light MAZDA 6 2002 Suplement User Guide

OUTLINE
F1–5
F1
11 Knock sensor
12 CKP sensor
13 CMP sensor
14 Fuel injector No.1
15 Fuel injector No.2
16 Fuel injector No.3
17 Fuel injector No.4
18 IAC valve
19 Oxygen sensor heater (front)
20 Oxygen sensor heater (rear)
21 A/C relay22 Cooling fan relay
23 Cooling fan relay
24 Cooling fan relay
25 TR switch
26 Fuel pump relay
27 Coil
28 Security light
29 Ignition switch
30 Main relay
31 TR switch
32 Starter relay

F1–6
OUTLINE
.
1AA
1Q
1Z
1AC
1K
1C1D 4M4R 4N4K 4H4E
4T 4C4U 1AD1B 1A 2AB4X
39
38
37
35
36
33
40
45
46
44
43
41
42
34
48
47
A6E39022002
33 Generator
34 Refrigerant pressure switch (middle)
35 PSP switch
36 Blower motor
37 Refrigerant pressure switch (high and low)
38 A/C switch
39 Brake switch
40 Brake light41 Ignition coil
42 Generator
43 Purge solenoid valve
44 VAD control solenoid valve
45 EGR valve
46 Variable tumble control solenoid valve
47 VIS control solenoid valve
48 OCV

F1–8
OUTLINE
.
15 Fuel injector No.2
16 Fuel injector No.3
17 Fuel injector No.4
18 IAC valve
19 Oxygen sensor heater (front)
20 Oxygen sensor heater (rear)
21 A/C relay22 Cooling fan relay
23 Cooling fan relay
24 Cooling fan relay
25 Cooling fan relay
26 Fuel pump relay
27 Ignition switch
28 Main relay
1AA
1Q
1Z
1AC
1K
1C1D 4M4R 4N4K 4H4E
4T 4C4U 1AD1B 1A 2AB4X
39
38
37
35
36
33
31
32
40
44
43
41
42
34
29
30
A6E39022004
29 Generator
30 Refrigerant pressure switch (middle)
31 PSP switch
32 Blower motor
33 Refrigerant pressure switch (high and low)
34 A/C switch
35 Brake switch
36 Brake light37 Ignition coil
38 Generator
39 Purge solenoid valve
40 VAD control solenoid valve
41 EGR valve
42 Variable tumble control solenoid valve
43 VIS control solenoid valve
44 OCV

CONTROL SYSTEM
F1–21
F1
CONTROLLER AREA NETWORK (CAN)A6E394018880205•PCM transmit/received the information in the CAN. For detail information of the CAN, see the “MULTIPLEX
COMMUNICATION SYSTEM.” (See T–3 OUTLINE.)
Transmit Information (4WD ATX Model)
•Engine control condition
•Torque reduction inhibit
•Engine speed
•Vehicle Speed
•TP
•Engine torque (without torque reduction)
•Engine torque (with torque reduction)
•Battery reconnection
•Engine loss torque
•ECT
•Travelled distance
•Fuel injection information
•MIL condition
•Generator warning light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
Received Information (4WD ATX Model)
From ABS HU/CM, ABS/TCS HU/CM, or DSC HU/CM
•Wheel speed
—Front left, Front right, Rear left, and Rear right
•Travelled distance
•Brake system status
•Torque reduction request
•Brake system configuration
From TCM
•Desired torque
•Upper torque limit
•Turbineshaft speed
•Vehicle speed
•Torque reduction request
•Idle speed up request
•Racing select determination
•MIL indicate request
•Desired gear/selector lever position
•AT warning indicator light condition
•TCC condition
End Of Sie

