fuel MAZDA 6 2002 Workshop Manual Suplement

TROUBLESHOOTING
F2–165
F2
SYMPTOM DIAGNOSTIC INDEXA6E408018881201
TROUBLESHOOTING
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
1 Melting of main or other fuses—(See F2–173 NO.1 MELTING
OF MAIN OR OTHER FUSES)
2 MIL illuminates MIL is illuminated incorrectly.(See F2–174 NO.2 MIL
ILLUMINATES)
3 Will not crank Starter does not work.(See F2–174 NO.3 WILL NOT
CRANK)
4Hard start/long crank/erratic start/
erratic crankStarter cranks engine at normal speed but
engine requires excessive cranking time
before starting.(See F2–176 NO.4 HARD
START/LONG CRANK/
ERRATIC START/ERRATIC
CRANK)
5 Engine stalls After start/at idleEngine stops unexpectedly at idle and/or
after start.(See F2–178 NO.5 ENGINE
STALLS-AFTER START/AT
IDLE)
6 Cranks normally but will not startStarter cranks engine at normal speed but
engine will not run.(See F2–181 NO.6 CRANKS
NORMALLY BUT WILL NOT
START)
7 Slow return to idleEngine takes more time than normal to
return to idle speed.(See F2–184 NO.7 SLOW
RETURN TO IDLE)
8 Engine runs rough/rolling idleEngine speed fluctuates between specified
idle speed and lower speed and engine
shakes excessively.(See F2–186 NO.8 ENGINE
RUNS ROUGH/ROLLING
IDLE)
9 Fast idle/runs onEngine speed continues at fast idle after
warm-up.
Engine runs after engine switch is turned to
OFF.(See F2–189 NO.9 FAST
IDLE/RUNS ON)
10 Low idle/stalls during decelerationEngine stops unexpectedly at beginning of
deceleration or recovery from deceleration.(See F2–190 NO.10 LOW
IDLE/STALLS DURING
DECELERATION)
11Engine stalls/quitsAcceleration/
cruiseEngine stops unexpectedly at beginning of
acceleration or during acceleration.
Engine stops unexpectedly while cruising.
(See F2–192 NO.11 ENGINE
STALLS/QUITS, ENGINE
RUNS ROUGH, MISSES,
BUCK/JERK, HESITATION/
STUMBLE, SURGES) Engine runs roughAcceleration/
cruiseEngine speed fluctuates during acceleration
or cruising.
MissesAcceleration/
cruiseEngine misses during acceleration or
cruising.
Buck/jerkAcceleration/
cruise/
decelerationVehicle bucks/jerks during acceleration,
cruising, or deceleration.
Hesitation/stumble AccelerationMomentary pause at beginning of
acceleration or during acceleration.
SurgesAcceleration/
cruiseMomentary minor irregularity in engine
output.
12 Lack/loss of powerAcceleration/
cruisePerformance is poor under load (e.g. power
down when climbing hills).(See F2–195 NO.12 LACK/
LOSS OF POWER-
ACCELERATION/CRUISE)
13 Knocking/pingingExcessive shrilly knocking sound from
engine.(See F2–199 NO.13
KNOCKING/PINGING)
14 Poor fuel economy Fuel economy is unsatisfactory.(See F2–202 NO.14 POOR
FUEL ECONOMY)
15 Emissions compliance Fails emissions test.(See F2–205 NO.15
EMISSION COMPLIANCE)
16 High oil consumption/leakage Oil consumption is excessive.(See F2–209 NO.16 HIGH OIL
CONSUMPTION/LEAKAGE)
17Cooling system
concernsOverheatingEngine runs at higher than normal
temperature/overheats.(See F2–210 NO.17 COOLING
SYSTEM CONCERNS-
OVERHEATING)

