light MAZDA 6 2002 Suplement Owner's Manual

ON-BOARD DIAGNOSTIC
F1–53
F1
3. Perform no load racing at the engine speed
shown in the graph, then idle the engine for more
than 30 s after the cooling fan is stopped. If
possible, monitor RPM PID for engine speed and
FAN1 PID for cooling fan condition during this
procedure.
4. Turn ignition key off then on again.
5. Access to RFCFLAG PID to confirm PCM
adaptive memory condition. If RFCFLAG PID is
“Learnt”, PCM Adaptive Memory Procedure Drive
is completed.
6. If RFCFLAGPID is still “Not Learnt”, go back to
Step 1.
HO2S Heater, HO2S, and TWC Repair Verification Drive Mode
1. Access to RFCFLAG PID to confirm PCM adaptive memory condition. If RFCFLAG PID is OFF, perform PCM
Adaptive Memory Procedure Drive first.
2. If RFCFLAG PID is ON, start the engine and warm it up completely.
3. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
4. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F.
Driving condition before the constant speed driving is not specified.
For MTX
2,800—3,200 rpm
IDLE
Above
30 sAbove
30 s
ENGINE SPEEDIDLE
A6E3970W003
ZoneShift
PositionVehicle Speed
km/h {mph}Time
Sec.
O Neutral 0 T1: Above 455
A2nd40—50 {25—32}
T2: Above 30
B3rd65—75 {41—47}
C2nd60—75 {38—46}
T3: Above 20
D3rd75—100 {47—62}
E4th50—75 {31—46}
T4: Above 120
F5th75—100 {47—62}
km/h {mph}
100 {62}
50 {31}
0 {0}O
T1 T2 T3 T4A BD
C
E F
A6E3970W004

CONTROL SYSTEM
F2–17
F2
Output Device
×:Applicable –: Not applicable
Control System
×:Applicable –: Not applicable
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ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Suction control valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
IDM×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VBC solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vacuum)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vent)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve (half)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve (full)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow indicator light×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cruise main indicator light×–Same function as Mazda6 (GG) L series engine model
Cruise set indicator light×–Same function as Mazda6 (GG) L series engine model
Glow plug relay×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cooling fan relay No.1×–Same function as cooling fan relay of 626 (GF, GW) RF Turbo
engine model
Cooling fan relay No.2×–Same function as condenser fan relay of 626 (GF, GW) RF
Turbo engine model
A/C relay×Same function as 626 (GF, GW) RF Turbo engine model
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Idle speed control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Boost pressure control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel injection amount control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel injection timing control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Multiple fuel injection control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel pressure control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cruise control system×–Newly adopted
Electrical fan control×Same function as 626 (GF, GW) RF Turbo engine model
A/C cut-off control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Immobilizer system×Same function as Mazda6 (GG) L series engine model

CONTROL SYSTEM
F2–19
F2
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1PCM (with built-in BARO sensor and immobilizer
unit)
2Battery
3Starter
4 Starter relay
5 Clutch switch
6 Neutral switch
7 Brake switch
8 Idle switch
9 Cruise control switch
10 Accelerator position sensor
11 MAF/IAT sensor
12 IAT sensor No.2
13 ECT sensor
14 Fuel temperature sensor
15 Boost sensor
16 Fuel pressure sensor
17 CMP sensor
18 CKP sensor
19 VSS
20 Calibration resistor
21 Suction control valve
22 IDM
23 VSC solenoid valve
24 VBC solenoid valve
25 EGR control solenoid valve
26 EGR solenoid valve (vacuum)
27 EGR solenoid valve (vent)
28 Intake shutter solenoid valve (half)
29 Intake shutter solenoid valve (full)
30 Glow indicator light
31 Cruise main indicator light
32 Cruise set indicator light
33 Glow plug relay
34 Cooling fan relay No.1
35 Cooling fan relay No.2
36 A/C relay
37 PCM control relay
38 L.H.D.
39 R.H.D.

CONTROL SYSTEM
F2–21
F2
End Of Sie
1PCM
2 Idle speed control
3Glow control
4 VSC
5 Boost pressure control
6 Fuel injection amount control
7 Fuel injection timing control
8 Multiple fuel injection control
9 Fuel pressure control
10 EGR control
11 Cruise control system
12 Electrical fan control
13 A/C cut-off control
14 Immobilizer system
15 Battery
16 Starter (starter signal)
17 Starter relay
18 Clutch switch
19 Neutral switch
20 Brake switch
21 Idle switch
22 A/C switch
23 Refrigerant pressure switch
24 Cruise control switch
25 Accelerator position sensor
26 MAF/IAT sensor
27 IAT sensor No.2
28 ECT sensor
29 Fuel temperature sensor
30 BARO sensor (integrated in PCM)
31 Boost sensor
32 Fuel pressure sensor
33 CMP sensor
34 CKP sensor
35 VSS
36 Calibration resistor
37 Immobilizer unit (integrated in PCM)
38 Suction control valve
39 IDM
40 VSC solenoid valve
41 VBC solenoid valve
42 EGR control solenoid valve
43 EGR solenoid valve (vacuum)
44 EGR solenoid valve (vent)
45 Intake shutter solenoid valve (half)
46 Intake shutter solenoid valve (full)
47 Glow indicator light
48 Cruise main indicator light
49 Cruise set indicator light
50 Glow plug relay
51 Cooling fan relay No.1
52 Cooling fan relay No.2
53 A/C relay

F2–22
CONTROL SYSTEM
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E404018881204
×: Applicable
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Item
Input device
Battery××
Starter (starter signal)××××××××× ×
Starter relay××××××××× ×
Clutch switch× × ××× ×× ×
Neutral switch× × ××× ×× ×
Brake switch×
Idle switch× × ××× × ×
A/C switch×××××
Refrigerant pressure switch×××××
Cruise control switch×
Accelerator position sensor××××××××
MAF/IAT sensor× ××××
IAT sensor No.2××
ECT sensor××× ××××× ××
Fuel temperature sensor×
BARO sensor (integrated in PCM)×××
Boost sensor××× ×
Fuel pressure sensor×× ××
CMP sensor×××××
CKP sensor× ××××××× ×
VSS××× ××× ××
Calibration resistor××
Immobilizer unit (integrated in PCM)×
Output device
Suction control valve××
IDM× ××× × ×
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)×
Glow indicator light×
Cruise main indicator light×
Cruise set indicator light×
Glow plug relay×
Cooling fan relay No.1×
Cooling fan relay No.2×
A/C relay×
Idle speed controlGlow controlVSCBoost pressure controlFuel injection amount controlFuel injection timing controlMultiple fuel injection controlFuel pressure controlEGR controlCruise control systemElectrical fan controlA/C cut-off controlImmobilizer system

CONTROL SYSTEM
F2–23
F2
CRUISE CONTROL SYSTEMA6E404018881205Outline
•The cruise control system has been adopted for MZR-CD (RF Turbo) engine models.
•Cruise control module has been equipped into the PCM. Due to this, the PCM controls cruise control system.
•Function of the cruise control system is basically the same as that of the Mazda6 (GG) L series engine model,
except for the following:
—The PCM controls the fuel injection amount to maintain vehicle speed.
.
Operation
Operating condition
•The PCM can excute cruise control when the following conditions are met:
—Cruise control main switch is on
—Brake pedal is released (brake switch 1 is off, brake switch 2 is on)
—Clutch pedal is released (clutch switch is off)
—Gear is not neutral position (neutral switch is off)
—Vehicle speed of 27 km/h {16.7 mph} or more
—No DTC is memorized
Driving at set speed
•Once the desired speed has been set, the PCM determines the target fuel injection amount based on the
vehicle speed signal.
•If the actual vehicle speed goes below the set speed, the PCM increases the fuel injection amount, and if it
goes above the set speed the PCM decreases the fuel injection amount.
Tap up/Tap down operation
•When driving at a set speed, if the SET/COAST or RESUME/ACCEL signal is input to the PCM for a very short
interval, the set speed will be increased or decreased respectively by 6 km/h {3.7 mph}.
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CRUISE
MAIN
CRUISE
8
7
5
4
3
6
1
2
9
A6E40402025
1PCM
2 Clutch switch
3 Neutral switch
4 Brake switch
5 Cruise control switch6 VSS
7IDM
8 Cruise main indicator light
9 Cruise set indicator light

