timing belt MAZDA 6 2002 Suplement Owner's Manual

F1–58
TROUBLESHOOTING
QUICK DIAGNOSTIC CHARTA6E398018881202
X: Applicable
Possible factor
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch is open.
Starter interlock switch malfunction (MTX with starter
interlock system)
Improper engine oil level
Low or dead battery
Charging system malfunction
Improper engine compression
Improper valve timing
Hydrolocked engine
Improper engine oil viscosity
Improper dipstick
Base engine malfunction
Drive plate or flywheel are seized.
Improper tension or damaged drive belts
Improper engine coolant level
Water and anti-freeze mixture is improper.
Cooling system malfunction (Radiator, hoses,
overflow system, thermostat, etc.)
Cooling fan system malfunction
Engine or transaxle mounts are improperly installed.
Cooling fan or condenser fan seat are improper.
Accelerator cable free play misadjustment
Cruise control cable misadjustment
Fuel quality
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not start x x x x7 Slow return to idlex8 Engine runs rough/rolling idle x x x9 Fast idle/runs onxx10 Low idle/stalls during decelerationEngine stalls/quits. Acceleration/cruise x x xEngine runs rough. Acceleration/cruise x x xMissesAcceleration/cruise x x xBuck/jerk Acceleration/cruise/
decelerationxx x
Hesitation/stumble Acceleration x x x
11
Surges Acceleration/cruis
exx x12 Lack/loss of powerAcceleration/cruisexx x13 Knocking/pingingAcceleration/cruisexx14 Poor fuel economy x x x x x x15 Emission compliance x x x x16 High oil consumption/leakage x x x17 Cooling system concerns Overheatingxx x x x18 Cooling system concernsRuns cold x x19 Exhaust smoke x x x20 Fuel odor (in engine compartment)21 Engine noise x x x22 Vibration concerns (engine) x x x23 A/C does not work sufficiently.24 A/C is always on or A/C compressor runs
continuously.
25 A/C is not cut off under WOT conditions.26 Exhaust sulfur smellx27 Constant voltage28 Spark plug condition x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802001

F1–62
TROUBLESHOOTING
NO.14 POOR FUEL ECONOMYA6E398018881203
Diagnostic procedure
14 POOR FUEL ECONOMY
DESCRIPTIONFuel economy is unsatisfactory.
POSSIBLE CAUSE•Contaminated air cleaner element
•VIS malfunction (if equipped)
•Engine cooling system malfunction
•Improper ATF level (ATX)
•Weak spark
•Poor fuel quality
•Erratic or no signal from CMP sensor
•Clutch slippage (MTX)
•VTCS malfunction
•Improper variable valve timing control system operation (if equipped)
•Improper coolant level
•Inadequate fuel pressure
•Spark plug malfunction
•PCV valve malfunction
•Brake dragging
•Improper valve timing due to jumping out of timing belt
•Contaminated MAF sensor
•Improper engine compression
•Exhaust system clogging
•Improper electrically controlled 4WD system operation
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before performing 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 injuries 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.
Caution
•Disconnecting/connecting quick release connector without cleaning it may possibly cause
damage to fuel pipe and quick release connector. Always clean quick release connector
joint area before disconnecting/connecting, and make sure that it is free of foreign material.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Air cleaner element for contamination
•ATF level
•Fuel quality
•Coolant level
•Brake dragging
•Clutch slippage
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Connect WDS or equivalent to DLC-2.
Retrieve any continuous memory, KOEO and
KOER DTCs.
Are there any DTCs displayed?YesDTC is displayed:
Go to appropriate DTC test.
NoNo DTC is displayed:
Go to next step.
3 Access ECT PID.
Drive vehicle while monitoring PID.
(See F1–33 PCM INSPECTION (4WD).)
Is PID within specification?Yes Go to next step.
No Inspect for coolant leakage, cooling fan and condenser
fan operations or thermostat operation.

