heating MAZDA 6 2002 Suplement Owner's Manual

TROUBLESHOOTING
F2–193
F2
Diagnostic Procedure
STEP INSPECTION RESULTS ACTION
1 Is idle speed stable? Yes Go to next step.
No Go to symptom troubleshooting “NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE”.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS—OVERHEATING”.
No Go to next step.
3 Perform self-test function using WDS or
equivalent.
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 for 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.
4 Inspect for following:
•Fuel quality (e.g.: including water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging and/or restriction
•Intake-air system restriction or clogging
•Exhaust system and/or catalyst converter
restriction
•Cooling fan No.1 or cooling fan No.2 seat
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 4.
5 Does engine run normal after warm-up? Yes Inspect glow system operation.
(See T–19 RELAY INSPECTION)
Replace any malfunctioning part as necessary.
If glow system is okay, go to next step.
No Go to next step.
6Note
•The following test should be performed on
the vehicles with A/C system. If the
following test cannot be performed due to
engine stalling, go to next step.
•Go to next step for the vehicle without A/C
system.
Connect pressure gauge to A/C line.
Turn blower and A/C switches on.
Is pressure within specifications?Yes Go to next step.
NoA/C is always on:
Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS CONTINUITY”.
Other symptoms:
Inspect following:
•Refrigerant charging amount
•Cooling fan No.1 and/or cooling fan No.2 operation
7 Inspect hose bands between following parts:
•Turbocharger compressor housing and air
cleaner
•Turbocharger compressor housing and
charge air cooler
Are hose bands loose?Yes Retighten hose bands.
If concern is resolved, complete inspection.
If concern still exists, go to next step.
No Go to next step.
8 Inspect for improper operation, kinks, clogging or
disconnection on guide blade actuator.
Is guide blade actuator okay?Yes Turbocharger is okay.
Go to next step.
No Repair or replace as necessary.
If concern is resolved, complete inspection.
If concern still exists, turbocharger is okay.
Go to next step.
9 Perform EGR system inspection.
Is EGR system okay?Yes Go to next step.
No Repair or replace malfunctioning part according to
EGR system operation results.
10 Inspect idle speed.
(See F2–34 IDLE SPEED INSPECTION)
Is idle speed correct?Yes Go to next step.
No Repair or replace malfunctioning part according to idle
speed inspection results.

TROUBLESHOOTING
F2–195
F2
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISEA6E408018881214
Diagnostic Procedure
12 LACK/LOSS OF POWER-ACCELERATION CRUISE
DESCRIPTION•Performance is poor under load (e.g., power down when climbing hills).
POSSIBLE
CAUSE•Poor fuel quality
•Air leakage from intake-air system
•Intake-air system restriction or clogging
•Engine overheating
•A/C system improper operation
•Improper operation of A/C cut-off control
•Variable boost control (VBC) system malfunction
•Variable swirl control (VSC) system malfunction
•EGR system malfunction
•Vacuum leakage
•Clutch slippage
•Exhaust system and/or catalyst converter restriction
•Fuel line or clogging or restriction
•Fuel filter clogging or restriction
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Boost sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•IAT sensor No.2 or related circuit malfunction
•Incorrect adjustment accelerator position sensor and/or idle switch
•Incorrect idle speed
•Inadequate fuel pressure
•Fuel pressure sensor or related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•Improper valve timing
•Cooling fan No.1 or cooling fan No.2 seat are improper
•Turbocharger malfunction
•Charge air cooler malfunction
•Brake system dragging
•Intake shutter valve malfunction
•Guide blade valve malfunction
•IDM or related circuit 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 Is idle speed stable? Yes Go to next step.
No Go to symptom troubleshooting “NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE”.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS—OVERHEATING”.
No Go to next step.

TROUBLESHOOTING
F2–205
F2
NO.15 EMISSION COMPLIANCEA6E408018881217
Diagnostic Procedure
15 EMISSION COMPLIANCE
DESCRIPTION•Fails emissions test.
POSSIBLE
CAUSE•Poor fuel quality
•Vacuum leakage
•Air leakage from intake-air system
•Intake-air system restriction or clogging
•Variable swirl control (VSC) system malfunction
•Variable boost control (VBC) system malfunction
•Intake shutter valve stuck close
•VSC valve stuck close
•Turbocharger malfunction
•Guide blade valve malfunction
•Charge air cooler malfunction
•Glow system malfunction
•EGR system malfunction
•EGR water cooler malfunction
•Low coolant temperature
•Engine overheating
•Inadequate fuel pressure
•Fuel pressure limiter malfunction (built-in common rail)
•Suction control valve inspection (built-in supply pump)
•ECT sensor or related circuit malfunction
•MAF/IAT sensor related circuit malfunction
•IAT sensor No.2 or related circuit malfunction
•Fuel pressure sensor or related circuit malfunction
•Incorrect adjustment accelerator position sensor and/or idle switch
•Accelerator position sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•Fuel line rclogging or restriction
•Supply pump malfunction
•Fuel injector malfunction
•Incorrect fuel injection timing
•Incorrect idle speed
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Boost sensor or related circuit malfunction
•Neutral switch or related circuit malfunction
•VSS or related circuit malfunction
•Low engine compression
•Improper valve timing
•Base engine malfunction
•Exhaust system and/or catalyst converter restriction
•Catalyst converter malfunction
•IDM or related circuit 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 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS—OVERHEATING”.
No Go to next step.
2 Does engine run cold? Yes Go to symptom troubleshooting “NO.18 COOLING
SYSTEM CONCERNS—RUNS COLD”.
No Go to next step.

F2–210
TROUBLESHOOTING
End Of SieNO.17 COOLING SYSTEM CONCERNS-OVERHEATINGA6E408018881219
Diagnostic Procedure
17
COOLING SYSTEM CONCERNS-OVERHEATING
DESCRIPTION•Engine runs at higher than normal temperature/overheats.
POSSIBLE
CAUSE•Cooling fan No.2 malfunction
•Cooling fan No.1 malfunction
•Low drive belt tension
•Drive belt damage
•Improper coolant level
•Thermostat malfunction
•Radiator clogging
•Improper water/anti-freeze mixture
•Improper or damaged radiator cap
•Radiator hose damage
•Coolant leakage (engine internal, turbocharger, external)
•A/C system malfunction
•EGR system malfunction
•Coolant heater system malfunction
STEP INSPECTION RESULTS ACTION
1 Inspect following:
•Engine coolant level
•Coolant leakage (around heater unit in
passenger compartment, coolant hoses and/
or radiator, and around coolant heater unit.)
•Water and anti-freeze mixture
•Radiator condition
•Collapsed or restricted radiator hoses
•Radiator pressure cap
•Drive belt tension
•Drive belt
•Fan rotational direction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Perform self-test function using WDS or
equivalent.
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 for 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.

TROUBLESHOOTING
K2–199
K2
End Of SieNO.23 TRANSAXLE OVERHEATSA6E578001030226
Diagnostic procedure
End Of SieNO.24 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITIONA6E578001030227
2•Do following symptoms concurrently occur?
—Engine flares up or slips during
acceleration
—Engine flares up or slips when shiftingYes Go to symptom troubleshooting No.14 “Engine flares up or
slips when upshifting or downshifting” or No.15 “Engine
flares up or slips when accelerating vehicle”.
No Go to next step.
3•Verify test results.
—If okay, return to diagnostic index to service any additional symptoms.
—If malfunction remains, inspect related Service Informations and perform repair or diagnosis.
—If vehicle repaired, troubleshooting completed.
—If vehicle not repaired or additional diagnostic information not available, replace TCM. STEP INSPECTION ACTION
23 Transaxle Overheat
DESCRIPTION•Burnt smell emitted from transaxle.
•Smoke emitted from transaxle.
POSSIBLE
CAUSE•Malfunction is restricted to hindrance of coolant at oil cooler. In addition, overheating of transaxle may
be caused by a malfunction of TFT sensor.
—Line pressure low
•ATF level low
•Incorrect throttle position signal
•Misadjustment of throttle cable
—Oil cooler malfunction (Foreign material mixed in with ATF)
—TFT sensor malfunction
—Excessive amount of ATF
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Is line pressure okay?
(See K2–72 Line Pressure Test.)Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.
2•Is stall speed okay?
(See K2–74 Stall Speed Test.)Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.
3•Inspect TFT sensor and related harness:
vibration, intermittent open/short circuit
•Is it okay?Yes Go to next step.
No Repair or replace part if necessary.
4•Inspect pressure control solenoid circuit.
•Is it okay?Yes Go to next step.
No•Inspect for pressure control solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
5•Inspect for bend, damage, corrosion or kinks
of oil cooler pipes.
•Are oil cooler pipes okay?Yes•Overhaul control valve body and repair or replace any
defective parts.
(See ATX Workshop Manual.)
•If problem remains, replace or overhaul transaxle and
repair or replace any defective parts.
(See ATX Workshop Manual.)
No Replace any defective parts.
6•Verify test results.
—If okay, return to diagnostic index to service any additional symptoms.
—If malfunction remains, inspect related Service Informations and perform repair or diagnosis.
—If vehicle repaired, troubleshooting completed.
—If vehicle not repaired or additional diagnostic information not available, replace TCM.
24 Engine stalls when shifted to D range, or in R position
DESCRIPTION•Engine stalls when shifting from N or P position to D range or R position at idle.
POSSIBLE
CAUSE•Malfunction is on the engine control side (e.g. IAC system). Otherwise, malfunction is in input/turbine
speed sensor (engine sometimes starts) or TCC piston circuit (engine always stalls).
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic and
Automatic Transaxle Basic Inspection are conducted.

U–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E850201038201•The construction and operation of the air conditioner system is essentially carried over from that of the previous
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E850201038202Improved Comfort
•The water heater system has been adopted. (For MZR-CD (RF Turbo) European (L.H.D.) specs.)
End Of Sie
SPECIFICATIONSA6E850201038203Manual Air Conditioner
OUTLINE
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} (R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup

U–4
OUTLINE
Full-auto Air Conditioner
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} {R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup