engine oil MAZDA 6 2002 Suplement Repair Manual

TROUBLESHOOTING
F2–171
F2
×: 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××××× ×
PCM control relay malfunctionECT sensor or related circuit malfunctionNeutral switch or related circuit malfunctionMAF/IAT sensor or related circuit malfunctionIAT sensor No.2 or related circuit malfunctionBoost sensor or related circuit malfunctionAccelerator position sensor or related circuit malfunctionAccelerator position sensor misadjustment
(including looseness)Idle switch or related circuit malfunctionIdle switch misadjustment (including looseness)Fuel pressure sensor or related circuit malfunctionImproper refrigerant charging amount

F2–172
TROUBLESHOOTING
×: Applicable
End Of Sie
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
A/C relay (A/C control siganl) circuit malfunctionA/C magnetic clutch or related circuit malfunctionCooling fan No.1 system malfunctionClutch slippageAir in power steering fuluid lineVSS or related circuit malfunctionBrake draggingLoose partsImproper balance of wheel or tiresDriveline malfunctionSuspension malfunctionImmobilizer system and/or circuit malfunctionCoolant heater system malfunction

F2–174
TROUBLESHOOTING
NO.2 MIL ILLUMINATESA6E408018881204
Diagnostic procedure
End Of Sie
NO.3 WILL NOT CRANKA6E408018881205
Diagnostic procedure
2 MIL ILLUMINATES
DESCRIPTION•MIL illuminates incorrectly.
POSSIBLE
CAUSE•PCM illuminates for emission-related concern (DTC is stored in PCM)
•Instrument cluster malfunction
Note
•If MIL blinks at steady rate, misfire condition could possibly exist.
STEP INSPECTION RESULTS ACTION
1 Connect WDS or equivalent to DLC-2.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
•Go to appropriate DTC test.
NoNo DTC is displayed:
•Inspect instrument cluster operation.
2 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)
3 WILL NOT CRANK
DESCRIPTION•Starter does not work.
POSSIBLE
CAUSE•Open starter circuit between engine switch and starter
•Starter malfunction
•Seized/hydrolocked engine, flywheel
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•Low or dead battery
•Charging system malfunction
STEP INSPECTION RESULTS ACTION
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.

TROUBLESHOOTING
F2–175
F2
End Of Sie
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 Inspect following:
•Battery connection
•Battery condition
•Fuses
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 10.
11 Is clicking sound heard from starter when engine
switch is turned to START?Yes Go to Step 13.
No Go to next step.
12 Inspect starting system.
Is starting system okay?Yes Inspect for seized/hydrolocked engine, flywheel.
No Repair or replace components as required.
13 Do any other electrical accessories work? Yes Go to next step.
No Inspect charging system.
14 Connect WDS or equivalent to DLC-2.
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:
Inspect for following:
•START circuit in engine switch
•Open circuit between engine switch and starter
15 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

F2–178
TROUBLESHOOTING
End Of Sie
NO.5 ENGINE STALLS-AFTER START/AT IDLEA6E408018881207
Diagnostic Procedure
18 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
5 ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION•Engine stops unexpectedly.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction or clogging
•Engine overheating
•A/C system improper operation
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•PCM control relay malfunction
•Glow system malfunction
•Inadequate fuel pressure
•Fuel pressure sensor related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel leakage
•Fuel line clogging or restriction
•Fuel filter clogging or restriction
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•Improper valve timing
•Exhaust system and/or catalyst converter restriction or clogging
•EGR system malfunction
•ECT sensor or related circuit malfunction
•Accelerator positions sensor or related circuit malfunction
•Accelerator positions sensor misadjustment
•MAF/IAT sensor or related circuit malfunction
•V-reference voltage supply circuit 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
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.