F2–166
TROUBLESHOOTING
End Of Sie
18Cooling system
concernsRuns coldEngine does not reach normal operating
temperature.(See F2–212 NO.18 COOLING
SYSTEM CONCERNS-RUNS
COLD)
19 Excessive black smokeExcessive black smoke is observed in
exhaust gas.(See F2–213 NO.19
EXCESSIVE BLACK SMOKE)
20 Fuel odor (in engine compartment) Fuel smell or visible leakage.(See F2–216 NO.20 FUEL
ODOR (IN ENGINE
COMPARTMENT)
21 Engine noise Engine noise from under hood.(See F2–217 NO.21 ENGINE
NOISE)
22 Vibration concerns (engine) Vibration from under hood or driveline.(See F2–220 NO.22
VIBRATION CONCERNS
(ENGINE)
23 A/C does not work sufficientlyA/C compressor magnetic clutch does not
engage when A/C is turned on.(See F2–222 NO.23 A/C
DOES NOT WORK
SUFFICIENTLY)
24A/C always on or A/C compressor runs
continuouslyA/C compressor magnetic clutch does not
disengage.(See F2–223 NO.24 A/C
ALWAYS ON OR A/C
COMPRESSOR RUNS
CONTINUOUSLY)
25A/C does not cut off under wide open
throttle conditionsA/C compressor magnetic clutch does not
disengage under wide open throttle.(See F2–224 NO.25 A/C
DOES NOT CUT OFF UNDER
WIDE OPEN THROTTLE
CONDITIONS)
26 Constant voltage Incorrect Constant voltage.(See F2–225 NO.26
CONSTANT VOLTAGE) No. TROUBLESHOOTING ITEM DESCRIPTION PAGE

TROUBLESHOOTING
F2–167
F2
SYMPTOM QUICK DIAGNOSIS CHARTA6E408018881202
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank×× ×× × ×
4 Hard start/long crank/erratic start/erratic crank×× ×
5 Engine stalls After start/at idle××
6 Cranks normally but will not start××
7 Slow return to idle
8 Engine runs rough/rolling idle××
9 Fast idle/runs on
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××
Engine runs rough Acceleration/cruise××
Misses Acceleration/cruise××
Buck/jerk Acceleration/cruise/ deceleration××
Hesitation/stumble Acceleration××
Surges Acceleration/cruise××
12 Lack/loss of power Acceleration/cruise××
13 Knocking/pinging××
14 Poor fuel economy××
15 Emissions compliance×× ×
16 High oil consumption/leakage××××
17 Cooling system concerns Overheating××
18 Cooling system concerns Runs cold
19 Excessive black smoke×
20 Fuel odor (in engine compartment)
21 Engine noise×× × ×
22 Vibration concerns (engine)×
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Starter motor malfunction (Mechanical or electrical)Starter circuit including engine switch is openImproper engine oil levelLow or dead bateryCharging system malfunctionLow engine compressionImproper valve timingHydrolocked egineImproper engine oil viscosityImproper dipstickBase engine malfunctionSeized flywheelImproper tension or damaged drivebelts

F2–168
TROUBLESHOOTING
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×××
5 Engine stalls After start/at idle×××
6 Cranks normally but will not start××
7 Slow return to idle×
8 Engine runs rough/rolling idle××××
9 Fast idle/runs on×
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise×××× ×
Misses Acceleration/cruise××××××
Buck/jerk Acceleration/cruise/ deceleration××××××
Hesitation/stumble Acceleration××××××
Surges Acceleration/cruise××××××
12 Lack/loss of power Acceleration/cruise×××××××
13 Knocking/pinging×××××
14 Poor fuel economy××××
15 Emissions compliance× ××××××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×× × ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke××××
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)×× ×
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Improper engine coolant levelWater and anti-freeze mixture is improperCooling system malfunction (Radiator, hose,
over-flow system, thermostat, etc.)Cooling fan system malfunctionEngine or transaxle mounts are improperly installedCooling fan No.1 or No.2 seat are improperFuel qualityEngine overheatingIntake-air system clogging or restrictionAir leakage from intake-air systemVSC system malfunctionVacuum leakage

