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I would be suspicious of low fuel pressure. One psi in this system can mean the difference between starting and not starting.
Minimum fuel pressure should be 56psi. 54 or 55 will cause it not to start. It needs the pressure to open the mechanical poppets at the end of each injector. To low of pressure and the poppets will not open.
When end it does not start give it a couple shots or carb spray while s helper cranks it over. If it starts and stays running than stick with the low fuel pressure theory. Under vacuum, or once the vehicle is running, the poppets require less fuel pressure to open.
First of all you need to access the Engine Control Module (ECM) using suitable diagnostic equipment (VAS, VAG-COM or similar) connected to the data link connector of the car, in order to pull out all DTC's memored. DTC = Diagnostic Trouble Code. Then you will bu full informed about the root cause of the problem, and you will be able to repair & replace bad pieces and reset the ECM.
Yes you do have to take it to the dealer, This is a common problem in these trucks. This is caused by a bad encoder sensor in the shifter on the side of the transfer case. The sensor can be replaced with out having to replace the shifter assembly. THe best test is to get the code from the system. This sensor is a sliding resistor and the material wears off causing a false reading. That is why the lights were showing Nothing, but you were able to drive. The code for the sensor is C0327. TBS: #PIP3480M: Rattle Drone Or Buffeting Noise At Highway Speed In 2WD Or DTC C0327 - keywords 246 2hi 2high 4WD auto awd buffet buzz case click indicator knock lamp light service tick transfercase transfer vibrati - (Mar 4, 2008) Vehicles involved were built approximately between 01/01/04 and 03/06/06. The noise condition if not noticed by the customer may cause eventual encoder sensor wear causing DTC C0327 set in the Transfer Case Control Module (TCCM).
An updated TCCM calibration has been released to apply light pressure to the transfer case clutch pack and reduce the rattle. The calibration was released on 3/18/07 and the title line will read "to correct transfer case rattle at highway speeds and possible DTC C0327". For Rattle only (no current DTC C0327 set), Install the updated calibration and if necessary follow the diagnostics listed below
If the vehicle has a current or history dtc C0327 and can be diagnosed to the encoder sensor, re-flash with the updated calibrations and replace the encoder sensor as necessary. Important Note: All NV246 transfer cases built 02/25/06 and beyond are manufactured with pressed fit parts to help reduce the rattle. Inspect the ID tag on the transfer case for this build date and verify the tccm has the latest calibration before repairs are initiated. Thank you fur using Fixya and good luck.
There are to many things that can cause the no start. Here is a link that can help you understand the possible problems and links to how to retrieve the DTC codes which is activating your Auto Shutdown relay.
Good luck and hope this helps. Keep me posted
I don't have a solution to the problem, but Mazda should. I have replaced 3 different ignition coils in the last 3 months. I am spending more on repairs than I was in a car payment. Mazda has been no help at all!