TROUBLESHOOTING
F2–179
F2
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 Inspect for following:
•Fuel quality (e.g.: include water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging
•Intake-air system restriction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 10.
11 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS-OVERHEATING”.
No Go to next step.
12Note
•Ignore DTC P0122, P0123, P0222 or
P0223 while performing this test.
Disconnect accelerator position sensor
connector.
Measure voltage at accelerator position sensor
connector VREF terminal (terminal D) with
engine switch ON.
Specification
4.5—5.5 V
Is voltage okay?Yes Go to next step.
No Go to symptom troubleshooting “NO.26 CONSTANT
VOLTAGE”.
13 Connect WDS or equivalent to DLC-2.
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.
14 Does engine start normally 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. STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–181
F2
End Of Sie
NO.6 CRANKS NORMALLY BUT WILL NOT STARTA6E408018881208
Diagnostic Procedure
28 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
29 Inspect EGR system operation.
Is EGR system operation normal?Yes Remove and inspect supply pump and common rail.
No Repair or replace malfunctioning part according to
EGR system operation results.
30 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
6 CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION•Starter cranks engine at normal speed but engine will not run.
•Refer to symptom troubleshooting “No.5 Engine stalls” if this symptom appears after engine stall.
•Fuel is in fuel tank.
•Battery is in normal condition.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction
•Fuel line restriction
•EGR system malfunction
•Glow system malfunction
•Fuel pressure sensor or related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel leakage
•Fuel filter clogging
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•V-reference supply circuit malfunction
•ECT sensor or related circuit malfunction
•Supply pump malfunction
•Fuel injector malfunction
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•Low engine compression
•Improper valve timing
•IDM or related circuit malfunction
•PCM control repay 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
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.

F2–182
TROUBLESHOOTING
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 Inspect for following:
•Fuel quality (e.g.: include water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging
•Intake-air system restriction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 10.
11Note
•Ignore DTC P0122, P0123, P0222 or
P0223 while performing this test.
Disconnect accelerator position sensor
connector.
Measure voltage at accelerator position sensor
connector VREF terminal (terminal D) with
engine switch ON.
Specification
4.5—5.5 V
Is voltage okay?Yes Go to next step.
No Go to symptom troubleshooting “NO.26 CONSTANT
VOLTAGE”.
12 Connect WDS or equivalent to DLC-2.
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. STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–197
F2
13 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
14 Is any engine oil found inside turbocharger
turbine housing?YesExcessive amount of oil is found:
Replace turbocharger.
Small amount of oil is found:
Wipe oil off of vehicle, then go to next step.
No Go to next step.
15 Is any engine oil found inside turbocharger
compressor hosing?Yes Wipe oil off of vehicle and install all removed parts in
Step 10. Then, go to next step.
No Turbocharger is okay.
Install all parts removed in Step10.
Then, go to next step.
16 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.
17 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.
18 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)
19 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.
20 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.
21 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
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.
22 Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
Is fuel pressure okay?Yes Go to next step.
No Replace common rail.
23 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) STEP INSPECTION RESULTS ACTION

F2–200
TROUBLESHOOTING
4 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.
5 Inspect intake shutter valve and VSC valve
operations.
(See F2–229 ENGINE CONTROL SYSTEM
OPERATION INSPECTION)
Is there any problem?Yes Repair or replace as necessary.
No Go to next step.
6 Inspect guide blade valve operation.
(See F2–229 ENGINE CONTROL SYSTEM
OPERATION INSPECTION)
Is there any problem?Yes Repair or replace as necessary.
No Go to next step.
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.
(See F2–229 ENGINE CONTROL SYSTEM
OPERATION INSPECTION)
Is actuator okay?Yes 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 Remove parts necessary to inspect
turbocharger.
Do not remove turbocharger.
Inspect if turbocharger compressor wheel is
bent, damaged, or interfering with housing on
vehicle.
(See F2–38 TURBOCHARGER INSPECTION)
Is there any problem?Yes Replace turbocharger.
No Go to next step.
10 Inspect if turbocharger compressor wheel
locknut is loose or has fallen down inside
turbocharger.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
11 Inspect turbocharger compressor wheel by
hand.
Does wheel turn easily and smoothly?Yes Go to next step.
No Replace turbocharger.
12 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
13 Is any engine oil found inside turbocharger
turbine housing?YesExcessive amount of oil is found:
Replace turbocharger.
Small amount of oil is found:
Wipe oil off of vehicle, then go to next step.
No Go to next step. STEP INSPECTION RESULTS ACTION