must admit I don't know exactly what I'm looking at.

Help!!
 

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#2 ·
Let's try this again

Hi!

Been lurking around this forum for a long time. As above, I finally came across something that spurred me to post.

Plan on helping out wherever I can.


Probably shouldn't have been so long winded on my first post!!

Still having same issue. Swapping out coil packs to eliminate that.


Rod
 
#3 ·
No, no, you're fine.

I'm not really sure what your readings should be on the precats...but it seems like they're okay. If it looks like the catalyst has started to crack and break apart, you may have issues.

Any unusual noises? The car I got with precat failure would get up to highway speed, but like you said, no chance of passing anyone. But it was making loads of noise.

I'm not so sure on the coils - if they were that bad I would imagine it would throw misfire codes.


CEL on or blinking at any time?

Also, your repairs look good - did you have to straighten anything or was it all bolt on parts?
 
#4 ·
No, no, you're fine.

I'm not really sure what your readings should be on the precats...but it seems like they're okay. If it looks like the catalyst has started to crack and break apart, you may have issues.

Any unusual noises? The car I got with precat failure would get up to highway speed, but like you said, no chance of passing anyone. But it was making loads of noise.

I'm not so sure on the coils - if they were that bad I would imagine it would throw misfire codes.


CEL on or blinking at any time?

Also, your repairs look good - did you have to straighten anything or was it all bolt on parts?
Thanks Kevin,

Guidance I saw said less than 2.5psi at idle, something similar at 2500RPM.. Not really getting anything to indicate I have a backpressure issue.

Noises... While driving, no noises to speak of. If you rev a whole bunch you will get some 'popping' coming from the intake area, almost like a blow back of some sort... Another interesting note, if you start it cold, and let it idle, as it heats you get some loud cracking noises that seem to come from the plastic intake, usually 3 or 4 sharp cracks until it is up to temp. I've pulled the intake completely, and can't find any indications of damage. Remember it did hit the firewall hard enough to slice the rubber hose coming out the back. Have also closely inspected the lower intake assembly (metal on this car) and both heads, as much as I could.

No misfire codes. No CEL. Only pending code was relating to me running it with one of the O2 sensors unplugged while testing (bad heater circuit indication).

I'm not sold on the coils either, but I will say that my MPV (140k miles) has the same engine, and I've replaced just about all of them. On a couple it did not throw misfire codes. For the $70 for 6 coils, I'll give it a shot.

Straightening... She went under the SUV, so the front bumper remained intact. Did bend where it attaches to radiator core support, and top flanges of the bumper, nothing a hammer couldn't fix. If you look real close in the finished picture, the gap between hood and fender is wide on both sides, just sheet metal getting pushed I believe. Will address that after I am sure the engine is coming around. Similar approach to the passenger air bag, I'm not pulling that dashboard until I'm sure the car is getting back on the road.

Rod
 
#6 · (Edited)
Link below are some videos, Watch them. Should give you some insight about the coil packs.
- That car should move right along. I'd be highly suspect of BIG vacuum leak and/OR the coil packs (COPs). DO nOt exceed the recommended plug gap when put new plugs in. Check them and be careful not damage them if adjustment is required. Also measure the old ones and report back. If over spec, it cause this....

- PS just because you have no misfire codes doesn't mean much. So ya, crank up the Droid and post up a log file (save as xxxx.txt here in the forum). If possible telling us along the way what the conditions were. IIRC the default profile captures plenty in the PRO version.

ping me with @Final Impact and I'll take a look.

Watch these and look through this thread.
http://forum.mazda6club.com/3-0l-v6...l-v6/258158-final-impacts-running-list-links-help-solve-issues.html#post3481346
See also post # 11, 13, 33
 
#7 ·
Link below are some videos, Watch them. Should give you some insight about the coil packs.
- That car should move right along. I'd be highly suspect of BIG vacuum leak and/OR the coil packs (COPs). DO nOt exceed the recommended plug gap when put new plugs in. Check them and be careful not damage them if adjustment is required. Also measure the old ones and report back. If over spec, it cause this....

- PS just because you have no misfire codes doesn't mean much. So ya, crank up the Droid and post up a log file (save as xxxx.txt here in the forum). If possible telling us along the way what the conditions were. IIRC the default profile captures plenty in the PRO version.

ping me with @Final Impact and I'll take a look.

Watch these and look through this thread.
http://forum.mazda6club.com/3-0l-v6...l-v6/258158-final-impacts-running-list-links-help-solve-issues.html#post3481346
See also post # 11, 13, 33
Thanks..

I replaced the plugs ~20k ago, and was extremely anal about setting the appropriate gap. However, I do plan on pulling them all to recheck.

The Android app and OBDII plug was brought over by a friend, not sure if he has the pro version of Torque. The report he sent was a list of tests. The only oddity being this entry..
MID:$21 TID:$27
- Catalyst Monitor Bank 1
Max: 3mHz Min: 20,561mHz
Test result value: 10,016mHz
FAIL
Looks to be an issue with the range (Max > Min),, appears they are reversed..

I'll see if I can borrow again this weekend, and if it is the Pro version. I also ordered the ELM327 WIFI OBD2 reader for myself, as I don't have an Android device. Any recommendation on either iOS or PC software that would be good with this? I'm not someone who is going to be clocking my 0-60 times while driving, just want it for diagnostics.

Plan for weekend.
-Pull Intake
-Check all plugs and CPs
-Check EGR, clean as required
-If possible get some logs..

Will report back soon.
 

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#12 ·
Rod - ditch these and ADD RPM!!!!

Fuel Rail Pressure(psi) Intake Manifold Pressure(psi)

It will make it much more useful.... Good Job!

Also, look at the O2 screens; B1S1, B2S1 and maybe get a screen shot of each at cruise on a flat road and at idle in gear parked. Your trims are whacked!
 
#13 ·
Rod - ditch these and ADD RPM!!!!

Fuel Rail Pressure(psi) Intake Manifold Pressure(psi)

It will make it much more useful.... Good Job!

Also, look at the O2 screens; B1S1, B2S1 and maybe get a screen shot of each at cruise on a flat road and at idle in gear parked. Your trims are whacked!
Here is a new file with more interesting data..

What does the Turbo Boost/Vacuum gauge give you on a non turbo vehicle.. I added it in toward the end of this data set. I noticed that the vacuum indication is relatively steady at 26 hg/in or something like that.. When I get in the gas to cause the issue, it loses the vacuum and goes to the boost side.

I had issues capturing the screen shots while driving.. Will have to get someone to help me out tomorrow. I attached a few, but I'm not 100% on when each one was taken..

Rod
 

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#14 · (Edited)
Tell again when it runs bad?
I'd assume it idles ok, pulls light throttle OK, but falls on its face under heavy load?

Example is at 8:05 in your log, has about 75% load, 50% throttle, and 2600 RPM. Your STFTs go negative indicating its being told to LEAN it out when it should be richening it it up.

So, either you have big vacuum leak only under load; like the coupler from the air box to the TB is torn, or a big vacuum leak elsewhere. Don't be alarmed about the EGR doing its thing its normal. However, if the EGR pipe is moded to change the flow pattern, this could be hurting you. Do you know, is it cut off?

Other than that, that leaves the MAF under reporting the facts. Its flowing more than it reports, making it lean and retarding the timing so it falls on its face.
It been a while since I studied these logs. The MAF flow rates would have been good to know as well as ignition advance. Sorry I'm rusty. What I see is your L and STFT are roughly 12 to 14 full points lower than mine for the same load, RPM, TPS. I didn't see the Ignition advance but can only speculate that its low as in 7 degrees advance which kills its motivation.

Also, can you list all repairs made thus far. Condensed.
Tks!

You ever drive it with the upper o2 sensors out? I personally I have never seen logs from a car with plugged cats but I think this may be the cause of nothing can be pinned to a leak or the MAF. Do you have the busted air box? Has it ever ran proper with the CAI? Any chance the busted air box could go back on. It could be combination of things. Restrictive cats (or even downstream) and MAF issues. Best guess....
 
#15 ·
Tell again when it runs bad?
I'd assume it idles ok, pulls light throttle OK, but falls on its face under heavy load?
Yeah, you got it right. If I always ease into the throttle, it will work OK. Also, when cold it runs better than when hot.

So, either you have big vacuum leak only under load; like the coupler from the air box to the TB is torn, or a big vacuum leak elsewhere. Don't be alarmed about the EGR doing its thing its normal. However, if the EGR pipe is moded to change the flow pattern, this could be hurting you. Do you know, is it cut off?
I'm the original owner, no mods to the EGR.

Other than that, that leaves the MAF under reporting the facts. Its flowing more than it reports, making it lean and retarding the timing so it falls on its face.
It been a while since I studied these logs. The MAF flow rates would have been good to know as well as ignition advance. Sorry I'm rusty. What I see is your L and STFT are roughly 12 to 14 full points lower than mine for the same load, RPM, TPS. I didn't see the Ignition advance but can only speculate that its low as in 7 degrees advance which kills its motivation.
Gonna pull everything apart today, maybe I'll find that big leak!! Then I'll add in these other items..

Also, can you list all repairs made thus far. Condensed.
Tks!
No engine bay repairs since new, other than clutch at 17k miles. The accident took out the airbox, hose from airbox to TB, rad, condenser, passenger engine mount. Also, left most vacuum hose on back of intake manifold. The p/s pump pully has some damage, but appears round and true. I mention this because once when the symptoms were at there worst, I got a squealing noise from under the hood. Have contemplated running without the accessory belt just to rule out anything over there.

You ever drive it with the upper o2 sensors out? I personally I have never seen logs from a car with plugged cats but I think this may be the cause of nothing can be pinned to a leak or the MAF.
Ran it with them out, but didn't drive it. Throttle response seemed good. Was a bit concerned with all that hot air blowing around under the hood. I did test for back pressure, and the results seem to indicate no restriction.

Do you have the busted air box? Has it ever ran proper with the CAI? Any chance the busted air box could go back on. It could be combination of things. Restrictive cats (or even downstream) and MAF issues. Best guess....
It's in pretty bad shape, and the hose has a huge crack as well. I'll see if I can tape it up.


Rod
 
#16 ·
From the accident, I wouldn't rule out the intake being cracked. Any chance it hit the cab and maybe has a crack in it?

Other than the wiring harness, it only takes about 45" to pull it. It might be worth looking at.

Q? Does it just not go, or is it popping, shaking, chugging, misfiring, etc. More detail so we know its not COPs. The trims on Bank 2 (front of engine) in the worst shape. If I were you and had the manifold off, I'd inspect the plug and grab one of the coil testers like those shown here in post #2 .
Without some detail its very hard to pinpoint what it is over the web as so many things are unknown to me.
 
#17 ·
Take a look at all these ports and make sure none are snapped or cracked...
Image


Also, I rescaned the whole thread - the O2 sensors look like crap. Not sure if thats a logging issue or what but they don't look much like a sinusuidal wave form at all.

Image
Image


From another software, AutoTap:
Image




Plugs should look like so:
Image
 
#18 · (Edited)
I think we got it!!

First I would like to thank Final Impact, Kevin and Brandon for helping me out with this.

Been a long day, thought I would take you through it.

Pulled the intake this morning, and inspected it thoroughly (3rd time I have done this).


For good measure I disconnected the throttle body to have a look.


Also pulled off and inspected the EGR.. I didn't end up doing the full cleaning. Hand cycling the valve was smooth and required little effort. Could also hold pressure with the valve closed, and pass air when open.

When I pulled the cylinder 1 coil pack, I noticed it was quite black.. Subsequently pulling the plug revealed that it was very scorched.

:eek:

Did I mention how anal I am?? I can almost guarantee that I checked and re-checked the torques on the plugs when I replaced them 20k ago... However, I am 42 and the memory does slip on occasion.. Replaced plugs with 6 new NGKs..

There was a bit of oil in the bottom of Cyl 2 and Cyl 3 spark plug wells. So I went ahead and replaced the head cover gasket. Had this on hand since I did the front when that was off.

Had to remove the VVT hydraulic actuator in order to remove the head cover.


I ordered the 6 pack of CPs for $70 on Amazon.
Amazon.com: #IC23 02-07 Mazda Ignition Coil 6pcs Dg513 Uf406 Mpv Mazda 6 V6 3.0 02 03 04 05 06 07: Automotive

Did a quick continuity check, and found 5 of 6 to check out OK.. Looking at them doesn't inspire a lot of confidence (no part number, seem cheap, see in the pic how it curves?). I'm happy that they appear to work, I substituted a known good CP that I had laying around for the faulty one I received.






Just took a long test drive, and the problem did not occur.

One last thing I need to do before I can drive it to work next week. One of the brake lines from the master cylinder to the ABS was crushed by the engine mount in the accident. Still works, as it wasn't severed. Guess I just need to replace and bleed.

Thanks Again!!

Rod
 
#19 ·
Looks like you made good progress. So the threads in the head were OK - no damage? That boot and plug looked nasty. AND NO MISFIRE CODE??? Oh my!! Please tell me it had P030X code! If not this explains how these things end up in the grave as crank misfire detection means nothing!!!! DEAD HOLE!!!

Anything else found along the way? A gasket out of place, Hoes off, Anything?
Points for you for digging in! I personally would of went with the Beck & Arnley units. Not more more and they have a name on them! I hope these last. Are you saying you rejected one because of the tweaked boot?

THanks for sharing...
 
#20 · (Edited)
Threads were black, but still looked sharp. New plug threaded in and torqued without issue. No codes!? As I mentioned, idle was good.. Must have still been firing a good bit. Top of plug was stuck in boot.

Did replace PCV valve, because I was there. Also, head cover gasket. Didn't find anything else.

Wasn't real sure this car was making it back, thus the cheap CPs. I'll keep those Beck and Arnley units in mind for future. Rejected one because where 5 of them read 10.32k ohms from primary to secondary, this one read open circuit.

I now like the sound of the CAI!

Rod
 
#23 ·
Dataset

I've been plotting some of the data in Excel.. The O2 graphs certainly don't look very smooth. I'll investigate what update rate the Torque app will tolerate, to try to smooth it out a bit.

Looking at RPM versus MAF, I'm a bit surprised that they don't follow more closely. For instance, in the dataset @ 6:52:23AM the MAF drops to 29CFM for that one reading, but the RPM was apparently steady around 3000RPM..



Thoughts? Car is running OK.

Rod
 
#24 ·
Another view of RPM versus MAF

Here is another view, different time period.. RPM versus MAF (CFM x 10). I multiplied the CFM x 10 to help with the scale.



After examining this for a bit, I realized that the CFM will plummet when I let my foot off the gas.. If I put the throttle position on here as well, I'm sure you would see it. The speed also brings this out...

Rod
 
#25 ·
Log for way home from work

I setup the logging for synchronous, so it would only log after full sweep.

At 4:58pm I got on I95 for about 3 minutes.

Seems to be running really well. Better than before the accident. Much more low end responsiveness.


Decided I better get on with replacing the passenger airbag.. Just pulled it, connectors on both sides are completely melted :mad:

Rod
 

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#28 ·
I setup the logging for synchronous, so it would only log after full sweep.

At 4:58pm I got on I95 for about 3 minutes.

Seems to be running really well. Better than before the accident. Much more low end responsiveness.


Decided I better get on with replacing the passenger airbag.. Just pulled it, connectors on both sides are completely melted :mad:

Rod
Also, at the very bottom, your CAT temps go from 1400 to 300. Any clue what happened there? Looks like it was sitting at idle and maybe turned off? 26:40:02 whereby the load was at 50% parked. It all just looks strange there.
 
#27 ·
Under heavy load your LTFTs are still going negative. Not crazy but IMO not typical for our pig Rich 6s. So, lets say it has no vacuum leaks. I'd guess your MAF/intake combo might be under reporting the volume. IDK

The other observation is the CAT temps. Mine top out at 1280 and yours are up to 1700. Because these are calculated, I'm not sure what to make of it. That is, I'm pretty sure the sensors are not reporting the temps as they have a heater and piezo sensor. But I've always wondered if the heater circuit is being used to report the temps. IDK

Seems odd our cars have so much difference. Almost 500F.

Q? Are the tail pipe on yours sooty looking after a freeway run? Mine never clean up but the plugs look white as could be and I get 21 22 mpg mixed freeway city action. How about that one?

Thanks for sharing! I appreciate it.
 
#29 ·
The other observation is the CAT temps. Mine top out at 1280 and yours are up to 1700. Because these are calculated, I'm not sure what to make of it. That is, I'm pretty sure the sensors are not reporting the temps as they have a heater and piezo sensor. But I've always wondered if the heater circuit is being used to report the temps. IDK

Seems odd our cars have so much difference. Almost 500F.
I have a 2004 also and mine run in the 1500-1600 range on my 50 mile drive to work (mostly Interstate at 70mph crossing the Blue Ridge Mountains). I was surprised to see the "temperatures" track almost exactly the same on both and one is original and the second a replacement (270,000 miles on the original and 50,000 miles on the replacement).

Scott
 
#30 ·
Scott, I'm pretty sure they always match as the software we're using is calculating those values based upon the calculated AFR, load, vacuum, advance ect. There is no temperature sensor in the O2 sensor.

I see the timing tanks on his when the pedal is mashed too and tops out at the same # @42 degrees before TDC. I'm not sure if either are detecting a knock signature or if thats just how its mapped. It sure kills performance where we need tho!
@rdnyhffmn, @HerronScott
 
#32 ·
Scott, I'm pretty sure they always match as the software we're using is calculating those values based upon the calculated AFR, load, vacuum, advance ect. There is no temperature sensor in the O2 sensor.
My post was more to indicate that my 2004 also shows the higher temperatures as well unlike your 2006 (?). :)

Scott
 
#34 ·
I'm guessing your battery getting disconnected is playing a big role in LTFTs.

About your O2 sensors; there is another thread going about an engine that has the RPMs all over the map and it is said the root cause is the O2 sensor. It was also said that it went upwards of 3000 rpm with no throttle applied. IMO - it needs air to do this and the with these TBW (throttle by wire) machines, who knows.... I can see 1500 but double from an O2 sensor? I'm having a hard time with that.

In torque if you build a graph looking only at the calculated load and both upstream O2 sensors AND set the time interval to the shortest value, you can grab both O2 sensors and compare them. In the ideal world you could include the load, LTFT B1 & B2 AND STFT B1 & B2. But this gets a little busy for this app.

The goal here is seeing lag or delay, the sensor not reacting to the change in trims/load applied.
Image


This is from my 95 Camry 3.0 V6. Notice bank 2 sensor1 has minimal output and is cutting corners or getting lazy. That was about 215,000 miles. Bank1 was replaced at 180,000.
Image


Scott, thanks. I knew that! :)

FWIW: looking into her darkest area - (tail pipes) mine are always black and never clean up. Makes me think the CATs are not well. How about you two? Pipes ever clean up?

Also - be careful polling the ECM (checking for CEL codes; I had mine shut down the CAN buss, hammer it with errors knocking it off line. I was in a corner applying moderate brake action. It freaked out the anti-lock brake and applied MORE brakes. It was FUBAR, also threw it into limp mode for a minute. >> http://forum.mazda6club.com/electri...93-warning-can-bus-scanners-scanner-shutdown-link-applied-brakes-u1900-abs.html
 
#35 ·
This is from my 95 Camry 3.0 V6. Notice bank 2 sensor1 has minimal output and is cutting corners or getting lazy. That was about 215,000 miles. Bank1 was replaced at 180,000.
Image
What i didn't mention here is the sensor B2S1 is switching at half the rate as the B1S1. That is the BIG clue its DONE and needs replaced! Well plus its amplitude is low. Not enough to trigger a cell and it ran pretty good. Most would never suspect an issue. :cool:

I'm not sure how the I4 guys figure this out unless they have a base line from the past to compare too.

Great thread gentlemen! Thanks!
 
#38 ·
^^ let me say where not to go! AutoTap. It has potential but OMG is the software buggy & so F'ffffng crashable!!!! They don't seem to be on the ball doing ANY updates to fix it. It was a waste of money///:mad::mad: :(

I started a thread in the Speed6 section on the same topic cause those guys like to tinker. However I have not looked it up in long while so you might look there. Even if they didn't chime in, plenty of them are using software so ask about.