MAZDA 6 2002 Workshop Manual Suplement

ON-BOARD DIAGNOSTIC
F2–89
F2
DTC P0088A6E407001082202
Diagnostic procedure
End Of Sie
DTC P0088 Fuel pressure system too high
DETECTION
CONDITION•PCM monitors fuel pressure in common rail from fuel pressure sensor while engine running. If fuel pressure
is higher than preprogrammed criteria, PCM determines fuel pressure system too high.
POSSIBLE
CAUSE•Suction control valve malfunction
•Fuel pressure sensor malfunction
•Fuel pressure limiter malfunction
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
2FOLLOW OTHER DETECTED DTC FIRST
•Turn engine switch to OFF.
•Start engine.
•Have P0091, P0092, P0191, P0192, P0193
been detected?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Go to next step.
3INSPECT SUCTION CONTROL VALVE
•Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
•Is there any malfunction?Yes Repair supply pump, go to Step 6.
(See F2–54 SUPPLY PUMP INSPECTION)
No Go to next step.
4INSPECT FUEL PRESSURE SENSOR
•Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
•Is there any malfunction?Yes Replace common rail, go to Step 6.
(See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION)
No Go to next step.
5INSPECT COMMON RAIL
•Inspect common rail.
(See F2–54 COMMON RAIL INSPECTION)
•Is there any malfunction?Yes Replace common rail, go to next step.
(See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION)
No Go to next step.
6VERIFY TROUBLESHOOTING OF DTC P0088
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
7VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed.

F2–90
ON-BOARD DIAGNOSTIC
DTC P0091A6E407001082203
Diagnostic procedure
DTC P0091 Suction control valve circuit low input
DETECTION
CONDITION•PCM monitors input voltage from suction control valve while engine is running. If input voltage from suction
control valve does not change from off to on, PCM determines suction control valve circuit low input.
POSSIBLE
CAUSE•Suction control valve malfunction
•Connector or terminal malfunction
•Short to GND in wiring between suction control valve terminal A and PCM terminal 93
•Short to GND in wiring between suction control valve terminal B and PCM terminal 94
•Open circuit in wiring between suction control valve terminal A and PCM terminal 93
•Open circuit in wiring between suction control valve terminal B and PCM terminal 94
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
A
B93
94
BA SUCTION CONTROL VALVE
HARNESS SIDE CONNECTOR
94
93PCM
HARNESS SIDE CONNECTORPCM
SUCTION CONTROL VALVE
5
4
36
2
2
365

ON-BOARD DIAGNOSTIC
F2–91
F2
End Of Sie
2INSPECT POOR CONNECTION OF SUCTION
CONTROL VALVE CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
3INSPECT SUCTION CONTROL VALVE CIRCUIT
FOR SHORT TO GND
•Turn engine switch to OFF.
•Inspect continuity between following
harnesses:
—Suction control valve terminal A and body
GND.
—Suction control valve terminal B and body
GND.
•Is there continuity?Yes Repair or replace harness for short to GND, go to Step 7.
No Go to next step.
4INSPECT SUCTION CONTROL VALVE
•Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
• Is there any malfunction?Yes Repair supply pump, go to Step 7.
(See F2–54 SUPPLY PUMP INSPECTION)
No Go to next step.
5INSPECT POOR CONNECTION OF PCM
CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
6INSPECT SUCTION CONTROL VALVE CIRCUIT
FOR OPEN
•Turn engine switch to OFF.
•Inspect continuity between following
harnesses:
—Suction control valve terminal A and PCM
terminal 93.
—Suction control valve terminal B and PCM
terminal 94.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open, go to next step.
7VERIFY TROUBLESHOOTING OF DTC P0091
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed. STEP INSPECTION ACTION

F2–92
ON-BOARD DIAGNOSTIC
DTC P0092A6E407001082204
Diagnostic procedure
DTC P0092 Suction control valve circuit high input
DETECTION
CONDITION•PCM monitors input voltage from suction control valve while engine is running. If input voltage from suction
control valve does not change from on to off, PCM determines suction control valve circuit high input.
POSSIBLE
CAUSE•Suction control valve malfunction
•Connector or terminal malfunction
•Short to power circuit in wiring between suction control valve terminal A and PCM terminal 93
•Short to power circuit in wiring between suction control valve terminal B and PCM terminal 94
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
2
2
3
3
5
593
94 A
B
4
BA
94 93PCM
SUCTION CONTROL VALVE
SUCTION CONTROL VALVE
HARNESS SIDE CONNECTORPCM
HARNESS SIDE CONNECTOR

