2002 MAZDA 6 fuel

F2–22
CONTROL SYSTEM
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E404018881204
×: Applicable
End Of Sie
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}.
End Of Sie
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
End Of Sie
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.
End Of Sie
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
F2–25
F2
P0112 IAT sensor No.2 circuit low input Input voltage from IAT sensor No.2 is below 0.1 V.××
P0113 IAT sensor No.2 circuit high input Input voltage from IAT sensor No.2 is above 5.0 V.××
P0117 ECT sensor circuit low input Input voltage from ECT sensor is below 0.1 V.××
P0118 ECT sensor circuit high input Input voltage from ECT sensor is above 5.0V.××
P0121Accelerator position sensor No.1 circuit
performance problemInput voltage from accelerator position sensor No.1
is above 1.3 V when accelerator pedal is
depressed.××
P0122Accelerator position sensor No.1 circuit
low inputInput voltage from accelerator position sensor No.1
is below 0.3 V.××
P0123Accelerator position sensor No.1 circuit
high inputInput voltage from accelerator position sensor No.1
is above 4.7 V.××
P0182 Fuel temperature sensor circuit low inputInput voltage from fuel temperature sensor is below
0.1 V.××
P0183 Fuel temperature sensor circuit high inputInput voltage from fuel temperature sensor is above
5.0 V.××
P0191Fuel pressure sensor circuit performance
problemPressure difference between actual fuel pressure
and target fuel pressure exceeds preprogrammed
criteria.××
P0192 Fuel pressure sensor circuit low inputInput voltage from fuel pressure sensor is below 0.4
V.××
P0193 Fuel pressure sensor circuit high inputInput voltage from fuel pressure sensor is above
4.8 V.××
P0200 Fuel injector circuit malfunction Injection confirmation signal is not input normally.××
P0221Accelerator position sensor No.2 circuit
performance problemVoltage difference between accelerator position
sensor No.1 and accelerator position sensor No.2
exceeds 0.9 V.××
P0222Accelerator position sensor No.2 circuit
low inputInput voltage from accelerator position sensor No.2
is below 0.3 V.××
P0223Accelerator position sensor No.2 circuit
high inputInput voltage from accelerator position sensor No.2
is above 4.7 V.××
P0300 Random misfire detectionInterval time of CKP sensor input signal exceeds
preprogrammed criteria.××
P0336 CKP sensor circuit performance problemInput signal from CKP sensor is not proper pulse
number.××
P0337 CKP sensor circuit low inputInput signal from CKP sensor is not input at 12
crankshaft revolutions.××
P0341 CMP sensor circuit performance problemInput signal from CMP sensor is not proper pulse
number.××
P0342 CMP sensor circuit low inputInput signal from CMP sensor is not input at 12
crankshaft revolutions.××
P0380 Glow plug relay circuit malfunctionInput voltage from glow plug relay is as following:
—1.0 V or below when glow plug relay is on.
—4.0 V or above when glow plug relay is off.××
P0504Brake switch signal correlation
malfunctionInput signal from brake switch 1 brake switch 2 is as
following:.
—Brake switch 1 is ON and brake switch 2 is ON.
—Brake switch 1 is OFF and brake switch 2 is
OFF.××
P0510 Idle switch circuit malfunctionInput voltage from idle switch is B+ when
accelerator position sensor No.1 voltage is below
0.7 V.××
P0512 Engine switch circuit malfunctionInput voltage from engine switch is B+ when engine
speed is 1,200 rpm or above.××
P0564 Cruise control signal malfunctionInput voltage from cruise control switch is as
following for 120 s:
—Below 0.1 V.
—1.4—1.9 V.
—3.7—3.9 V.
—4.5—4.6 V.××
P0602 PCM programming error No configuration data in PCM.××
P0606 PCM malfunction PCM does not read DTC from output devices.×× DTC Condition Detection condition MILMemory
function