F2–24
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC
CONTROLLER AREA NETWORK (CAN)A6E404018881206Outline
•The PCM transmit/received the information other units using CAN to simplify the system.
Transmit Information
•Engine speed
•Vehicle speed
•Accelerator pedal position
•Fuel injection information
•Torque reduction inhibit
•Intake air temperature
•Engine coolant temperature
•Travelled distance
•Glow indicator light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
•Cruise main indicator light conditions
•Cruise set indicator light conditions
Received Information
•Torque reduction request from DSC HU/CM
•Wheel speed from ABS HU/CM or DSC HU/CM
—Front left
—Front right
•Travelled distance from ABS HU/CM or DSC HU/CM
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OUTLINEA6E407018881201•The on-board diagnostic system is essentially carried over from that of the current MPV (LW) MZR-CD (RF
Turbo) engine models, except for the following. (See MPV Workshop Manual Supplement 1737-1*-02C.)
—DTCs, PID monitoring items, and simulation items have been changed.
—KOEO/KOER self-test items have been changed.
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DTCA6E407018881202
×: Applicable –: Not applicable
ON-BOARD DIAGNOSTIC
DTC Condition Detection condition MILMemory
function
P0016Crankshaft position-camshaft position
correlation malfunctionInput signals from CKP sensor and CMP sensor
are misaligned.××
P0088 Fuel pressure system too highFuel pressure is higher than preprogrammed
criteria.–×
P0091 Suction control valve circuit low inputInput voltage from suction control valve does not
change from off to on.××
P0092 Suction control valve circuit high inputInput voltage from suction control valve does not
change from on to off.××
P0093 Fuel system leak detectionFuel pressure after fuel injection is lower than
preprogrammed criteria.××
P0097 IAT sensor No.1 circuit low input Input voltage from IAT sensor No.1 is below 0.1 V.××
P0098 IAT sensor No.1 circuit high input Input voltage from IAT sensor No.1 is above 5.0 V.××
P0102 MAF sensor circuit low input Input voltage from MAF sensor is below 0.2 V.××
P0103 MAF sensor circuit high input Input voltage from MAF sensor is above 4.9 V.××
P0107 Boost sensor circuit low inputInput voltage from boost sensor is below 1.9 V
when engine speed is 2,400 rpm or above and
accelerator opening angle is 50% or above.××
P0108 Boost sensor circuit high input Input voltage from boost sensor is above 4.9 V.××

ON-BOARD DIAGNOSTIC
F2–27
F2
PID/DATA MONITOR AND RECORDA6E407018881204PID monitoring item table
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SIMULATION TESTA6E407018881205Simulation test item table
×: Applicable
Item Definition Condition/unit PCM terminal
ACCS A/C relay ON/OFF 73
ACSW A/C switch ON/OFF 84
APS1 Accelerator position sensor No.1 signal voltage V 10
APS2 Accelerator position sensor No.2 signal voltage V 88
BAROBarometric pressure kPa, inHg
-
Barometric pressure signal voltage V
BOO Brake switch ON/OFF 7
CPP Clutch switch ON/OFF 33
CPP/PNP Neutral switch Neutral/Drive 56
CRUISESW Cruise control switch ON/OFF 64
DTCCNT DTC count - -
ECTEngine coolant temperature°C, °F
87
Engine coolant temperature signal voltage V
FAN2 Cooling fan relay No.2 ON/OFF 76
FAN3 Cooling fan relay No.1 ON/OFF 102
IATIntake air temperature°C, °F
60
Intake air temperature signal voltage V
IMRC VSC solenoid valve ON/OFF 101
INGEAR In gear ON/OFF 33, 56
INJ_LRN_DIS Distance from the last injector learning Km, Mile -
MAFMass air flow amount g/s
9
Mass air flow signal voltage V
MAF_LRN_DIS Distance from the last MAF learning Km, Mile -
MAINRLY PCM control relay ON/OFF 69
MAPManifold absolute pressure kPa, inHg
36
Manifold absolute pressure signal voltage V
MIL Malfunction indicator lamp ON/OFF 71
NUMKEYS Number of keys stored in module - -
RPM Engine speed rpm 3, 29
VPWR Battery positive voltage V 27
VSS Vehicle speed km/h, mph 13, 39
Item Definition OperationTest condition
PCM
terminal
Key ON Idle
ACCS A/C relay ON or OFF××73
EGRA EGR solenoid valve (vent)Actuated by any duty value
(0—100%)××72
EGRV EGR solenoid valve (vacuum)Actuated by any duty value
(0—100%)××99
EGRV2 EGR control solenoid valve ON or OFF××77
FAN Cooling fan No.2 ON or OFF××76
FAN3 Cooling fan No.1 ON or OFF××102
GP_LMP Glow indicator light ON or OFF××97
GPC Glow plug relay ON or OFF××68
IASV Intake shutter solenoid valve (half) ON or OFF××74
IASV2 Intake shutter solenoid valve (full) ON or OFF××100
IMRC VSC solenoid valve ON or OFF××101
VBCV VBC solenoid valveActuated by any duty value
(0—100%)××67

F2–38
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTIONA6E401013700201
Note
•If the following problems exist, diagnosis the turbocharger using the following symptom troubleshooting
procedures.
1. Lack of power: perform “NO.12 LACK/LOSS OF POWER”. (See F2–195 NO.12 LACK/LOSS OF POWER-
ACCELERATION/CRUISE.)
2. Oil leak: perform “NO.16 HIGH OIL CONSUMPTION/LEAKAGE”. (See F2–209 NO.16 HIGH OIL
CONSUMPTION/LEAKAGE.)
3. Noise: perform “NO. 21 ENGINE NOISE”. (See F2–217 NO.21 ENGINE NOISE.)
Compressor Wheel Inspection
1. Remove the air pipe between the air cleaner and the turbocharger. (See F2–36 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Visually inspect the compressor wheel from view A and verify that all fins are free from damage, cracks or
bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the compressor wheel is interfering with
the compressor housing, it is likely that the
fin edges are cracked, damaged, or bent.
•If the compressor wheel is damaged, check
the following before replacing the
turbocharger to avoid reoccurrence of the
problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
MIRROR
A
A6E40102009

INTAKE-AIR SYSTEM
F2–39
F2
Turbine Wheel Inspection
1. Remove the warm up oxidation catalytic converter between the flexible pipe and the turbocharger. (See F2–57
EXHAUST SYSTEM REMOVAL/INSTALLATION.)
2. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the turbine wheel is interfering with the
turbine housing, it is likely that the fin edges
are cracked, damaged, or bent.
•If the turbine wheel is damaged, check the
following before replacing the turbocharger
to avoid reoccurrence of the problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
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GUIDE BLADE ACTUATOR INSPECTIONA6E4010137002021. Disconnect the vacuum hose from the guide blade actuator.
2. Connect the vacuum pump to the guide blade
actuator.
3. Apply vacuum and verify that the rod moves as
specified.
•If not as specified, replace the turbocharger.
Specification
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MIRRORB
GRINDING MARK
A6E40102010
Vacuum (kPa {mmHg, inHg}) Rod movement
Below –14.5 {–108, –4.27} Starts to move
Above –44.9 {–337, –13.3} Fully pulled
VACUUM PUMP
ROD
A6E40102011