F1–22
OUTLINE, ENGINE TUNE-UP
SUPPLEMENTAL SERVICE INFORMATIONA6E390218881206•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1621-10-98E).
Idle speed
•Adjustment procedure has been modified.
Fuel tank
•Removal/installation procedure has been modified.
Fuel pump unit
•Removal/installation procedure has been modified.
Quick release connector (fuel tank side, transfer hose part)
•Removal/installation procedure has been added.
Exhaust system
•Removal/installation procedure has been modified.
PCM
•Inspection procedure has been modified.
On-board diagnostic
•Inspection procedure has been modified.
Troubleshooting
•Inspection procedure has been modified.
End Of Sie
IDLE SPEED INSPECTION (4WD)A6E390802000201
Note
•Ignition timing is not adjustable.
•Ignition timing verification requires WDS or equivalent.
1. Turn off the electrical loads.
2. Warm up the engine as follows.
(1) Start the engine.
(2) Maintain the engine speed at approx. 3,000 rpm until the cooling fans start to operate.
(3) Release the accelerator pedal.
(4) Wait until the cooling fans stop.
3. Verify that the idle speed (WDS: RPM PID) is within the specification using WDS or equivalent.
Idle speed
*1 : Excludes temporary idle speed drop just after the electrical loads are turned on.
*2 : Blower motor is operating at high speed. Headlight switch is turned on. Rear window defroster switch is turned
on. Cooling fans are operating.
End Of Sie
OUTLINE
ENGINE TUNE-UP
Condition
Engine speed (rpm)*1
No load 650—750
Electrical loads*
2 ON650—750
P/S ON 650—750
A/C ON and refrigerant
pressure switch (middle) OFF650—750
A/C ON and refrigerant
pressure switch (middle) ON700—800

F1–28
FUEL SYSTEM
Fuel Pump Cap Installation Note
1. Verify that the fuel tank mark is aligned with the
fuel pump unit mark as shown.
2. Using the SST, tighten the fuel pump cap without
shifting the mark.
Tightening torque
80—90 N·m {8.2—9.1 kgf·m, 60—66 ft·lbf}
Plastic Fuel Hose Installation Note
Note
•A checker tab is integrated with quick
release connector for new plastic fuel hoses.
The checker tab will be released from the
quick release connector after it is completely
engaged with the fuel pipe.
1. Inspect the fuel pump unit sealing surface for
damage and deformation, and replace as
necessary.
•If the quick release connector O-ring is
damaged, replace the plastic fuel hose.
2. Slightly apply clean engine oil to the sealing
surface of the fuel pump unit.
3. Align the fuel pipe on the fuel pump unit and quick
release connector so that the tabs of the retainer
are correctly fitted into the quick release
connector. Push the quick release connector
straight into the retainer until a click is heard.
4. Lightly pull and push the quick release connector
a few times by hand and verify that it can move
2.0—3.0 mm {0.08—0.11 in} and it is connected
securely.
•If quick release connector does not move at
all, verify that O-ring is not damaged and
slipped, and reconnect the quick release
connector.
Fuel Leak Inspection After Fuel Pump Unit Installation
1. Drive the vehicle.
2. Perform a quick start and a hard brake 5—6 times.
3. Stop the vehicle.
4. Verify that there is no fuel leakage near the fuel pump unit in the vehicle interior.
End Of Sie
A6E39122013
CHECKER
TA B
NEW PLASTIC
FUEL HOSE
A6E3912W004
OILOIL
PLASTIC FUEL HOSE QUICK RELEASE
CONNECTOR SEALING
SURFACE
A6E3912W006

FUEL SYSTEM
F1–29
F1
FUEL HOSE (FUEL TANK SIDE, TRANSFER HOSE PART) REMOVAL/INSTALLATIONA6E391242692202
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
Removal
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
Note
•Squeezing the tab while lightly pushing the fuel hose on the fuel pipe side will make removal easier.
3. Squeeze the tabs on the quick release connector
and disconnect the quick release connector from
the fuel pipe by pulling it straight back.
4. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Installation
Caution
•If the quick release connector O-ring is damaged, replace the plastic fuel hose. A fuel leak may be
caused.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
2. Slightly apply clean engine oil to the sealing surface of the fuel pump unit.
3. Align the fuel pipe and quick release connector. Push the quick release connector straight into the fuel pipe
until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 mm
{0.08—0.11 in} and it is connected securely.
•If the quick release connector does not move at all, verify that O-ring is not damaged and slipped, and
reconnect the quick release connector.
5. Complete the “AFTER REPAIR PROCEDURE”.
End Of Sie
QUICK RELEASE
CONNECTOR TA BDISCONNECT
FUEL PIPE
A6E39122007
A6E39122014

F1–34
CONTROL SYSTEM
BARO*7
(Barometric pressure)kPa, inHgIgnition switch ON (at sea level):
approx. 101 kPa {29.8 inHg}
Inspect BARO sensor. 1G
VIgnition switch ON (at sea level):
approx. 4.1 V
BOO
(Brake switch)ON/OFFBrake pedal depressed: ON
Brake pedal released: OFFInspect brake switch. 1K
CHRGLP (Generator
warning light)ON/OFFIgnition switch ON: ON
Idle: OFFPerform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
COLP*
4 (Refrigerant
pressure switch
(middle))ON/OFFRefrigerant pressure switch (middle)
ON *2 at idle: ON
Refrigerant pressure switch (middle)
OFF
*3 at idle: OFFInspect refrigerant pressure switch. 1Q
CPP*
8
(Clutch pedal position)ON/OFFClutch pedal depressed: ON
Clutch pedal released: OFFInspect clutch switch. 1R
CPP/PNP*
8 (Shift
lever position)Drive/
NeutralNeutral position: Neutral
Others: DriveInspect neutral switch. 1W
DTCCNT (Number of
DTC detected)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
ECT (Engine coolant
temperature)°C°FECT 20 °C {68 °F}: 20 °C {68 °F}
ECT 60 °C {140 °F}: 60 °C {140 °F}
Inspect ECT sensor. 1M
VECT 20 °C {68 °F}: 3.04—3.14 V
ECT 60 °C {140 °F}: 1.29—1.39 V
EVAPCP (Purge
solenoid valve duty
value)%Ignition switch ON: 0%
Idle: 0%Inspect following PIDs: IAT, RPM,
ECT, MAF, O2S11,BARO, INGEAR,
TR, VPWR.4U
FAN1
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4L
FAN2
(Cooling fan control)ON/OFFECT below 108 °C {226 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is OFF, and ECT
below 108 °C {226 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4F
FAN3
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is ON, and ECT
below 108 °C {226 °F}: OFF
Other: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4B
FDPDTC
(Pending code caused
FFD storage)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
FP (Fuel pump relay) ON/OFFIgnition switch ON: OFF
Idle: ON
Cranking: ONInspect following PIDs: RPM.
Inspect fuel pump relay.4P
*5
4Q*6
FUELPW (Fuel
injector duration)msIgnition switch ON: 0 ms
Idle (after warm up): approx. 2.5 msInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.4W, 4Z,
4AA,
4AD
FUELSYS
(Fuel system status)OL_Drive/
OL/
CL_Fault/
OL_Fault/CLIgnition switch ON: OL
Idle (after warm up): CLInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.—
GENVDSD
(Generator voltage
desired)VIgnition switch ON: 0 V
Idle: Approx. 14.9 V
*1 (E/L not
operating)Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
HTR11
(HO2S heater (front))ON/OFF Idle (after warm up): ON⇔OFFInspect following PIDs: IAT, MAF, TP,
ECT, RPM, ACSW.4A Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal

F1–40
CONTROL SYSTEM
2TCoil*
9 (Immobilizer
system)CoilBecause this terminal is for communication,
good/no good judgment by terminal voltage
is not possible.•Inspect coil
•Inspect related
harness
—*
10————
2U CAN (+)Instrument cluster,
ABS HU/CM,
ABS/TCS HU/CM,
DSC HU/CM,
TCM*
12
Because this terminal is for CAN, good/no
good judgment by terminal voltage is not
possible.•Inspect related
harness
2V—— — ——
2WSecurity light
control*
9Instrument cluster
(Security light)Security light illuminate—
•Inspect related
harness
Others Below 1.0
—*
10————
2X Main relay control Main relayIgnition switch OFF B+•Inspect main relay
•Inspect related
harness Ignition switch ON Below 1.0
2Y B+ Main relayIgnition switch OFF Below 1.0•Inspect battery
•Inspect related
harness Ignition switch ON B+
2ZBack-up power
supplyBattery (positive
terminal)Under any condition B+•Inspect battery
•Inspect related
harness
2AA—— — ——
2AB GND GND Under any condition Below 1.0•Inspect related
harness
2AC GND GND Under any condition Below 1.0•Inspect related
harness
2AD—— — ——
3A—— — ——
3B—— — ——
3CVehicle speed*
3VSS•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect VSS
•Inspect related
harness
—*
13————
3DATF temperature*
11TFT sensorIgnition switch
ONTFT 20 °C
{68 °F}Approx.
3.3
•Inspect TFT sensor
•Inspect related
harness TFT 40 °C
{104 °F}Approx.
2.4
TFT 60 °C
{140 °F}Approx.
1.5
—*
14————
3E—— — ——
3F—— — ——
3GInput/turbine speed
sensor (+)*
11Input/turbine
speed sensor•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect input/turbine
speed sensor
•Inspect related
harness
—*
14————
3H—— — ——
3I—— — ——
3JInput/turbine speed
sensor (–)*
11Input/turbine
speed sensor•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect input/turbine
speed sensor
•Inspect related
harness
—*
14———— Terminal Signal Connected to Test conditionVoltage
(V)Action

F1–52
ON-BOARD DIAGNOSTIC
End Of Sie
DTC (4WD)A6E397018881204•Detection logics and conditions are as shown below.
Controller Area Network (CAN)
PCM cannot receive any signals from TCM (U0101)
•PCM cannot receive any signals from TCM.
End Of Sie
OBD DRIVE MODEA6E397018881205•Performing the Drive Mode inspects the OBD system for proper operation. The Drive Mode must be performed
to ensure that no additional DTCs are present.
•During Drive Mode, the following systems are inspected:
—Oxygen sensor (HO2S)
—Oxygen sensor heater
—Catalytic converter (TWC)
Caution
•While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
•When the WDS or equivalent is used to observe monitor system condition while driving, be sure to
have another technician with you, or record the data in the WDS or equivalent using the PID/DATA
MONITOR AND RECORD function and inspect later.
Note
•Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer
and tachometer. Use the WDS or equivalent to monitor vehicle speed.
•If the OBD system inspection is not completed during the Drive Mode, the following causes are
considered:
1. The OBD system detects the malfunction.
2. The Drive Mode procedure is not completed correctly.
•Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
PCM Adaptive Memory Procedure Drive Mode
Note
•The PCM adaptive memory condition can be confirmed with RFCFLAG PID.
•If RFCFLAG PID is “Learnt”, PCM Adaptive Memory Procedure Drive Mode is not necessary, because
PCM already has adaptive memory.
•If RFCFLAG PID is “Not Learnt”, PCM Adaptive Memory Procedure Drive should be performed before
HO2S Heater, HO2S, and TWC Repair Verification Drive Mode.
1. Start the engine and warm it up completely.
2. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
U0101 PCM cannot receive any signals from TCM ON 1 Other×
U0121PCM cannot receive any signals from ABS, ABS/TCS
or DSC HU/CMON 1 Other×
U0155PCM cannot receive any signals from instrument
clusterON 1 Other× DTC No. Condition MIL DC Monitor itemMemory
function