LOCATION INDEX
F2–29
F2
End Of Sie
FUEL SYSTEMA6E400001006201Engine room side
1 Air cleaner
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
(See F2–37 AIR CLEANER ELEMENT
INSPECTION)
2 Turbocharger
(See F2–38 TURBOCHARGER INSPECTION)
3 Charge air cooler
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
4 Intake manifold
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
5 Guide blade actuator
(See F2–39 GUIDE BLADE ACTUATOR
INSPECTION)
6 VBC solenoid valve
(See F2–40 VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION)7 VBC check valve
(See F2–41 VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION)
8 VSC valve actuator
(See F2–41 VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION)
9 VSC solenoid valve
(See F2–42 VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION)
10 Accelerator pedal component
(See F2–44 ACCELERATOR PEDAL
COMPONENT REMOVAL/INSTALLATION)
(See F2–44 ACCELERATOR PEDAL
COMPONENT DISASSEMBLY/ASSEMBLY)
11 Glow plug
(See F2–42 GLOW PLUG REMOVAL/
INSTALLATION)
(See F2–43 GLOW PLUG INSPECTION)
12 Glow plug lead
(See F2–43 GLOW PLUG LEAD INSPECTION)
9
8
7
5
4
3
6
10
6
4
3
L.H.D.
R.H.D.
A6E40002003

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)

LOCATION INDEX
F2–33
F2
End Of Sie
1 PCM (with built-in BARO sensor and immobilizer
unit)
(SeeF2–64 PCM REMOVAL/INSTALLATION)
(SeeF2–65 PCM INSPECTION)
(SeeF2–68 PCM CONFIGURATION)
2 Clutch switch
(SeeF2–68 CLUTCH SWITCH INSPECTION)
3 Neutral switch
(SeeF2–69 NEUTRAL SWITCH INSPECTION)
4 Idle switch
(SeeF2–70 IDLE SWITCH INSPECTION)
(SeeF2–71 IDLE SWITCH ADJUSTMENT)
5 Accelerator position sensor
(SeeF2–72 ACCELERATOR POSITION SENSOR
INSPECTION)
(SeeF2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
6 MAF/IAT sensor
(SeeF2–74 MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION)
7 IAT sensor No.2
(SeeF2–75 INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION)
8ECT sensor
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION)
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION)
9 Fuel temperature sensor
(SeeF2–77 FUEL TEMPERATURE SENSOR
INSPECTION)
10 Boost sensor
(SeeF2–78 BOOST SENSOR INSPECTION)
11 Fuel pressure sensor
(SeeF2–79 FUEL PRESSURE SENSOR
INSPECTION)
12 CMP sensor
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION)
13 CKP sensor
(SeeF2–81 CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–82 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION)
14 Calibration resistor
(SeeF2–83 CALIBRATION RESISTOR
INSPECTION)
15 IDM
(SeeF2–84 INJECTOR DRIVER MODULE (IDM)
INSPECTION)

F2–34
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATIONA6E4008020002011. Start the engine and warm up completely.
2. Verify that the gear is in neutral position.
3. Verify that the accelerator pedal is released.
4. Turn off the A/C switch.
5. Turn off all electrical loads.
6. Verify that no DTC is present.
7. Connect the WDS or equivalent to the DLC-2.
8. Wait until the electrical fan stops.
End Of Sie
IDLE SPEED INSPECTIONA6E4008020002021. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Monitor the RPM PID using the WDS or equivalent.
3. Verify that engine speed is within specification.
•If not as specified, inspect the following.
—Suction control valve
—Fuel injector
—Accelerator position sensor
—ECT sensor
—Fuel pressure sensor
—CMP sensor
—CKP sensor
Specification
End Of Sie
CORRECTION PROCEDUREA6E400802000203
Note
•Perform each procedure by selecting the corresponding menu on the WDS screen. These procedures
appear when “Powertrain” in the “Toolbox tab” is selected.
Correction after Parts Installation
Note
•Perform this procedure after replacing the PCM and/or fuel injectors.
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “Correction after Parts Installation” using the WDS or equivalent.
ENGINE TUNE-UP
DLC-2
A6E40702001
Load condition Engine speed (rpm)
No load 725—825 (775±50)
A/C switch is on 725—825 (775±50)