CONTROL SYSTEM
F2–81
F2
Resistance Inspection
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Disconnect the CMP sensor connector.
4. Inspect the resistance between the terminals
under the following condition.
•If not as specified, replace the CMP sensor.
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•if there is open/short circuit, repair or replace
wiring harnesses.
Open circuit
•CMP sensor terminal A and PCM terminal 81
•CMP sensor terminal B and PCM terminal 55
Short circuit
•CMP sensor terminal A and PCM terminal 81 to GND
•CMP sensor terminal B and PCM terminal 55 to GND
End Of Sie
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATIONA6E404018230201
Caution
•When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect engine control. Be sure there is
no foreign material on the CKP sensor when replacing.
•Do not forcefully pull the wiring harness of the CKP sensor. Doing so will break the harness.
1. Disconnect the negative battery cable.
2. Remove the crankshaft pulley. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
3. Remove the lower timing belt cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
End Of Sie
TerminalAtmospheric
temperature (°C {°F})Resistance
(kilohm)
A—B 20 {68} 1.85—2.45
A
B
A6E40702052
1 CKP sensor installation bolt
2 CKP sensor
N·m {kgf·cm, in·lbf} 16—23 {1.6—2.4, 12—17}12
A6E40702053

F2–82
CONTROL SYSTEM
CRANKSHAFT POSITION (CKP) SENSOR INSPECTIONA6E404018230202
Note
•Perform the following test only when directed.
Caution
•When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect engine control. Be sure there is
no foreign material on the CKP sensor when replacing.
•Do not forcefully pull the wiring harness of the CKP sensor. Doing so will break the harness.
Visual Inspection
1. Verify that the CKP sensor and the pulsar are free of any metallic shavings or particles.
•If any are found on the CKP sensor and the pulsar, clean them off.
Air Gap Inspection
1. Disconnect the negative battery cable.
2. Remove the crankshaft pulley. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
3. Remove the crankshaft pulley. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
4. Verify that clearance A between the CKP sensor
and the pulsar is within the specification.
•If not as specified, replace the CKP sensor.
Clearance A
1.5—2.5 mm {0.059—0.098 in}
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the CKP sensor connector.
3. Measure the resistance between the CKP sensor
terminals under the following condition.
•If not as specified, replace the CKP sensor.
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following wiring harnesses.
•If there is open/short circuit, repair or replace wiring harnesses.
Open circuit
•CKP sensor terminal A and PCM terminal 29
•CKP sensor terminal B and PCM terminal 3
Short circuit
•CKP sensor terminal A and PCM terminal 29 to GND
•CKP sensor terminal B and PCM terminal 3 to GND
End Of Sie
TerminalAtmospheric
temperature °C {°F}Resistance (kilohm)
A—B 20 {68} 1.8—2.45
CLEARANCE A
A6E40702054
A
BC
A6E40702055

F2–88
ON-BOARD DIAGNOSTIC
End Of SieDTC P0016A6E407001082201
Diagnostic procedure
End Of Sie
DTC P0016 Crankshaft position-camshaft position correlation malfunction
DETECTION
CONDITION•PCM monitors input signals from CKP sensor and CMP sensor while engine is running. If input signals
from CKP sensor and CMP sensor are misaligned, PCM determines crankshaft position-camshaft position
correlation malfunction.
POSSIBLE
CAUSE•CKP sensor malfunction
•CMP sensor malfunction
•Timing belt is loose
•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.
2VERIFY DTC P0016 DETECTED AGAIN
•Clear DTC from PCM memory using WDS or
equivalent.
•Start engine.
•Is same DTC present?Yes Go to next step.
No Intermittent concern exists. Go to “Intermittent Concern
Troubleshooting”.
(See F2–227 INTERMITTENT CONCERN
TROUBLESHOOTING)
3FOLLOW OTHER DETECTED DTC FIRST
•Turn engine switch to OFF.
•Start engine.
•Have P0336, P0337, P0341, P0342 been
detected?Yes Go to applicable DTC inspection.
(See F2–87 DTC TABLE)
No Go to next step.
4INSPECT CKP SENSOR
•Inspect CKP sensor.
(See F2–82 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION)
•Is there any malfunction?Yes Replace CKP sensor, go to Step 7.
(See F2–81 CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION)
No Go to next step.
5INSPECT CMP SENSOR
•Inspect CMP sensor.
(See F2–80 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION)
•Is there any malfunction?Yes Replace CMP sensor, go to Step 7.
(See F2–80 CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION)
No Go to next step.
6INSPECT TIMING BELT
•Inspect timing belt installation.
•Is there any malfunction?Yes Reinstall timing belt, go to next step.
No Go to next step.
7VERIFY TROUBLESHOOTING OF DTC P0016
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.

