fuel pump MAZDA 6 2002 Suplement Owner's Guide

TROUBLESHOOTING
F1–63
F1
End Of Sie
4 Is strong blue spark visible at each disconnected
high-tension lead while cranking engine?Yes Inspect for following:
•Spark plugs malfunction
•CMP sensor is improperly installed.
•Trigger wheel damage on camshaft
•Open or short circuit on CMP sensor
•Open or short circuit between CMP sensor and
PCM terminal 2J or 2M
Repair or replace malfunctioning parts.
If okay, go to next step.
No Inspect following:
•High-tension leads
•Ignition coil and connector
5 Install fuel pressure gauge between fuel pipe
and fuel distributor.
Start engine and run it at idle.
Measure fuel line pressure at idle.
Is fuel line pressure correct at idle?Yes Go to next step.
NoZero or low:
Inspect for clogged fuel line.
If okay, replace fuel pump unit
High:
Replace fuel pump unit.
6 Inspect for VTCS operation.
Does VTCS work properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
7Note
•The following test should be performed for
vehicles with variable valve timing control
system. Go to next step for vehicles
without variable valve timing control
system.
Inspect for variable valve timing control system
operation.
Does variable valve timing control system work
properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
8Note
•The following test should be performed for
vehicles with VIS. Go to next step for
vehicles without VIS.
Inspect for VIS operation.
Does VIS work properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
9 Remove and shake PCV valve.
Does PCV valve rattle?Yes Go to next step.
No Replace PCV valve.
10 Inspect for restriction in the exhaust system.
Is there any restriction?Yes Inspect exhaust system.
No Go to next step.
11 Inspect for contaminated MAF sensor.
Is there any contamination?Yes Go to next step.
No Inspect for cause.
12 Inspect MAF sensor for contamination.
Is there any contamination?Yes Replace MAF sensor.
No Go to Step 14. (2WD)
Go to next step. (4WD)
13 Inspect electrically controlled 4WD system
operation.
Is operation of electrically controlled 4WD
system okay?Yes Go to next step.
No Repair or replace malfunctioning parts.
14 Is engine compression correct? Yes Inspect valve timing.
No Inspect for cause.
15 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. STEP INSPECTION RESULTS ACTION

F2–1
F2
F2FUEL AND EMISSION CONTROL SYSTEMS
[MZR-CD (RF Turbo)]
OUTLINE.............................................................. F2-3
OUTLINE OF CONSTRUCTION ....................... F2-3
FEATURES ........................................................ F2-3
SPECIFICATIONS ............................................. F2-3
CONTROL SYSTEM DIAGRAM ........................ F2-4
CONTROL SYSTEM WIRING DIAGRAM.......... F2-5
INTAKE-AIR SYSTEM.......................................... F2-8
OUTLINE ........................................................... F2-8
STRUCTURAL VIEW......................................... F2-9
FUEL SYSTEM................................................... F2-10
OUTLINE ......................................................... F2-10
STRUCTURAL VIEW....................................... F2-11
EXHAUST SYSTEM........................................... F2-13
OUTLINE ......................................................... F2-13
STRUCTURAL VIEW....................................... F2-13
EMISSION SYSTEM........................................... F2-14
OUTLINE ......................................................... F2-14
STRUCTURAL VIEW....................................... F2-15
WARM UP OXIDATION CATALYTIC
CONVERTER DESCRIPTION ...................... F2-16
CONTROL SYSTEM........................................... F2-16
OUTLINE ......................................................... F2-16
STRUCTURAL VIEW....................................... F2-18
BLOCK DIAGRAM ........................................... F2-20
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F2-22
CRUISE CONTROL SYSTEM ......................... F2-23
CONTROLLER AREA NETWORK (CAN) ....... F2-24
ON-BOARD DIAGNOSTIC................................. F2-24
OUTLINE ......................................................... F2-24
DTC.................................................................. F2-24
KOEO/KOER SELF-TEST ............................... F2-26
PID/DATA MONITOR AND RECORD ............. F2-27
SIMULATION TEST ......................................... F2-27
LOCATION INDEX............................................. F2-28
INTAKE-AIR SYSTEM ..................................... F2-28
FUEL SYSTEM ................................................ F2-29
EMISSION SYSTEM........................................ F2-31
CONTROL SYSTEM........................................ F2-32
ENGINE TUNE-UP............................................. F2-34
ENGINE TUNE-UP PREPARATION ............... F2-34
IDLE SPEED INSPECTION ............................. F2-34
CORRECTION PROCEDURE ......................... F2-34
INTAKE-AIR SYSTEM........................................ F2-35
VACUUM TUBE ROUTING DIAGRAM............ F2-35
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION .......................... F2-36
AIR CLEANER ELEMENT INSPECTION ........ F2-37
TURBOCHARGER INSPECTION ................... F2-38
GUIDE BLADE ACTUATOR INSPECTION ..... F2-39
VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION ................ F2-40VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION ...................... F2-41
VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION ............... F2-41
VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION ................ F2-42
GLOW PLUG REMOVAL/INSTALLATION ...... F2-42
GLOW PLUG INSPECTION ............................ F2-43
GLOW PLUG LEAD INSPECTION .................. F2-43
ACCELERATOR PEDAL COMPONENT
REMOVAL/INSTALLATION .......................... F2-44
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-44
FUEL SYSTEM................................................... F2-45
BEFORE REPAIR PROCEDURE .................... F2-45
AFTER REPAIR PROCEDURE ....................... F2-45
FUEL TANK REMOVAL/INSTALLATION ........ F2-45
FUEL TANK INSPECTION .............................. F2-49
NONRETURN VALVE INSPECTION............... F2-50
FUEL FILTER COMPONENT
REMOVAL/INSTALLATION .......................... F2-50
FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-51
FUEL WARMER INSPECTION........................ F2-51
SEDIMENTOR WATER DRAINING................. F2-52
SEDIMENTOR SWITCH INSPECTION ........... F2-52
SUPPLY PUMP REMOVAL/INSTALLATION .. F2-53
SUPPLY PUMP INSPECTION......................... F2-54
SUCTION CONTROL VALVE INSPECTION ... F2-54
COMMON RAIL INSPECTION ........................ F2-54
FUEL INJECTOR REMOVAL/INSTALLATION F2-55
FUEL INJECTOR INSPECTION ...................... F2-56
EXHAUST SYSTEM........................................... F2-57
EXHAUST SYSTEM INSPECTION ................. F2-57
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F2-57
EMISSION SYSTEM........................................... F2-59
EGR VALVE REMOVAL/INSTALLATION........ F2-59
EGR VALVE INSPECTION .............................. F2-59
EGR SOLENOID VALVE (VACUUM)
INSPECTION ................................................ F2-60
EGR SOLENOID VALVE (VENT)
INSPECTION ................................................ F2-60
EGR CONTROL SOLENOID VALVE
INSPECTION ................................................ F2-61
INTAKE SHUTTER VALVE ACTUATOR
INSPECTION ................................................ F2-62
INTAKE SHUTTER SOLENOID VALVE
INSPECTION ................................................ F2-63
CONTROL SYSTEM........................................... F2-64
PCM REMOVAL/INSTALLATION .................... F2-64
PCM INSPECTION .......................................... F2-65
PCM CONFIGURATION .................................. F2-68
CLUTCH SWITCH INSPECTION .................... F2-68
NEUTRAL SWITCH INSPECTION .................. F2-69
IDLE SWITCH INSPECTION ........................... F2-70
IDLE SWITCH ADJUSTMENT ......................... F2-71
ACCELERATOR POSITION SENSOR
INSPECTION ................................................ F2-72
ACCELERATOR POSITION SENSOR
ADJUSTMENT .............................................. F2-73 FEATURES
SERVICE

OUTLINE
F2–3
F2
OUTLINE OF CONSTRUCTIONA6E400218881201•The common rail injection system has been adopted for Mazda6 (GG, GY) MZR-CD (RF Turbo) engine
models.
•The fuel and emission control system is essentially carried over from that of the current MPV (LW) MZR-CD
(RF Turbo) engine models, except for the following features. (See MPV Workshop Manual Supplement 1737-
1*-02C.)
End Of Sie
FEATURESA6E400218881202Improved Emission Performance
•Warm up oxidation catalytic converter capacity has been increased.
System Simplification
•Immobilizer unit has been equipped into PCM
•Cruise control system has been adopted.
•Electrical fan control has been changed.
•CAN has been changed.
Improved Serviceability
•DTCs, PID monitoring items, and simulation test items have been changed.
•KOEO/KOER self-test items have been changed.
End Of Sie
SPECIFICATIONSA6E400218881203
Bold frames: New specifications
End Of Sie
OUTLINE
ItemNew Mazda6 (GG, GY) Current MPV (LW)
MZR-CD (RF Turbo)
Air cleaner element Type Non woven fabric (dry)
Supercharger Type Turbocharger
Glow plug Type Metal
Pump Type Supply pump
Fuel tankCapacity
64 {16.9, 14.1} 75 {19.8, 16.5}
(L {US gal, lmp gal})
Catalyst Type Warm up oxidation catalyst, Oxidation catalyst
EGR control Type Duty control
PCV system Type Closed

F2–4
OUTLINE
CONTROL SYSTEM DIAGRAMA6E400218881204
.
End Of Sie
5
4
3
6
1
2
8
7
910
13
11
12
19
18
17
1516
14
202928
27
25
26
24
2321
22
30
393837
35
3633
31
32
40
34
494847
45
464443
4142
50
54
515253
A
A
BB
A6E40022001
1 Air cleaner
2 Vacuum chamber
3 VBC check valve
4 MAF/IAT sensor
5 VBC solenoid valve
6 Vacuum damper
7 Guide blade actuator
8 Turbocharger
9 Charge air cooler
10 IAT sensor No.2
11 Boost sensor
12 Intake shutter valve actuator
13 Intake shutter solenoid valve (half)
14 Intake shutter solenoid valve (full)
15 EGR solenoid valve (vacuum)
16 EGR solenoid valve (vent)
17 EGR control solenoid valve
18 EGR valve
19 EGR water cooler
20 VSC valve actuator
21 VSC solenoid valve
22 Fuel tank
23 Fuel filter
24 Fuel warmer
25 Supply pump
26 Suction control valve
27 Fuel temperature sensor28 Common rail
29 Fuel pressure sensor
30 Fuel pressure limiter
31 Glow plug
32 Fuel injector
33 ECT sensor
34 Calibration resistor
35 CMP sensor
36 Warm up oxidation catalytic converter
37 Oxidation catalytic converter
38 Silencer
39 Vacuum pump
40 CKP sensor
41 Idle switch
42 Accelerator position sensor
43 Glow plug relay
44 IDM
45 PCM
46 BARO sensor
47 PCM control relay
48 Engine switch
49 Starter (starter signal)
50 Neutral switch
51 Clutch switch
52 A/C switch
53 CAN bus
54 To PCM

F2–6
OUTLINE
.
a
b
c
d
e
f
gCBD
A
CBD
ACBD
ACBD
A
3762
89 11C
BABABABABABABABABA
81 55 29 3 99 72
1017410067 77
h
i
j
k
l
m
n
oA
B
C36
10
A
BCD8831
90
A B CA
BA
B
A B 6135
87 94 93 8
A
B76
E
C
A D
M84
10273 8668
AB
C D
M
M A B
29282725262430
1
393837353633
31
3240
49
48
47454644
4341
42
50
59
58
57
55
5654
60
64
63
61
62
34
51
5253
A6E40022003
1PCM
2DLC-2
3 Water heater unit
4Fuel pump
5 Other unit6IDM
7Battery
8 Engine switch
9 Starter relay
10 Starter

F2–10
FUEL SYSTEM
End Of Sie
OUTLINEA6E401201006201•The fuel system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
model. (See MPV Wordshop Manual Supplement 1737-1*-02D.)
×:Applicable
*1: With fuel warmer
End Of Sie
FUEL SYSTEM
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Fuel tank×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Fuel gauge sender unit×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Fuel filter bodyFuel filter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Priming pump×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel warmer
*1×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Common rail injection system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

FUEL SYSTEM
F2–11
F2
STRUCTURAL VIEWA6E401201006202Engine room side
.
1
2
3
4
5
6
7
9
8
10
11
12
10
A6E40122031
1 Fuel warmer
2 Sedimentor switch
3 Supply pump
4 Suction control valve
5 Common rail
6 Priming pump7 L.H.D.
8 Fuel injector
9 Priming pump
10 Fuel filter
11 R.H.D.
12 Sedimentor switch

F2–12
FUEL SYSTEM
Fuel tank side
.
End Of Sie
4
31
2
A6E40122032
1 Fuel tank
2Fuel pump3 Nonreturn valve
4 Fuel filler cap

F2–30
LOCATION INDEX
Fuel tank side
.
End Of Sie
21
A6E40002004
1 Fuel tank
(See F2–45 FUEL TANK REMOVAL/
INSTALLATION)
(See F2–49 FUEL TANK INSPECTION)
2 Nonreturn valve
(See F2–50 NONRETURN VALVE INSPECTION)
3 Sedimentor switch
(See F2–52 SEDIMENTOR SWITCH INSPECTION)
4 Fuel filter
(See F2–50 FUEL FILTER COMPONENT
REMOVAL/INSTALLATION)
(See F2–51 FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY)
5 Fuel warmer
(See F2–51 FUEL WARMER INSPECTION)6 Priming pump
(See F2–52 SEDIMENTOR WATER DRAINING)
7 Supply pump
(See F2–53 SUPPLY PUMP REMOVAL/
INSTALLATION)
(See F2–54 SUPPLY PUMP INSPECTION)
8 Suction control valve
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
9 Common rail
(See F2–54 COMMON RAIL INSPECTION)
10 Fuel injector
(See F2–55 FUEL INJECTOR REMOVAL/
INSTALLATION)
(See F2–56 FUEL INJECTOR INSPECTION)

F2–48
FUEL SYSTEM
Breather Hose Installation Note
1. Fit the breather hose onto the respective fittings,
and install clamps as shown.
Joint Hose Installation Note
1. Fit the joint hose onto the respective fittings, and
install clamps as shown.
Fuel Gauge Sender Unit Installation Note
1. Verify that the fuel tank mark is aligned with the
fuel pump mark as shown.
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. When the retainer is not removed, perform the
following procedure.
(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.
FUEL TANK SIDE
10 mm {0.39 in}
A6E3912W038
8—12 mm
{0.32—0.47 in}
5 mm {0.20 in} MIN
TANK
APPROX. 45° FUEL TANK SIDE
A6E3912W040
A6E40122026
CHECKER
TA B
NEW PLASTIC
FUEL HOSE
A6E3912W004