ON-BOARD DIAGNOSTIC
F2–93
F2
End Of Sie
2INSPECT POOR CONNECTION OF SUCTION
CONTROL VALVE CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
• Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 6.
No Go to next step.
3INSPECT SUCTION CONTROL VALVE CIRCUIT
FOR SHORT TO POWER
•Turn engine switch to ON (Engine OFF).
•Inspected voltage between following
harnesses:
—Suction control valve terminal A and body
GND.
—Suction control valve terminal B and body
GND.
•Is voltage below 1.0 V?Yes Go to next step.
No Repair or replace harness for short to power, go to Step 6.
4INSPECT SUCTION CONTROL VALVE
•Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
• Is there any malfunction?Yes Repair supply pump, go to Step 6.
(See F2–54 SUPPLY PUMP INSPECTION)
No Go to next step.
5INSPECT POOR CONNECTION OF PCM
CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 6.
No Go to next step.
6VERIFY TROUBLESHOOTING OF DTC P0092
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
7VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
• Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed. STEP INSPECTION ACTION

F2–94
ON-BOARD DIAGNOSTIC
DTC P0093A6E407001082205
Diagnostic procedure
End Of Sie
DTC P0093 Fuel system leak detection
DETECTION
CONDITION•PCM monitors fuel pressure in common rail from fuel pressure sensor while engine running. If fuel pressure
is lower after fuel injection than preprogrammed criteria, PCM determines fuel system leak detection.
POSSIBLE
CAUSE•Fuel leakage or clogged fuel line
•Suction control valve malfunction
•Fuel pressure sensor malfunction
•Fuel injector malfunction
•PCM malfunction
STEP INSPECTION ACTION
1VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Information
availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available Service
Information.
•If vehicle is not repaired, go to next step.
No Go to next step.
2FOLLOW OTHER DETECTED DTC FIRST
•Turn engine switch to OFF.
•Start engine.
•Have P0192, P0193, P1190 been detected?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Go to next step.
3INSPECT FUEL LINE
•Turn engine switch to OFF.
•Inspect for fuel leakage or clogs in following
fuel lines for each cylinder:
—Supply pump and Common rail.
—Common rail and fuel injector.
• Is there any malfunction?Yes Repair or replace suspected fuel line, go to Step 7.
No Go to next step.
4INSPECT SUCTION CONTROL VALVE
•Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
•Is there any malfunction?Yes Repair supply pump, go to Step 7.
(See F2–54 SUPPLY PUMP INSPECTION)
No Go to next step.
5INSPECT FUEL PRESSURE SENSOR
•Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
•Is there any malfunction?Yes Replace common rail, go to Step 7.
(See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION)
No Go to next step.
6INSPECT FUEL INJECTOR
•Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
•Is there any malfunction?Yes Replace fuel injector, go to next step.
(See F2–55 FUEL INJECTOR REMOVAL/INSTALLATION)
No Go to next step.
7VERIFY TROUBLESHOOTING OF DTC P0093
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed.

ON-BOARD DIAGNOSTIC
F2–95
F2
DTC P0097A6E407001082206
Diagnostic procedure
DTC P0097 IAT sensor No.1 circuit low input
DETECTION
CONDITION•PCM monitors input voltage from IAT sensor No.1 while engine is running. If input voltage from IAT sensor
No.1 is below 0.1 V, PCM determines IAT sensor No.1 circuit low input.
POSSIBLE
CAUSE•IAT sensor No.1 malfunction
•Connector or terminal malfunction
•Short to GND in wiring between MAF/IAT sensor terminal D and PCM terminal 60
•IAT sensor No.1 signal and GND circuits short each other
•PCM malfunction
STEP INSPECTION ACTION
1PERFORM DTC CONFIRMATION PROCEDURE
•Perform “DTC Confirmation Procedure”.
(See F2–85 DTC CONFIRMATION
PROCEDURE)
•Is same DTC present during KOEO or KOER
self-test?Yes Go to next step.
No Intermittent concern exists. Go to “Intermittent Concern
Troubleshooting”.
(See F2–227 INTERMITTENT CONCERN
TROUBLESHOOTING)
2INSPECT POOR CONNECTION OF IAT
SENSOR NO.1 CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
3CLASSIFY IAT SENSOR NO.1 MALFUNCTION
OR HARNESS MALFUNCTION
•Turn engine switch to ON (Engine OFF).
•Disconnect MAF/IAT sensor connector.
•Access IAT PID using WDS or equivalent.
•Is IAT PID below 0.1 V?Yes Go to next step.
No Replace MAF/IAT sensor, go to Step 7.
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
4INSPECT IAT SENSOR NO.1 SIGNAL CIRCUIT
FOR SHORT TO GND
•Turn engine switch to OFF.
•Inspect continuity between MAF/IAT sensor
terminal D and body GND.
•Is there continuity?Yes Repair or replace harness for short to GND, go to Step 7.
No Go to next step.
D
E
2
24
5
5
6
660
91 IAT SENSOR NO.1PCM
ED
C
B
A
60 91 MAF/IAT SENSOR
HARNESS SIDE CONNECTORPCM
HARNESS SIDE CONNECTOR

F2–96
ON-BOARD DIAGNOSTIC
End Of Sie
5INSPECT IAT SENSOR NO.1 CIRCUIT FOR
SHORT WITH EACH OTHER
•Turn engine switch to OFF.
•Inspect continuity between MAF/IAT sensor
terminals D and E.
•Is there continuity?Yes Repair or replace harness for short with each other, go to
Step 7.
No Go to next step.
6INSPECT POOR CONNECTION OF PCM
CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to next step.
No Go to next step.
7VERIFY TROUBLESHOOTING OF DTC P0097
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Perform KOEO/KOER self-test.
(See F2–86 KOEO/KOER SELF-TEST
PROCEDURE)
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed. STEP INSPECTION ACTION

ON-BOARD DIAGNOSTIC
F2–97
F2
DTC P0098A6E407001082207
Diagnostic procedure
DTC P0098 IAT sensor No.1 circuit high input
DETECTION
CONDITION•PCM monitors input voltage from IAT sensor No.1 while engine is running. If input voltage from IAT sensor
No.1 is above 5.0 V, PCM determines IAT sensor No.1 circuit high input.
POSSIBLE
CAUSE•IAT sensor No.1 malfunction
•Connector or terminal malfunction
•Short to power circuit in wiring between MAF/IAT sensor terminal D and PCM terminal 60
•Open circuit in wiring between MAF/IAT sensor terminal D and PCM terminal 60
•Open circuit in wiring between MAF/IAT sensor terminal E and PCM terminal 91
•PCM malfunction
STEP INSPECTION ACTION
1PERFORM DTC CONFIRMATION PROCEDURE
•Perform “DTC Confirmation Procedure”.
(See F2–85 DTC CONFIRMATION
PROCEDURE)
•Is same DTC present during KOEO or KOER
self-test?Yes Go to next step.
No Intermittent concern exists. Go to “Intermittent Concern
Troubleshooting”.
(See F2–227 INTERMITTENT CONCERN
TROUBLESHOOTING)
2INSPECT POOR CONNECTION OF IAT
SENSOR NO.1 CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
3CLASSIFY IAT SENSOR NO.1 MALFUNCTION
OR HARNESS MALFUNCTION
•Turn engine switch to ON (Engine OFF).
•Connect jumper wire between MAF/IAT sensor
connector terminal D and E.
•Access IAT PID using WDS or equivalent.
•Is IAT PID below 1.0 V?Yes Replace MAF/IAT sensor, go to Step 7.
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
No Go to next step.
D
E
2
246
65
560
91 IAT SENSOR NO.1PCM
9160 EDCB
A MAF/IAT SENSOR
HARNESS SIDE CONNECTORPCM
HARNESS SIDE CONNECTOR

F2–98
ON-BOARD DIAGNOSTIC
End Of Sie
4INSPECT IAT SENSOR NO.1 SIGNAL CIRCUIT
FOR SHORT TO POWER
•Turn engine switch to ON (Engine OFF).
•Inspect voltage between MAF/IAT sensor
terminal D and body GND.
•Is voltage below 1.0 V?Yes Go to next step.
No Repair or replace harness for short to power, go to Step 7.
5INSPECT POOR CONNECTION OF PCM
CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
6INSPECT IAT SENSOR NO.1 CIRCUIT FOR
OPEN
•Turn engine switch to OFF.
•Inspect continuity between following
harnesses:
—MAF/IAT sensor terminal D and PCM
terminal 60.
—MAF/IAT sensor terminal E and PCM
terminal 91.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open, go to next step.
7VERIFY TROUBLESHOOTING OF DTC P0098
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from PCM memory using WDS or
equivalent.
•Perform KOEO/KOER self-test.
(See F2–86 KOEO/KOER SELF-TEST
PROCEDURE)
•Is same DTC present?Yes Replace PCM, go to next step.
(See F2–64 PCM REMOVAL/INSTALLATION)
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See F2–86 AFTER REPAIR PROCEDURE)
•Is there any DTC present?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Troubleshooting completed. STEP INSPECTION ACTION