TROUBLESHOOTING
F2–169
F2
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates×× × ×
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×× ×××××××
5 Engine stalls After start/at idle×× ×××××××
6 Cranks normally but will not start×× ×××××××
7 Slow return to idle××××××××
8 Engine runs rough/rolling idle×××××××××
9 Fast idle/runs on×
10 Low idle/stalls during deceleration××××××××××
11Engine stalls/quits Acceleration/cruise× × ×××××××
Engine runs rough Acceleration/cruise× ××××××××××
Misses Acceleration/cruise× ××××××××××
Buck/jerk Acceleration/cruise/ deceleration× ××××××××××
Hesitation/stumble Acceleration× ××××××××××
Surges Acceleration/cruise× ×× ×××××××
12 Lack/loss of power Acceleration/cruise××× ×××××××××
13 Knocking/pinging××××× ××× × ×
14 Poor fuel economy××× ×××××× ×
15 Emissions compliance×××××××××××××
16 High oil consumption/leakage×
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke××× × ××× ×××
20 Fuel odor (in engine compartment)××
21 Engine noise× ××× ×
22 Vibration concerns (engine)
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Turbocharger malfunctionCarge air cooler malfunctionVBC system malfunctionGlow system malfunctionIncorrect fuel injection timingIncorrect idle speedCKP sensor is damaged (e.g.: open or short circuits)CKP sensor pulse wheel is damagedImproper gap between CKP sensor and pulse wheelSupply pump malfunctionSuction control valve malfunctionFuel pressure limiter malfunctionFuel line restriction or clogging

F2–170
TROUBLESHOOTING
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates××
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank× × ××××× ×
5 Engine stalls After start/at idle×××××××××
6 Cranks normally but will not start× × ×××× × ×
7 Slow return to idle××××
8 Engine runs rough/rolling idle× × ×××× ××
9 Fast idle/runs on××
10 Low idle/stalls during deceleration× × ×××× ×
11Engine stalls/quits Acceleration/cruise× ××××× ×
Engine runs rough Acceleration/cruise× ××××× ×
Misses Acceleration/cruise× ××××× ×
Buck/jerk Acceleration/cruise/ deceleration× ××××× ×
Hesitation/stumble Acceleration× ××××× ×
Surges Acceleration/cruise× ××××× ×
12 Lack/loss of power Acceleration/cruise× ××××× ×
13 Knocking/pinging××××
14 Poor fuel economy×××××××
15 Emissions compliance× ×××××××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke××××
20 Fuel odor (in engine compartment)×
21 Engine noise××××
22 Vibration concerns (engine)×××
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage×
Fuel injectors malfunction (Leakage or clogging,
inoperative)Fuel leakage from fuel system (including insulator,
fuel injector)Fuel filter restriction or cloggingCMP sensor is damaged (e.g: open or short circuit)CMP sensor pulse wheel is damagedIDM or related circuit malfunctionExhaust system restriction or cloggingCatalyst converter malfunctionEGR system malfunctionEGR water cooler malfunctionV-reference voltage supply circuit malfunction

TROUBLESHOOTING
F2–171
F2
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates×××××× × ×××
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×× ×× ×
5 Engine stalls After start/at idle×× × × × ××
6 Cranks normally but will not start×× ×
7 Slow return to idle××× × × ×××
8 Engine runs rough/rolling idle××× × × ××××
9 Fast idle/runs on×××
10 Low idle/stalls during deceleration××× × × ××××
11Engine stalls/quits Acceleration/cruise× × × × ××××
Engine runs rough Acceleration/cruise××× × × ××××
Misses Acceleration/cruise× × × × ××××
Buck/jerk Acceleration/cruise/ deceleration× ×××× × ××××
Hesitation/stumble Acceleration× ×××× × ××××
Surges Acceleration/cruise× ×××× × ××××
12 Lack/loss of power Acceleration/cruise× ×××× × ××××
13 Knocking/pinging××××× ×
14 Poor fuel economy× ×××× ×××
15 Emissions compliance×××××× × ×××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke×× ×
20 Fuel odor (in engine compartment)×
21 Engine noise××××× ×
22 Vibration concerns (engine)×× ××××
23 A/C does not work sufficiently×
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions××
26 Constant voltage××××× ×
PCM control relay malfunctionECT sensor or related circuit malfunctionNeutral switch or related circuit malfunctionMAF/IAT sensor or related circuit malfunctionIAT sensor No.2 or related circuit malfunctionBoost sensor or related circuit malfunctionAccelerator position sensor or related circuit malfunctionAccelerator position sensor misadjustment
(including looseness)Idle switch or related circuit malfunctionIdle switch misadjustment (including looseness)Fuel pressure sensor or related circuit malfunctionImproper refrigerant charging amount

F2–172
TROUBLESHOOTING
×: Applicable
End Of Sie
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank×
4 Hard start/long crank/erratic start/erratic crank
5 Engine stalls After start/at idle×× ×
6 Cranks normally but will not start×
7 Slow return to idle
8 Engine runs rough/rolling idle×××
9 Fast idle/runs on
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise××××
Misses Acceleration/cruise××××
Buck/jerk Acceleration/cruise/ deceleration××××
Hesitation/stumble Acceleration××××
Surges Acceleration/cruise××××
12 Lack/loss of power Acceleration/cruise×× × ×
13 Knocking/pinging
14 Poor fuel economy××××× ×
15 Emissions compliance×
16 High oil consumption/leakage
17 Cooling system concerns Overheating××× ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)××××
23 A/C does not work sufficiently××
24 A/C always on or A/C compressor runs continuously××
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
A/C relay (A/C control siganl) circuit malfunctionA/C magnetic clutch or related circuit malfunctionCooling fan No.1 system malfunctionClutch slippageAir in power steering fuluid lineVSS or related circuit malfunctionBrake draggingLoose partsImproper balance of wheel or tiresDriveline malfunctionSuspension malfunctionImmobilizer system and/or circuit malfunctionCoolant heater system malfunction

TROUBLESHOOTING
F2–173
F2
NO.1 MELTING OF MAIN OR OTHER FUSESA6E408018881203
End Of Sie
1 Melting of main or other fuses
[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
Damaged fuse Related wiring harness
MAINMAIN fuse
•BTN fuse
•FAN fuse
•AD FAN fuse
•IG KEY 2 fuse
IG KEY 1IG KEY 1 fuse
•Engine switch
—ENGINE fuse
FUEL PUMPFUEL PUMP fuse
•Fuel warmer
•PCM control relay
BTNBTN fuse
•ROOM fuse
IG KEY 2IG KEY 2 fuse
•Engine switch
ROOMROOM fuse
•DLC-2
ENGINEENGINE fuse
•PCM
INJINJ fuse
•PCM
•IDM
•MAF/IAT sensor
•VSC solenoid valve
•VBC solenoid valve
•EGR control solenoid valve
•EGR solenoid valve (vacuum)
•EGR solenoid valve (vent)
•Intake shutter solenoid valve (half)
•Intake shutter solenoid valve (full)
GLOWGLOW fuse
•Glow plug relay
—Glow plug
—GLOW SIG
ENG+BENG+B fuse
•PCM
FANFAN fuse
•Cooling fan relay No.2
AD FANAD FAN fuse
•Cooling fan relay No.1
Shorted harness
Repair shorted harness and replace fuseFuseDeterioration
Replace fuse

F2–176
TROUBLESHOOTING
NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANKA6E408018881206
Diagnostic Procedure
4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION•Starter cranks engine at normal speed but engine requires excessive cranking time before starting.
•Battery is in normal condition.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction or clogging
•Starting system malfunction
•Inadequate fuel pressure
•Fuel pressure limiter malfunction (built-in common rail)
•Suction control valve malfunction (built-in supply pump)
•Engine overheating
•Glow system malfunction
•Fuel filter clogging or restriction
•Fuel line clogging or restriction
•Fuel leakage
•Exhaust system and/or catalyst converter restriction or clogging
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•Accelerator position sensor misadjustment
•MAF/IAT sensor or related circuit malfunction
•Fuel pressure sensor or related circuit malfunction
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•IDM or related circuit malfunction
•EGR system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Fuel quality (e.g.: include water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging
•Intake-air system restriction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS-OVERHEATING”.
No Go to next step.
3 Connect WDS or equivalent to DLC-2.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.