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

F2–194
TROUBLESHOOTING
End Of Sie
11 Inspect adjustment of accelerator position
sensor and idle switch.
(See F2–72 ACCELERATOR POSITION
SENSOR INSPECTION)
(See F2–70 IDLE SWITCH INSPECTION)
Are accelerator position sensor and idle switch
adjusted correctly?Yes Go to next step.
No Adjust accelerator position sensor and idle switch
correctly.
(See F2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
(See F2–71 IDLE SWITCH ADJUSTMENT)
12 Inspect adjustment of neutral switch.
(See F2–69 NEUTRAL SWITCH INSPECTION)
Is neutral switch adjusted correctly?Yes Go to next step.
No Adjust neutral switch correctly.
13 Visually inspect CKP sensor and teeth of pulse
wheel.
Are CKP sensor and teeth of pulse wheel okay?Yes Go to next step.
No Replace malfunctioning parts.
14 Measure gap between CKP sensor and teeth of
pulse wheel.
Specification
1.5—2.5 mm {0.059—0.098 in}
Is gap within specification?Yes Go to next step.
No Adjust CKP sensor position.
15 Visually inspect CMP sensor and teeth of pulse
wheel.
Are CMP sensor and teeth of pulse wheel okay?Yes Inspect following PIDs:
(See F2–65 PCM INSPECTION)
•ECT
•IAT
•MAF
•RPM
If PID value is not as specified, repair or replace
malfunctioning parts.
If PID value is okay, go to next step.
No Replace malfunctioning parts.
16 Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
Is fuel pressure okay?Yes Go to next step.
No Replace common rail.
17 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION)
18 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
19 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
20 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
21 Inspect timing belt for following:
•Chipping of gear teeth
•Low tension
•Breakage damage or cracks
Is timing belt okay?Yes Inspect following:
•Clutch slippage
•CKP sensor
•VSS
If okay, remove and inspect supply pump and common
rail.
No If timing is incorrect, adjust valve timing.
If timing belt is not okay, replace timing belt.
22 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

F2–198
TROUBLESHOOTING
End Of Sie
24 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
25 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
26 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
27 Inspect timing belt for following:
•Chipping of gear teeth
•Low tension
•Breakage damage or cracks
Is timing belt okay?Yes Inspect following:
•Clutch slippage
•CKP sensor
•Boost sensor and related circuit
•Brake system for dragging
If okay, remove and inspect supply pump and common
rail.
No If valve timing is incorrect, adjust valve timing.
If timing belt is not okay, replace timing belt.
28 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

F2–204
TROUBLESHOOTING
End Of Sie
14 Measure gap between CKP sensor and teeth of
pulse wheel.
Specification
1.5—2.5 mm {0.059—0.098 in}
Is gap within specification?Yes Go to next step.
No Adjust CKP sensor position.
15 Visually inspect CMP sensor and teeth of pulse
wheel.
Are CMP sensor and teeth of pulse wheel okay?Yes Inspect following PIDs:
(See F2–65 PCM INSPECTION)
•ECT
•IAT
•MAF
•MAP
•RPM
•VSS
If PID value is not as specified, repair or replace
malfunctioning parts.
If PID value is okay, go to next step.
No Replace malfunctioning parts.
16 Inspect timing belt for following:
•Chipping of gear teeth
•Low tension
•Breakage damage or cracks
Is timing belt okay?Yes Inspect following:
•Clutch slippage
•CKP sensor
•Boost sensor and related circuit
•Brake system for dragging
•Coolant heater system
•Glow system
If okay, remove and inspect supply pump.
No If timing is incorrect, adjust valve timing.
If timing belt is not okay, replace timing belt.
17 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

F2–208
TROUBLESHOOTING
End Of Sie
25 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
26 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
27 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
28 Inspect timing belt for followings:
•Chipping of gear teeth
•Low tension
•Breakage damage or cracks
Is timing belt okay?Yes Inspect following:
•ECT sensor
•Boost sensor
•MAF/IAT sensor
•Catalyst converter
If okay, remove and inspect supply pump and common
rail.
No If timing is incorrect, adjust valve timing.
If timing belt is not okay, replace timing belt.
29 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION