Service Bulletin Mazda North American Operations

Irvine, CA 92618-2922

Subject: Bulletin No: 01-001/03

CAMSHAFT POSITION CMP SYNCHRONIZER TOOL USE DTC P1336 P1309
P0340 Last Issued: 01/07/2003

1995-2003 TRUCK (3.0L & 4.0L OHV) INCORRECT CAMSHAFT POSITION (CMP) SENSOR
SYNCHRONIZER INSTALLATION MAY CAUSE: LOSS OF POWER, SURGE, HESITATION, ROLLING IDLE,
RUNS ROUGH, DTC P1336, P1309, P0340
APPLICABLE MODEL(S)/VINS
1996-2000 Truck B4000 (OHV engines only)
1995-2003 Truck B3000

DESCRIPTION
An incorrectly installed Camshaft Position Sensor (CMP) synchronizer may be difficult to diagnose. The CMP
identifies the #1 cylinder compression stroke to the PCM. It is important to install a gear driven Camshaft Posi-
tion (CMP) Sensor synchronizer correctly.
If a sensor is installed incorrectly, it may exhibit poor fuel economy, drive ability concerns (loss of power, surge,
hesitation, rolling idle, runs rough), the MIL may come on with DTCs (P1336, P1309, P0340).
CMP SYNCHRONIZER ASSEMBLY

VRS-TYPE CAMSHAFT HALL-TYPE

SYNCHRONIZER POSITION SYNCHRONIZER
(CMP) SENSOR
INSTALLATION INSTALLATION
TOOL (TYPICAL) TOOL (TYPICAL)

SYNCHRONIZER BOLT AND

ASSEMBLY CLAMP
ASSEMBLY

OIL PUMP
INTERMEDIATE FRONT OF
SHAFT ENGINE

02_1134d

Incorrect installation includes:

- Engine was not set to TDC #1 cylinder before CMP sensor synchronizer installation
- The incorrect CMP synchronizer installation tool was used
- Incorrect alignment of the CMP synchronizer tool
- The CMP synchronizer was turned after installation
This bulletin describes how to diagnose an incorrectly installed CMP sensor synchronizer using WDS and

CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership.
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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

proper procedure and tools for installing a CMP sensor synchronizer.

CMP SENSOR TYPES

There are two types of CMP sensors:
TWO PIN
VARIABLE
RELUCTANCE SENSOR

THREE PIN
HALL EFFECT

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1. Hall Effect CMP Sensor

- 3-pins
- Uses differential voltage across windings to generate a signal
- Waveform appears similar to a sine wave
2. Variable Reluctance CMP Sensor
- 2-pins
- Uses a magnet and Hall Effect device to generate a signal
- Waveform appears as a square wave
CMP SIGNALS AS DISPLAYED IN THE WDS OSCILLOSCOPE MODE

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ITEM DESCRIPTION ITEM DESCRIPTION

1 SINE WAVE-TYPE (VARIABLE RELUCTANCE) SIGNAL 2 SQUARE W AVE (HALL-EFFECT) SIGNAL

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

DIAGNOSIS USING WDS

NOTE: Before performing this diagnosis, inspect service history to determine if it is possible that a repair was
performed that could lead to incorrect CMP synchronizer installation.
1. Run WDS Power Balance test to inspect for possible misfire:
- If misfire is present, perform Workshop Manual diagnosis to correct the cause of misfire.
- If misfire is no present go to step 2.
2. Turn ignition OFF
3. Disconnect number one cylinder Fuel Injector electrical connector (passenger side front).
4. Start the engine.
5. Perform WDS Power Balance Test.
6. The Power Balance Test should indicate power loss on the #1 cylinder:
- If power loss is indicated in the #1 cylinder, the CMP synchronizer is installed correctly, go to step 7.
WDS SCREED SHOWING POWER LOSS IN # 1 CYLINDER

1 4 2 5 3 6

+50

+25

-25

-50

-75

RPM 743
0 2000 4000 6000

ABCD

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- If any cylinder other than #1 is indicated, then the CMP synchronizer assembly is installed incorrectly and

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

must be reinstalled. Perform the CMP SENSOR SYNCHRONIZER INSTALLATION PROCEDURE,

7. Connect the # 1 cylinder injector electrical connector.
8. Connect the 104 Pin Breakout Box (49UN-01-1300) between the PCM and the PCM electrical connector.
9. Connect the WDS probes to the Breakout Box:
- Red WDS probe to Breakout box pin #21.
- Black WDS probe to Breakout box pin #85.
10. Select Oscilloscope from the WDS Toolbox.
A. Select “Channel one Auto Mode”.
- Select CKP sensor.
B. Select “Channel two Auto Mode”
- Select the correct CMP sensor:
• 2-wire sensors are VRS
• 3-wire sensors are Hall Effect

WDS SCREEN SHOWING CKP AND CMP SELECTION IN AUTO MODE

Channel 1
Auto - CKP
None
CKP

CMP-VRS
T
CMP-HALL
INJECT OR

2V/div O2
OSS

VSS

AL T RIPPLE
CAN+
Man ual
T Channel 2
100% Trig g er Channel 1 Rising 3.62V 9.9ms
T
5 ms/div 1
ABCD

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C. Press the Start button.

D. Monitor and compare the CMP and CKP sensor waveforms:

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

e. CMP Sensor Waveforms:

• 2-wire VRS
Verify that the falling edge of the CMP waveform should cross the zero reference line between the
7th and 10th peak past the missing tooth of the CKP sensor.
- The CKP sensor waveform has a missing tooth which appears as an extra space between the
waveforms. This position is 60 degrees BTDC
- If the falling edge falls between the 7th and 10th peak compared to the CKP, then the CMP is
installed correctly and is not the source of your symptom, proceed with Normal DTC or Symp-
tom troubleshooting in the Workshop Manual.
- If the falling edge does not fall between the 7th and 10th peak compared to the CKP, the CMP
synchronizer is not installed correctly, perform the CMP SENSOR SYNCHRONIZER INSTAL-
LATION PROCEDURE.

WDS SCREEN SHOWING KNOWN GOOD (6 CYLINDER ENGINE) CKP/CMP (2-PIN,VRS) WAVE FORMS

1
2
T 3

4T2

500
mV/div

T
100% Trig g er Channel 2 Rising 1.51V 14.3ms

2 5 ms/div
T
1
02_1134h

ABCD

ITEM DESCRIPTION ITEM DESCRIPTION

1 CKP WAVE FORM (APPEARS IN YELLOW ON WDS SCREEN)
MISSING TOOTH ON CKP TRIGGER WHEEL
(60 BTDC ON THIS 6 CYLINDER APPLICATION)
2 CMP WAVE FORM FALLING EDGE
(APPEARS IN RED ON WDS SCREEN)
3 BOX INDICATES ACCEPTABLE RANGE
WHERE CMP WAVE FORM FALLING EDGE
SHOULD OCCUR RELA TIVE TO CKP
MISSING TOOTH (BETWEEN 7TH
AND 10TH PEAK)

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

• 3-wire Hall Effect

The rising edge of the CMP timing waveform should occur between the 7th and 10th peak past the
missing CKP tooth.
- The CKP sensor waveform has a missing tooth which appears as an extra space between the
waveforms. This position is 60 degrees BTDC
- If the rising edge falls between the 7th and 10th peak compared to the CKP, then the CMP is
installed correctly and is not the source of your symptom, proceed with Normal DTC or Symptom
troubleshooting in the Workshop Manual.
- If the rising edge does not fall between the 7th and 10th peak compared to the CKP, the CMP syn-
chronizer is not installed correctly, perform the CMP SENSOR SYNCHRONIZER INSTALLATION
PROCEDURE.

WDS SCREEN SHOWING KNOWN GOOD CKP/CMP (3-PIN, HALL EFFECT) WAVE FORMS

1
3
2

T 4T2

100%

T
T T 1 2
02_1134g

ABCD

ITEM DESCRIPTION ITEM DESCRIPTION

1 CKP WAVE FORM (APPEARS IN YELLOW ON WDS SCREEN)
MISSING TOOTH ON CKP TRIGGER WHEEL
(60 BTDC ON THIS 6 CYLINDER APPLICATION)
2 CMP WAVE FORM RISING EDGE
(APPEARS IN RED ON WDS SCREEN)
3 BOX INDICATES ACCEPTABLE RANGE
WHERE CMP WAVE FORM RISING EDGE
SHOULD OCCUR RELATIVE TO CKP
MISSING TOOTH (BETWEEN 7TH
AND 10TH PEAK)

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

CMP SENSOR SYNCHRONIZER INSTALLATION PROCEDURE

1. Set #1 cylinder to TDC of compression stroke.
NOTE: This is the most critical step of the procedure, it is important to correctly set #1 to TDC of compres-
sion, or the synchronizer will be incorrectly installed.
2. Record customer radio station pre-sets.
3. Disconnect battery ground cable.
4. Remove the CMP sensor from the synchronizer assembly.
5. Remove synchronizer clamp bolt and the synchronizer assembly.
NOTE: The oil pump intermediate shaft may not come out with the synchronizer assembly, if it does not,
retrieve it.
6. Obtain the correct Engine Synchro Positioning Tool:
- 3.0L 1995-1997 (3-wire CMP sensor) use 303-529 or 49-UN01-148
- 3.0L 1998-2003 (2-wire CMP sensor) use 303-589 (303-638 cannot be used, the handle will not clear the
intake manifold)
- 4.0L 1996-mid 1998 (3-wire CMP sensor) use 303-529 or 49-UN01-148
- 4.0L mid 1998-2000 (2-wire CMP sensor) use 303-638 or 303-589

SST 303-529
SST 303-589 49-UN01-1480

SST 303-638

02_ 1134k

7. Coat the synchronizer drive gear with clean engine oil.

8. Install the Engine Synchro Positioning Tool to the synchronizer assembly:
a. Rotate the tool until it engages the notches in the camshaft synchronizer housing and the armature
b. The arrow on the tool will rotate during installation until the intermediate shaft and camshaft gear fully
engage

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

c. While installing the camshaft synchronizer, make sure the arrow points to the correct position:
- 3.0L (1995) 38 degrees from the engine centerline
- 3.0L (1996-1997) 75 degrees from the engine centerline
- 3.0L (1998-2003) 38 degrees from the engine centerline
- 4.0L (1995-1997) 60 degrees from the engine centerline
- 4.0L (1998) 54 degrees from the engine centerline
- 4.0L (1999 to mid 2000) 15 degrees from the engine centerline
NOTE: This step is critical for alignment of the CMP electrical connector, it does not affect
timing. However, you must use this tool and procedure, if you attempt to rotate the
CMP to connect the CMP electrical connector after synchronizer installation, timing
will be affected. The only way to adjust the synchronizer assembly position is to time
the engine to #1 TDC compression and use the Engine Synchro Positioning Tool.

CENTERLINE
OF ENGINE
75
60
54
38

15

ENGINE SYNCHRO
POSITIONING TOOL

FRONT OF ENGINE

02_ 1134b

9. Install the synchronizer clamp bolt.

- Torque the bolt to 25 Nm (18 lb-ft)
10. Remove the Engine Synchro Positioning Tool.
11. Install the CMP sensor.
- Torque the CMP bolts to 3 Nm (27 Lb-in)
12. Connect the battery ground cable.
13. Reset customers radio station pre-sets.
14. Verify repair.

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 Bulletin No: 01-001/03 Last Issued: 01/07/2003

WARRANTY INFORMATION
Note: The process of setting the correct CMP position is a normal part of servicing the CMP sensor and is
included in the labor operation for that individual repair.

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